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VC8
User Manual
48 pgs968.72 Kb0

Goodman Mfg VC8 User Manual

I
NSTALLATION
I
NSTRUCTIONS
(CATEGORY I )
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements em­bodied in the American National Standard / Na­tional Standard of Canada ANSI Z21.47·CSA-
2.3 Gas Fired Central Furnaces.
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
FOR
*(D, M)VC8 G
C
AS
F
URNACE
®
US
ATTENTION INSTALLING PERSONNEL
As a professional installer, you have an obligation to know the product better than the customer.
This includes all safety precautions and related items.
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual.
Pay special attention to all safety warnings. Often during installation or repair, it is possible to place yourself
in a position which is more hazardous than when the unit is in operation.
Remember, it is your responsibility to install the product safely and to know it well enough
to be able to instruct a customer in its safe use.
Safety is a matter of common sense...a matter of thinking before acting.
Most dealers have a list of specific, good safety practices...follow them.
The precautions listed in this Installation Manual are intended as supplemental to existing practices.
However, if there is a direct conflict between existing practices and the content of this manual,
the precautions listed here take precedence.
NOTE: Please contact your distributor or our website for the applicable Specification Sheet
referred to in this manual.
WARNING
G
OODMANWILLNOTBERESPO NSIBLEFORANYINJURYORPROPERTY
DAMAGEARISINGFROMIMPROPERSERVICEORSERVICEPROCEDURES
FYOUINSTALLORPERFORMSERVICEONTHISUNIT,YOUASSUME
I
RESPO NSIBILITYFORANYPERSONALINJURYORPROPERTYDAMAGE
WHICHMAYRESULT
INSTALLORSERVICEHEATINGANDAIRCONDITIONINGEQUIPMENT
.M
ANYJURISDICTIONSREQUIREALICENSETO
 .
.
IO-361C
5151 San Felipe Suite 500 • Houston, TX 77056
www.goodmanmfg.com • www.amana-hac.com
© 2009-2010 Goodman Manufacturing Company, L.P.
12/10
Table of Contents
AFETY PRECAUTIONS ................................................................................................................................. 4
S
A
DDITIONAL SAFETY CONSIDERATIONS ...................................................................................................... 5
HIPPING INSPECTION ........................................................................................................................... 5
S E
LECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ..................................................................................... 5
O THE INSTALLER .............................................................................................................................. 5
T I
MPORTANT NOTE TO THE OWNER REGARDING PRODUCT WARRANTY ............................................................... 5
RODUCT DESCRIPTION ............................................................................................................................... 6
P
F
EATURES .......................................................................................................................................... 6
PRODUCT APPLICATION ............................................................................................................................... 6
LOCATION REQUIREMENTS AND CONSIDERATIONS ................................................................................................ 7
LEARANCES AND A CCESSIBILITY ............................................................................................................ 8
C H
ORIZONTAL INSTALLATION (*MVC8 MODELS O NLY).................................................................................. 8
URNACE SUSPENSION .......................................................................................................................... 8
F E
XISTING FURNACE REMOVAL ................................................................................................................ 8
THERMOSTAT LOCATION ........................................................................................................................ 9
COMBUSTION AND VENTILATION A IR REQUIREMENTS ............................................................................................ 9
CATEGORY I VENTING (VERTICAL VENTING) .................................................................................................... 10
EXTERIOR MASONRY CHIMNEYS (CATEGORY I FURNACES ONLY) .......................................................................... 11
HECKLIST SUMMARY .........................................................................................................................11
C
C
HECK 1 - PROPER CHIMNEY TERMINATION. ............................................................................................. 12
CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL ...................................... 12
CHECK 3 - CHIMNEY CROWN CONDITION. ................................................................................................ 13
CHECK 4 - DEBRIS IN CLEANOUT .......................................................................................................... 13
CHECK 5 - LINER CONDITION................................................................................................................ 13
CHECK 6 - DILUTION AIR. ................................................................................................................... 13
CHECK 7 - COMPLETE THE INSTALLATION. ............................................................................................... 13
FIX 1 - LINER TERMINATION ................................................................................................................. 14
FIX 2 -CHANGE V ENTING A RRANGEMENTS ............................................................................................... 14
FIX 3 - REBUILD THE CROWN ............................................................................................................... 14
FIX 4 - RELINING .............................................................................................................................. 14
ELECTRICAL CONNECTIONS ........................................................................................................................ 15
WIRING HARNESS .............................................................................................................................. 15
115 VOLT L INE C ONNECTIONS ............................................................................................................. 15
JUNCTION BOX RELOCATION ................................................................................................................ 16
24 VOLT T HERMOSTAT WIRING ............................................................................................................ 16
SINGLE-STAGE HEATING THERMOSTAT APPLICATION .................................................................................. 17
24 VOLT D EHUMIDISTAT WIRING ........................................................................................................... 17
FOSSIL FUEL A PPLICATIONS ................................................................................................................ 17
115 VOLT LINE CONNECTION OF A CCESSORIES (H UMIDIFIER AND ELECTRONIC A IR CLEANER) ............................. 18
24 VOLT HUMIDIFIER ......................................................................................................................... 18
GAS SUPPLY AND P IPING ........................................................................................................................... 18
HIGH ALTITUDE DERATE ...................................................................................................................... 18
PROPANE GAS CONVERSION ................................................................................................................ 18
GAS PIPING CONNECTIONS .................................................................................................................. 18
UPFLOW INSTALLATIONS ..................................................................................................................... 20
COUNTERFLOW INSTALLATIONS .............................................................................................................. 20
GAS PIPING C HECKS ......................................................................................................................... 20
PROPANE GAS TANKS AND PIPING ......................................................................................................... 21
CIRCULATING A IR AND FILTERS .................................................................................................................... 21
CHECKING DUCT STATIC ..................................................................................................................... 22
FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN A IR DUCTWORK ............................................ 22
UPRIGHT INSTALLATIONS ..................................................................................................................... 23
2
Table of Contents
CIRCULATION A IR FILTERS ................................................................................................................... 23
HORIZONTAL INSTALLATIONS ................................................................................................................ 23
S
TART-UP PROCEDURE A ND ADJUSTMENT ....................................................................................................... 23
HEAT A NTICIPATOR SETTING ................................................................................................................ 23
FURNACE OPERATION ......................................................................................................................... 23
GAS SUPPLY PRESSURE MEASUREMENT .................................................................................................. 23
AS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ....................................................................... 25
G
GAS INPUT RAT E M EASUREMENT (NATURAL GAS ONLY) ............................................................................ 25
T
EMPERATURE RISE ........................................................................................................................... 26
CIRCULATOR BLOWER SPEEDS ............................................................................................................. 26
BLOWER HEAT OFF DELAY TIMINGS ...................................................................................................... 28
COMFORTNET™ SYSTEM ......................................................................................................................... 29
OVERVIEW ....................................................................................................................................... 29
IFRLOW CONSIDERATIONS .................................................................................................................. 29
A F
OSSIL FUEL A PPLICATIONS ................................................................................................................ 30
CTK01AA WIRING .......................................................................................................................... 30
COMFORTNET SYSTEM A DVANCED FEATURES .......................................................................................... 30
NETWORK TROUBLESHOOTING ................................................................................................................ 33
SYSTEM TROUBLESHOOTING ................................................................................................................. 33
NORMAL SEQUENCE OF OPERATION .............................................................................................................. 34
POWER UP ...................................................................................................................................... 34
HEATING MODE ................................................................................................................................. 34
COOLING MODE ................................................................................................................................35
FAN ONLY MODE .............................................................................................................................. 35
OPERATIONAL CHECKS .............................................................................................................................. 35
SAFETY CIRCUIT D ESCRIPTION .................................................................................................................... 36
INTEGRATED C ONTROL MODULE ............................................................................................................. 36
PRIMARY LIMIT ................................................................................................................................36
AUXILIARY LIMIT ............................................................................................................................... 36
ROLLOUT LIMIT ................................................................................................................................36
PRESSURE SWITCHES ......................................................................................................................... 36
FLAME SENSOR ................................................................................................................................36
TROUBLESHOOTING ................................................................................................................................... 36
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................... 36
DIAGNOSTIC CHART........................................................................................................................... 36
FAULT RECALL ................................................................................................................................37
RESETTING FROM LOCKOUT ................................................................................................................ 37
MAINTENANCE ......................................................................................................................................... 37
ANNUAL INSPECTION ........................................................................................................................... 37
FILTERS .......................................................................................................................................... 37
BURNERS ......................................................................................................................................... 38
INDUCED DRAFT AND CIRCULATOR B LOWERS ............................................................................................ 38
FLAME SENSOR (QUALIFIED SERVICER ONLY) .......................................................................................... 38
FLUE PASSAGES (QUALIFIED SERVICER ONLY) ......................................................................................... 38
BEFORE LEAVING AN INSTALLATION ............................................................................................................... 38
REPAIR AND REPLACEMENT PARTS .............................................................................................................. 38
TROUBLESHOOTING CHART ......................................................................................................................... 39
STATUS CODES ....................................................................................................................................... 44
AIR FLOW DATA .................................................................................................................................... 45
DIP SWITCHES ........................................................................................................................................ 45
*MVC8___AA WIRING DIAGRAM ............................................................................................................. 46
*MVC8___AB, *DVC8___AA WIRING DIAGRAM ..................................................................................... 47
3
S
AFETY
P
RECAUTIONS
Adhere to the following warnings and cautions when install­ing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.
WARNING
TO
PREVENTPERSONALINJURYORDEATHDUETOIMPROPER
INSTALLATION,ADJUSTMENT,ALTERATION,SERVICEORMAINTENANCE
REFERTOTHISMANUAL
INFORMATION,CONSULTAQUALIFIEDINSTALLER,SERVICERAGENCYOR
THEGASSUPPLIER
.FOR
ADDITIONALASSISTANCEOR
.
WARNING
IF
THEINFORMATIONINTHESEINSTRUCTIONSISNOTFOLLOWED EXACTLY,AFIREOREXPLOSIONMAYRESULTCAUSINGPROPERTY DAMAGE
,
PERSONALINJURYORLOSSOFLIFE
DO
NOTSTOREORUSEGASO LINEOROTHERFLAMMABLEVAPORSAND
LIQUIDSINTHEVICINITYOFTHISORANYOTHERAPPLIANCE
.
.
WHATTODOIFYOUSMELLGAS:
D
ONOTTRYTOLIGHTANYAPPLIANCE
D
ONOTTOUCHANYELECTRICALSWITCH;DONOTUSEANYPHONE
INYOURBUILDING
I
MMEDIATELYCALLYOURGASSUPPLIERFROMANEIGHBOR’S
PHONE
.F
I
FYOUCANNOTREACHYOURGASSUPPLIER,CALLTHEFIRE
DEPARTMENT
I
NSTALLATIONANDSERVICEMUSTBEPERFORMEDBYAQUALIFIED
INSTALLER,SERVICEAGENCYORTHEGASSUPPLIER
.
OLLOWTHEGASSUPPLIER’SINSTRUCTIONS
.
.
.
.
,
CARBON MONOXIDE POISONING HAZARD
Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas
Carbon monoxide producing devices (such as an automobile, space heater, ga s water heate r, etc.) should not be operat ed 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 o perated 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 mono xide producing device continues to operat e in the enclo sed area. Carb on monoxide emissions ca n be (re)circu lated 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
T
HISPRODUCTCONTAINSORPRODUCESACHEMICALORCHEMICALS WHICHMAYCAUSESERIOUSILLNESSORDEATHANDWHICHARE KNOWNTOTHESTATEOFCALIFORNIATOCAUSECANCER,BIRTH DEFECTSOROTHERREPRODUCTIVEHARM
.
WARNING
H
EATINGUNITSHOULDNOTBEUTILIZEDWITHOUTREASONABLE
ROUTINE,INSPECTION,MAINTENANCEANDSUPERVISION
BUILDINGINWHICHANYSUCHDEVICEISLOCATEDWILLBEVACANT
CARESHOULDBETAKENTHATSUCHDEVICEISROUTINELYINSPECTED
MAINTAINEDANDMONITORED.INTHEEVENTTHATTHEBUILDING
MAYBEEXPOSEDTOFREEZINGTEMPERATURESANDWILLBEVACANT
ALLWATER‐BEARINGPIPESSHOULDBEDRAINED,THEBUILDINGSHOULD
BEPROPERLYWINTERIZED,ANDTHEWATERSOURCECLOSED.INTHE
EVENTTHATTHEBUILDINGMAYBEEXPOSEDTOFREEZING
TEMPERATURESANDWILLBEVACANT,ANYHYDRONICCOILUNITS
SHOULDBEDRAINEDASWELLAND,INSUCHCASE,ALTERNATIVEHEAT
SOURCESSHOULDBEUTILIZED
.
.IF
THE
,
,
,
,
WARNING
TO
PREVENTPOSSIBLEPROPERTYDAMAGE,PERSONALINJURYOR DEATHDUETOELECTRICALSHOCK,THEFURNACEMUSTBELOCATEDTO PROTECTTHEELECTRICALCOMPONENTSFROMWATER
.
WARNING
S
HOULDOVERHEATINGOCCURORTHEGASSUPPLYFAILTOSHUTOFF TURNOFFTHEMANUALGASSHUTOFFVALVEEXTERNALTOTHE FURNACEBEFORETURNINGOFFTHEELECTRICALSUPPLY
.
,
WARNING
P
OSSIBLEPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETO
FIRE,EXPLOSION,SMOKE,SOOT,CONDENSATION,ELECTRICALSHOCK
ORCARBO NMONOXIDEMAYRESULTFROMIMPROPERINSTALLATION
REPAIROPERATION,ORMAINTENANCEOFTHISPRODUCT
.
,
WARNING
TO
PREVENTPERSONALINJURYORDEATHDUETOIMPROPER
INSTALLATION,ADJUSTMENT,ALTERATION,SERVICEORMAINTENANCE
REFERTOTHISMANUAL
INFORMATION,CONSULTAQUALIFIEDINSTALLER,SERVICERAGENCYOR
THEGASSUPPLIER
.FOR
ADDITIONALASSISTANCEOR
.
,
WARNING
T
HISUNITMUSTNOTBEUSEDASA“CONSTRUCTIONHEATER”DURING
THEFINISHINGPHASESOFCONSTRUCTIONONANEWSTRUCTURE
TYPEOFUSEMAYRESU LTINPREMATUREFAILUREOFTHEUNITDUETO
EXTREMELYLOWRETU RNAIRTEMPERATURESANDEXPOSURETO
CORROSIVEORVERYDIRTYATMOSPHERES
.
.T
HIS
4
P
RODUCT
A
PPLICATION
WARNING
TO
PREVENTPERSONALINJURYORDEATHDUETOASPHYXIATION,THIS
FURNACEMUSTBECATEGORY
ATEGORY
C P
ROVISIONSMUSTBEMADEFORVENTINGCOMBUSTIONPRODUCTS
OUTDOORSTHROUGHAPROPERVENTINGSYSTEM
FLUEPIPECOULDBEALIMITINGFACTORINLOCATINGTHEFURNACE
III
VENTING
I
VENTED
.DO
NOTVENTUSING
.
.THE
LENGTHOF
.
ADDITIONAL S AFETY C ONSIDERATIONS
• 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 I NSPECTION
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.
The carrier is responsible for making prompt inspection of dam­age and for a thorough investigation of each claim. The distribu­tor or manufacturer will not accept claims from dealers for trans­portation damage.
Keep this literature in a safe place for future reference.
ELECTROSTATIC D ISCHARGE (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 T HE I NSTALLER
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.
IMPORTANT N OTE TO THE O WNER R EGARDING P RODUCT WARRANTY
Complete warranty details and instructions are available from your local dealer or at www.goodmanmfg.com and www.amana­hac.com. Your warranty certificate is supplied as a separate document with the unit installed by your contractor. Read the limited warranty certificate carefully to determine what is and is not covered and keep the warranty certificate in a safe place. If you are unable to locate the warranty certificate please contact your installing contractor or contact customer service (877-254-
4729) to obtain a copy.
To receive the Lifetime Heat Exchanger Limited Warranty, good for as long as you own your home, and the 10-year Parts Lim­ited Warranty, online registration must be completed within 60 days of installation. Online registration is not required in Cali­fornia or Quebec.
IMPORTANT: To register your Goodman brand unit, go to www.goodmanmfg.com. Click on the word “Warranty” located on the left side of the home page. Next, click on the word “Product Registration” located on the left side of the Warranty page and complete the forms in the manner indicated on the Product Registration page.
To register your Amana brand unit, go to www.amana-hac.com. Click on the word “Warranty” located on the top right of the
5
L
OCATION
R
EQUIREMENTS
AND
C
ONSIDERATIONS
home page. Next, click on the word “Product Registration” located on the left side of the Warranty page and complete the forms in the manner indicated on the Product Registration page.
Product limited warranty certificates for models currently in pro­duction can be viewed at hac.com. If your model is not currently in production or does not appear on the website, please contact your installing con­tractor or contact customer service at (877-254-4729) to obtain a copy of your warranty certificate.
Each product overview page contains a Product Warranty link; by clicking on it you will be able to view the limited warranty coverage for that specific product. To view warranty registration information, click on the Product Warranty text on the left navi­gation panel on the home page of each website. The Online Product Registration pages are located in this same section.
www.goodmanmfg.com or www.amana-
WARNING
TO
PREVENTPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETO FIRE,DONOTINSTALLTHISFURNACEINAMOBILEHOME,TRAILER,OR RECREATIONALVEHICLE
P
RODUCT DESCRIPTION
.
FEATURES
This furnace is a part of the ComfortNet™ family of products. The CTK01 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 VAC thermostat.
This product may also be installed with the ComfortNet ther­mostat and a non-ComfortNet compatible single stage air con­ditioning unit. However, this reduces the benefits of the ComfortNet system as the enhancements will only apply to the furnace.
• 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.
P
RODUCT APPLICATION
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:
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
TO
PREVENTPROPERTYDAMAGE,PERSONALINJURYORDEATHDUETO FIRE,DONOTINSTALLTHISFURNACEINAMOBILEHOME,TRAILER,OR RECREATIONALVEHICLE
6
.
L
OCATION
R
EQUIREMENTS
AND
C
ONSIDERATIONS
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 (NFPA 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 (NFPA 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 Valley
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
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.
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” (NFPA 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 NFPA 90B - Warm Air Heating and Air Conditioning System.
All venting shall be in accordance with PART 7, Venting 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.
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.
L
OCATION REQUIREMENTS AND CONSIDERATIONS
Your 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- ZONTAL OR UPFLOW INSTALLATIONS. For these models, use only the instructions for downflow installation only.
WARNING
TO
PREVENTPOSSIBLEEQUIPMENT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.
• 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
.
,
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OCATION
R
EQUIREMENTS
AND
C
ONSIDERATIONS
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 details). 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 Pipe Clearance to Combustibles­6" 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 A CCESSIBILITY
Unobstructed front clearance of 24" for servicing is recom- mended.
VENT
B1-VENT SINGLE
1" 6" 1" 3" 0" 1"
Top clearance for horizontal configuration - 1"
SIDES FRONT BACK
TOP
(PLENUM)
HORIZONTAL I NSTALLATION (*MVC8 MODELS O NLY)
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 TAKE 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 S USPENSION
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.
8
C
OMBUSTION
Suspended Furnace
& V
ENTILATION
C
ATEGORY
EXISTING F URNACE R EMOVAL
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. Test 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;
I V
ENTING
g. If improper venting is observed during any of the above
tests, the common venting system must be corrected.
Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 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.
AIR R
EQUIREMENTS
THERMOSTAT L OCATION
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.
C
OMBUSTION AND VENTILATION AIR REQUIREMENTS
WARNING
TO
AVOIDPROPERTYDAMAGE,PERSONALINJURYORDEATH
SUFFICIENTFRESHAIRFORPROPERCOMBUSTIONANDVENTILATIONOF
FLUEGASESMUSTBESUPPLIED
SUPPLIEDINTOTHEFURNACEAREA
Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing
.M
OSTHOMESREQUIREOUTSID EAIRBE
.
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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.
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.
C
ATEGORY
I V
ENTING
(V
ERTICAL VENTING
)
MINIM UM VENT
MODEL
UPFLOW COUNTERFLOW
70 4 inch 4 inch 90 4 inch 4 inch
115 5 inch 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 ROTATION.
Vent the furnace in accordance with the National Fuel Gas Code NFPA 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
WARNING
TO
PREVENTPOSSIBLEPERSONALINJURYORDEATHDUETO
ASPHYXIATION,THISFURNACEMUSTBECATEGORY
VENTUSINGCATEGORY
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 NFPA 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.
III
VENTING
.
I
VENTED
.DO
NOT
WARNING
TO
PREVENTPOSSIBLEPERSONALINJURYORDEATHDUETO
ASPHYXIATION,COMMONVENTINGWITHOTHERMANUFACTURER’S
INDUCEDDRAFTAPPLIANCESISNOTALLOWED
The minimum vent diameter for the Category I venting system is as shown:
.
THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORI­ZONTALLY VENTED.
To rotate the induced draft blower clockwise, you will need to purchase one (0270F01119) 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.
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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.
Counterflow units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” as viewed for a counterflow installation.)
Vent the furnace in accordance with the National Fuel Gas Code NFPA54/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.
WARNING
N
EVERALLOWTHEPRODUCTSOFCOMBUSTION,INCLUDINGCARBO N
MONOXIDE,TOENTERTHERETURNDUCTWORKORCIRCULATIONAIR
SUPPLY
.
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XTERIOR MASONRY CHIMNEYS
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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
Was h
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. Ve nt Connector
First Flo or
Water Heater Vent Connect or
Natural Draft Wate r Heat er
Basement Floor
CHECKLIST S UMMARY
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 check-
)
list to perform a yearly inspection of the furnace venting sys­tem.
This checklist is only a summary. For detailed 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.
P
OSSIBILITYOFPROPERTYDAMAGE,PERSONALINJURYORDEATH
DAMAGINGCONDENSATIONCANOCCURINSIDEMASONRYCHIMNEYS
WHENASINGLEFAN‐ASSISTEDCATEGORY
FURNACE)ISVENTEDWITHOUTADEQUATEDILUTIONAIR
CONNECTAN
FURNACEISCOMMONVENTEDWITHADRAFTHOODEQUIPPED
APPLIANCEORTHECHIMNEYISLINEDWITHAMETALLINERORTYPE
METALVENT
SIZEDINACCORDANCEWITHTHEAPPROPRIATEVENTINGTABLES
80%
APPLIANCE,THEPOTENTIALFORCONDENSATIONDAMAGEMAYSTILL
EXISTWITHEXTREMELYCOLDCONDITIONS,LONGVENTCONNECTORS
EXTERIORCHIMNEYS,ORANYCOMBINATIONOFTHESECONDITIONS
HERISKOFCONDENSATIONDAMAGEISBESTAVOIDEDBYUSING
T
MASONRYCHIMNEYASAPATHWAYFORPROPERLYSIZEDMETALLINER
ORTYPE
80%
FURNACETOAMASONRYCHIMNEYUNLESSTHE
.ALL
INSTALLATIONSUSINGMASONRYCHIMNEYSMUSTBE
FURNACEISCOMMO NVENTEDWITHADRAFTHOODEQUIPPED
B
METALVENT
.
I
APPLIANCE
(80%AFUE
.DO
NOT
.IFAN
.
B
 
,
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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)
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.
2' Min.
Wall or Parapet
Chimney
10' or Less
2' Min.
Chimney
3' Min.
3' Min.
Liner in good
condition?
(Check 5)
Dilution air
available? (Check 6)
Reline (Fix 4)
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.
Termination 10 Feet Or Less From Ridge, Wall or Parapet
More than 10’
3’ Min.
NOTE:
No Height
above parapet
Wall or Parapet
Ridge
Termination More Than 10 Feet From Ridge, Wall or Parapet
required when distance from walls or parape t is more than 10 feet.
More than 10’
Chimney
10’
2” Min.
Chimney
Height above any roof surface within 10 feet horiz ontally.
3’ Min.
CHECK 2 - ANY S OLID OR L IQUID F UEL A PPLIANCES V ENTED
THIS C HIMNEY C HANNEL
INTO
Solid fuel appliances include fireplaces, wood stoves, coal fur­naces, and incinerators.
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Liquid fuel appliances include oil furnaces, oil-fired boilers and oil-fired water heaters.
Appliances which burn propane (sometimes referred to as LP (liquefied petroleum)) gas are considered gas-fired appliances.
CHECK 3 - CHIMNEY C ROWN C ONDITION.
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.)
For problems a, b, or c, see Fix 3. If problems d, e, or f are present, see Fix 4. IMPORTANT: It may be necessary to follow both Fix 3 and Fix 4.
CHECK 4 - DEBRIS IN C LEANOUT.
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 C ONDITION.
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).
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 A IR.
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
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).
CHECK 7 - COMPLETE THE I NSTALLATION.
If Checks 1 through 6 have been satisfactory, and the liner is an acceptable size as determined by the tables in National Fuel
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ONNECTIONS
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 installer 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 T ERMINATION
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 V ENTING A RRANGEMENTS
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.
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 Vent.
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 C ROWN
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, Vents, 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. Sup­ports (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 Standard of Canada, CAN/CSA B149.1 and CAN/ CSA B149.2 - latest editions and amendments may be used.
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. Various 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).
For sizing of flexible liners, see Note 22 and the tables in the National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition
14
E
LECTRICAL
C
ONNECTIONS
and in the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments.
To install 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.
Finally, cap the chimney and terminate the liner in accordance with the liner manufacturer’s instructions.
E
LECTRICAL CONNECTIONS
WARNING
HIGHVOLTAGE!
TO
AVOIDTHERISKOFELECTRICALSHOCK,WIRINGTO
THEUNITMUSTBEPOLARIZEDANDGROUNDED
.
WARNING
HIGHVOLTAGE!
TO
AVOIDPERSONALINJURYORDEATHDUETO
ELECTRICALSHOCK,DISCONNECTELECTRICALPOWER
BEFORESERVICINGORCHANGINGANYELECTRICAL
WIRING
.
WARNING
HIGHVOLTAGE!
TO
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
N
.
WIRING H ARNESS
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 L INE C ONNECTIONS
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. To relocate the junction box, follow the steps shown below.
NOTE: Wire routing must not to interfere with circulator blower operation, filter removal, or routine maintenance.
CAUTION
L
ABELALLWIRESPRIORTODISCONNECTIONWHENSERVICING
CONTROLS
OPERATION
.W
IRINGERRORSCANCAUSEIMPROPERANDDANGEROUS
.V
ERIFYPROPEROPERATIONAFTERSERVICING
.
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