Heat Controller GLUA90-E4B, GLUA60-E3B, GLUA75-E3C, GLUA75-E4C, GLUA90-E5B Installation Instructions Manual
...
ISO 9001:2008
HEAT CONTROLLER
INSTALLATION INSTRUCTIONS
FOR HIGH EFFICIENCY CONDENSING GAS FURNACES
GLUA UPFLOW SERIES
GLDH DOWNFLOW/HORIZONTAL SERIES
Upflow Models Downflow/Horizontal Models
Model Number Input (Btu) Tons Model Number Input (Btu) Tons
GLUA45-E3B 45,000 3 GLDH45-E3B 45,000 3
GLUA60-E3B 60,000 3 GLDH60-E3B 60,000 3
GLUA75-E3C 75,000 3 GLDH75-E3B 75,000 3
GLUA75-E4C 75,000 4 GLDH75-E4B 75,000 4
GLUA90-E4B 90,000 4 GLDH90-E4B 90,000 4
GLUA90-E5B 90,000 5 GLDH90-E5B 90,000 4.5
GLUA105-E5B 105,000 4.5 GLDH105-E5B 105,000 4.5
GLUA120-E5B 120,000 5 GLDH120-E5B 120,000 5
U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all
applications, and their installation should be in accordance with the manufacturer’s
recommendations and/or local laws, rules, regulations, or customs.
SUPERSEDES 92-24161-70-06
92-24161-70-07
INSTALLATION CHECK LIST
REFER TO INSTALLATION INSTRUCTIONS
GAS SUPPLY
Adequate pipe size
orrect supply pressure (during furnace operation)
C
Manifold pressure
No gas leaks
L.P. Kit Number (if applicable)
ELECTRICAL
115 V.A.C. supply (Single Circuit)
Polarity observed
Furnace properly grounded
Adequate wire size
FURNACE INSTALLATION
Adequate clearance to combustibles
Adequate clearance for service (at front)
DUCT STATIC PRESSURE
in. w.c. on heating speed
in. w.c. on cooling speed
Air temperature rise
TERMINATIONS – DIRECT VENT
VERTICAL
Intake – 12" min. above roof/snow level
orrect relationship – exhaust to intake
C
HORIZONTAL/VERTICAL – CONCENTRIC (RXGY-E03A)
Intake – 12" min. above roof/snow level
Intake “Y” rotated above center
Exhaust sloped toward furnace
HORIZONTAL – STANDARD (RXGY-D02, -D02A, -D03,
-D03A)
Correct relationship – exhaust to intake
12" min. above grade/snow level
HORIZONTAL – ALTERNATE (RXGY-D02, -D02A, -D03,
-D03A, -D04 OR -D04A)
Correct relationship – exhaust to intake
Above anticipated snow level
VENTING – NON-DIRECT VENT
in. diameter – exhaust pipe
ft. of pipe – exhaust
CONDENSATE LINE
Trap filled with water
Vented
Sloped toward drain
Condensate drain line hoses connected
and clamped
Freeze protection (if necessary)
VENTING – DIRECT VENT
in. diameter – intake pipe
in. diameter – exhaust pipe
ft. of pipe – intake air
no. of elbows – intake air
ft. of pipe – exhaust pipe
no. of elbows – exhaust pipe
Exhaust vent temp.
no. of elbows
TERMINATION – NON-DIRECT VENT
VERTICAL
12" min. above roof/snow level
HORIZONTAL – STANDARD
12" min. above grade/snow level
HORIZONTAL – ALTERNATE
Above anticipated snow level
Model Number
Serial #
Date of Installation
2
IMPORTANT: All manufacturer
products meet current Federal OSHA
Guidelines for safety. California
Proposition 65 warnings are required
for certain products, which are not
covered by the OSHA standards.
California's Proposition 65 requires
arnings for products sold in California
w
that contain, or produce, any of over
600 listed chemicals known to the State
f California to cause cancer or birth
o
defects such as fiberglass insulation,
lead in brass, and combustion products
rom natural gas.
f
All “new equipment” shipped for sale in
California will have labels stating that
the product contains and/or produces
Proposition 65 chemicals. Although we
have not changed our processes,
having the same label on all our
products facilitates manufacturing and
shipping. We cannot always know
“when, or if” products will be sold in the
California market.
You may receive inquiries from
customers about chemicals found in, or
produced by, some of our heating and
air-conditioning equipment, or found in
natural gas used with some of our
products. Listed below are those
chemicals and substances commonly
associated with similar equipment in
our industry and other manufacturers.
• Glass Wool (Fiberglass) Insulation
• Carbon Monoxide (CO)
• Formaldehyde
• Benzene
More details are available at the
Websites for OSHA (Occupational
Safety and Health Administration), at
www.osha.gov
California's OEHHA (Office of
Environmental Health Hazard
Assessment), at www.oehha.org.
Consumer education is important since
the chemicals and substances on the
list are found in our daily lives. Most
consumers are aware that products
present safety and health risks, when
improperly used, handled and
maintained.
and the State of
CONTENTS
afety Precautions ...................................................................................................1
S
Installation Check List ............................................................................................2
Safety Information ..................................................................................................4
General Information ...............................................................................................9
Location Requirements and Considerations ........................................................11
Ducting.................................................................................................................16
Venting and Combustion Air Piping .....................................................................17
Combustion and Ventilation Air............................................................................19
Vent Pipe Installation ...........................................................................................22
Condensate Drain/Neutralizer..............................................................................35
Gas Supply and Piping ........................................................................................40
Electrical Wiring ...................................................................................................45
Accessories..........................................................................................................46
Furnace Twinning ................................................................................................46
High Altitude Instructions .....................................................................................47
Start-Up Procedures ............................................................................................50
Air Flow ................................................................................................................52
Maintenance ........................................................................................................55
Troubleshooting ...................................................................................................58
Wiring Diagram ...............................................................................................59-60
IMPORTANT: TO INSURE PROPER INSTALLATION AND OPERATION OF
THIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TO
ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIR
THIS PRODUCT. UPON UNPACKING OF THE FURNACE, INSPECT ALL
PARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.
3
SAFETY INFORMATION
WARNING
!
USE ONLY WITH TYPE OF GAS
APPROVED FOR THIS FURNACE.
REFER TO THE FURNACE RATING
PLATE.
WARNING
!
NSTALL THIS FURNACE ONLY IN
I
LOCATION AND POSITION AS
A
PECIFIED IN THE LOCATION
S
EQUIREMENTS AND
R
ONSIDERATIONS SECTION OF
C
HESE INSTRUCTIONS. PROVIDE
T
DEQUATE COMBUSTION AND
A
VENTILATION AIR TO THE
FURNACE SPACE AS SPECIFIED
IN THE VENTING SECTION OF
THESE INSTRUCTIONS.
WARNING
!
PROVIDE ADEQUATE
COMBUSTION AND VENTILATION
AIR TO THE FURNACE SPACE AS
SPECIFIED IN THE COMBUSTION
AND VENTILATION AIR SECTION
OF THESE INSTRUCTIONS.
WARNING
!
COMBUSTION PRODUCTS MUST
BE DISCHARGED OUTDOORS.
CONNECT THIS FURNACE TO AN
APPROVED VENT SYSTEM ONLY,
AS SPECIFIED IN VENT PIPE
INSTALLATION SECTION OF
THESE INSTRUCTIONS.
WARNING
!
DO NOT OPERATE THE SYSTEM
FOR EXTENDED PERIODS
WITHOUT FILTERS. A PORTION
OF THE DUST ENTRAINED IN THE
AIR MAY TEMPORARILY LODGE
IN THE AIR DUCT RUNS AND AT
THE SUPPLY REGISTERS. ANY
CIRCULATED DUST PARTICLES
WILL BE HEATED AND CHARRED
BY CONTACT WITH THE
FURNACE HEAT EXCHANGER.
THIS SOOTY RESIDUE WILL SOIL
CEILINGS, WALLS, DRAPES,
CARPETS AND OTHER
HOUSEHOLD ARTICLES. SOOT
DAMAGE MAY ALSO RESULT
WITH, OR WITHOUT, FILTERS IN
PLACE, WHEN CERTAIN TYPES
OF CANDLES ARE BURNED, OR
CANDLEWICKS ARE LEFT
UNTRIMMED.
WARNING
!
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 THESE
INSTRUCTIONS.
WARNING
!
ALWAYS INSTALL FURNACE TO
OPERATE WITHIN THE
FURNACE'S INTENDED
TEMPERATURE-RISE RANGE
WITH A DUCT SYSTEM WHICH
HAS AN EXTERNAL STATIC
PRESSURE WITHIN THE
ALLOWABLE RANGE, AS
SPECIFIED IN DUCTING SECTION
OF THESE INSTRUCTIONS. SEE
ALSO FURNACE RATING PLATE.
WARNING
!
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.
WARNING
!
DO NOT INSTALL THIS FURNACE
IN A MOBILE HOME!! THIS
FURNACE IS NOT APPROVED
FOR INSTALLATION IN A MOBILE
HOME. DOING SO COULD CAUSE
FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
WARNING
!
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.
WARNING
!
WHEN THIS FURNACE IS
INSTALLED IN A RESIDENTIAL
GARAGE, IT MUST BE INSTALLED
SO THE BURNERS AND IGNITION
SOURCE ARE LOCATED NO LESS
THAN 18 INCHES ABOVE THE
FLOOR. THIS IS TO REDUCE THE
RISK OF IGNITING FLAMMABLE
VAPORS WHICH MAY
BE PRESENT IN A GARAGE.
ALSO, THE FURNACE MUST BE
LOCATED OR PROTECTED TO
AVOID PHYSICAL DAMAGE BY
VEHICLES. FAILURE TO FOLLOW
THESE WARNINGS CAN CAUSE A
FIRE OR EXPLOSION, RESULTING
IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
WARNING
!
INSTALLATION MUST COMPLY
WITH ALL INSTALLATION
INSTRUCTIONS INCLUDING:
• PROPER VENT INSTALLATION;
• FURNACE OPERATING UNDER
THERMOSTATIC CONTROL;
• RETURN AIR DUCT SEALED TO
THE FURNACE;
• AIR FILTERS IN PLACE;
• SET FURNACE INPUT RATE
AND TEMPERATURE RISE PER
RATING PLATE MARKING;
• MEANS FOR PROVIDING
OUTDOOR AIR REQUIRED FOR
COMBUSTION;
• RETURN AIR TEMPERATURE
MAINTAINED BETWEEN 55°F
(13°C) AND 80°F (27°C); AND
• CLEAN FURNACE, DUCT WORK
AND COMPONENTS UPON
SUBSTANTIAL COMPLETION OF
THE CONSTRUCTION
PROCESS, AND VERIFY
FURNACE OPERATING
CONDITIONS INCLUDING
IGNITION, INPUT RATE,
TEMPERATURE RISE AND
VENTING, ACCORDING TO THE
INSTRUCTIONS.
4
WARNING
!
IF THE INFORMATION IN THESE
INSTRUCTIONS IS NOT
FOLLOWED EXACTLY, A FIRE OR
EXPLOSION MAY RESULT,
CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
WARNING
!
THESE INSTRUCTIONS ARE
INTENDED AS AN AID TO
QUALIFIED SERVICE PERSONNEL
FOR PROPER INSTALLATION,
ADJUSTMENT AND OPERATION
OF THIS UNIT. READ THESE
INSTRUCTIONS THOROUGHLY
BEFORE ATTEMPTING
INSTALLATION OR OPERATION.
FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN
IMPROPER INSTALLATION,
ADJUSTMENT, SERVICE OR
MAINTENANCE, POSSIBLY
RESULTING IN FIRE, ELECTRICAL
SHOCK, CARBON MONOXIDE
POISONING, EXPLOSION,
PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
WARNING
!
PROPOSITION 65 WARNING: THIS
PRODUCT CONTAINS CHEMICALS
KNOWN TO THE STATE OF
CALIFORNIA TO CAUSE CANCER,
BIRTH DEFECTS OR OTHER
REPRODUCTIVE HARM.
WARNING
!
– DO NOT STORE OR USE
GASOLINE OR OTHER
FLAMMABLE VAPORS AND
LIQUIDS, OR OTHER
COMBUSTIBLE MATERIALS IN
THE VICINITY OF THIS OR ANY
OTHER APPLIANCE.
– WHAT TO DO IF YOU SMELL GAS
• DO NOT TRY TO LIGHT ANY
APPLIANCE.
• DO NOT TOUCH ANY
ELECTRICAL SWITCH; DO NOT
USE ANY PHONE IN YOUR
BUILDING.
• IMMEDIATELY CALL YOUR GAS
SUPPLIER FROM A
NEIGHBOR’S PHONE. FOLLOW
THE GAS SUPPLIER’S
INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR
GAS SUPPLIER, CALL THE FIRE
DEPARTMENT.
• DO NOT RETURN TO YOUR
HOME UNTIL AUTHORIZED BY
THE GAS SUPPLIER OR FIRE
DEPARTMENT.
– DO NOT RELY ON SMELL ALONE
TO DETECT LEAKS. DUE TO
VARIOUS FACTORS, YOU MAY
NOT BE ABLE TO SMELL FUEL
GASES.
• U.L. RECOGNIZED FUEL GAS
AND CO (CARBON MONOXIDE)
DETECTORS ARE
RECOMMENDED IN ALL
APPLICATIONS, AND THEIR
INSTALLATION SHOULD BE IN
ACCORDANCE WITH THE
MANUFACTURER’S
RECOMMENDATIONS AND/OR
LOCAL LAWS, RULES,
REGULATIONS, OR CUSTOMS.
– IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION,
SERVICE OR MAINTENANCE
CAN CAUSE INJURY, PROPERTY
DAMAGE OR DEATH. REFER TO
THIS MANUAL. INSTALLATION
AND SERVICE MUST BE
PERFORMED BY A QUALIFIED
INSTALLER, SERVICE AGENCY
OR THE GAS SUPPLIER. IN THE
COMMONWEALTH OF
MASSACHUSETTS,
INSTALLATION MUST BE
PERFORMED BY A LICENSED
PLUMBER OR GAS FILTER FOR
APPROPRIATE FUEL.
WARNING
!
DUCT LEAKS CAN CREATE AN
UNBALANCED SYSTEM AND
DRAW POLLUTANTS SUCH AS
DIRT, DUST, FUMES AND ODORS
INTO THE HOME CAUSING
PROPERTY DAMAGE. FUMES AND
ODORS FROM TOXIC, VOLATILE
OR FLAMMABLE CHEMICALS, AS
WELL AS AUTOMOBILE EXHAUST
AND CARBON MONOXIDE (CO),
CAN BE DRAWN INTO THE LIVING
SPACE THROUGH LEAKING
DUCTS AND UNBALANCED DUCT
SYSTEMS CAUSING PERSONAL
INJURY OR DEATH (SEE FIGURE
3).
• IF AIR-MOVING EQUIPMENT OR
DUCTWORK IS LOCATED IN
GARAGES OR OFF-GARAGE
STORAGE AREAS - ALL JOINTS,
SEAMS, AND OPENINGS IN THE
EQUIPMENT AND DUCT MUST
BE SEALED TO LIMIT THE
MIGRATION OF TOXIC FUMES
AND ODORS INCLUDING
CARBON MONOXIDE FROM
MIGRATING INTO THE LIVING
SPACE.
• IF AIR-MOVING EQUIPMENT OR
DUCTWORK IS LOCATED IN
SPACES CONTAINING FUEL
BURNING APPLIANCES SUCH AS
WATER HEATERS OR BOILERS ALL JOINTS, SEAMS, AND
OPENINGS IN THE EQUIPMENT
AND DUCT MUST ALSO BE
SEALED TO PREVENT
DEPRESSURIZATION OF THE
SPACE AND POSSIBLE
MIGRATION OF COMBUSTION
BYPRODUCTS INCLUDING
CARBON MONOXIDE INTO THE
LIVING SPACE.
NOTICE
!
IN COMPLIANCE WITH
RECOGNIZED CODES, IT IS
RECOMMENDED THAT AN
AUXILIARY DRAIN PAN BE
INSTALLED UNDER ALL
EVAPORATOR COILS OR UNITS
CONTAINING EVAPORATOR COILS
OR GAS FURNACES USED WITH
EVAPORATOR COILS THAT ARE
LOCATED IN ANY AREA OF A
STRUCTURE WHERE DAMAGE TO
THE BUILDING OR BUILDING
CONTENTS MAY OCCUR AS A
RESULT OF AN OVERFLOW OF
THE COIL DRAIN PAN OR A
STOPPAGE IN THE PRIMARY
CONDENSATE DRAIN PIPING.
5
NOTICE
!
IMPROPER INSTALLATION, OR
INSTALLATION NOT MADE IN
ACCORDANCE WITH THE CSA
INTERNATIONAL (CSA)
CERTIFICATION OR THESE
INSTRUCTIONS, CAN RESULT IN
UNSATISFACTORY OPERATION
AND/OR DANGEROUS CONDITIONS AND ARE NOT COVERED
BY THE UNIT WARRANTY.
WARNING
!
DO NOT USE THIS FURNACE
DURING CONSTRUCTION IF AIR
LADEN CORROSIVE COMPOUNDS
ARE PRESENT SUCH AS
CHLORINE AND FLUORINE.
OTHERWISE, PROVISIONS MUST
BE TAKEN TO PROVIDE CLEAN,
UNCONTAMINATED COMBUSTION
AND VENTILATION AIR TO THE
FURNACE. FURNACE
COMBUSTION AND VENTILATION
AIR CONTAMINATED WITH THESE
COMPOUNDS FORMS ACIDS
DURING COMBUSTION WHICH
CORRODES THE HEAT
EXCHANGER AND COMPONENT
PARTS. SOME OF THESE
CONTAMINANTS ARE FOUND IN,
BUT NOT LIMITED TO, PANELING,
DRY WALL, ADHESIVES, PAINTS,
STAINS, VARNISHES, SEALERS,
AND MASONRY CLEANING
MATERIALS.
WARNING
!
DO NOT INSTALL THIS FURNACE
IN A MOBILE HOME!! This furnace
is not approved for installation in a
mobile home. Doing so could cause
FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
WARNING
!
WHEN THIS FURNACE IS
INSTALLED IN A RESIDENTIAL
GARAGE, IT MUST BE INSTALLED
SO THE BURNERS AND IGNITION
SOURCE ARE LOCATED NO LESS
THAN 18 INCHES ABOVE THE
FLOOR. THIS IS TO PREVENT
THE RISK OF IGNITING
FLAMMABLE VAPORS WHICH
MAY BE PRESENT IN A GARAGE.
ALSO, THE FURNACE MUST BE
LOCATED OR PROTECTED TO
AVOID PHYSICAL DAMAGE BY
VEHICLES. FAILURE TO FOLLOW
THESE WARNINGS CAN CAUSE A
FIRE OR EXPLOSION, RESULTING
IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
WARNING
!
PFLOW AND HORIZONTAL
U
URNACES ARE DESIGN-
F
ERTIFIED FOR INSTALLATION
C
N COMBUSTIBLE FLOORS.
O
OTE, HOWEVER, THAT
N
URNACES MUST NOT BE
F
NSTALLED DIRECTLY ON
I
ARPETING, TILE OR OTHER
C
OMBUSTIBLE MATERIAL OTHER
C
HAN WOOD FLOORING.
T
NSTALLATION ON A
I
OMBUSTIBLE MATERIAL CAN
C
ESULT IN FIRE, CAUSING
R
ROPERTY DAMAGE, PERSONAL
P
NJURY OR DEATH.
I
WARNING
!
DO NOT LIFT THE UNIT BY THE
HEAT EXCHANGER TUBES.
DOING SO CAN CRACK THE HEAT
EXCHANGER ASSEMBLY AND
CAUSE CO2 TO BE RELEASED
INTO THE ENVIRONMENT, WHICH
CAN RESULT IN PERSONAL
INJURY OR DEATH.
WARNING
!
COMBUSTIBLE MATERIAL MUST
NOT BE PLACED ON OR AGAINST
THE FURNACE JACKET. THE AREA
AROUND THE FURNACE MUST BE
KEPT CLEAR AND FREE OF ALL
COMBUSTIBLE MATERIALS
INCLUDING GASOLINE AND
OTHER FLAMMABLE VAPORS AND
LIQUIDS. PLACEMENT OF
COMBUSTIBLE MATERIALS ON,
AGAINST OR AROUND THE
FURNACE JACKET CAN CAUSE
AN EXPLOSION OR FIRE
RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY OR
DEATH. THE HOMEOWNER
SHOULD BE CAUTIONED THAT
THE FURNACE AREA MUST NOT
BE USED AS A BROOM CLOSET
OR FOR ANY OTHER STORAGE
PURPOSES.
WARNING
!
EVER ALLOW THE PRODUCTS
N
F COMBUSTION FROM THE
O
LUE TO ENTER THE RETURN AIR
F
UCTWORK OR THE CIRCULATED
D
IR SUPPLY. ALL RETURN
A
UCTWORK MUST BE
D
DEQUATELY SEALED AND
A
ECURED TO THE FURNACE
S
ITH SHEET METAL SCREWS;
W
ND JOINTS, TAPED. ALL OTHER
A
UCT JOINTS MUST BE SECURED
D
ITH APPROVED CONNECTIONS
W
ND SEALED AIRTIGHT. WHEN
A
N UPFLOW FURNACE IS
A
OUNTED ON A PLATFORM WITH
M
ETURN THROUGH THE BOTTOM,
R
T MUST BE SEALED AIRTIGHT
I
ETWEEN THE FURNACE AND
B
THE RETURN AIR PLENUM. THE
FLOOR OR PLATFORM MUST
PROVIDE SOUND PHYSICAL
SUPPORT OF THE FURNACE
WITHOUT SAGGING, CRACKS, OR
GAPS, AROUND THE BASE,
PROVIDING A SEAL BETWEEN
THE SUPPORT AND THE BASE.
FAILURE TO PREVENT
PRODUCTS OF COMBUSTION
FROM BEING CIRCULATED INTO
THE LIVING SPACE CAN CREATE
POTENTIALLY HAZARDOUS
CONDITIONS, INCLUDING
CARBON MONOXIDE POISONING
THAT COULD RESULT IN
PERSONAL INJURY OR DEATH.
DO NOT, UNDER ANY
CIRCUMSTANCES, CONNECT
RETURN OR SUPPLY DUCTWORK
TO OR FROM ANY OTHER HEAT
PRODUCING DEVICE SUCH AS A
FIREPLACE INSERT, STOVE, ETC.
DOING SO MAY RESULT IN FIRE,
CARBON MONOXIDE POISONING,
EXPLOSION, PERSONAL INJURY
OR PROPERTY DAMAGE.
WARNING
!
UPFLOW FURNACE: A SOLID
METAL BASE PLATE MUST BE
INSTALLED IN THE FURNACE
BOTTOM WHEN USING SIDE
RETURN. FAILURE TO INSTALL A
BASE PLATE COULD CAUSE THE
PRODUCTS OF COMBUSTION TO
CIRCULATE INTO THE LIVING
SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS,
INCLUDING CARBON MONOXIDE
POISONING OR DEATH.
CAUTION
!
If this furnace is installed in a
garage, attic and/or any
unconditioned space, install a selfregulating heat tape around the
condensate trap and along the
entire length of the condensate
drain in the unconditioned space.
See Figure 4.
6
WARNING
!
THE DOWNFLOW FURNACE
DESIGN IS CERTIFIED FOR
INSTALLATION ON A NONCOMBUSTIBLE FLOOR. USE THE
SPECIAL BASE SPECIFIED ON
THE FURNACE CLEARANCE
LABEL. FAILURE TO INSTALL THE
SPECIAL BASE MAY RESULT IN
FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
THIS SPECIAL BASE IS SHIPPED
FROM THE FACTORY AS AN
ACCESSORY.
WARNING
!
READ AND FOLLOW ALL
INSTRUCTIONS IN THIS SECTION.
FAILURE TO PROPERLY VENT
THIS FURNACE CAN CAUSE
CARBON MONOXIDE POISONING
OR AN EXPLOSION OR FIRE,
RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY
OR DEATH.
WARNING
!
IN CANADA, PRODUCTS CERTIFIED
FOR INSTALLATION AND
INTENDED TO BE VENTED WITH
PLASTIC VENT SYSTEMS (PVC,
CPVC) MUST USE VENT SYSTEMS
THAT ARE CERTIFIED TO THE
STANDARD FOR TYPE BH GAS
VENTING SYSTEMS, ULC S636.
THE COMPONENTS OF THE
CERTIFIED MATERIAL MUST NOT
BE INTERCHANGED WITH OTHER
VENT SYSTEMS OR UNLISTED
PIPE/FITTINGS.
PLASTIC COMPONENTS AND
SPECIFIED PRIMERS AND GLUES
OF THE CERTIFIED SYSTEM MUST
BE FROM A SINGLE SYSTEM
MANUFACTURER AND NOT
INTERMIXED WITH OTHER SYSTEM
MANUFACTURER’S PARTS.
WARNING
!
DO NOT JUMPER THESE DEVICES!
IF ONE OF THESE SWITCHES
SHOULD TRIP, A QUALIFIED
INSTALLER, SERVICE AGENCY OR
THE GAS SUPPLIER MUST BE
CALLED TO CHECK AND/OR
CORRECT FOR ADEQUATE
COMBUSTION AIR SUPPLY. DO
NOT RESET THE SWITCHES
WITHOUT TAKING CORRECTIVE
ACTION TO ASSURE THAT AN
ADEQUATE SUPPLY OF
COMBUSTION AIR IS MAINTAINED
UNDER ALL CONDITIONS OF
OPERATION. FAILURE TO DO SO
CAN RESULT IN CARBON
MONOXIDE POISONING OR
DEATH. IF THIS UNIT IS MOUNTED
IN A CLOSET, THE DOOR MUST BE
CLOSED WHEN MAKING THIS
CHECK.
REPLACE THESE SWITCHES
ONLY WITH THE IDENTICAL
REPLACEMENT PART.
WARNING
!
VC SOLVENT CEMENTS AND
P
RIMERS ARE HIGHLY
P
LAMMABLE. PROVIDE
F
DEQUATE VENTILATION AND DO
A
OT ASSEMBLE NEAR HEAT
N
OURCE OR AN OPEN FLAME. DO
S
OT SMOKE. AVOID SKIN OR EYE
N
ONTACT. OBSERVE ALL
C
AUTIONS AND WARNINGS
C
RINTED ON MATERIAL
P
ONTAINERS. FAILURE TO
C
OLLOW THESE GUIDELINES MAY
F
ESULT IN FIRE, EXPLOSION OR
R
SPHYXIATION CAUSING
A
ERSONAL INJURY OR DEATH.
P
WARNING
!
THE FURNACE AND ANY OTHER
FUEL-BURNING APPLIANCE MUST
BE PROVIDED WITH ENOUGH
FRESH AIR FOR PROPER
COMBUSTION AND VENTILATION
OF THE FLUE GASES. MOST
HOMES WILL REQUIRE THAT
OUTSIDE AIR BE SUPPLIED INTO
THE FURNACE AREA. FAILURE
TO DO SO CAN CAUSE
PERSONAL INJURY OR DEATH
FROM CARBON MONOXIDE
POISONING.
WARNING
!
ALL FURNACE INSTALLATIONS
MUST COMPLY WITH THE
NATIONAL FUEL GAS CODE AND
LOCAL CODES TO PROVIDE
ADEQUATE COMBUSTION AND
VENTILATION AIR FOR THE
FURNACE. FAILURE TO DO SO
CAN RESULT IN EXPLOSION,
FIRE, PROPERTY DAMAGE,
CARBON MONOXIDE POISONING,
PERSONAL INJURY OR DEATH.
CAUTION
!
MOISTURE IN THE COMBUSTION
PRODUCTS CONDENSES AS IT
LEAVES THE TERMINATION. THIS
CONDENSATE CAN FREEZE ON
EXTERIOR WALLS, UNDER THE
EAVES, AND ON SURROUNDING
OBJECTS. SOME DISCOLORATION
IS TO BE EXPECTED. HOWEVER,
IMPROPER LOCATION OR
INSTALLATION CAN CAUSE
STRUCTURAL OR EXTERIOR
FINISH DAMAGE TO THE
BUILDING.
WARNING
!
READ AND FOLLOW ALL
INSTRUCTIONS IN THIS SECTION.
FAILURE TO PROPERLY VENT
THIS FURNACE CAN CAUSE
CARBON MONOXIDE POISONING
OR AN EXPLOSION OR FIRE,
RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY
OR DEATH.
CAUTION
!
THE COMBUSTION PRODUCTS
AND MOISTURE IN THE FLUE
GASES WILL CONDENSE AS THEY
LEAVE THE TERMINATION. THE
CONDENSATE CAN FREEZE ON
THE EXTERIOR WALL, UNDER THE
EAVES AND ON SURROUNDING
OBJECTS. SOME DISCOLORATION
TO THE EXTERIOR OF THE
BUILDING IS TO BE EXPECTED.
HOWEVER, IMPROPER LOCATION
OR INSTALLATION CAN RESULT IN
STRUCTURAL OR EXTERIOR
FINISH DAMAGE TO THE BUILDING
AND MAY RECIRCULATE
PRODUCTS OF COMBUSTION INTO
THE COMBUSTION AIR TERMINAL
AND FREEZE.
CAUTION
!
DO NOT RUN DRAIN OUTDOORS.
FREEZING OF CONDENSATE CAN
CAUSE PROPERTY DAMAGE.
WARNING
!
THIS FURNACE IS EQUIPPED AT
THE FACTORY FOR USE ON
NATURAL GAS ONLY.
CONVERSION TO LP GAS
REQUIRES A SPECIAL KIT
SUPPLIED BY THE DISTRIBUTOR
OR MANUFACTURER. MAILING
ADDRESS IS LISTED ON THE
WARRANTY. FAILURE TO USE
THE PROPER CONVERSION KIT
CAN CAUSE FIRE, CARBON
MONOXIDE POISONING,
EXPLOSION, PROPERTY
DAMAGE, PERSONAL INJURY OR
DEATH. See the conversion kit
index supplied with the furnace.
This index identifies the proper LP
Gas Conversion Kit required for
each particular furnace.
CAUTION
!
ELEVATIONS ABOVE 2000 FT
REQUIRE THAT THE FURNACE
INPUT RATING BE ADJUSTED
AND THAT THE SIZE OF THE
BURNER ORIFICES BE RECALCULATED BASED ON
ELEVATION AND GAS HEATING
VALUE. THE BURNER ORIFICES
MAY (OR MAY NOT) NEED TO BE
CHANGED. SEE THE SECTION
TITLED “HIGH ALTITUDE
INSTALLATIONS” OF THIS BOOK
FOR INSTRUCTIONS.
WARNING
!
NEVER PURGE A GAS LINE INTO
THE COMBUSTION CHAMBER.
NEVER USE MATCHES, FLAME OR
ANY IGNITION SOURCE FOR
CHECKING LEAKAGE. FAILURE
TO ADHERE TO THIS WARNING
CAN CAUSE A FIRE OR
EXPLOSION RESULTING IN
PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
7
CAUTION
!
LEVATIONS ABOVE 2000 FT
E
EQUIRE THAT THE FURNACE
R
NPUT RATING BE ADJUSTED
I
ND THAT THE SIZE OF THE
A
URNER ORIFICES BE RE-
B
ALCULATED BASED ON
C
LEVATION AND GAS HEATING
E
ALUE. THE BURNER ORIFICES
V
AY (OR MAY NOT) NEED TO BE
M
HANGED. SEE THE SECTION
C
ITLED “HIGH ALTITUDE
T
NSTALLATIONS” OF THIS BOOK
I
OR INSTRUCTIONS.
F
WARNING
!
TURN OFF ELECTRIC POWER AT
FUSE BOX OR SERVICE PANEL
BEFORE MAKING ANY
ELECTRICAL CONNECTIONS.
FAILURE TO DO SO CAN CAUSE
ELECTRICAL SHOCK RESULTING
IN PERSONAL INJURY OR DEATH.
WARNING
!
THE CABINET MUST HAVE AN
UNINTERRUPTED GROUND
ACCORDING TO THE LATEST
EDITION OF THE NATIONAL
ELECTRICAL CODE, ANSI/
NFPA70- OR IN CANADA, THE
CANADIAN ELECTRICAL CODE,
CSA-C221 OR LOCAL CODES
THAT APPLY. DO NOT USE GAS
PIPING AS AN ELECTRICAL
GROUND. A GROUND SCREW IS
PROVIDED IN THE JUNCTION
BOX. FAILURE TO DO SO CAN
CAUSE ELECTRICAL SHOCK
RESULTING IN PERSONAL
INJURY OR DEATH.
WARNING
!
THIS FURNACE IS EQUIPPED
WITH A BLOWER DOOR SAFETY
SWITCH. DO NOT DISABLE THIS
SWITCH. FAILURE TO FOLLOW
THIS WARNING CAN RESULT IN
ELECTRICAL SHOCK, PERSONAL
INJURY OR DEATH.
CAUTION
!
INSTALLATION OF THIS FURNACE
AT ALTITUDES ABOVE 2000 FT
(610 m) SHALL BE IN
ACCORDANCE WITH LOCAL
CODES, OR IN THE ABSENCE OF
LOCAL CODES, THE NATIONAL
FUEL GAS CODE, ANSI
Z223.1/NFPA 54 OR NATIONAL
STANDARD OF CANADA,
NATURAL GAS AND PROPANE
INSTALLATION CODE, CAN
B149.1.
INSTALLATION OF THIS
APPLIANCE AT OR ABOVE 5000
FT (1525 M) SHALL BE MADE IN
ACCORDANCE WITH THE LISTED
HIGH ALTITUDE CONVERSION KIT
AVAILABLE WITH THIS FURNACE.
CAUTION
!
ELEVATIONS ABOVE 2000 FT
REQUIRE THAT THE FURNACE
INPUT RATING BE ADJUSTED
AND THAT THE SIZE OF THE
BURNER ORIFICES BE RECALCULATED BASED ON
ELEVATION AND GAS HEATING
VALUE. THE BURNER ORIFICES
MAY (OR MAY NOT) NEED TO BE
CHANGED. THE FOLLOWING
EXAMPLES SHOW HOW TO
DETERMINE IF AN ORIFICE
CHANGE WILL BE NECESSARY
AND HOW TO DETERMINE THE
NEW ORIFICE SIZE.
IN CANADA, AS AN ALTERNATE
TO ADJUSTING THE BURNER
ORIFICE SIZE, THE MANIFOLD
GAS PRESSURE MAY BE
ADJUSTED. THIS METHOD IS
COVERED LATER IN THIS
SECTION. THIS METHOD OF
ADJUSTING MANIFOLD
PRESSURE MAY ONLY BE USED
IN CANADIAN INSTALLATIONS.
WARNING
!
SHOULD OVERHEATING OCCUR
OR THE GAS SUPPLY FAIL TO
SHUT OFF, CLOSE THE MANUAL
GAS VALVE FOR THE APPLIANCE
BEFORE SHUTTING OFF THE
ELECTRICAL SUPPLY. FAILURE
TO DO SO CAN CAUSE AN
EXPLOSION OR FIRE RESULTING
IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
CAUTION
!
IT IS IMPORTANT THAT EACH
DUCT SYSTEM BE SIZED AND
INSTALLED FOR THE SPECIFIC
APPLICATION BY PROPERLY
APPLYING THE APPROPRIATE
INDUSTRY ACCEPTED
STANDARD. IF LESS THAN
MINIMUM STANDARDS ARE
APPLIED, THE EQUIPMENT USER
COULD EXPECT TO EXPERIENCE
HIGHER UTILITY BILLS, MAJOR
COMPONENT FAILURE, VARYING
DEGREES OF AIR NOISE OR
OTHER UNSATISFACTORY
ISSUES, OVER WHICH THE
MANUFACTURER HAS NO
CONTROL.
CAUTION
!
DO NOT OPERATE THE SYSTEM
FOR EXTENDED PERIODS
WITHOUT FILTERS. A PORTION OF
THE DUST ENTRAINED IN THE AIR
MAY TEMPORARILY LODGE IN
THE AIR DUCT RUNS AND AT THE
SUPPLY REGISTERS. ANY
RECIRCULATED DUST PARTICLES
WILL BE HEATED AND CHARRED
BY CONTACT WITH THE FURNACE
HEAT EXCHANGER. THIS RESIDUE
WILL SOIL CEILINGS, WALLS,
DRAPES, CARPETS AND OTHER
HOUSEHOLD ARTICLES.
WARNING
!
THE MEASURED TEMPERATURE
RISE SHOULD BE AS CLOSE TO
THE MIDDLE OF THE STATED
RANGE AS POSSIBLE. FOR
EXAMPLE, IF THE RISE RANGE IS
40 TO 70 DEGREES, THE MOST
IDEAL RISE WOULD BE 55
DEGREES (THE MIDDLE OF THE
RISE RANGE). IN ALL
APPLICATIONS, THE INSTALLER
MUST ADJUST THE
TEMPERATURE RISE TO THIS
"MIDDLE" POINT AS CLOSELY AS
POSSIBLE. ALSO, THE
TEMPERATURE RISE SHOULD
NEVER BE ABOVE OR FALL
BELOW THE STATED RANGE.
DOING SO COULD CAUSE
DAMAGE TO THE HEAT
EXCHANGER OR INTERMITTENT
OPERATION WHICH COULD CAUSE
INJURY OR DEATH AND WILL VOID
THE MANUFACTURER'S
WARRANTY FOR THIS PRODUCT.
WARNING
!
DISCONNECT THE ELECTRICAL
SUPPLY TO THE FURNACE
BEFORE ATTEMPTING TO
CHANGE THE BLOWER SPEED.
FAILURE TO DO SO CAN CAUSE
ELECTRICAL SHOCK RESULTING
IN PERSONAL INJURY OR DEATH.
WARNING
!
THESE INSTRUCTIONS ARE
INTENDED AS AN AID TO
QUALIFIED SERVICE
PERSONNEL FOR PROPER
INSTALLATION, ADJUSTMENT
AND OPERATION OF THIS UNIT.
READ THESE INSTRUCTIONS
THOROUGHLY BEFORE
ATTEMPTING INSTALLATION OR
OPERATION. FAILURE TO
FOLLOW THESE INSTRUCTIONS
MAY RESULT IN IMPROPER
INSTALLATION, ADJUSTMENT,
SERVICE OR MAINTENANCE,
POSSIBLY RESULTING IN FIRE,
ELECTRICAL SHOCK, CARBON
MONOXIDE POISONING,
EXPLOSION, PROPERTY
DAMAGE, PERSONAL INJURY
OR DEATH.
DISCONNECT MAIN ELECTRICAL
POWER TO THE UNIT BEFORE
ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN
CAUSE ELECTRICAL SHOCK
RESULTING IN PERSONAL INJURY
OR DEATH.
WARNING
!
HOLES IN THE VENT PIPE OR
HEAT EXCHANGER CAN CAUSE
TOXIC FUMES TO ENTER THE
HOME, RESULTING IN CARBON
MONOXIDE POISONING OR
DEATH. THE VENT PIPE OR HEAT
EXCHANGER MUST BE
REPLACED IF THEY LEAK.
8
IMPORTANT!
THE COMMONWEALTH OF
MASSACHUSETTS REQUIRES
COMPLIANCE WITH REGULATION
248 CMR 4.00 AND 5.00 FOR
INSTALLATION OF THROUGH-THE-
ALL VENTED GAS APPLIANCES
W
AS FOLLOWS:
(a) For all side wall horizontally vented
gas fueled equipment installed in every
dwelling, building or structure used in
hole or in part for residential purposes,
w
including those owned or operated by
the Commonwealth and where the side
wall exhaust vent termination is less
than seven (7) feet above finished
grade in the area of the venting,
including but not limited to decks and
porches, the following requirements
shall be satisfied:
1. INSTALLATION OF CARBON
MONOXIDE DETECTORS. At the time
of installation of the side wall horizontal
vented gas fueled equipment, the
installing plumber or gasfitter shall
observe that a hard wired carbon
monoxide detector with an alarm and
battery back-up is installed on the floor
level where the gas equipment is to be
installed. In addition, the installing
plumber or gasfitter shall observe that a
battery operated or hard wired carbon
monoxide detector with an alarm is
installed on each additional level of the
dwelling, building or structure served by
the side wall horizontal vented gas
fueled equipment. It shall be the
responsibility of the property owner to
secure the services of qualified licensed
professionals for the installation of hard
wired carbon monoxide detectors.
a. In the event that the side wall
horizontally vented gas fueled
equipment is installed in a crawl space
or an attic, the hard wired carbon
monoxide detector with alarm and
battery back-up may be installed on the
next adjacent floor level.
b. In the event that the requirements of
this subdivision can not be met at the
time of completion of installation, the
owner shall have a period of thirty (30)
days to comply with the above
requirements; provided, however, that
during said thirty (30) day period, a
battery operated carbon monoxide
detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE
DETECTORS. Each carbon monoxide
detector as required in accordance with
he above provisions shall comply with
t
NFPA 720 and be ANSI/UL 2034 listed
and IAS certified.
3. SIGNAGE. A metal or plastic
identification plate shall be permanently
ounted to the exterior of the building
m
at a minimum height of eight (8) feet
above grade directly in line with the
exhaust vent terminal for the
horizontally vented gas fueled heating
appliance or equipment. The sign shall
read, in print size no less than one-half
(1/2) inch in size, “GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF
ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas
inspector of the side wall horizontally
vented gas fueled equipment shall not
approve the installation unless, upon
inspection, the inspector observes
carbon monoxide detectors and
signage installed in accordance with the
provisions of 248 CMR 5.08(2)(a) 1
through 4.
(b) EXEMPTIONS: The following
equipment is exempt from 248 CMR
5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10
entitled “Equipment Not Required To Be
Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
2. Product Approved side wall
horizontally vented gas fueled
equipment installed in a room or
structure separate from the dwelling,
building or structure used in whole or in
part for residential purposes.
(c) MANUFACTURER
REQUIREMENTS – GAS EQUIPMENT
VENTING SYSTEM PROVIDED. When
the manufacturer of Product Approved
side wall horizontally vented gas
equipment provides a venting system
design or venting system components
with the equipment, the instructions
provided by the manufacturer for
installation of the equipment and the
venting system shall include:
1. Detailed instructions for the
installation of the venting system
design or the venting system
components; and
. A complete parts list for the venting
2
system design or venting system.
(d) MANUFACTURER
REQUIREMENTS – GAS
EQUIPMENT VENTING SYSTEM
NOT PROVIDED. When the
manufacturer of a Product Approved
ide wall horizontally vented gas
s
fueled equipment does not provide
the parts for venting the flue gases,
but identifies “special venting
systems”, the following requirements
shall be satisfied by the manufacturer:
1. The referenced “special venting
system” instructions shall be included
with the appliance or equipment
installation instructions; and
2. The “special venting systems” shall
be Product Approved by the Board,
and the instructions for that system
shall include a parts list and detailed
installation instructions.
(e) A copy of all installation
instructions for all Product Approved
side wall horizontally vented gas
fueled equipment, all venting
instructions, all parts lists for venting
instructions, and/or all venting design
instructions shall remain with the
appliance or equipment at the
completion of the installation.
9
GENERAL INFORMATION
These 90% Condensing Gas
Furnaces are design-certified by CSA
for use with natural and propane
gases as follows:
. As non-direct vent central forced
1
air furnaces taking combustion
air from the installation area or
using air ducted from the outside.
2. As direct vent central forced air
furnaces with all combustion air
supplied directly to the furnace
urners through a special air
b
intake system outlined in these
instructions.
Install this furnace in accordance with
the American National Standard
Z223.1 – latest edition entitled
“National Fuel Gas Code” (NFPA54)
and requirements or codes of the
local utilities or other authorities
having jurisdiction. This is available
rom the following:
f
National Fire Protection
Association, Inc.
Batterymarch Park
Quincy, MA 02269
CSA-INTERNATIONAL
8501 East Pleasant Valley Road
Cleveland, Ohio 44131-5575
Install units in Canada in accordance
with CSA-B149, local installation
codes and authorities having
jurisdiction. CSA-B149 is available
from:
SA-INTERNATIONAL
C
178 Rexdale Blvd.
Toronto, Ontario
Canada M9W, 1R3
FIGURE 1
PFLOW FURNACE
U
FIGURE 2
OWNFLOW/HORIZONTAL FURNACE
D
ITEM ITEM
NO. PART NAME NO. PART NAME
1 CONDENSATE TRAP 13 TOP PLATE
2 DOOR SWITCH 14 BURNER
3 JUNCTION BOX 15 IGNITER (HSI ONLY)
4 TRANSFORMER 16 COMBUSTION AIR INLET
5 BLOCKED DRAIN PRESSURE SWITCH 17 GAS VALVE
6 MAIN PRESSURE SWITCH 18 INDUCED DRAFT BLOWER
7 EXHAUST TRANSITION 19 CAPACITOR
8 CONNECTOR 20 LOW VOLTAGE (THERMOSTAT)
9 OUTLET AIR PIPE TERMINAL
10 SHIPPING PLUG 21 CONTROL MOUNTING PLATE
11 FLAME SENSOR 22 BLOWER
12 OVERTEMPERATURE SWITCH
10
I409 I409
ITEM ITEM
NO. PART NAME NO. PART NAME
1 INDUCED DRAFT BLOWER 14 LOW VOLTAGE TERMINAL (THERMOSTAT)
2 CAPACITOR 15 TRANSFORMER
3 INLET AIR CHASE 16 PRESSURE SWITCH
4 DOOR SWITCH 17 OUTLET AIR PIPE
5 JUNCTION BOX 18 GAS VALVE
6 INLET PIPE CONNECTOR 19 CONNECTOR
7 TOP PLATE 20 EXHAUST TRANSITION
8 CONTROL MOUNTING PLATE 21 CONDENSATE TRAP
9 AUXILIARY LIMIT 22 IGNITER (HSI)
10 SHIPPING PLUG 23 MANIFOLD
11 EXHAUST CONNECTION 24 OVERTEMPERATURE SWITCH
12 BLOWER 25 ROLLOUT SWITCH
13 EXHAUST PIPE EXTENSION 26 FLAME SENSOR
27 BURNER
IMPORTANT INFORMATION
ABOUT EFFICIENCY AND
INDOOR AIR QUALITY
Central cooling and heating equipment
is only as efficient as the duct system
that carries the cooled or heated air. To
maintain efficiency, comfort and good
indoor air quality, it is important to have
he proper balance between the air
t
being supplied to each room and the air
returning to the cooling and heating
equipment.
Proper balance and sealing of the duct
system improves the efficiency of the
heating and air conditioning system
and improves the indoor air quality of
the home by reducing the amount of
airborne pollutants that enter homes
from spaces where the ductwork and /
or equipment is located. The
manufacturer and the U.S.
Environmental Protection Agency’s
Energy Star Program recommend that
central duct systems be checked by a
qualified contractor for proper balance
and sealing.
WARNING
!
DUCT LEAKS CAN CREATE AN
UNBALANCED SYSTEM AND DRAW
POLLUTANTS SUCH AS DIRT,
DUST, FUMES AND ODORS INTO
THE HOME CAUSING PROPERTY
DAMAGE. FUMES AND ODORS
FROM TOXIC, VOLATILE OR
FLAMMABLE CHEMICALS, AS
WELL AS AUTOMOBILE EXHAUST
AND CARBON MONOXIDE (CO),
CAN BE DRAWN INTO THE LIVING
SPACE THROUGH LEAKING DUCTS
AND UNBALANCED DUCT
SYSTEMS CAUSING PERSONAL
INJURY OR DEATH (SEE FIGURE 3).
• IF AIR-MOVING EQUIPMENT OR
DUCTWORK IS LOCATED IN
GARAGES OR OFF-GARAGE
STORAGE AREAS - ALL JOINTS,
SEAMS, AND OPENINGS IN THE
EQUIPMENT AND DUCT MUST BE
SEALED TO LIMIT THE
MIGRATION OF TOXIC FUMES
AND ODORS INCLUDING CARBON
MONOXIDE FROM MIGRATING
INTO THE LIVING SPACE.
• IF AIR-MOVING EQUIPMENT OR
DUCTWORK IS LOCATED IN
SPACES CONTAINING FUEL
BURNING APPLIANCES SUCH AS
WATER HEATERS OR BOILERS ALL JOINTS, SEAMS, AND
OPENINGS IN THE EQUIPMENT
AND DUCT MUST ALSO BE
SEALED TO PREVENT
DEPRESSURIZATION OF THE
SPACE AND POSSIBLE
MIGRATION OF COMBUSTION
BYPRODUCTS INCLUDING
CARBON MONOXIDE INTO THE
LIVING SPACE.
FIGURE 3
IGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES
M
NOTICE
IMPROPER INSTALLATION, OR
INSTALLATION NOT MADE IN
ACCORDANCE WITH THE CSA
INTERNATIONAL (CSA)
CERTIFICATION OR THESE
INSTRUCTIONS, CAN RESULT IN
UNSATISFACTORY OPERATION
AND/OR DANGEROUS CONDITIONS AND ARE NOT COVERED BY
THE UNIT WARRANTY.
NOTICE
IN COMPLIANCE WITH RECOGNIZED
CODES, IT IS RECOMMENDED THAT
AN AUXILIARY DRAIN PAN BE
INSTALLED UNDER ALL
EVAPORATOR COILS OR UNITS
CONTAINING EVAPORATOR COILS
OR GAS FURNACES USED WITH
EVAPORATOR COILS THAT ARE
LOCATED IN ANY AREA OF A
STRUCTURE WHERE DAMAGE TO
THE BUILDING OR BUILDING
CONTENTS MAY OCCUR AS A
RESULT OF AN OVERFLOW OF THE
COIL DRAIN PAN OR A STOPPAGE
IN THE PRIMARY CONDENSATE
DRAIN PIPING.
RECEIVING
Immediately upon receipt, all cartons
and contents should be inspected for
transit damage. Units with damaged
cartons should be opened immediately.
If damage is found, it should be noted
on the delivery papers, and a damage
claim filed with the last carrier.
• After unit has been delivered to job
site, remove carton taking care not to
damage unit.
• Check the unit rating plate for unit
size, electric heat, coil, voltage,
phase, etc. to be sure equipment
matches what is required for the job
specification.
• Read the entire instructions before
starting the installation.
• Some building codes require extra
cabinet insulation and gasketing
when unit is installed in attic
applications.
• If installed in an unconditioned
space, apply caulking around the
power wires, control wires,
refrigerant tubing and condensate
line where they enter the cabinet.
Seal the power wires on the inside
where they exit conduit opening.
Caulking is required to prevent air
leakage into and condensate from
forming inside the unit, control box,
and on electrical controls.
• Install the unit in such a way as to
allow necessary access to the
coil/filter rack and blower/control
compartment.
• Install the unit in a level position to
ensure proper condensate
drainage. Make sure unit is level in
both directions within 1/8”.
• Install the unit in accordance with
any local code which may apply
and the national codes. Latest
editions are available from:
“National Fire Protection
Association, Inc., Batterymarch
Park, Quincy, MA 02269.” These
publications are:
• ANSI/NFPA No. 70-(Latest Edition)
National Electrical Code.
• NFPA90A Installation of Air
Conditioning and Ventilating
Systems.
• NFPA90B Installation of warm air
heating and air conditioning
systems.
• The equipment has been
evaluated in accordance with the
Code of Federal Regulations,
Chapter XX, Part 3280.
11
LOCATION REQUIREMENTS AND CONSIDERATIONS
GENERAL INFORMATION
WARNING
!
DO NOT USE THIS FURNACE
DURING CONSTRUCTION IF AIR
LADEN CORROSIVE COMPOUNDS
ARE PRESENT SUCH AS
CHLORINE AND FLUORINE.
OTHERWISE, PROVISIONS MUST
BE TAKEN TO PROVIDE CLEAN,
UNCONTAMINATED COMBUSTION
AND VENTILATION AIR TO THE
FURNACE. FURNACE
COMBUSTION AND VENTILATION
AIR CONTAMINATED WITH THESE
COMPOUNDS FORMS ACIDS
DURING COMBUSTION WHICH
CORRODES THE HEAT
EXCHANGER AND COMPONENT
PARTS. SOME OF THESE
CONTAMINANTS ARE FOUND IN,
BUT NOT LIMITED TO, PANELING,
DRY WALL, ADHESIVES, PAINTS,
STAINS, VARNISHES, SEALERS,
AND MASONRY CLEANING
MATERIALS.
WARNING
!
DO NOT INSTALL THIS FURNACE
IN A MOBILE HOME!! This furnace
is not approved for installation in a
mobile home. Doing so could cause
FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
WARNING
!
WHEN THIS FURNACE IS
INSTALLED IN A RESIDENTIAL
GARAGE, IT MUST BE INSTALLED
SO THE BURNERS AND IGNITION
SOURCE ARE LOCATED NO LESS
THAN 18 INCHES ABOVE THE
FLOOR. THIS IS TO PREVENT
THE RISK OF IGNITING
FLAMMABLE VAPORS WHICH
MAY BE PRESENT IN A GARAGE.
ALSO, THE FURNACE MUST BE
LOCATED OR PROTECTED TO
AVOID PHYSICAL DAMAGE BY
VEHICLES. FAILURE TO FOLLOW
THESE WARNINGS CAN CAUSE A
FIRE OR EXPLOSION, RESULTING
IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
1. IMPORTANT: If installing the unit
over a finished ceiling or living
rea, be certain to install an
a
auxiliary condensate drain pan
under the entire unit. This
uxiliary drain pan should extend
a
under any evaporator coil
installed with the furnace and the
pen portion of the condensate
o
drain assembly. See
“Condensate Drain/Neutralizer”
section for more details.
2. IMPORTANT: If using a cooling
evaporator coil with this furnace:
a. be sure the air passes over
the heat exchanger before
passing over the cooling
coil. The cooled air passing
over the warm ambient air
inside the heat exchanger
tubes can cause
condensation inside the tubes
resulting in corrosion and
eventual failure.
b. install a parallel duct system
to divert all the air from the
furnace allowing it to pass
over the cooling coil only. Use
dampers or other means to
prevent chilled air from
passing over the heat
exchanger.
If these are manual dampers, they
must be equipped to prevent heating
or cooling operation unless the
damper is in the full heat or cool
position.
FIGURE 4
HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP
DRAIN
PIPE
3. IMPORTANT: Install the furnace
level. If it is not level, condensate
annot drain properly, possibly
c
causing furnace shut down.
NOTE: These furnaces are approved
for installation in attics, as well as
alcoves, utility rooms, closets and
crawlspaces. Provisions must be
made to prevent freezing of
condensate.
4.
!
If this furnace is installed in a
garage, attic and/or any
unconditioned space, install a
self-regulating heat tape
around the condensate trap
and along the entire length of
the condensate drain in the
unconditioned space. See
Figure 4.
When the condensing horizontal
gas furnace is installed in an
unconditioned space where the
temperature would be capable of
reaching close to or below 32°F
(0°C). a self-regulating heat tape
is required on the condensate
drain, along with an insulation
wrap. The heat tape should meet
the following requirements:
a. The heat tape must be UL
b. The heat tape must be
CAUTION
listed.
installed per the
manufacturer’s instructions for
the entire length of drain pipe
in the unconditioned space.
12
HEAT
TAPE
TRAP
I526
c. The heat tape should be rated
at 5 or 6 watts per foot at
20V.
1
IMPORTANT: Support this unit
when installed. Since this furnace
is suitable for attic or crawl space
installation, it may be installed on
combustible wood flooring or by
using support brackets. See
Figure 5.
5. IMPORTANT: If installing in a
utility room, be sure the door
is wide enough to:
a. allow the largest part of the
furnace to pass; or
b. allow any other appliance
(such as a water heater)
to pass.
6. IMPORTANT: This furnace is not
approved or recommended for
installation on its back, with
access doors facing upwards.
IGURE 5
F
ORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS
H
AS
G
IPE
P
T
RAP
NTAKE
I
ENT
V
ELECTRICAL
CONDUIT
XHAUST
E
AN
F
I522
CLEARANCE ACCESSIBILITY
The design of forced air furnaces with
input ratings as listed in the tables
under Figures 6, 7, and 8 are certified
by CSA-International for the
clearances to combustible materials
shown in inches.
See name/rating plate and clearance
label for specific model number and
clearance information.
Service clearance of at least 24
inches is recommended in front of
all furnaces.
NOTE: Use recommended 24”
clearance if accessibility clearances
are greater than fire protection
clearances.
WARNING
!
UPFLOW AND HORIZONTAL
FURNACES ARE DESIGNCERTIFIED FOR INSTALLATION
ON COMBUSTIBLE FLOORS.
NOTE, HOWEVER, THAT
FURNACES MUST NOT BE
INSTALLED DIRECTLY ON
CARPETING, TILE OR OTHER
COMBUSTIBLE MATERIAL OTHER
THAN WOOD FLOORING.
INSTALLATION ON A
COMBUSTIBLE MATERIAL CAN
RESULT IN FIRE, CAUSING
PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
Upflow furnaces are shipped with a
bottom closure panel installed.
When bottom return air is used,
remove the panel by removing the
two screws attaching the panel to
the front base angle.
SITE SELECTION
1. Select a site in the building near
the center of the proposed, or
existing, duct system.
2. Give consideration to the vent
system piping when selecting the
furnace location. Be sure the
venting system can get from the
furnace to the termination with
minimal length and elbows.
3. Locate the furnace near the
existing gas piping. Or, if running
a new gas line, locate the
furnace to minimize the length
and elbows in the gas piping.
4. Locate the furnace to maintain
proper clearance to combustibles
as shown in the following tables.
WARNING
!
DO NOT LIFT THE UNIT BY THE
HEAT EXCHANGER TUBES.
DOING SO CAN CRACK THE HEAT
EXCHANGER ASSEMBLY AND
CAUSE CO2 TO BE RELEASED
INTO THE ENVIRONMENT, WHICH
CAN RESULT IN PERSONAL
INJURY OR DEATH.
WARNING
!
COMBUSTIBLE MATERIAL MUST
NOT BE PLACED ON OR AGAINST
THE FURNACE JACKET. THE
AREA AROUND THE FURNACE
MUST BE KEPT CLEAR AND FREE
OF ALL COMBUSTIBLE
MATERIALS INCLUDING
GASOLINE AND OTHER
FLAMMABLE VAPORS AND
LIQUIDS. PLACEMENT OF
COMBUSTIBLE MATERIALS ON,
AGAINST OR AROUND THE
FURNACE JACKET CAN CAUSE
AN EXPLOSION OR FIRE
RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY OR
DEATH. THE HOMEOWNER
SHOULD BE CAUTIONED THAT
THE FURNACE AREA MUST NOT
BE USED AS A BROOM CLOSET
OR FOR ANY OTHER STORAGE
PURPOSES.
13
IGURE 6
F
LEARANCE TO COMBUSTIBLES, UPFLOW UNITS
C
WGTS
BACK TOP FRONT VENT
SIDE SIDE
LEFT RIGHT SHIP
⁄32 0 0 0 1 2* 0 111
⁄32 0 0 0 1 2* 0 117
⁄32 0 0 0 1 2* 0 123
⁄32 0 0 0 1 2* 0 123
25
⁄8 2 15 13
5
9
25
25
⁄2 17
1
⁄8 2 15 13
⁄8 2 15 13
⁄8 2 18
5
5
1
⁄32 0 0 0 1 2* 0 160
⁄32 0 0 0 1 2* 0 148
⁄32 0 0 0 1 2* 0 152
9
9
25
⁄2 17
⁄2 17
1
1
⁄8 2 18
⁄8 2 18
⁄8 2 22 20
1
1
5
2 DIA.
GAS CONNECTION
⁄32 15
⁄32 15
⁄32 15
⁄32 19
⁄32 19
⁄32 19
11
11
11
27
UPFLOW MODELS MINIMUM CLEARANCE (IN.)
⁄2 16
⁄2 16
⁄2 16
1
1
1
kBtu
INPUT
2 45 17
3 75 17
4 75 21 19
2.5 60 17
TONS A B C D E F
⁄32 22
27
27
11
⁄2 23
1
5 120 24
4.5 105 21 19
4 & 5 90 21 19
AIR
*A service clearance of at least 24 inches is recommended in front of all furnaces.
A - Narrow Cabinet
B - Wide Cabinet
AIRFLOW
⁄8
3
27
RETURN
2 DIA.
AIR
SUPPLY
GAS CONNECTION
⁄16
7
26
14
I392
IGURE 7
F
LEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS
C
WGTS
BACK TOP FRONT VENT
SIDE SIDE
LEFT RIGHT SHIP
⁄8 0 0 0 1 2* 0 111
⁄8 0 0 0 1 2* 0 117
⁄8 0 0 0 1 2* 0 123
⁄8 0 0 0 1 2* 0 123
⁄8 0 0 0 1 2* 0 148
⁄8 0 0 0 1 2* 0 152
7
7
7
3
⁄8 13
⁄8 13
⁄8 13
5
⁄8 2 16
5
⁄8 17
5
5
1
⁄8 2 16
⁄8 2 16
⁄16 2 20
5
5
3
⁄8 0 0 0 1 2* 0 160
3
3
7
⁄8 17
⁄8 17
⁄8 20
1
1
5
⁄8 2 23
⁄16 2 20
⁄16 2 20
5
3
3
⁄16
13
25
2 DIA.
ALT. GAS
CONNECTION
⁄8
3
4
⁄32 15
⁄32 15
⁄32 15
⁄32 19
⁄32 19
⁄32 19
11
11
11
DOWNFLOW MODELS MINIMUM CLEARANCE (IN.)
⁄2 16
1
A B C D E F
45 17
kBtu
INPUT
2
TONS
11
⁄2 16
⁄2 16
1
1
60 17
75 17
75 21 19
3
4
2.5
⁄32 22
11
11
11
⁄2 23
1
90 21 19
105 21 19
120 24
5
4.5
4 & 4.5
AIR
SUPPLY
*A service clearance of at least 24 inches is recommended in front of all furnaces.
NOTE: RXGY-H01 is required for left-hand alternate condensate drain.
AIRFLOW
AIR
RETURN
GAS CONNECTION
2 DIA.
NOTE: IN DOWNFLOW CONFIGURATION, OPTIONAL AIR CUTOUT IS NOT PERMITTED.
I393
15
IGURE 8
F
LEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS
C
WGTS
BACK TOP FRONT VENT
SIDE SIDE
LEFT RIGHT SHIP
⁄8 0 0 0 1 2* 0 111
⁄8 0 0 0 1 2* 0 117
⁄8 0 0 0 1 2* 0 123
⁄8 0 0 0 1 2* 0 123
⁄8 0 0 0 1 2* 0 148
⁄8 0 0 0 1 2* 0 152
7
7
7
3
⁄8 13
⁄8 13
⁄8 13
5
⁄8 2 16
5
⁄32 15
11
HORIZONTAL MODELS MINIMUM CLEARANCE (IN.)
⁄2 16
1
A B C D E F
⁄8 17
5
5
1
⁄8 2 16
⁄8 2 16
⁄16 2 20
5
5
3
⁄32 15
⁄32 15
⁄32 19
11
11
27
⁄2 16
⁄2 16
1
1
⁄8 0 0 0 1 2* 0 160
3
3
5
⁄8 17
⁄8 17
⁄8 20
1
1
5
⁄8 2 23
⁄16 2 20
⁄16 2 20
5
3
3
⁄32 19
⁄32 19
⁄32 22
27
27
11
⁄2 23
1
IMPORTANT: This furnace is not approved or recommended for
installation on its back, with access doors facing upwards.
45 17
60 17
75 17
75 21 19
90 21 19
105 21 19
kBtu
INPUT
2
3
4
2.5
TONS
120 24
5
4.5
4 & 4.5
GAS
2 DIA.
CONNECTION
*A service clearance of at least 24 inches is recommended in front of all furnaces.
⁄16
13
25
2 DIA.
ALT. GAS
CONNECTION
⁄8
3
4
16
I520
DUCTING
JACKET
DRILL (2)
3/16" DIA.
HOLES
8.000
4.875
1.531
roper air flow is required for the
P
orrect operation of this furnace.
c
oo little air flow can cause erratic
T
peration and can damage the heat
o
xchanger. The duct system must
e
arry the correct amount of air for
c
eating and cooling if summer air
h
onditioning is used.
c
Size the ducts according to
acceptable industry standards and
methods. The total static pressure
drop of the air distribution system
should not exceed 0.5" w.c.
NOTE: Return air grilles and warm air
registers must not be obstructed
WARNING
!
NEVER ALLOW THE PRODUCTS
OF COMBUSTION FROM THE
FLUE TO ENTER THE RETURN AIR
DUCTWORK OR THE CIRCULATED
AIR SUPPLY. ALL RETURN
DUCTWORK MUST BE
ADEQUATELY SEALED AND
SECURED TO THE FURNACE
WITH SHEET METAL SCREWS;
AND JOINTS, TAPED. ALL OTHER
DUCT JOINTS MUST BE SECURED
WITH APPROVED CONNECTIONS
AND SEALED AIRTIGHT. WHEN
AN UPFLOW FURNACE IS
MOUNTED ON A PLATFORM WITH
RETURN THROUGH THE BOTTOM,
IT MUST BE SEALED AIRTIGHT
BETWEEN THE FURNACE AND
THE RETURN AIR PLENUM. THE
FLOOR OR PLATFORM MUST
PROVIDE SOUND PHYSICAL
SUPPORT OF THE FURNACE
WITHOUT SAGGING, CRACKS, OR
GAPS, AROUND THE BASE,
PROVIDING A SEAL BETWEEN
THE SUPPORT AND THE BASE.
FAILURE TO PREVENT
PRODUCTS OF COMBUSTION
FROM BEING CIRCULATED INTO
THE LIVING SPACE CAN CREATE
POTENTIALLY HAZARDOUS
CONDITIONS, INCLUDING
CARBON MONOXIDE POISONING
THAT COULD RESULT IN
PERSONAL INJURY OR DEATH.
DO NOT, UNDER ANY
CIRCUMSTANCES, CONNECT
RETURN OR SUPPLY DUCTWORK
TO OR FROM ANY OTHER HEAT
PRODUCING DEVICE SUCH AS A
FIREPLACE INSERT, STOVE, ETC.
DOING SO MAY RESULT IN FIRE,
CARBON MONOXIDE POISONING,
EXPLOSION, PERSONAL INJURY
OR PROPERTY DAMAGE.
IMPORTANT: Some high efficiency
filters have a greater than normal
resistance to air flow. This can
adversely affect furnace operation.
BE SURE TO CHECK AIR FLOW.
IMPORTANT: When using outside
air, design and adjust the system to
maintain a return air temperature
ABOVE 55° F during the heating
season.
UPFLOW UNITS
1. Position the unit to minimize long
runs of duct or runs of duct with
any turns and elbows.
m
2. Open the return air compartment.
WARNING
!
UPFLOW FURNACE: A SOLID
METAL BASE PLATE MUST BE
INSTALLED IN THE FURNACE
BOTTOM WHEN USING SIDE
RETURN. FAILURE TO INSTALL A
BASE PLATE COULD CAUSE THE
PRODUCTS OF COMBUSTION TO
CIRCULATE INTO THE LIVING
PACE AND CREATE POTENTIAL-
S
LY HAZARDOUS CONDITIONS,
INCLUDING CARBON MONOXIDE
POISONING OR DEATH.
a. Cut an opening in the side.
The opening should
be cut the full width of the
knockouts on the unit. See
Figure 9.
NOTE: Where the maximum air flow
is 1800 CFM or more, both sides or
the bottom must be used for return
air.
3. Connect the return duct or return
air cabinet to the unit. Make the
connection air tight to prevent
entraining combustion gases
from an adjacent fuel-burning
appliance.
4. Be sure to have adequate
space for the unit filter.
NOTE: DO NOT take return air
from bathrooms, kitchens,
furnace rooms, garages, utility or
laundry rooms, or cold areas.
NOTE: DO NOT use a rear air
return.
FIGURE 9
CUTOUT AND DRILL INFORMATION
5. If summer air conditioning is
desired, position the indoor coil
on the top of the unit. Insure that
no air can bypass this coil.
. Connect the supply air plenum to
6
the furnace plenum opening.
IMPORTANT: If a flexible duct
connector must be used, it
MUST
be rated for a minimum
temperature of 250°F
continuous.
.
DOWNFLOW UNITS
1. Position the unit to minimize long
uns of duct or runs of duct with
r
many turns and elbows.
2. If summer air conditioning is
desired, position the indoor coil
on the bottom of the unit. Insure
that no air can bypass this coil.
3. If installing on a combustible floor
and not using an air
conditioning plenum, install the
special non-combustible floor
base. See Figure 10.
WARNING
!
THE DOWNFLOW FURNACE
DESIGN IS CERTIFIED FOR
INSTALLATION ON A NONCOMBUSTIBLE FLOOR. USE THE
SPECIAL BASE SPECIFIED ON
THE FURNACE CLEARANCE
LABEL. FAILURE TO INSTALL THE
SPECIAL BASE MAY RESULT IN
FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
THIS SPECIAL BASE IS SHIPPED
FROM THE FACTORY AS AN
ACCESSORY.
17
4. Connect the furnace to the
supply air plenum.
5. Connect the return air ducting to
the return air opening at the top
of the unit. Make the connection
air tight to prevent entraining
combustion gases from an
adjacent fuel-burning appliance.
6. Be sure to have adequate
space for the unit filter.
NOTE: DO NOT take return air
from bathrooms, kitchens,
furnace rooms, garages, utility or
laundry rooms, or cold areas.
HORIZONTAL UNIT
IMPORTANT: This furnace may only
be installed so as when facing the
front of the furnace, supply air is
discharged on the left hand side.
1. Position the unit to minimize long
runs or runs with many turns and
elbows.
2. If summer air conditioning is
desired, position the indoor coil
on the left end of the unit. Insure
that no air can bypass this coil.
3. Connect the furnace to the
supply air plenum.
4. Connect the return air ducting to
the return air opening at the right
end of the unit. Make the
connection air tight to prevent
pulling combustion gases from
an adjacent fuel-burning
appliance.
FIGURE 10
OMBUSTIBLE FLOOR BASE
C
5. Be sure to have adequate
space for the unit filter.
NOTE: DO NOT take return air
from bathrooms, kitchens,
furnace rooms, garages, utility or
laundry rooms, or cold areas.
VENTING AND COMBUSTION AIR PIPING
VENTING AND COMBUSTION AIR PIPING
GENERAL INFORMATION
WARNING
!
READ AND FOLLOW ALL
INSTRUCTIONS IN THIS SECTION.
FAILURE TO PROPERLY VENT
THIS FURNACE CAN CAUSE
CARBON MONOXIDE POISONING
OR AN EXPLOSION OR FIRE,
RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY
OR DEATH.
This furnace removes both sensible
and latent heat from the combustion
flue gases. Removal of latent heat
results in condensation of flue gas
water vapor. This condensed water
vapor drains from the secondary heat
exchanger and out of the unit into a
drain trap.
When installed as a non-direct vent
furnace, only exhaust piping is
required and inside combustion air
may be used. Refer to section on
“
COMBUSTION & VENTILATION AIR
FOR FURNACE INSTALLATIONS.”
Direct vent installations require a
dedicated combustion air and venting
system. All air for combustion is taken
from the outside atmosphere and all
combustion products are discharged
to the outdoors.
The combustion air and vent pipe
fittings must conform to American
National Standards Institute (ANSI)
and American Society for Testing
Materials (ASTM) standards as
shown below:
WARNING
!
IN CANADA, PRODUCTS
CERTIFIED FOR INSTALLATION
AND INTENDED TO BE VENTED
WITH PLASTIC VENT SYSTEMS
(PVC, CPVC) MUST USE VENT
SYSTEMS THAT ARE CERTIFIED
TO THE STANDARD FOR TYPE BH
GAS VENTING SYSTEMS, ULC
S636.
THE COMPONENTS OF THE
CERTIFIED MATERIAL MUST NOT
BE INTERCHANGED WITH OTHER
PIPE & FITTING MATERIAL
Schedule 40 PVC (Pipe) D1785
Schedule 40 PVC (Cellular Core Pipe) F891
Schedule 40 PVC (Fittings) D2466
SDR-21PVC (Pipe) D2241
SDR-26 PVC (Pipe) D2241
Schedule 40 ABS Cellular Core DWV (Pipe) F628
Schedule 40 ABS (Pipe) D1527
Schedule 40 ABS (Fittings) D2468
ABS-DWV (Drain Waste & Vent)
(Pipe & Fittings)
PVC-DWV (Drain Waste & Vent)
(Pipe & Fittings)
VENT SYSTEMS OR UNLISTED
PIPE/FITTINGS.
PLASTIC COMPONENTS AND
SPECIFIED PRIMERS AND GLUES
OF THE CERTIFIED SYSTEM MUST
BE FROM A SINGLE SYSTEM
MANUFACTURER AND NOT
INTERMIXED WITH OTHER
SYSTEM MANUFACTURER’S
PARTS.
NOTE: INLET AIR PIPING IS NOT
CONSIDERED TO BE A PART OF
THE “VENTING SYSTEM”. THE
REQUIREMENT THAT VENT
MATERIAL BE CERTIFIED TO ULC
S636 DOES NOT APPLY TO INLET
AIR PIPING.
ASTM
SPECIFICATION
D2661
D2665
18
OVERTEMPERATURE
SAFETY SWITCHES
Furnaces are equipped with safety
switches in the control compartment to
protect against overtemperature
conditions caused by inadequate
combustion air supply. The switches for
the upflow and downflow models are
located in the burner compartment. If a
switch is tripped it must be manually
reset.
WARNING
!
DO NOT JUMPER THESE DEVICES!
IF ONE OF THESE SWITCHES
SHOULD TRIP, A QUALIFIED
INSTALLER, SERVICE AGENCY OR
THE GAS SUPPLIER MUST BE
CALLED TO CHECK AND/OR
CORRECT FOR ADEQUATE
COMBUSTION AIR SUPPLY. DO NOT
RESET THE SWITCHES WITHOUT
TAKING CORRECTIVE ACTION TO
ASSURE THAT AN ADEQUATE
SUPPLY OF COMBUSTION AIR IS
MAINTAINED UNDER ALL
CONDITIONS OF OPERATION.
FAILURE TO DO SO CAN RESULT IN
CARBON MONOXIDE POISONING
OR DEATH. IF THIS UNIT IS
MOUNTED IN A CLOSET, THE DOOR
MUST BE CLOSED WHEN MAKING
THIS CHECK.
REPLACE THESE SWITCHES ONLY
WITH THE IDENTICAL
REPLACEMENT PART.
EXISTING VENT SYSTEMS
When the installation of this furnace
replaces an existing furnace that is
removed from a vent system serving
other appliances, the vent system is
likely to be too large to properly vent the
remaining attached appliances.
The following steps should be followed
with each appliance remaining
connected to the original common vent
system. Place the appliance to be tested
in operation, while the other appliances
remaining connected to the common
vent system are not in operation. Test
the operation of each appliance
individually by the following method.
1. Permanently seal any unused
openings in the common venting
system.
2. Visually inspect the venting system
for proper size and horizontal pitch
and determine that there is no
blockage, restriction, leakage,
corrosion or other deficiencies
which could cause an unsafe
condition.
3. If practical, close all building doors,
windows and all doors between the
space where the appliances
remaining connected to the
common venting system are
located.
Turn on clothes dryers and any
appliance not connected to the
common venting system. Turn on
any exhaust fans, such as range
hoods and bathroom exhausts, so
they will operate at maximum
speed. Do not operate a summer
exhaust fan. Close fireplace
dampers.
4. Follow the lighting instructions.
Place the appliance being
inspected into operation. Adjust the
thermostat so the appliance will
operate continuously.
5. Test for spillage at the draft hood
relief opening after 5 minutes of
main burner operation. Use the
flame of a match or candle, or
smoke from a cigarette, cigar
or pipe.
6. After it has been determined that
each appliance that remains
connected to the common 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.
7. If improper venting is observed
during any of the above tests, the
common venting system must be
resized. See vent tables in these
instructions
When the furnace is installed in the
same space with other gas appliances
such as a water heater, be sure there is
an adequate supply of combustion and
ventilation air for the other appliances.
Do not delete or reduce the combustion
air supply required by the other gas
appliances in this space. See Z223.1,
National Fuel Gas Code (NFPA54) for
determining the combustion air
requirements for gas appliances. An
unconfined space must have at least 50
cubic feet (volume) for each
1,000 BTUH of the total input of all
appliances in the space. If the open
space containing the appliances is in a
building with tight construction
(contemporary construction), outside air
may still be required for the appliances
to burn and vent properly. Outside air
openings should be sized the same as
for a confined space.
JOINING PIPE AND
FITTINGS
WARNING
!
PVC SOLVENT CEMENTS AND
PRIMERS ARE HIGHLY FLAMMABLE.
PROVIDE ADEQUATE VENTILATION
AND DO NOT ASSEMBLE NEAR
HEAT SOURCE OR AN OPEN FLAME.
DO NOT SMOKE. AVOID SKIN OR
EYE CONTACT. OBSERVE ALL
CAUTIONS AND WARNINGS
PRINTED ON MATERIAL
CONTAINERS. FAILURE TO FOLLOW
THESE GUIDELINES MAY RESULT IN
FIRE, EXPLOSION OR
ASPHYXIATION CAUSING
PERSONAL INJURY OR DEATH.
All pipe, fittings, solvent cement, primers
and procedures must conform to
American National Standard Institute
and American Society for Testing and
Materials (ANSI/ASTM) standards in the
U.S.
Pipe and Fittings - ASTM-D1785,
D2466, D2665, D2231, D2661 and
F628.
PVC Primer and Solvent Cement ASTM-D2564
ABS Pipe and Fittings - Use ABS
Primer and Solvent Cement D2235
Procedure for Cementing Joints ASTM-D2855
IMPORTANT: The plastic combustion
air and venting components are of
PVC. If using ABS piping, ensure that
the solvent cement is compatible for
joining PVC to ABS components or
use a mechanical connection that can
withstand the vent temperatures and
are corrosion resistant.
CEMENTING JOINTS
Properly seal all joints in the PVC vent
using the following materials and
procedures.
PVC CLEANER-PRIMER AND
PVC MEDIUM-BODY SOLVENT
CEMENT
IMPORTANT: After cutting pipe,
remove all ragged edges and burrs.
This is important to prevent reduction
in pressure drop throughout the
system.
1. Cut pipe end square. Chamfer
edge of pipe. Clean fitting socket
and pipe joint area of all dirt,
grease and moisture.
2. After checking pipe and socket
for proper fit, wipe socket and
pipe with cleaner-primer. Apply
a liberal coat of primer to inside
surface of socket and outside of
pipe. Read instructions included
with the primer for proper
application.
3. Apply a thin coat of cement
evenly in the socket. Quickly
apply a heavy coat of cement to
the pipe end and insert pipe into
fitting with a slight twisting
movement until it bottoms out.
NOTE: Cement must be fluid; if
not, recoat.
4. Hold the pipe in the fitting for 30
seconds to prevent the tapered
socket from pushing the pipe out
of the fitting.
5. Wipe all excess cement from the
joint with a rag. Allow 15 minutes
before handling. Cure time varies
according to fit, temperature and
humidity.
NOTE: Stir the solvent cement
frequently while using. Use a natural
bristle brush or the dauber supplied
with the can. The proper brush size is
one inch.
IMPORTANT: For Proper Installation
DO NOT use solvent cement that
has become curdled, lumpy or
thickened.
DO NOT thin. Observe shelf
precautions printed on containers.
For application below 32°F, use only
low-temperature-type solvent
cement.
19
COMBUSTION AND VENTILATION AIR
NON-DIRECT
Halogen type refrigerants
FURNACE INSTALLATIONS
WARNING
!
THE FURNACE AND ANY OTHER
UEL-BURNING APPLIANCE MUST
F
BE PROVIDED WITH ENOUGH
FRESH AIR FOR PROPER
COMBUSTION AND VENTILATION
OF THE FLUE GASES. MOST
HOMES WILL REQUIRE THAT
OUTSIDE AIR BE SUPPLIED INTO
THE FURNACE AREA. FAILURE
TO DO SO CAN CAUSE
PERSONAL INJURY OR DEATH
FROM CARBON MONOXIDE
POISONING.
Adequate facilities for providing air for
combustion and ventilation must be
provided in accordance with section
5.3, “Air for Combustion and
Ventilation” of the National Fuel Gas
Code, ANSI Z223.1 (latest edition) or
applicable provisions for the local
building codes, and not obstructed so
as to prevent the flow of air to the
furnace.
IMPORTANT: Air for combustion and
ventilation must not come from a
corrosive atmosphere. Any failure
due to corrosive elements in the
atmosphere is excluded from
warranty coverage.
The following types of installation
(but not limited to the following) will
require OUTDOOR AIR for
combustion, due to chemical
exposures:
• Commercial buildings
• Buildings with indoor pools
• Furnaces installed in laundry rooms
• Furnaces in hobby or craft rooms
• Furnaces installed near chemical
storage areas.
Exposure to the following substances
in the combustion air supply (but not
limited to the following) will also
require OUTDOOR AIR for
combustion:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine-based swimming pool
chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
•
• Cleaning solvents (such as
perchloroethylene)
• Printing inks, paint removers,
varnishes, etc.
• Hydrochloric acid
Cements and glues
•
• Antistatic fabric softeners for
clothes dryers
• Masonry curing and acid washing
materials
Combustion air must be free of acidforming chemicals such as sulphur,
fluorine and chlorine. These elements
are found in aerosol sprays,
detergents, bleaches, cleaning
solvents, air fresheners, paint and
varnish removers, refrigerants and
many other commercial and
household products. When burned in
a gas flame, vapors from these
products form acid compounds. The
acid compounds increase the dew
point temperature of the flue products
and are highly corrosive after they
condense.
WARNING
!
ALL FURNACE INSTALLATIONS
MUST COMPLY WITH THE
NATIONAL FUEL GAS CODE AND
LOCAL CODES TO PROVIDE
ADEQUATE COMBUSTION AND
VENTILATION AIR FOR THE
FURNACE. FAILURE TO DO SO
CAN RESULT IN EXPLOSION,
FIRE, PROPERTY DAMAGE,
CARBON MONOXIDE POISONING,
PERSONAL INJURY OR DEATH.
Combustion air requirements are
determined by whether the furnace is
in an open (unconfined) area or in a
confined space such as a closet or
small room.
EXAMPLE 1:
FURNACE LOCATED IN AN
UNCONFINED SPACE
Using indoor air for combustion.
An unconfined space must have at
least 50 cubic feet for each 1,000
BTUH of the total input for all
appliances in the space. Here are a
few examples of the room sizes
required for different inputs. The sizes
are based on 8-foot ceilings.
TUH Minimum Sq. Feet Typical Room Size
B
Input With 8' Ceiling With 8' Ceiling
5,000 281 14' x 20' OR 16' x 18'
4
0,000 375 15' x 25' OR 19' x 20'
6
5,000 469 15' x 31' OR 20' x 24'
7
0,000 563 20’ x 28’ OR 24’ x 24’
9
105,000 657 20' x 33' OR 26' x 25'
120,000 750 25' x 30' OR 24' x 32'
If the open space containing the
furnace is in a building with tight
construction, outside air may still be
required for the furnace to operate
and vent properly. Outside air
openings should be sized the same
as for a confined space.
EXAMPLE 2:
FURNACE LOCATED IN A
CONFINED SPACE
A confined space (any space smaller
than shown above as “unconfined”)
must have openings into the space
which are located in accordance with
the requirements set forth in the
following subsections A and B. Size
the openings by how they are
connected to the heated area or to
the outside,
and by the input of all appliances in
the space.
If confined space is within a building
with tight construction, combustion air
must be taken from outdoors or area
freely communicating with the
outdoors.
A. USING INDOOR AIR FOR
COMBUSTION
IMPORTANT: Air should not be
taken from a heated space with a
fireplace, exhaust fan or other
device that may produce a
negative pressure.
If combustion air is taken from the
heated area, the openings must
each have at least 100 square
inches of free area. Each opening
must have at least one square inch
of free area for each 1,000 BTUH
of total input in the space. Here
are some examples of typical
openings required.
20
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