ICP C8DNL, H8DNL, T8DNL Installation Instructions Manual

Printed in U.S.A. 441 01 2314 06 July 2010
INSTALLATION INSTRUCTIONS
80% Single Stage, Downflow,
Category I, Gas Furnace
C8DNL, H8DNL, T8DNL
These instructions must be read and understood completely before attempting installation.
Safety Labeling and Signal Words
The signal words DANGER, WARNING, CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manual that may apply to the product.
DANGER Immediate hazards which will result in severe personal injury or death.
WARNING Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which may result in minor personal injury or product or property damage.
NOTE − Used to highlight suggestions which will result in enhanced installation, reliability, or operation.
!
WARNING
Signal Words in Manuals
The signal word CAUTION is used throughout this manual in the following manner:
!
CAUTION
Signal Words on Product Labeling
Signal words are used in combination with colors and/or pictures or product labels.
The signal word WARNING is used throughout this manual in the following manner:
Safetyalert symbol
When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 2...................
Safe Installation Requirements 3..................
INSTALLATION 4...............................
Combustion & Ventilation Air 6....................
Gas Vent Installation 9...........................
Venting (Horizonta) 10............................
Venting (Chimney Adapter) 12.....................
Gas Supply and Piping 15.........................
Electrical Wiring 17...............................
Ductwork and Filter 18............................
Checks and Adjustments 23.......................
Furnace Maintenance 27..........................
Sequence of Operation & Diagnostics (*8DNL) 28....
Wiring Diagram (*8DNL) 32.......................
International Comfort Products, LLC
Lewisburg, TN 37091 U.S.A.
!
WARNING
PERSONAL INJURY, AND/OR PROPERTY DAMAGE HAZARD
Failure to carefully read and follow this warning could result in equipment malfunction, property damage, personal injury and/or death. Installation or repairs made by unqualified persons could result in equipment malfunction, property damage, personal injury and/or death. The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with proper tools and test instruments. Installation must conform with local building codes and with the Natural Fuel Gas Code (NFCG) NFPA 54/ANSI Z223.1, and National standards of Canada CAN/CSAB149.1 and .2 Natural Gas and Propane Installation Codes.
INSTALLER: Affix these instructions on or adjacent to the furnace. CONSUMER: Retain these instructions for future refer­ence.
Portions of the text and tables are reprinted from NFPA 54 /ANSI Z223.12009©, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington,
DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI, on the referenced subject, which is represented only by the standard in its entirety.
441 01 2314 06
Specifications are subject to change without notice
2
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factoryauthorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel Gas Code (NFCG) NFPA 54/ANSI Z223.1, and the National Electrical Code (NEC) NFPA 70.
In Canada refer to the current editions of the National standards of Canada CAN/CSA−B149.1 and .2 Natural Gas and Propane Installation Codes, and Canadian Electrical Code CSA C22.1.
Recognize safety information. This is the safety−alert symbol
. When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these signal words; DANGER, WARNING, and CAUTION. These words are used with the safety−alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause personal injury or death.
Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lockout tag. Unit may have more than one power switch.
!
WARNING
CARBON MONOXIDE POISONING AND FIRE HAZARD
Failure to follow safety warnings could result in personal injury, death, and/or property damage.
This furnace is not designed for use in mobile homes, trailers or recreational vehicles.
!
WARNING
CUT HAZARD
Failure to follow this caution may result in damage personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.
CAUTION
!
441 01 2314 06
Specifications are subject to change without notice.
2
STARTUP CHECK SHEET
For 80+ Furnace
(This sheet is optional. Keep this page for future reference.)
Date of Start−Up:
Dealer Name:
Address:
City, State(Province), Zip or Postal Code:
Phone:
Owner Name:
Address:
City, State(Province), Zip or Postal Code:
Model Number:
Serial Number:
Setup Checks
Check the box when task is complete
Thermostat: Heat
Cooling Fan
Subbase level:
Anticipator Set: Setting of Anticipator ____
All Electrical Connections Tight:
Supply voltage: ____
Blower Motor H.P.: ____
Fan “Time ON” setting: ____ Fan “Time OFF” Setting ___
Manual Gas ShutOff Upstream of Furnace/Drip−Leg?
Gas Valve turned ON?
Type of Gas: Natural: Propane:
Filter Type and Size:
Calculated Firing Rate:(See Checks and Adjustments Sec-
tion).
Heating Check
Measured Line Pressure when Firing Unit:
Measured Manifold Gas Pressure:
Temperature of Supply Air: (°)
Temperature of Return Air: (°)
Temperature Rise (supplyreturn temperature): (°)
In Rise (see furnace rating plate)? (°)
Static Pressure (Ducts): Supply Air Return
Blower speed tap used for heating
Limit Opens: (°) Limit Closes: (°)
Optional Check: CO ? CO2 ?
Cooling Check
Temperature of Supply Air: (°)
Temperature of Return Air: (°)
Temperature Difference: (°)
Static Pressure (Ducts) cooling: Supply Air Return
Blower Speed Tap used for cooling: _______
Dealer Comments:
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Specifications are subject to change without notice.
3
1. Safe Installation Requirements
FIRE, EXPLOSION, AND ASPHYXIATING HAZARD Improper adjustment, alteration, service,
maintenance or installation could cause death, personal injury, and/or property damage.
Installation or repairs made by unqualified persons could result in hazards to you and others. Installation MUST conform with local codes or, in the absence of local codes, with codes of all governmental authorities having jurisdiction.
The information contained in this manual is intended for use by a qualified service agency that is experienced in such work, is familiar with all precautions and safety procedures required in such work, and is equipped with the proper tools and test instruments.
!
WARNING
NOTE: This furnace is designcertified by CSA International (for-
merly AGA and CGA) for installation in the United States and Can­ada. Refer to the appropriate codes, along with this manual, for proper installation.
Use only the Type of gas approved for this furnace (see Rat-
ing Plate on unit). Overfiring will result in failure of heat ex-
changer and cause dangerous operation. (Furnaces can be converted to Propane gas with approved kit.)
Install this furnace only in a location and position as speci-
fied in “Installation” of these instructions.
Provide adequate combustion and ventilation air to the fur-
nace as specified in “Combustion and Ventilation Air” of these instructions.
Combustion products must be discharged outdoors. Con-
nect this furnace to an approved vent system only, as speci­fied in “Gas Vent Installation, Horizontal Venting and Masonry Chimney Venting” of these instructions.
Never test for gas leaks with an open flame. Use a commer-
cially available soap solution made specifically for the detec­tion of leaks to check all connections, as specified in “Gas Supply and Piping, Final Check” of these instructions.
Always install furnace to operate within the furnace’s in-
tended temperaturerise range with a duct system which has an external static pressure within the allowable range, as specified in “Technical Support Manual” of these instruc­tions. See furnace rating plate.
When a furnace is installed so that supply ducts carry air cir-
culated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.
A gas−fired furnace for installation in a residential garage
must be installed as specified in “Installation” of these in­structions.
This furnace is not to be used for temporary heating of build-
ings or structures under construction. See “ Installation”
This furnace is NOT approved for installation in mobile
homes, trailers or recreation vehicles.
Seal around supply and return air ducts.
Install correct filter type and size.
Unit MUST be installed so electrical components are pro-
tected from direct contact with water.
Safety Rules
Your unit is built to provide many years of safe and dependable service providing it is properly installed and maintained. However, abuse and/or improper use can shorten the life of the unit and create hazards for you, the owner.
A. The U.S. Consumer Product Safety Commission encourages
installation of carbon monoxide alarms. There can be various sources of carbon monoxide in a building or dwelling. The sources could be gasfired clothes dryers, gas cooking stoves, water heaters, furnaces, gasfired fireplaces, wood fireplaces.
Carbon monoxide can cause bodily injury and/or death. Car­bon monoxide or “CO” is a colorless and odorless gas pro­duced when fuel is not burned completely or when the flame does not receive sufficient oxygen.
Therefore, to help alert people of potentially dangerous carbon monoxide levels, you should have a commercially available carbon monoxide alarm that is listed by a nationally recog­nized testing agency in accordance with Underwriters Labora­tories Inc. Standard for Single and Multiple Station Carbon Monoxide Alarms, ANSI/UL 2034 or the CSA 6.1901 Resi­dential Carbon Alarming Devices installed and maintained in the building or dwelling concurrently with the gas−fired furnace installation (see Note below). The alarm should be installed as recommended by the alarm manufacturer’s installation in­structions.
B. There can be numerous sources of fire or smoke in a building
or dwelling. Fire or smoke can cause bodily injury, death, and/ or property damage. Therefore, in order to alert people of po­tentially dangerous fire or smoke, you should have fire extinguisher and smoke alarms listed by Underwriters Labora­tories installed and maintained in the building or dwelling (see Note below).
Note: The manufacturer of your furnace does not test any alarms
and makes no representations regarding any brand or type of alarms.
C. To ensure safe and efficient operation of your unit, you should
do the following:
1. Thoroughly read this manual and labels on the unit. This will help you understand how your unit operates and the haz­ards involved with gas and electricity.
2. Do not use this unit if any part has been under water. Im­mediately call a qualified service agency to inspect the unit and to replace any part of the control system and any gas control which has been under water.
3. Never obstruct the vent grilles, or any ducts that provide air to the unit. Air must be provided for proper combustion and ventilation of flue gases.
Frozen Water Pipe Hazard
WATER DAMAGE TO PROPERTY HAZARD Failure to follow this warning could result in
property damage. Do not leave your home unattended for long
periods during freezing weather without turning off water supply and draining water pipes or otherwise protecting against the risk of frozen pipes and resultant damage.
!
WARNING
441 01 2314 06
Specifications are subject to change without notice.
4
Your furnace is designed solely to provide a safe and comfortable living environment. The furnace is NOT designed to ensure that water pipes will not freeze. It is equipped with several safety de­vices that are designed to turn the furnace off and prevent it from restarting in the event of various potentially unsafe conditions.
If your furnace remains off for an extended time, the pipes in your home could freeze and burst, resulting in water damage.
If the structure will be unattended during cold weather you should take these precautions.
1. Turn off the water supply to the structure and drain the water lines if possible and add an antifreeze for potable water to drain traps and toilet tanks. Open faucets in appropriate areas.
or
2. Have someone check the structure frequently during cold weather to make sure it is warm enough to prevent pipes from freezing. Instruct them on a service agency to call to provide service, if required.
or
3. Install a reliable remote sensing device that will notify some­body of freezing conditions within the home.
2. Installation
CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in
personal injury or death. If this furnace is replacing a previously common-
vented furnace, it may be necessary to resize the existing vent system to prevent oversizing prob­lems for the other remaining appliances(s). See
Venting and Combustion Air Check in the Gas Vent Installation section of this instruction.
!
WARNING
Location and Clearances
If furnace is a replacement, it is usually best to install the furnace where the old one was. Choose the location or evaluate the exist­ing location based upon the minimum clearance and furnace di­mensions (Figure 1).
CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in
personal injury or death. Do NOT operate furnace in a corrosive
atmosphere containing chlorine, fluorine or any other damaging chemicals, which could shorten furnace life.
Refer to Combustion & Ventilation Air section, Contaminated Combustion Air for combustion air evaluation and remedy.
!
WARNING
Installation Requirements
1. Install furnace level.
2. This furnace is NOT to be used for temporary heat of buildings or structures under construction.
3. Install furnace as centralized as practical with respect to the heat distribution system.
4. Install the vent pipes as short as practical. (See Gas Vent Installation section).
5. Do NOT install furnace directly on carpeting, tile or other com­bustible material. See Ductwork and Filter Subbase for Com­bustible Floors.
6. Maintain clearance for fire safety and servicing. A front clear­ance of 24″ (609.6mm) required and 30″ (762mm) recommen-
ded for access to the burner, controls and filter. See clearance requirements in Figure 1.
7. Use a raised base if the floor is damp or wet at times.
8. Residential garage installations require:
Burners and ignition sources installed at least 18″ above
the floor.
Furnace must be located or physically protected from
possible damage by a vehicle.
9. If the furnace is to be suspended from the floor joists in a base­ment or a crawl space or the rafters in an attic, it is necessary to use steel pipe straps or an angle iron frame to attach the fur­nace. These straps should be attached to the furnace bottom side with sheet metal screws and to the rafters or joists with bolts. The preferred method is to use an angle iron frame bolted to the rafters or joists.
10. This furnace may be used for construction heat provided that:
The furnace is permanently installed with all electrical wir-
ing, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion prod­ucts into the structure.
The furnace is controlled by a thermostat. It may not be
“hot wired” to provide heat continuously to the structure without thermostatic control.
Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrain­ment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.
The temperature of the return air to the furnace is main-
tained between 55° F (13° C) and 80° F (27° C) , with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.
The air temperature rise is within the rated rise range on
the furnace rating plate, and the firing rate has been set to the rating plate value.
The filters used to clean the circulating air during the
construction process must be either changed or thorough­ly cleaned prior to occupancy.
The furnace, ductwork and filters are cleaned as neces-
sary to remove drywall dust and construction debris from all HVAC system components after construction is com­pleted.
Verify proper furnace operating conditions including igni-
tion, gas input rate, air temperature rise, and venting ac­cording to these installation instructions.
23/
16
37/
8
415/
16
ALL DIMENSIONS in(mm)
1 in = 25.4 mm
Drawing is representative, some models may vary in appearance
NOTE: Evaporator “A” coil drain pan dimensions may vary from furnace duct opening size. Always consult evaporator specifications for duct size requirements.
Unit is designed for top return ONLY.
Return air through back of unit is NOT allowed.
TOP
water heater
252415a1
30
165/
8
11
/
16
81/
4
BOTTOM
D
LEFT SIDE
2415/
16
91/
8
181/
2
93/
16
213/
16
11/
16
3
/
4
FRONT
11
/
16
A
B
RIGHT SIDE
181/
2
37/
8
11/
16
93/
16
2415/
16
121/
16
33/
4
40
A
281/
2
313/
16
C
11
/
16
(724)
(470)
(762)
(17)
(97)
(19)
(27)
(232)
(633)
(71)
(98)
(233)
(125)
(17)
(210)
(422)
(95)
(306)
(633)
(267)
(1016)
(27)
(56)
(233)
(17)
(98)
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Specifications are subject to change without notice.
5
Figure 1 UNIT Dimensions and Clearances (*8DNL)DIMENSIONS
MINIMUM CLEARANCES TO COMBUSTIBLE
MATERIALS FOR ALL UNITS
REAR 0
FRONT 3(76 mm)
Recommended For Service 30(762 mm)
ALL SIDES Of SUPPLY PLENUM 1 (25 mm)
SIDES 0
VENT
Single Wall Vent 6(152 mm)
Type B1 Double Wall Vent 1(25 mm)
TOP OF FURNACE 1 (25 mm)
Horizontal position: Line contact is permissible only between lines formed by intersections of top and two sides of furnace jacket, and building joists, studs or framing.
DIMENSIONAL INFORMATION
Unit
Capacity
Cabinet Top Bottom
A B C D
*8DNL050B12 *8DNL075B12
15 1/
2
(394)
14
(356)
55/
16
(135)
14 1/
8
(359)
*8DNL075F16 *8DNL100F14
19 1/
8
(486)
17 5/
8
(447)
7 3/
4
(197)
17 11/
16
(449)
*8DNL100L20 *8DNL125L20
24
1
/
2
(622)
23
(584)
10 7/
16
(265)
23 1/
8
(587)
* Denotes Brand
Furnace Installation
Inspect the rating plate to be certain the model number begins with “*8DNL”. This identifies the furnace as a dedicated downflow fur­nace that is permitted to be Installed in a Downflow position. (see Figure 2). * Denotes Brand
Downflow
The minimum clearances to combustible material MUST be main­tained between the furnace and adjacent construction, as shown in Figure 1.
FIRE HAZARD Failure to follow this warning could result in
personal injury, death and/or property damage. Place furnace on noncombustible subbase on
downflow applications, unless installing on noncombustible flooring.
!
WARNING
In addition to clearances in Figure 1, clearance for the vent pipe must be considered.
A subbase for combustible floors MUST be used when the furnace is installed on combustible material. See “Ductwork and Filter”.
441 01 2314 06
Specifications are subject to change without notice.
6
Typical Downflow Installation
Figure 2
VENT
GAS SUPPLY
SUPPLY
AIR
RETURN
AIR
252438
3. Combustion & Ventilation Air
CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in
personal injury or death. Use methods described here to provide
combustion and ventilation air.
!
WARNING
Furnaces require ventilation openings to provide sufficient air for proper combustion and ventilation of flue gases. All duct or open­ings for supplying combustion and ventilation air must comply with the gas codes, or in the absence of local codes, the applicable na­tional codes.
Combustion and ventilation air must be supplied in accordance with one of the following:
Note: The Combustion & Ventilation Air Section in this document,
uses tables and information from the ANSI Z223.1/NFPA
54. For use in Canada, use CSA B149.1 for this information.
1. Section 9.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, (NFGC), ANSI Z223.1/NFPA 54−2009 in the U.S.,
2. Sections 8.2, 8.3, 8.5, 8.6, 8.7, and 8.8 of National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC), CSA B149.1−05 in Canada,
3. Applicable provisions of the local building code.
When the installation is complete, check that all appliances have adequate combustion air and are venting properly. See Venting And Combustion Air Check in “Gas Vent Installation” Section in this manual.
Contaminated Combustion Air
Installations in certain areas or types of structures could cause ex­cessive exposure to contaminated air having chemicals or halo­gens that will result in safety and performance related problems and may harm the furnace. These instances must use only out­door air for combustion.
The following areas or types of structures may contain or have ex­posure to the substances listed below. The installation must be
evaluated carefully as it may be necessary to provide outdoor air for combustion.
Commercial buildings.
Buildings with indoor pools.
Furnaces installed in laundry rooms.
Furnaces installed in hobby or craft rooms.
Furnaces installed near chemical storage areas.
Permanent wave solutions for hair.
Chlorinated waxes and cleaners.
Chlorine based swimming pool chemicals.
Water softening chemicals.
Deicing salts or chemicals.
Carbon tetrachloride.
Halogen type refrigerants.
Cleaning solvents (such as perchloroethylene).
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid.
Sulfuric Acid.
Solvent cements and glues.
Antistatic fabric softeners for clothes dryers.
Masonry acid washing materials.
Outdoor Combustion Air Method
A space having less than 50 cubic feet per 1,000 BTUH (22 cm
2
/kW) input rating for all gas appliances installed in the space
requires outdoor air for combustion and ventilation.
Air Openings and Connecting Ducts
1. Total input rating for all gas appliances in the space MUST be considered when determining free area of openings.
2. Connect ducts or openings directly to the outdoors.
3. When screens are used to cover openings, the openings MUST be no smaller than
1
/4″ (6.4mm) mesh.
4. The minimum dimension of air ducts MUST NOT be less than 3(76.2mm)
5. When sizing a grille, louver, or screen use the free area of opening. If free area is NOT stamped or marked on grill or lou­ver, assume a 20% free area for wood and 60% for metal. Screens shall have a mesh size not smaller than
1
/4″ (6.4mm)
requirements
441 01 2314 06
Specifications are subject to change without notice.
7
1. Provide the space with sufficient air for proper combustion and ventilation of flue gases using horizontal or vertical ducts or openings.
2. Figure 3 illustrates how to provide combustion and ventilation air when two permanent openings, one inlet and one outlet, are used.
a. One opening MUST commence within 12 (304.8mm) of
the floor and the second opening MUST commence within 12 (304.8mm) of the ceiling.
b. Size openings and ducts per Table 1.
Furnace
Furnace
Minimum One Inlet and One Outlet Air Supply is Required
May be in and Combination Shown
Inlet Air Opening Must be Within 12(304.8 mm) of floor
Outlet Air Opening Must be Within 12(304.8 mm) of ceiling
(1) 1 Square Inch per 4000 BTUH
(2) 1 Square Inch per 2000 BTUH
Outside Air (This is ONLY a guide. Subject to codes of country having jurisdiction.)
Figure 3
This installation NOT approved in Canada
Gas Vent
Gas Vent
Gas Vent
Gable Vent
Gable Vent
Outlet Air (1)
Outlet Air (1)
Outlet Air (1)
Furnace
Outlet Air (2)
Optional Inlet Air (1)
Ventilated Attic
Ventilated Attic
Ventilated Crawl Space
Inlet Air (1)
Inlet Air (1)
Inlet Air (1)
Inlet Air (2)
Inlet Air (2)
Top Above Insulation
Top Above Insulation
Soffit Vent
Soffit Vent
c. Horizontal duct openings require 1 square inch of free area
per 2,000 BTUH (11 cm
2
/kW) of combined input for all gas
appliances in the space (see Table 1).
d. Vertical duct openings or openings directly communicating
with the outdoors require 1 square inch of free area per 4,000 BTUH (5.5 cm
2
/kW) for combined input of all gas ap-
pliances in the space (see Table 1).
3. When one permanent outdoor opening is used, the opening requires:
a. 1 sq. in of free area per 3,000 BTUH (7 cm
2
/kW) for com­bined input of all gas appliances in the space (see Table 1) and
b. Not less than the sum of the areas of all vent connectors in
the space.
The opening shall commence within 12 (304.8mm) of the top of the enclosure. Appliances shall have clearances of at least 1 (25.4mm) from the sides and back and 6 from the front. The open-
ing shall directly communicate with the outdoors or shall communi­cate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
4. Combination of Indoor and Outdoor Air shall have: a. Indoor openings that comply with the Indoor Combus-
tion Air Method below and
b. Outdoor openings located as required in the Outdoor
Combustion Air Method above and
c. Outdoor openings sized as follows.
1) Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method.
2) Outdoor opening size reduction Factor is 1 minus the Ratio in 1) above.
3) Minimum size of Outdoor openings shall be the size re­quired in Outdoor Combustion Air Method above multi- plied by reduction Factor.
Table 1
Free Area
BTUH (kW)
Input
Rating
Minimum Free Area Required for Each Opening or Duct to Outdoors
Two Horizontal Ducts
BTUH (kW)
sq. in./2,000(1 cm
2
/.09)
Single Opening
BTUH (kW)
sq. in./3,000 (1 cm
2
/.135)
Two Vertical Ducts or Openings
BTUH (kW)
sq. in./4,000(1 cm
2
/.18)
Round Duct
BTUH (kW)
sq. in./4,000(6.5cm
2
/.18)
50,000 (14.65) 25 sq. in. (161 cm2) 16.7 sq. in. (108 cm2) 12.5 sq. in. (81 cm2) 4(101.6mm)
75,000 (21.98) 37.5 sq. in. (242 cm2) 25 sq. in. (161 cm2) 18.75 sq. in. (121 cm2) 5 (127mm)
100,000 (29.31) 50 sq. in. (322 cm2) 33.3 sq. in. (215 cm2) 25 sq. in. (161 cm2) 6 (152.4mm)
125,000 (36.63) 62.50 sq. in. (403 cm2) 41.7 sq. in. (269 cm2) 31.25 sq. in. (202 cm2) 7(177.8mm)
150,000 (43.95) 75 sq. in. (484 cm2) 50 sq. in. (322 cm2) 37.5 sq. in. (242 cm2) 7(177.8mm)
EXAMPLE: Determining Free Area
Furnace 100,000
29.31 Furnace 100,000
29.31
+
+
Water Heater
30,000
8.8
Water Heater
30,000
8.8
=
=
Total Input
(130,000 ÷ 4,000)
(38.11 ÷ .18)
Total Input
(130,000 ÷ 2,000)
(38.11 ÷ .09)
= 32.5 Sq. In. Vertical = 210 c
m
2
Vertical
= 65 Sq. In. Horizontal = 423
cm
2
Horizontal
441 01 2314 06
Specifications are subject to change without notice.
8
Indoor Combustion Air
!
CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in
personal injury or death. Most homes will require additional air from
outdoors for combustion and ventilation. A space with at least 50 cubic feet per 1,000 BTUH (4.8 cubic meters per kW) input rating or homes with tight construction may need outdoor air, supplied through ducts, to supplement air infiltration for proper combustion and ventilation of flue gases.
WARNING
Standard and Known-Air-Infiltration Rate Methods
NFPA & AGA
Indoor air is permitted for combustion and ventilation, if the Stan- dard or KnownAirInfiltration Rate Method is used.
The Standard Method may be used, if the space has no less vol­ume than 50 cubic feet per 1,000 BTUH (4.8 cubic meters per kW) input rating for all gas appliances installed in the space. The stan- dard method permits indoor air to be used for combustion and ven­tilation air.
The Known Air Infiltration Rate Method shall be used if the in- filtration rate is known to be less than 0.40 air changes per hour (ACH) and equal to or greater than 0.10 ACH. Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 2 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space, and add the volumes together to get the total minimum required vol­ume for the space.
Table 2
MINIMUM SPACE VOLUME FOR 100% COMBUSTION AND VENTILATION AIR FROM INDOORS
Other Than Fan-Assisted Total Fan-assisted Total
ACH
30,000 BTU
(8.79 kW)
40,000 BTU
(11.72 kW)
50,000 BTU
(14.65 kW)
50,000 BTU
(14.65 kW)
75,000
(21.98 kW)
100,000 BTU
(29.30 kW)
125,000 BTU
(36.63 kW)
150,000 BTU
(43.95 kW)
ft
3
(m3)
0.60 1,050 (29.7) 1,400 (39.2) 1,750 (49) 1,250 (35) 1,875 (52.5) 2,500 (70) 3,125 (87.5) 3,750 (105)
0.50 1,260 (35.3) 1,680 (47.04) 2,100 (58.8) 1,500 (42) 2,250 (63) 3,000 (84) 3,750 (105) 4,500 (126)
0.40 1,575 (44.1) 2,100 (58.8) 2,625 (73.5) 1,875 (52.5) 2,813 (78.8) 3,750 (105) 4,688 (131.3) 5,625 (158)
0.30 2,100 (58.8) 2,800 (78.4) 3,500 (98) 2,500 (70) 3,750 (105) 5,000 (140) 6,250 (175) 7,500 (210.6)
0.20 3,150 (88.2) 4,200 (117.6) 5,250 (147) 3,750 (105) 5,625 (157.5) 7,500 (210) 9,375 (262.5) 11,250 (316)
0.10 6,300 (176.4) 8,400 (235.2) 10,500 (294) 7,500 (210) 11,250 (315) 15,000 (420) 18,750 (525) 22,500 (632)
0.00 NP NP NP NP NP NP NP NP
NP = Not Permitted Table 2 Minimum Space Volumes were determined by using the
following equations from the National Fuel Gas Code ANSI Z223.1/NFPA 54−2009, 9.3.3.2:
1. For other than fanassisted appliances such as a draft hoodequipped water heater,
1000 BTUH
21 ft
3
(
I
other
)
Vol ume
other
=
ACH
.293 kW
59 m
3
(
I
other
)
Required Vol ume
other
ACH
2. For fanassisted appliances such as this furnace,
If:
I
other
= combined input of all other than fanassisted
appliances in BTUH
I
fan
= combined input of all fanassisted appliances in
BTUH
ACH = air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.
Adjoining rooms can be considered part of a space, if there
are no closable doors between rooms.
Combining spaces on the same floor level. Each opening
shall have a free area of at least 1 in.
2
/1,000 BTUH (22
cm
2
/kW) of the total input rating of all gas appliances in the
space, but not less than 100 in.
2
(645 cm2). Once opening shall commence within 12” (604.8mm) of the ceiling and the second opening shall commence within 12” (604.8mm) of the floor. The minimum dimension of air openings shall be at least 3 in(76.2mm).
An attic or crawl space may be considered a space that freely
communicates with the outdoors provided there are adequate ventilation openings directly to outdoors. Openings MUST re­main open and NOT have any means of being closed off. Ven­tilation openings to outdoors MUST be at least 1 square inch of free area per 4,000 BTUH (5.5 cm
2
/kW) of total input rating
for all gas appliances in the space.
In spaces that use the Indoor Combustion Air Method, in-
filtration should be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be pro­vided using the methods described in section titled Outdoor Combustion Air Method:
Unusually tight construction is defined as Construction with:
1. Walls and ceilings exposed to the outdoors have a continu­ous, sealed vapor barrier. Openings are gasketed or sealed and
2. Doors and openable windows are weather stripped and
441 01 2314 06
Specifications are subject to change without notice.
9
3. Other openings are caulked or sealed. These include joints around window and door frames, between sole plates and floors, between wall−ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.
Ventilation Air
Some provincial codes and local municipalities require ventilation or makeup air be brought into the conditioned space as replace-
ment air. Whichever method is used, the mixed return air tempera­ture across the heat exchanger MUST not fall below 60° F(1C) continuously, or 55° F(13° C) on an intermittent basis so that flue gases will not condense excessively in the heat exchanger. Ex­cessive condensation will shorten the life of the heat exchanger and possibly void your warranty.
4. Gas Vent Installation
CARBON MONOXIDE POISONING, FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death and/or property damage.
Read and follow all instructions in this section.
!
WARNING
Install the vent in compliance with codes of the country having ju­risdiction, local codes or ordinances and these instructions.
This Category I furnace is fanassisted. A fan assisted appliance is an appliance equipped with an integral mechanical means to ei­ther draw or force products of combustion through the heat ex­changer.
Category I furnace definition: A central furnace which operates with a non−positive vent static pressure and with a flue loss not less than 17 percent. These furnaces are approved for common venting and multistory venting with other fanassisted or draft hoodequipped appliances in accordance with the NFGC or NSCNGPIC.
Category I Safe Venting Requirements
Category I furnace vent installations shall be in accordance with Parts 10 and 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54−2009; and/or Section 8 and Appendix C of the CSA B149.1−05, National Standard of Canada, Natural Gas and Propane Installation Code; the local building codes; furnace and vent manufacturer’s instructions.
NOTE: The following instructions comply with the ANSI Z223.1/NFPA 54 National Fuel Gas Code and CSA B149.1 Natu­ral Gas and Propane Installation code, based on the input rate on the furnace rating plate.
1. If a Category I vent passes through an attic, any concealed space or floor, use ONLY Type B or Type L double wall vent pipe. If vent pipe passes through interior wall, use Type B vent pipe with ventilated thimble ONLY.
2. Do NOT vent furnace into any chimney serving an open fire- place or solid fuel burning appliance.
3. Use the same diameter Category I connector or pipe as per­mitted by:
the National Fuel Gas Code Code ANSI Z223.1/NFPA
542009 Sections 12 and 13 venting requirements in the United States,
or
the National Standard of Canada Natural Gas and Pro-
pane Installation Code (NSCNGPIC) CSA B149.105
Section 8 and appendix C venting requirements in Cana­da.
4. Push the vent connector onto the furnace flue collar of the venter assembly until it touches the bead [at least
5
/8″ (15.9mm) overlap] and fasten with at least two fieldsupplied, corrosionresistant, sheet metal screws located at least 140° apart.
5. Keep vertical Category I vent pipe or vent connector runs as short and direct as possible.
6. Vertical outdoor runs of Type−B or ANY single wall vent pipe below the roof line are NOT permitted.
7. Slope all horizontal runs up from furnace to the vent terminal a minimum of
1
/4″ per foot (10mm/m)
8. Rigidly support all horizontal portions of the venting system ev­ery 6(1.8m) or less using proper clamps and metal straps to prevent sagging and ensure there is no movement after instal­lation.
9. Check existing gas vent or chimney to ensure they meet clear­ances and local codes. See Figure 1
10. The furnace MUST be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction. Venting into an unlined ma-
sonry chimney or concrete chimney is prohibited. See the Masonry Chimney Venting section in these instructions.
11. Fanassisted combustion system Category I furnaces shall not be vented into singlewall metal vents.
12. Category I furnaces must be vented vertically or nearly verti­cally, unless equipped with a listed mechanical venter.
13. Vent connectors serving Category I furnaces shall not be con­nected into any portion of mechanical draft systems operating under positive pressure.
A 4−to−3 inch (101.6−to−76.2mm) reducer is permitted at the flue collar when installing a 50,000 BTUH (14.5 kW) gas input furnace, if the installation meets all the following requirements for sizing the vent connectors and vents:
1. The National Fuel Gas Code, ANSI Z223.1/NFPA542009, Sections 12.6.3.1(1),
12.7.3.1(2), 12.11.3.1, 13.1.2, 13.1 (e), and 13.2.24(1) through (3) in the U.S. or
2. The Natural Gas and Propane Installation Code CSA B149.105, Sections 8.13.1(b), 8.13.2(b), 8.18.5(b), and Appendix C−GVR no. 2. in Canada.
Venting and Combustion Air Check
NOTE: When an existing Category I furnace is removed or re­placed, the original venting system may no longer be sized to prop­erly vent the attached appliances, and to make sure there is adequate combustion air for all appliances, MAKE THE FOL-
LOWING CHECK.
Vent Check
Draft HoodVent Pipe
Match
Typical Gas Water Heater
Figure 4
NOTE: If flame pulls towards draft hood, this indicates
sufficient infiltration air.
441 01 2314 06
Specifications are subject to change without notice.
10
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation, could result in carbon monoxide poisoning or death:
The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:
1.Seal any unused openings in the venting system.
2.Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 or CSA B149.1, Natural Gas and Propane Installation Code and these instructions. Determine that
there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3.As 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.
4.Close fireplace dampers.
5.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 are operating at maximum speed. Do not operate a summer exhaust fan.
6.Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.
7.Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. (Figure 4)
8.If improper venting is observed, during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.
9.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 gasfired burning appliance to their previous conditions of use.
!
WARNING
Venting to Existing Masonry Chimney
Dedicated venting of one fan assisted furnace into any ma­sonry chimney is restricted. A chimney must first be lined with
either Type B vent sized in accordance with NFGC tables 13.1 or
13.2 or a listed metal lining system, sized in accordance with the NFGC Section 13.1.7 for a single appliance or 13.2.20 for multiple appliances, or NSCNGPIC Appendix C, Section 10. (See Masonry Chimney Venting of these instructions.)
Listed, corrugated metallic chimney liner systems in masonry chimneys shall be sized in the U.S. by using NFGC tables per
13.1.7 for dedicated venting and per 13.2.20 for common venting with the maximum capacity reduced by 20% (0.80 X maximum ca­pacity) and the minimum capacity as shown in the applicable table. Corrugated metal vent systems installed with bends or offsets re­quire additional reduction of 5% of the vent capacity for each bend up to 45° and 10% of the vent capacity for each bend from 45° up to 90°. In Canada, use the NSCNGPIC.
NOTE: Two(2) 45° elbows are equivalent to one (1) 90° elbow.
Combined Venting into a Masonry Chimney
Venting into a masonry or concrete chimney is only permitted as outlined in the NFGC or NSCNGPIC venting tables. Follow
all safe venting requirements.
Note: See section “Masonry Chimney Venting”.
5. Horizontal Venting
Category I Furnaces With External Power Venters
In order to maintain a Category I classification of fanassisted fur­naces when vented horizontally with sidewall termination, a power venter is REQUIRED to maintain a negative pressure in the vent- ing system.
In the U.S.: Per the NFGC, a listed power venter may be used, when approved by the authority having jurisdiction.
In Canada: Only power venters approved by the power venter manufacturer and where allowed by the authority having jurisdic­tion may be used.
Please consult the Fields Controls Co. or Tjernlund Products, Inc. for power venters certified for use with this furnaces.
Vent Termination
Venting Through a Non-Combustible and Combustible Wall
Consult External Power Venter manufacturer instructions.
Select the power venter to match the Btuh input of the furnace be­ing vented. Follow all of the power venter manufacturer’s installa­tion requirements included with the power venter for:
venting installation,
vent terminal location,
preventing blockage by snow,
protecting building materials from degradation by flue gases,
see Figure 5 for required vent termination.
NOTE: It is the responsibility of the installer to properly terminate the vent and provide adequate shielding. This is essential in order to avoid water/ice damage to building, shrubs and walkways.
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