ICP GDE075F16G1, GDE100F14G1, GDE100F20G1 Installation Guide

Upflow/HorizontalSeries

Downflow Series

SAFETY REQUIREMENTS

Recognize safety information. This is the safety-alert symbol _. When you see this symbol on the furnace and in instructions manuals be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, or CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards, those that will result in severe personal injury or death. WARNING signifies a hazard that could

result in personal injury or death. CAUTION is used to identify unsafe practices that could result in minor personal injuryor product and property damage.

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified person- nel should install, repair, or service heating equipment.

Untrained service personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in the literature, on tags,

and on labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes. In the United States, follow all safety codes including the current edition National Fuel Gas Code (NFGC) NFPA No. 54/ANSIZ223.1. In Canada, refer tothe current edition ofthe National Standard Canada CAN/CGA-B149.1 - and .2-M91 Natural

Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-

up and adjustment procedures and service calls.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential

construction practices. We require these instructions as a minimum for a safe installation.

Design Certified

byAGA

Manufactured by:

International Comfort Products Corporation (USA)

Lewisburg, TN USA 37091

Table of Contents

1.Installation............................... 2

2.Combustion&VentilationAir ................. 5

3.GasVentInstallation ....................... 7

4.HorizontalVenting ......................... 8

5.MasonryChimneyVenting ................... 9

Printed in U.S.A. LP1 1/12/2000 441 01 2308 01

6.GasSupplyandPiping .................... 10

7.ElectricalWiring ......................... 12

8. DuctworkandFilter(Upflow/Horizontal)....... 14

9.DuctworkandFilter(Downflow).............. 15

t0. ChecksandAdjustments.................. 17

11.FurnaceMaintenance..................... 18

Fire or Explosion hazard. This furnace is not designed for use in mobile

homes, trailers or recreational vehicles. Such use could result in death, bodily injury

and/or property damage.

1. Installation

Installation or repairs made by unqualified persons can 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 technician

who is experienced in such work, who is familiar with all precautions and safety procedures

required in such work, and is equipped with the proper tools and test instruments.

Failure to carefully read and follow all instruc-

tions in this manual can result in furnace

malfunction, death, personal injury and/or property damage.

NOTE: This furnace is design certified by the American Gas

Association and the Canadian Gas Association for installation in the United States and Canada. Refer to the appropriate codes,

along with this manual, for proper installation.

• This furnace is NOT approved for installation in mobile

homes, trailers or recreation vehicles.

• Do NOT use this furnace as a construction heater or to heat a building that is under construction.

Use only the Type of gas approved for this furnace (see Rating Plate on unit). Overfiring will result in failure of heat exchanger and cause dangerous operation. (Furnace can be converted to L.E gas with approved kit.)

• Do NOT use open flame to test for gas leak.

• Ensure adequate combustion and ventilation air is pro- vided to the furnace.

• Seal supply and return air ducts.

• The vent system MUST be checked to determine that it is the correct type and size.

A. The U.S. Consumer Product Safety Commission recom-

mends that users of gas-burning appliances install carbon monoxide detectors. There can be various sources of car-

bon monoxide in a building or dwelling. The sources could be gas-fired clothes dryers, gas cooking stoves, water heaters, furnaces, gas-fired fireplaces, wood fireplaces,

and several other items. Carbon monoxide can cause seri- ous bodily injury and/or death. Therefore, to help alert

people of potentially dangerous carbon monoxide levels, you should have carbon monoxide detectors listed by a na- tionally recognized agency (e.g. Underwriters Laborato-

ries or International Approval Services) installed and

maintained in the building or dwelling (see Note below).

B. There can be numerous sources of fire or smoke in a build-

ing or dwelling. Fire or smoke can cause serious bodily in- jury, death, and/or property damage. Therefore, in order to

alert people of potentially dangerous fire or smoke, you should have fire extinguisher and smoke detectors 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 detec-

tors and makes no representations regarding any brand or type of detector.

C. To ensure safe and efficient operation of your unit, you

should do the 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 technician 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 pro-

vide air to the unit. Air must be provided for proper com-

bustion and ventilation of flue gases. 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.

FreezingTemperaturesand Your Structure

• 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.

Freeze warning.

Turn off water system.

If your unit remains shut off during cold weather

the water pipes could freeze and burst, resulting

in serious water damage.

Your unit is equipped with safety devices that may keep itfrom op- erating if sensors detect abnormal conditions such as clogged ex-

haust flues.

Ifthe structure will be unattended during cold weather you should

take these precautions.

1. Turn off main supply water into the structure and drain the water lines if possible. Open faucets in appropriate areas.

44t 01230801

Havesomeonecheckthestructurefrequentlyduringcold

weathertomakesureit iswarmenoughtopreventpipes fromfreezing.Suggesttheycallaqualifiedserviceagency,

ifrequired.

Poison carbon monoxide gas hazard. If this furnace is replacing a previously

common-vented furnace, it may be necessary to resize the existing vent line and chimney to prevent oversizing problems for the other remaining appliances(s). See applicable codes and Venting and Combustion Air Check in Gas

Vent Installation section. Failure to properly vent this furnace or other

appliances can result in death, personal injury and/or property damage.

Upflow Dimensions and Clearances (NTC6/GNE & NTN6/NNE)

I K

HI K

Locationand 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 exist- ing location based upon the minimum clearance and furnace di-

mensions (Figure 1 and Figure 2).

Do NOT operate furnace in a corrosive atmosphere

containing chlorine, fluorine or any other damaging chemicals. Refer to Combustion & Ventilation Air sec-

tion, Contaminated Combustion Air.

t50,060 BTU ONLY AirBaffle DO NOTREMOVE

I ]

CAUTION

MINIMUM CLEARANCES TO

COMBUSTIBLE

MATERIALS FOR ALL UNITS

REAR 0 FRONT 3" (75mm)*

For Service 30" (760mm)

ALL SIDES Of SUPPLY PLENUM 1" (25mm) SIDES 0

VENT

Single Wall Vent 6" (150mm) Type B-1 Double Wall Vent 1" (25mm)

TOP OF FURNACE 6" (150mm)

* 6" with accessory Masonry Chimney drafthood kit installed.

30" min.

25-20-29a

DIMENSIONAL INFORMATION

MODEL

050FB / 075FB 050B12 / 075B12

075HF & 075F16 100KF / 100F20

100KJ / 100J20 125KJ / 125J20 40 223/4 281/2 150KJ / 150J20

mm Equivalents 40=1016 151/2 = 394 191/8 = 486 " 211/4 = 539 231/8 = 587 128/8 = 311 143/4 = 375

26 = 660 237/8 = 606

44101 2308 01

CABINET

A B C

40 151/2 281/2

40 191/8 281/2

SUPPLY AIR

D I E

181/2 I 14

181/2 I 175/8

181/2 I 211/4

ALL DIMENSIONSIN INCHES(millimeters)

RETURN AIR

BOTTOM SIDE

F IG i. iJ

231/8 125/8 121/4 221/2

231/8 143/4 141/2 221/2

231/8 183/4 141/2 221/2

223/4 = 578 281/2 = 724 181/2 = 470

183/4 = 476 121/4 = 311 141/2 = 368

GAS CONNECTION

K L M

281_ 26 237_

14 = 356 17_8=448

2216 = 572 281/4 = 717

Figure 2

I A K" I

30" MIN.

Dimensions and Clearances (NDN6/GDE)

MINIMUM CLEARANCES TO

COMBUSTIBLE

MATERIALS FOR ALL UNITS REAR 0 FRONT 3" (75mm)

For Service 30" (760mm)

ALL SIDES Of SUPPLY PLENUM 1" (25mm) SIDES 0

VENT

Single Wall Vent 6" (150mm) Type B-1 Double Wall Vent 1" (25mm)

TOP OF FURNACE 6" (150mm)

252045

ALL DIMENSIONS IN INCHES (mm)

DIMENSIONAL INFORMATION

MODEL

NDN6050/075FB GDE050/075B

NDN6075HF & NDN6100GF/KF GDE075F/100F

NDN6125KJ/GDE125J

mm Equivalents 15112=394 19118=486 223/4=578 28112=724 40 = 1016 14=356 t79/16=446 179/16=446 213/16=538

1817132=47t 913/16= 249 21/2= 64 411/16= 119

CABINET

A B C

t516 2816 40

t91_ 2816 40 223_ 2816 40

Installation Requirements

1. Install furnace level.

This furnace is NOT to be used for temporary heat of build- ings or structures under construction.

Install the vent pipes as short as practical. (See Gas Vent

Installation section).

BOTTOM RETURN

OPENING

D E

14 151/2

179/16 151/2 213/16 151/2

F G

14 1817/32

179/16 1817/32

213/16 1817/32

OPENING

GAS CONNECTIONS

H J K

913/16 21/2 411/16

7. Residential garage installations require:

• Burners and ignition sources installed at least 18" (457mm) above the floor.

• Furnace must be located or physically protected from pos- sible damage by a vehicle.

HorizontalFurnaceInstallation

IMPORTANT

Do NOT install furnace directly on carpeting, tile or other

combustible material other than wood flooring.

Maintain clearance for fire safety and servicing. A front clear-

ance of 30" (760mm) is minimum for access to the burner, controls and filter.

Use a raised base if the floor is damp or wet at times.

NOTE: Inspect unit rating plate to be certain model number be- gins with "NTC6", "GNE, "NTN6" or "NNE". This identifies unit

as horizontally mountable. If unit does NOT bear this designation, you may NOT mount this unit horizontally. Horizontal furnace may not be mounted on its back.

If you purchased a horizontally mountable furnace, it can be installed horizontally in an attic, basement, crawl space, alcove, or suspended from a ceiling in a basement or utility room in either a right or left airflow position. See Figure 3.

44t 01230801

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The minimum clearances to combustibles MUST be maintained

between the furnace and adjacent construction. As shown in

Figure 1, ONLY the corner of the cabinet is allowed to contact the rafters Figure 3. All other clearances MUST be observed as shown in Figure 1.

If the furnace is to be suspended from the floor joists in 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 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.

Ifthe furnace is to be installed ground level in a crawl space, con- sult local codes. A concrete pad 1" to 2" (25 to 50mm) thick is rec-

ommended.

Typical Horizontal Installation

wood floor and extend 12" (300mm) beyond the front of the fur- nace louver door. (This is a recommendation only, not a require- ment).

This furnace MUST NOT be installed directly on carpeting or tile or other combustible material other than wood flooring or sup-

ports.

Pressure Switch Relocation

Ifthe furnace is installed in a right to left airflow position (left side of

furnace facing down), the pressure switch will remain inthe same position as installed by the factory (see Figure 4). Ifthe furnace is

installed in a left to right airflow position (right side of furnace fac- ing down), the pressure switch MUST be relocated to the left side

of the furnace using the holes provided in the top panel. Position the pressure switch in the same orientation as the original loca- tion. To prevent possible kinking ofthe pressure switch hose, trim

the hose to remove excess.

Note: Care MUST be taken not to cut the tube too short.

Pressure Switch Relocation

Optionalpressure switch location for

Rightto Left

Airflow

ShownAs

Thirty inches (30")(760mm) between the front of the furnace and adjacent construction or other appliances MUST be maintained for service clearance.

Keep all insulating materials clear from Iouvered door. Insulating

materials may be combustible.

Itis recommended for further fire protection that cement board or sheet metal is placed between the furnace and the combustible

2. Combustion&VentilationAir

Poison carbon monoxide gas hazard. Use methods described here to provide combus-

tion and ventilation air.

Failure to provide adequate combustion and

ventilation air can result in death and/or personal

injury.

Furnaces require ventilation openings to provide sufficient air for

proper combustion and ventilation of flue gases. All duct or open-

ings for supplying combustion and ventilation air must comply with the gas codes, or in the absence of local codes, the applica-

ble national codes.

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.

rightside,relocate

switchto leftside in sameorientationas

originallymounted.

Contaminated CombustionAir

Installations in certain areas or types of structures will increase

the exposure to chemicals or halogens that may harm the fur- nace. These instances must use only outside air for combustion.

The following areas or types of structures may contain or have ex- posure to the substances listed below. The installation must be

evaluated carefully as it may be necessary to provide outside 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.

• De-icing salts or chemicals.

• Carbon tetrachloride.

• Halogen type refrigerants.

44101 2308 01 [_

• 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.

ConfinedSpaceInstallation

NOTE: A confined space is defined as an area with less than 50 cubic feet(1.4m 3) per 1,000 BTUH input rating for all gas ap-

pliances installed in the area.

Requirements

6. Vertical duct openings or openings directly to outside require 1square inch (6.5mm 3) of free area per 4,000 BTUH for com-

bined input of all gas appliances in area (see Table 1).

Air Openingsand ConnectingDucts

1. Total input rating for all gas appliances MUST be considered when determining free area of openings.

2. Connect ducts or openings directly to outside.

3. When screens are used to cover openings, the openings MUST be no smaller than 1/4" (Cmm) mesh.

4. The minimum dimension of rectangular air ducts MUST NOT be less than 3" (75mm).

1. Provide confined space with sufficient air for proper combus- tion and ventilation of flue gases using horizontal or vertical ducts or openings.

2. Figure 5 illustrates how to provide combustion and ventila- tion air. A minimum oftwo permanent openings, one inlet and one outlet, are required.

One opening MUST be within 12" (300mm) of the floor and the second opening within 12" (300mm) of the ceiling.

Size openings and ducts per Table 1.

Horizontal duct openings require 1 square inch(25sq, mm) of

free area per 2,000 BTUH of combined input for all gas ap- pliances in area (see Table 1).

Outside Air (This is ONLY a guide. Subject to codes of country having jurisdiction.)

This installation NOT approved in Canada

._ _ _ -Optional Inlet Air (1)

Soffit Vent

I ' ' n so%lit ent

°t'etAirl''II L

I _ .LI. II I Outlet

5. When sizing grille or louver, use the free area of opening. If free area is NOT stamped or marked on grill or louver, as-

sume a 20% free area for wood and 60% for metal.

One permanent opening, commencing within 12" (30 cm) of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1" (2.5 cm) from the sides and back and 6"

(16 cm) from the front of the appliance. The opening 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, and shall have a mini-

mum free area of:

• t sq. in per 3000 Btu per hr (7cm2per kW) ofthe total inputrating of all equipment located in the enclosure, and

• Not less than the sum of the areas of allvent connectors in the confined space.

i N iii

Inlet

Air (1)

t'l I I I _ _ Air(2)

MinimumOne Inlet and OneOutlet AirSupply is Required

May be in andCombinationShown

InletAir OpeningMustbe Withint2"(300mm)of floor OutletAir Opening Must be Withint2"(300mm)of ceiling (1) 1SquareInch (Ccm2) per4000BTUH

12)1SquareInch IOcm2}per2000BTUH

_] 44t 012308 01

Inlet Air (t)

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