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)

FreeArea

MinimumFreeAreaRequiredforEachOpening

BTUH

Input HorizontalDuct

Rating (sq. in./2,000BTUH)

50,000 25 sq. in.(161cm2)

75,000 35.5 sq. in.(242cm2) 100,000 50 sq. in.(323cm2) 125,000 62.5 sq. in.(403cm2)

EXAMPLE: Determining Free Area

Furnace Water Heater Total Input

100,000 + 30,000 = (130,000 + 4,000) = 32.5 Sq. In. Vertical

Furnace Water Heater Total Input 100,000 + 30,000 = (130,000 + 2,000) = 65 Sq. In. Horizontal

VerticalDuctoropenings

to outside

(sq. inJ4,000 BTUH)

12.5sq. in.(81cm2)

18.75sq. in.(121cm2) 25 sq. in. (161cm2)

31.25 sq.in. (202cm2)

(2t0 cm2)

(4t9 cm2)

RdDuct

(sq.in.

/4,000

BTUH)

An unconfined space is defined as an area having a minimum vol- ume of 50 cubic feet(1.4m 3)per 1,000 Btuh total input rating for all gas appliances in area.

Adjoining rooms can be considered part of an unconfined area if there are no doors between rooms.

An attic or crawl space may be considered an unconfined space provided there are adequate ventilation openings directly to out- doors. Openings MUST remain open and NOT have any means of being closed off. Ventilation openings to outdoors MUST be at

least 1 square inch (25mm 2) of free area per 4,000 BTUH of total input rating for all gas appliances in area.

In unconfined spaces, infiltration 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 Con-

fined Space Installation:

Unusually tight construction is defined as: Construction with

UnconfinedSpaceInstallation

Poison carbon monoxide gas hazard. Most homes will require additional air.

An unconfined space or homes with tight construction may not have adequate air infiltra- tion for proper combustion and ventilation of

flue gases.

Failure to supply additional air by means of ven-

tilation grilles or ducts could result in death and/ or personal injury.

3. GasVent Installation

Poison carbon monoxide gas, fire and explo- sion hazard.

Read and follow all instructions in this section. Failure to properly vent this furnace can result in

death, personal injury and/or property damage.

Install the vent in compliance with codes of the country having ju- risdiction, local codes or ordinances and these instructions.

These fan assisted combustion furnaces have been classified as

Category [ appliances which means that they MUST operate with

a negative vent pressure.

Category I Safe Venting Requirements

NOTE: The following instructions comply with the United States National Fuel Gas Code. Based on the highest input rate on the

furnace rating plate.

If a Category [ 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.

1 Walls and ceilings exposed to the outside have a continuous,

sealed vapor barrier. Openings are gasketed or sealed and

2 Doors and openable windows are weather stripped and

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.

VentilationAir

Some provincial codes and local municipalities require ventilation or make-up air be brought into the conditioned space as replace- ment air. Whichever method is used, the mixed return air temper-

ature across the heat exchanger MUST not fall below 60°F (15 ° c) or flue gases will condense in the heat exchanger. This will short- en the life of the heat exchanger and possibly void your warranty.

2. Do NOT vent furnace into any chimney serving an open fire- place or solid fuel burning appliance.

Use the same diameter Category [ connector or pipe as per- mitted by the United States National Fuel Gas Code vent- ing tables.

Keep vertical Category [ vent pipe or vent connector runs as short and direct as possible.

Vertical outdoor runs of type B or ANY single wall vent pipe below the roof line are NOT permitted.

Slope all horizontal runs up away from furnace a minimum of

1/4" (6mm) per foot.

Support all horizontal vent pipe every 6' (2m) using proper clamps and metal straps.

Check existing gas vent or chimney to ensure they meet clearances and local codes.

The furnace MUST be connected to a factory built chimney or vent complying with a recognized standard. Venting into a

masonry or concrete chimney is only permitted as out- lined in the United States National Fuel Gas Code vent-

ing tables or Masonry Chimney section in these instructions.

44101 2308 01 [_

Ventingand CombustionAir Check

NOTE: Ifthis installation removes an existing furnace from avent-

ing system serving one or more other appliances, and to make

sure there is adequate combustion air for all appliances, MAKE THE FOLLOWING CHECK.

1. Seal any unused openings in the venting system.

Visually inspect the venting system for proper size and hori- zontal pitch to ensure there is no blockage or restriction, leak-

age, corrosion or other deficiencies which could cause an unsafe condition.

Insofar as is practical, close all doors and windows and all

doors between the space in which the appliance(s) remain- ing connected to the venting system are located and other spaces of the building.

Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maxi-

mum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

Follow the lighting instructions for each appliance being in- spected. Adjust thermostat so appliance(s) will operate con- tinuously.

6. Allow 5 minutes of main burner operation, then check for spillage at the draft hood relief opening of each appliance.

Use the flame of a match or candle (Figure 6).

Vent Check

7. After it has been determined that each appliance vents prop- erly, return doors, windows, appliances etc. to their normal

condition.

8. If improper venting is observed, the cause MUST be cor- rected.

NOTE: If flame pulls towards draft hood, this indicates sufficient infiltration air.

Ventingto ExistingMasonryChimney

NOTE: The tables and notes referred to below are found in the most recent printing of the United States National Fuel Gas

Code venting tables.

Use the United States National Fuel Gas Code or NFGC Tables

to size the chimney or vent. Dedicated venting of one fan as- sisted furnace into any masonry chimney is restricted. The

chimney must first be lined with either type B vent sized in accor- dance with tables 1 or 2 or a listed single wall, metal lining system,

sized in accordance with the vent tables.

Listed, corrugated metallic chimney liner systems in masonry chimneys shall be sized by using United States National Fuel Gas Code tables for dedicated venting and United States Na- tional Fuel Gas Code tables for common venting with the maxi-

mum capacity reduced by 20% (0.80 X maximum capacity) and the minimum capacity as shown in the applicable table. Corru- gated metal vent systems installed with bends or offsets require

additional reduction of 10% of the vent capacity for each 90 ° el- bow.

Vent Pipe ---_1 I A/ Draft Hood

Typical Gas

Water Heater

Match

I I

4. HorizontalVenting

Category I FurnacesWith ExternalPower

Venters

Inorder to maintain a Category[ classification offan assisted fur-

naces when vented horizontally with sidewall termination, a pow- er venter is REQUIRED to maintain a negative pressure in the venting system. Please consult the Fields Controls Co. or Tjern-

lurid Products, Inc. for power venters certified for use with our fur-

naces.

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 per- mitted as outlined in the United States National Fuel Gas

Code venting tables. Follow all safe venting requirements.

VentTermination

Venting Through a Non-Combustibleand Combustible Wall

Consult External Power Venter manufacturer instructions.

CAUTION

It is the responsibility of the installer to properly termi-

nate the vent and provide adequate shielding. This is essential in order to avoid water/ice damage to build- ing, shrubs and walk-ways.

_] 44t 012308 01

5. MasonryChimneyVentingwithOptionalKit(Upflow/HorizontalFurnaces)

(USAONLY)Not recommendedwith downflowfurnaces

ChimneyInspection

All masonry chimney construction must conform to Standard ANSI/NFPA211 and to any state or local codes applicable. The chimney must be in good condition and a complete investigation

must be conducted prior to installation. If the inspection reveals damage or abnormal conditions, make necessary repairs or seek

expert help. See "The Chimney Inspection Chart". Measure area of tile-liner and exact height of chimney.

ConnectorType

To reduce flue gas heat loss and the chance of condensate prob-

lems, the vent connector must be double wall Type B vent.

VentingRestrictionsfor ChimneyTypes

Interior Chimney - has no sides exposed to the outside below the roofline. All installations can be single furnace or common

vented with another draft hood equipped Category [ appliance.

Exterior Chimney - has one or more sides exposed to the out- side below the roof line. All installations must be common vented

only with another draft hood equipped Category ! appliance.

I l Caution - failuretofollowtheseguide- I

lines may cause property damage.

OptionalMasonryVent Kit

DraftHoodAssy.Installation(SeeFigure7)

NOTE: These instructions apply to the NTC6 & GNE series fur-

naces only.

1. Disconnect power and gas supply to furnace.

2. Remove Iouvered door.

NTC6, GNE, NTN6 & NNE Series furnaces - Discard Iou-

vered door.

!!!!!!!!!!!

Draft Hood Assembly Installation

3. NTC6, GNE, NTN6 & NNE may be installed upflow or hori- zontal position per furnace application. When installing

NTC6, GNE, NTN6 & NNE furnaces in a horizontal left hand

application you will need to mount the pressure switch to the side of the cabinet.

4. NTC6, GNE, NTN6 & NNE series furnaces - Detach pres- sure switch from top panel by removing two screws. Set

aside screws.

5. Detach field connect box from top panel by removing two screws. Set aside screws.

6. Remove four screws holding top panel to casing. Remove top panel. Discard top panel. Set screws aside.

7. Install draft hood assy. to casing using four screws previously set aside.

8. Attach field connect box to draft hood assy. using two screws previously set aside.

9. NTC6, GNE, NTN6 & NNE Series furnaces - Attach pres- sure switch to draft hood assy. using two screws previously

set aside.

Vent Limit SwitchWiring (SeeFigureT)

1. Locate wire harness assy. which is supplied with kit. Attach terminals on one end of wire harness assy. to vent limit switch located on draft hood assy.

Locate furnace's main limit. Detach wire with insulated termi- nal from one side of main limit.

Route wire harness assy. from vent limit switch to main limit.

Attach female terminal of wire harness assy. to vacated main limit terminal. Attach male terminal of wire harness assy. to insulated terminal of wire previously detached from main lim-

it.

Completionof Installation

1. NTC6, GNE, NTN6 & NNE Series furnaces - Locate Iou- vered door supplied with kit. Install on furnace.

2. Refer to installation instructions provided with furnace to put the furnace into operation.

Pressure switch_'-_ (o°nld el_catiOn)

draft hood _ __.. L_'beation

old top panel // ( (_C )__

assembly /_ /_ _" >

Pressure s_, _ _ _((,_ ui Limit

-<,.z e _ J. . / '"- _newwire

wire harness __'_'_

25-21-98a assembly J

Masonry chimney venting shall be approached as follows: Using Table land Table 2 inthe masonry chimney draft hood kit instructions,

the NFGC Z223.1-1992 or the United Stated National Fuel Gas Code Venting Tables.

44101 2308 01 [_

// _switch

/_"_ harness

Main f assy.

Limit

pLefthand Horizontal

rassure

6. GasSupplyand Piping

3. Relight all appliances and ensure all pilots are operating.

Poison carbon monoxide gas, fire and explosion hazard.

Models designated for Natural Gas areto be used with Natural Gas ONLY, unless properly con- verted to use with LP gas.

Failure to follow these instructions can result in death, personal injury and/or property damage.

GasSupplyRequirements

• Use only the Type of gas approved for this furnace. See rat-

ing plate for approved gas type.

• Gas input must not exceed the rated input shown on the rat- ing plate. Overfiring will result in failure of heat exchanger

and cause dangerous operation.

• Do not allow minimum supply pressure to vary downward.

Doing so will decrease input to furnace. Refer to Table 2 for

Gas supply and manifold pressures.

Gas Pressures

Gas

Type

Natural

Propane

Recommended Max.

Table 3 Orifice Sizes (below 2000')for

Gas Manifold Specific (BTU per

Type Pressure Gravity Cubic Ft.)

Natural 800

Supply Pressure

7" 14"

(1.7 kPa) (3.5 kPa)

11" 14"

(2.7 kPa) (3.5 kPa)

Downflow

Heating Value

Min.

4.5"

(1.1 kPa)

1t"

(2.7 kPa)

3.5" w.c. 900

0.9kPa 0.6

W.C.

10" W.C.

Propane 2.5kPa 1.53 2500

w.c.

1000 1100

Manifold

Pressure

3.5 _

(0.9 kPa)

10"

(2.5 kPa)

Orifice Size

(Drill #)

40 41

42 43

Natural Gas InputRatingCheck

The gas meter can be used to measure input to furnace. Rating is

based on a natural gas BTU content of 1,000 BTU's per cubic foot. Check with gas supplier for actual BTU content.

1. Turn OFF gas supply to all appliances other than furnace and start furnace.

2. Time how many seconds it takes the smallest dial on the gas meter to make one complete revolution. Refer to Example.

Note: If meter uses a 2 cubic foot dial, divide results (se- conds) by two.

Example

Orifice Sizing

NOTE: Factory sized orifices for natural and LP gas are listed in the furnace Technical Support manual.

For downflow ensure furnace is equipped with the correct main

burner orifices. Refer to Table 3 for correct orifice size for a given heating value and specific gravity for natural and propane gas.

Note that this chart is ONLY for downflow installations below

2000' in altitude.

OperationAbove 2000' Altitude

Fire, Explosion, Poison carbon monoxide gas haz- ard.

This conversion shall be done by a qualified ser-

vice agency in accordance with the Manufactur-

er's instructions and all applicable codes and re- quirements, or in the absence of local codes, the applicable national codes.

Failure to follow these instructions exactly can re- sult in death, personal injury and/or property dam- age.

These units may be used at full input rating when installed at alti- tudes up to 2000'. When installed above 2000', the input must be

decreased 2% (natural) or 4% (LP) for each 1000' above sea level. This may be accomplished by a simple adjustment of manifold

pressure or an orifice change, or a combination of a pressure ad- justment and an orifice change. The changes required depend on the installation altitude and the heating value of the fuel. Table 4 & Table 5 show the proper furnace manifold pressure and gas ori-

fice size to achieve proper performance based on elevation above sea level for both natural gas and propane.

To use the natural gas table, first consult your local gas utility for the heating value of the gas supply. Select the heating value on

the vertical border and follow across the table until the appropriate elevation for the installation is reached. The first value in the box

at the intersection of the heating value and elevation will be the manifold pressure required. If a gas orifice change is also re- quired, the box is shaded. The required orifice size is shown atthe

bottom of the table.

Sea Level High Altitude Input Rate = Nameplate x (Multiplier)

Input Rate

Elevation

2000'-2999' 3000'-3999' 4000'-4999' 5000'-5999' 6000'-6999'

7000'-7999'

High Altitude Multiplier

Natural LP Gas

0.96 0.92

0.94 0.88

0.92 0.84

0.90 0.80

0.88 0.76

0.86 0.72

Natural Gas No. of Seconds Time Per Cubic BTU Per

BTU Content Per Hour Footin Seconds Hour

1,000 3,600 48 75,000

1,000 x3,600 + 48 = 75,000 BTUH

_] 44t 012308 01

A High Altitude Kit is available for downflow which includes re- strictors, orifices and installation instructions.

Natural Gas - 1160993 LP Gas - 1160992

MANIFOLDPRESSUREAND ORIFICESIZEFOR HIGHALTITUDEAPPLICATIONS

NATURALGAS

MEAN ELEVATION FEET ABOVE SEA LEVEL

HEATING VALUE 0 to 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to

BTU/CU. FT. 1999 2999 3999 4999 5999 6999 8000

800 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.5" wc 850 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.5" wc 900 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.4" wc

950 3.5" wc 3.5" wc 3.5" wc 3.5" wc 3.3" wc 3.2" wc 3.1" wc t000 3.5" wc 3.4" wc 3.3" wc 3.2" wc 3.0" wc 2.9" wc 2.8" wc t050 3.2" wc 3.t" wc 3.0" wc 2.9" wc 2.7" wc 2.6" wc 2.5" wc 1100 2.9" wc 2.8" wc 2.7" wc 2.6" wc 2.5" wc 2.4" wc 2.3" wc

Orifice Size #42 #42 #42 #42 #42 #42 #42

LP Gas

MEAN ELEVATION FEET ABOVE SEA LEVEL

HEATING VALUE 0 to 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to

BTU/CU. FT. 1999 2999 3999 4999 5999 6999 8000

2500 10.0" wc 10.0" wc 9.4" wc 10.0" wc 9.8" wc 8.8" wc 7.9" wc

Orifice Size #54 #54 #54 #55 #55 #55 #55

NOTE: NATURAL GAS DATA BASED ON 0.60 SPECIFIC GRAVITY. PROPANE DATA BASED ON 1.53 SPECIFIC GRAVITY. FOR FUELS WITH DIFFERENT SPECIFIC GRAVITY CONSULT THE LATEST EDITION OF THE NATIONAL FUEL GAS CODE ANSI

Z223.1 and CAN B149.

---"_;nanging Orifices Manifold (Downflow)

1. After disconnecting power and gas supply to the furnace, re- move the access door, exposing the burner compartment.

a. Remove the five (5) screws holding the burner box cover

to expose the manifold and burners. (Figure8 or

Figure 9)

2. Disconnect gas line and pilot tubing from gas valve so man- ifold can be removed.

3. Disconnect wiring at gas valve. Be sure to note the proper location of any and all electrical wiring disconnected.

4. Remove the four (4) screws holding the manifold and gas valve to the manifold supports. Do not discard any screws.

See Figure 8 or Figure 9.

iiiiiiiiiiiiiiiiiiiiiill¸;!i_i_i_i_i_i_i!_!_!_!_ii_!i!i!ii;_!_;i_:iiiii!iiiiiiiii_iiiiiiiiiii!i!i!i!i!i!i!i!i!i!i!i!i!i_!iii!_iiii!ii_i!_

Manifold (Upflow/Horizontal)

5. Carefully remove the manifold assembly.

6. Remove the orifices from the manifold and replace them with proper sized orifices. See Figure 10.

7. Tighten orifices so it is seated and gas tight.. See Figure 10.

Clearances

Measure from face of orifice

25-22-38

_m°at hi_ob_ck side Of the

__ 1 11' (28 2mm)

44101 2308 01 [_

8. Reassemble all parts in reverse order as removed. Be sure to engage the main burner orifices in the proper opening in the

burners.

9. After reassembling, turn gas on and check all joints for gas leaks using a soapy solution. All leaks must be repaired im-

mediately.

GasPipingRequirements

1. Install gas piping in accordance with local codes, or in the ab- sence of local codes, the applicable national codes.

2. Itis recommended that a manual shutoff valve be installed in the gas supply line outside the unit. Locate valve as close to

the furnace as possible where it is readily accessible. Refer to Figure 11.

Typical Gas Piping

ManuatValve

Bbow end sh_ nipple

25-22-31

3. Use black iron or steel pipe and fittings or other pipe ap- proved by local code.

4. Use pipe thread compound which is resistant to natural and

LP gases.

5. Install a drip leg no less than 3" long to trap dirt and moisture before it can enter gas valve.

6. Provide a 1/8" inch plug for test gauge connection immedi- ately up stream of gas supply connection to furnace.

7. Use two pipe wrenches when making connections to prevent gas valve from turning.

8. Flexible corrugated metal gas connector may NOT be used inside the furnace or be secured or supported by the furnace

or ductwork.

9. Properly size gas pipe to handle combined appliance load or run gas pipe directly from gas meter or LP gas regulator.

10. Install correct pipe size for run length and furnace rating.

11. Measure pipe length from gas meter or LP second stage reg- ulator.

Fire or explosion hazard. The flexible corrugated metal gas connector must

be properly installed, cannot go through the side of the furnace, and can not be used inside the

furnace. Failure to properly install metal gas connector

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

Additional LP Piping Requirements

• Have a licensed LP gas dealer make all connections at stor- age tank and check all connections from tank to furnace.

• Ifcopper tubing is used, it MUST comply with limitation set in

Local Codes, or in the absence of local codes, the gas codes

of the country having jurisdiction.

• Two-stage regulation of LP gas is recommended.

FinalCheck

• Test all pipe for leaks.

• If orifices where changed, make sure they are checked for leaks.

• During pressure testing of gas piping system, observe the following:

a. If test pressure does not exceed 1/2" PSIG, isolate the fur- nace by closing its individual manual shutoff valve.

b. Iftest pressure exceeds 1/2"PSIG, the furnace and its indi- vidual shutoff valve must be disconnected from the gas sup- ply system.

• To check for leaks apply soap suds or a liquid detergent to each joint. Bubbles forming indicate a leak.

• Do not use an open flame to test for gas leaks. Fire or explo- sion could occur.

• Correct even the smallest leak at once.

Fire or explosion hazard.

Liquid petroleum (LP) gas is heavier than air and

will settle and remain in low areas and open depressions.

Thoroughly ventilate area and dissipate gas. Do

NOT use a match or open flame to test for leaks,

or attempt to start up furnace before thoroughly ventilating area.

An open flame or spark can result in death,

personal injury and/or property damage.

7. ElectricalWiring

PowerSupplyWiring Field wiring connections must be made inside the furnace con-

The furnace MUST be electrically wired and grounded in accor- nection box. A suitable strain relief should be used at the point the dance with local codes, or in the absence of local codes, the appli- wires exit the furnace casing.

cable national codes.

44t 01230801

Copperconductorsshallbeused.Linevoltagewiresshouldbe

sizedfortheinputampsstatedontheratingplate.Furnacemust

beconnectedtoitsownseparatecircuit.

Thermostat

Thermostat location has an important effect on the operation of the unit. Follow instructions included with thermostat for correct

mounting and wiring. Low voltage connections to furnace must be made on terminal

board to fan control. Ifcooling is used, the Y from the thermostat must be connected to

the control board Y to energize cooling blower speed.*

Set thermostat heat anticipator in accordance with the Technical

Support Manual. * "Y" terminal on thermostat sub-base must be connected to "Y"

terminal on furnace fan timer for proper fan speed during opera- tion in air conditioning mode.

115V, 60Hz

NEUT.

Ground

E,ectrica,Connections

(Downflow)

Optional Equipment

All wiring from furnace to optional equipment MUST conform to

local codes or, in the absence of local codes, the applicable na-

tional codes. Install wiring in accordance with manufacturer's

instructions.

Humidifier/ElectronicAir Cleaner

The furnace is wired for humidifier and/or electronic air cleaner connection.

Electrical Connections

(Upflow/horizontal)

115v,60Hz

NEUT.

Connection Box

Ground

LowVoltage

TerminalBoard

25-21-05b

CAUTION

Do NOT exceed 115V/0.8 amp. maximum current load

for both the EAC terminal and the HUM terminal com- bined.

NOTE: The humidifier will be powered when the furnace is fired and the circulating air blower comes on. The electronic air cleaner will be powered anytime the thermostat calls for air movement.

However, the electronic air cleaner is NOT energized during con-

tinuous fan operation controlled by the electronic fan control.

Control Center Fuse

The 24V circuit contains a 5-amp, automotive-type fuse located on control center. (See Figure 14) Any electrical shorts of 24V wiring during installation, service, or maintenance may cause fuse to blow. If fuse replacement is required, use only a fuse of

identical size (5 amp.)

Fan Timer Connections

Fuse

Low Voltage Terminal Board

44101 2308 01 [_

8. DuctworkandFilter(Upflow/Horizontal)on NTC6/GNEor NTN6/NNE

When a refrigeration coil is used in conjunction with this unit, it must be installed on the discharge side of the unit to avoid

Poison carbon monoxide gas hazard. Do NOT draw return air from inside a closet or util-

ity room where furnace is located. Return air duct MUST be sealed to furnace casing.

Failure to properly seal duct can result in death and/or personal injury.

condensation on the heat exchanger.

Installation of locking-type dampers are recommended in all

branches, or in individual ducts to balance system's air flow.

Ifair return grille is located close to the fan inlet, install at least

one, 90° air turn between fan and inlet grille to reduce noise.

DuctConnections

This furnace may be installed in only a bottom or side return ap-

plication. Return air through the back of the unit is NOT allowed. Side connections can be made by cutting out the embossed area

shown in Figure 15.

Bottom returns can be made by removing the knockout panel in

the furnace base. Do NOT remove knock-out except for a bottom

return.

Cutting Side Return Air Opening

Starting

DuctDesign

Design and installair distribution system to comply withAir Condi-

tioning Contractors of America manuals or other approved meth- ods that conform to local codes and good trade practices.

When the furnace is located in an area near or adjacent to the liv-

ing area, the system should be carefully designed with returns to minimize noise transmission through the return air grille. Any blower moving a high volume of air will produce audible noise

which could be objectionable when the unit is located very close to a living area. It is often advisable to route the return air ducts

under the floor or through the attic.

• Refer to furnace Technical Support Manual (Blower Data) for air flow information.

• Ductwork installed in attic, or exposed to outside tempera- tures requires a minimum of 2" of insulation with outdoor type vapor barrier.

• Ductwork installed in an indoor unconditioned space re- quires a minimum of 1" of insulation with indoor type vapor barrier.

Inspection Panel

A removable access panel should be provided in the outlet duct when the furnace is installed without a cooling coil. This will allow smoke or reflected light to be observable inside the casing to indi-

cate the presence of leaks in the heat exchanger. This access cover shall be attached in such a manner as to prevent air leaks.

Filters

A filter MUST be used:

Filters are not supplied with these furnaces, but can be pur-

chased from your dealer.

Use either filter type:

• Washable, high velocity filters are based on a maximum air flow rating of 600 FPM

• Disposable, low velocity filters are based on a maximum air flow of 300 FPM when used with filter grille.

The furnaces, with 1600 or less CFM rating use a 16"x 25" high velocity filter. On these models the filter may be mounted internally for bottom return using factory kit or externally for side return.

The furnaces with greater than 1600 CFM requires that both left and right side returns are used in side return ap- plications. Filters must be mounted externally. If return air must be on one side only, an optional 20" x 25" filter

standoff rack kit can be used. For bottom return an op- tional 20" x 25" filter rack kit can be used.

• Size ductwork to handle air flow for heating and air condition- ing if used.

DuctInstallationRequirements

• When furnace supply ducts carry air outside furnace area, seal return air duct tofurnace casing and terminate duct out-

side furnace space.

NOTE: The 20 x 25" standoff filter rack gives more filter area but does not provide more air. Toachieve 2000 CFM a bottom return

or 2 side returns are still needed.

NOTE: Disposable, low velocity filters may be replaced with washable, high velocity filter providing they meet the minimum size areas. Washable, high velocity filters can be replaced ONLY

with same type and size.

44t 012308 01

9. DuctworkandFilter(Downflow)on NDN6/GDE

Sub-Basesfor Combustible Floors- Furnace Only

The Subbase for Combustible Floors MUST be used when a downflow furnace is set on combustible material even when the

furnace is installed on a coil box (cased coil).

NOTE: Supply opening is 37/8 " from the rear of the furnace.

Therefore maintain a 37/8', clearance from a wall behind the fur-

nace (where applicable).

Table

sub-base for Com-

bustible Floors

Part Number

(Furnace Only)

NAHH001SB NAHH002SB

NAHH003SB

sub-base for Cased Coil

NAHH004SB NAHH005SB NAHH006SB

Equivalents 195/16= 491

inmm

Outside Dimension Base Spacer Side To Side

Sub-bases for Combustible Floors Dimensions

1511/16=398

2215/16= 583

N _

t511/16

195/16

2215/16

t511/16

195/16

2215/16

sub-base for Combustible

Floor Dimensions

J* K**

283/4 149/16 283/4 183/16

283/4 2113/16

209/16 149/16 209/16 183/16

209/16 2113/16

149/16 = 370

283/4= 730 183/16 = 462

209/16 = 522 2113/16= 554

16 16

16 16 16

16= 406

1. Cut the opening in the floor according to Table 6. The hole in the floor must be cut to the dimensions listed in Table 6

since the base is equipped with locating tabs that center the base over the opening.

The opening in the base is 11/4"(32mm ) shorter and 11/8"(29mm ) narrower than the minimum required size of the opening in the

floor. This is done to maintain a 1" clearance between the floor and the plenum.

2. Fabricate the plenum to the dimensions given in Table 6. Note that the dimensions given are outside dimensions.

Opening In Floor

M N

161/4 t45/8 161/4 t81/4

161/4 217/8

161/4 t45/8 161/4 t81/4

161/4 217/8

145/8= 371

161/4=412 181/4=464

217/8=556

Opening In

Base For Plenum

P R

15 131/2 15 171/8

15 193/4

15 131/2 15 171/8

15 193/4

131/2= 343

15=381 171/8=435

193/4= 502

Typical Plenum

Dimensions

S T

15 131/2 15 171/8

15 193/4

15 131/2 15 171/8

15 193/4

15=381 171/8=435

131/2=343

193/4=502

Set the base over the opening in the floor, centering the opening in the base over the opening in the floor. Fasten the

base to the floor with screws or nails. See Figure 16 and Figure 18.

Drop the plenum through the opening in the base. The flange of the plenum should rest on top of the combustible floor base.

Exploded View of Base for

Figure 16 Furnace ONLY

44101 2308 01

Sub-base for Combustible Floors- Downflow Coil

Box

The Subbase for Combustible Floors MUST be used when a downflow furnace, used with a downflow coil box, is set on

combustible flooring. NOTE: Supply opening is 37/8', from the rear of the furnace.

Therefore maintain a 37/8', clearance from wall (where applica- ble).

Cut the opening in the floor according to Table 6. The hole in the floor must be cut to the dimensions listed in Table 6

since the base is equipped with locating tabs that center the base over the opening.

The opening in the base is 11/4"(32mm) shorter and 1 1/8"(29mm) narrower than the recommended size of the opening in the floor. This is done to provide a 1" clearance between the floor and the plenum.

2. Fabricate the plenum to the dimensions given in Table 6. Note that the dimensions given are outside dimensions.

3. Set the base over the opening in the floor, centering the

opening in the base over the opening in the floor. Fasten the base to the floor with screws or nails. See Figure 17 and Figure 18.

4. Drop the plenum through the opening in the base. The

flange of the plenum should rest on top of the combustible floor base.

Figure 17 Exploded View of Base for

Downflow Cased Coil

25-21-46b

Setting the Base

NOTE: The furnace is provided with high velocity type filter(s). The size, quantity, and type of filter supplied with the furnace will handle the airflow required if central air conditioning is used with

the furnace. NOTE: The return air plenum MUST extend a sufficient height

above dimension "A" (Figure 21 ) to provide for the attachment of a return air duct or grille above the filters.

Figure20 Filter Rack Installation

Subbase Insulation

Wood Floor

25 20 46A

This subbase for combustible floors has been designed so that the height of the sub-base raises the downflow coil off the floor to

allow easy installation of the condensate drain. See Figure 19.

Non-Combustible Floor:

Set the furnace over the opening in the floor. If necessary, grout

around the base to seal air leaks between the base and the floor.

Figure 19 Condensate Line Raised by Base

25-21-05C

Insert end of filter rack with 3/4" (19mm) flange into slot in

the back of the unit. See Figure 20.

With filter rack pushed back, insert front end with 1/4"

(6mm) flange into position and push into front slot. with filter

rack pushed as far forward as it will go, bend 1/4"(6mm) flange and 3/4"(19mm ) flange up 90 degrees. See

Figure 20.

Figure 21 Filter Installation

25-20-52

Filters:

The filters supplied with the furnace may be installed in the return air plenum above the furnace. A filter rack is supplied with each downflow furnace. See Figure 20 and Figure 21.

25-21-05d

NOTE: Plenum must be fitted as close to the return air flange of the unit as possible to eliminate any air bypassing the filters.

44t 01230801

Filterscanonlybeinstalledthroughtherighthandsideof theunitbloweropening.Slidefilterintounituntilitisinposi- tiontobepushedupandoverintoplaceonthelefthand

sideofunit.SeeFigure21. Slideremainingfilterintounitandupintoplaceonlefthand

sideofunit.SeeFigure21.

Ifthereisinsufficientplenumheightforthistypeofinstallation,fil-

tersmaybeinstalledinanyaccessiblelocationinthereturnair system.Insuchacase,thefiltersshouldbeofequivalentsizeand styleasoriginallysuppliedwiththefurnace.

10. ChecksandAdjustments

Filter Removal

1. Remove compartment door.

2. Reach up above right side of blower and lift dirty filters out of

rack at top of furnace.

3. Straighten up filters and pull straight down at side of blower. Pull out through right door opening.

4. Vacuum clean or wash with warm water and dry thoroughly

before replacing.

Startup

NOTE: Refer to startup procedures in the Users Information

Manual.

CAUTION

If any sparks, odors or unusual noises occur, immedi-

ately shut OFF power to furnace, Check for wiring er-

rors or obstruction to blower,

GasSupply Pressure

Gas supply pressure should be within minimum and maximum

values listed on rating plate. Pressures are usually set by gas sup-

pliers. (See L.P. Kit instruction manual for furnaces converted to L.R

gas)

ManifoldGas PressureAdjustment

NOTE: Make adjustment to manifold pressure with burners oper-

ating.

Fire or explosion hazard.

Turn OFF gas at shut off before connecting ma- nometer.

Failure to turn OFF gas at shut off before con- necting manometer can result in death and/or personal injury.

Pilot Burner

Flame Rod

Proper Flame _ /

_ / _"_ Hot Surface

10-11-65

MainBurner Flame Check

Allow the furnace to run approximately 10 minutes then inspect the main burner and pilot flames. See Figure 23.

Check for the following (Figure 23):

• Stable and blue flames. Dust may cause orange tips or wisps of yellow, but flames MUST NOT have solid, yel- low tips.

• Flames extending directly from burner into heat ex- changer.

• Flames do NOT touch sides of heat exchanger

Ifany problems with main burner flames are noted, it may be nec-

essary to adjust gas pressures, or check for drafts.

With gas OFF, Connect manometer to gas valve or maniflod tap. Use manometer with a 0to min. 12" water column range.

Turn gas ON and remove adjustment screw cover on gas valve. Turn counterclockwise to decrease pressure and

clockwise to increase.

NOTE: Adjustment screw cover MUST be placed on gas valve before reading manifold pressure and operating furnace.

3. For altitudes up to 2000', set pressure to value shown in Table 2. For altitudes between 2000' to 8000', see Section

6. "Gas Supply and Piping" for correct pressure value.

Adjust PilotBurner

The furnace has a pilot flame to light the main burner. The flame should surround 3/8" to 1/2" of the flame rod. See Figure 22. To

adjust, remove cap from pilot adjusting screw on gas valve. Turn screw counterclockwise to increase or clockwise to decrease

flame as required. Replace cap after adjusting screw.

44101 2308 01

Main Burner

Burner Face

10-10-78

TemperatureRise Check

The blower speed MUST be set to give the correct air temperatu re rise through the furnace as marked on the rating plate. Tempera-

ture rise is the difference between supply and return air tempera- tures.

To check temperature rise,use the following procedure:

1.. Placethermometersinsupplyandreturnairregistersas 2. closetofurnaceaspossible,avoidingdirectradiantheat

fromheatexchangers.

2. Takereadingsandcomparewithrangespecifiedonrating plate.

3. Ifthetemperatureriseisnotinthecorrectrange,theblower

speedmustbechanged.Ahigherblowerspeedwilllower thetemperaturerise.Alowerblowerspeedwillincrease

thetemperaturerise.

ChangingBlowerSpeed

Change the heat or cool blower motor speed by removing the motor lead from the "Heat" or "Cool" terminal and replace it with the desired motor speed lead from the "Unused Motor

Lead" location. Connect the wire previously removed from

the "Heat" or "Cool" terminal to the vacated "Unused Motor

Lead" terminal.

Ifthe same speed must be used for both heating and cooling,

remove the undesired motor speed lead from the "Heat" or

"Cool" terminal and connect that lead to the open terminal at

"Unused Motor Lead" location or tape off. Attach ajumper between the "Heat" and "Cool" terminals and the remaining motor speed lead.

Electrical shock hazard. Turn OFF power to furnace before changing speed

taps.

Failure to do so can result in death, personal injury and/or property damage.

NOTE: Wiring diagram may not reflect actual factory settings. In- staller/contractor must choose proper speed taps for individual applications.

Since the manufacturer cannot establish the static pressure that will be applied to the unit, it is the responsibility of the

installer dealer/contractor to select the proper speed taps for the application when the unit is installed.

If it is necessary to change speeds, refer to steps below.

1. Refer to Furnace Wiring Diagram for location of the heating and cooling speed taps located on the electronic fan control as well as location of unused blower motor speed leads. Use

the chart (Table 7) to determine the blower motor speed set- tings.

Blower Speed Chart

Wire Color

Black

Orange*

Blue

Red

* Med-High speed may not be provided on all models.

Motor Speed

High

Med-High

Medium

Low

Note: When using the same speed on motors with (4) speed leads, it will be necessary to tape off the terminal of the motor

speed lead removed from the "Heat" or "Cool" terminal with electrical tape since an open terminal will not be available at

the "Unused Motor Lead" location.

ContinuousFan Operation

A terminal is provided on the electronic fan control located in the circulating blower compartment for operation of the continuous fan option. This connection is intended for the low speed motor

tap, and has a lower contact rating (8 amps) than the heat and cool taps. When the low speed blower lead is connected to this terminal, this will provide low speed blower operation whenever the other two speeds (Heat or Cool) are not energized.

Thoroughly check the system after modification to ensure the proper operation of the circulating air blower in all modes of op-

eration.

Separate speed selections for Heat, Cool, and Continuous Fan

Connect low speed lead from circulating motor to the "Cont" ter- minal at the electronic fan control. The appropriate motor leads should already be connected to the "Heat" and "Cool" terminals.

Heatingand Continuous Blower Speed the Same

If it is necessary to operate the heating speed and continuous

blower speed using the same blower speed, connect ajumper be- tween the "Heat" and "Cont" terminals on the electronic fan con-

trol. Note: There should be only ONE motor lead going to the "Heat"

and "Cont" terminals.

11. FurnaceMaintenance

CAUTION

It is recommended that the furnace be inspected and

serviced on an annual basis (before the heating sea- son) by a qualified service technician.

_] 44t 012308 01

See "User's Information Manual".

ICP GDE075F16G1, GDE100F14G1, GDE100F20G1 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual