ICP GDJ125M20A1, GDJ100M12B1, GDJ075M12C1, GDJ100M16C2, GDJ100M12C1 Installation Instructions Manual

NDN5/GDJ

Downflow Only

Series

SAFETY CONSIDERATIONS

/k

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

UnderstandthesignalwordDANGER, WARNING, orCAUTION. Thesewordeareusedwiththesafety-alertsymbol. DANGERidenti-

ties the most serious hazards will result in severe personal injury or death. WARNING signifies a hazard that could result in personal

injuryor death. CAUT__Nisusedt_identifyunsafepracticeswhichw_u_dresu_tinmin_rpers_na_injury_rpr_ductandpr_pertydam-

age.

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 inthe 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 to the current edition ofthe National Standard Canada CAN/CGA-Bt 49.1 - and .2-M91 Natural

Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Havefire 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.

Table of Contents

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

2.Combustion&VentilationAir ................. 4

3.GasVent Installation ....................... 6

4.Horizontal................................ 7

5.GasSupplyandPiping ...................... 8

6.ElectricalWiring ........................

7.DuctworkandFilter ......................

8.ChecksandAdjustments..................

9.FurnaceMaintenance ....................

11
12
15

16

Design Certified

byAGA

Manufactured by:

Inter- City Products Corporation (USA)

Lewisburg, TN USA 37091

This furnace is not designed for use in mobile
homes, trailers or recreational vehicles. Such
use could result in property damage, bodily in-

jury and/or death.

LP3 4/14/97 441 01 2201 02

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 the

country having jurisdiction.
The information contained in this manual is

intended for use by a qualified service technician
familiar with safety procedures and 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, property damage, personal injury
and/or death.

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.

• Use only the Type of gas approved for this furnace (see
Rating Plate on unit). Overfiring will result infailure of heat
exchanger and cause dangerous operation.

• 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.

• Install correct filter type and size.

• Unit MUST be installed so electrical components are pro-
tected from direct contact with water.

• It is the suggestion of this manufacturer to install fire and
carbon monoxide detectors.

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 property damage,

personal injury and/or death.

Locationand Clearances

1. Refer to Figure 1for typical installation and basic connect-
ing parts required. Supply and return air plenums and duct
are also required.

May be vented with

another gas appliance.

Figure 1 1 Typical Installation

__ Roof Line

To ElectricaI Service

Entrance Panel

VentPipe _ _Return __-GasLine

_ _///////////:

ischarge

25-20-58

2.

Iffurnace isa replacement, it is usually best to install the fur-

nace where the old one was. Choose the location or evalu-
ate the existing location based upon the minimum

clearance and furnace dimensions (Figure 2).

CAUTION

Do NOT operate furnace in a contaminated atmosphere con-
taining chlorine, fluorine or any other damaging chemicals.

Refer to Combustion & Ventilation Air section, Contami-
nated Combustion Air.

Figure 2 [ Dimensions and Clearances

RECOMMENDED CLEARANCES TO

COMBUSTIBLE

MATERIALS FOR ALL UNITS

REAR 0
FRONT 3" (75mm)

Single Wall Vent 6" (150mm)
Type B-1 Double Wall Vent 3" (75mm)

For Service 30" (760mm)

ALL SIDES OF 1" (25mm)
SUPPLY PLENUM

SIDES 0
VENT

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

Thermoplastic Pipe 4" (102mm)

TOP OF FURNACE 6" (150mm)

DIMENSIONAL INFORMATION

MODEL

050BF
075BF
100BH
125BK

Equivalents
Inches (mm)

A

t51/2
t51/2
t91/6

223/4

I 151/2 394

19118(486)

223/4(578)

CABINET

B

281/2
281/2
281/2
281/2

281/2(724)

BOTTOM

OPENING

D E

14 151_

14 151_
17_16 151_
2t_16 151_

151_(394)

RETURN

C

40
40
40
40

I 14(356)

40 (1016) 179/16(446)

213/16(538)

GAS CONNECTIONS

H

913/16
913/16
913/16
913/16

OPENING

F G

t4 1817/32

t4 1817/32
179/16 1817/32
213/16 1817/32

14(356) I
179/16(446) I 1817/32(47t)213/16(538)

ALL DIMENSIONSIN INCHES(ram)

Fire Hazard.

913/16 (249)

J

21/2
21/2
21/2
21/2

21/2(64)

Installation Requirements

K

411/16
411/16
411/16
411/16

411t16(119)

1. Install furnace level.

Install fu mace as centralized as practical with respect to the

heat distribution system.

Place furnace on noncombustible cement board
or sheet metal.

Failure to install unit on noncombustible cement

board or sheet metal can result in property
damage, personal injury and/or death.

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

Installation section).

5. Maintain clearance for fire safety and servicing. A front
clearance of 30" (760mm) is recommended for access to

the burner, controls and filter.

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

Do NOT install furnace directly on combustible floors un-

less using a special noncombustible subbase. See Duct-
work and Filter section later in this manual.

7. Residential garage installations require:

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

• Located or physically protected from possible damage by a
vehicle.

G3

2. Combustion& VentilationAir

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

combustion and ventilation air.

Failure to provide adequate combustion and

ventilation air can result in personal injury
and/or death.

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 and electrical codes, or in the absence of local codes,
the applicable 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 this manual.

ContaminatedCombustionAir

Installations in certain areas or types of structures will increase
the exposure to chemicals or Halogens which may harm the fur-

nace. These instances must use only outside air for combustion.

The following areas ortypes 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.

• 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.

Confined Space Installation

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

pliances installed in the area.

Air Openings and Connecting Ducts

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

2. Connect ducts or openings directly to outside.

3. When screens are used to cover openings, they MUST be
no less than 1/4" (6ram) mesh.

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

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.

Requirements

1. Provide confined space with sufficient air for proper com-
bustion and ventilation of flue gases using horizontal or ver-

tical ducts or openings.

2. Figure 3 illustrates howto provide combustion and ventila-
tion air. A minimum of two permanent openings, one inlet
and one outlet, are required.

/33

Figure 3 Outside Air (This is ONLY a guide. Subject to codes of country having jurisdiction.)

ThisinstallationNOTapprovedin Canada Gas Vent

GasVent . GableVent)

=/

Soft, Vent

E_

Outlet
Air (1)

Inlet
Air(1

Furnace

Gas

fatal

' ieat_

m

Outlel
Air (2',

Inlet
Air (2

MinimumOneInlet andOne OutletAirSupplyinRequired

May be inand CombinationShown

InletAir OpeningMustbe Within12"(300mm)of floor

OutletAir OpeningMustbe Withint2"(300ram)of ceiling

(t) 1Square Inch(6cm2)per4000 BTUR
(2)1Square Inch(6cm2)per2000 BTUH

GasVent

11

Inlet t

Air(t)

._, GableVent

f VentilatedAttic_

Top Above Insulatio_h_=

I I _ I_"

OutletAir(1) II I SoffitVent

_ Inlet

Air(2)

3.

4.

5.

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
appliances in area (see Table 1).

Vertical duct openings or openings directly to outside re-

I 3

qu're 1 square inch(6.5mm ) of free area per 4,000 BTUH
for combined input of all gas appliances in area (see Table

t).

(16 cm) from the front of the appliance. The opening shall directly

communicate with the outdoors or shall communicate through a
vertical orhorizontal duct to the outdoors or spaces (crawl or attic)

that freely communicate with the outdoors, and shall have a mini-
mum free area of:

• 1sq. in per 3000 Btu per hr (7cm 2 per kW) of the total input
rating of all equipment located in the enclosure, and

• Not less than the sum of the areas of all vent connectors in

the confined space.

UnconfinedSpace Installation

Table1

FreeArea

MinimumFreeArea RequiredforEach Opening

BTUHIn-

putRat- HorizontalDuct

ing (2,000BTUH)

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

75,000 242cm2(35.5sq.in.)

100,000 323 cm 2 (50 sq. in.)
125,000 403 cm 2 (62.5 sq. in.)
150,000 484 cm 2 (71 sq. in.)

VerticalDuctoropenings

to outside

(4,000BTUH)

81 cm2(12.5sq.in.)

121cm2(18.75sq. in.)

161 cm 2(25 sq. in.)

202 cm 2 (31.25 sq. in.)

242 cm2 (37.5 sq. in.) 7"

Round

Duct

(4,000

BTUH)

4"

5"

6"

7"

EXAMPLE: Determining Free Area

Furnace Water Heater Total Input
100,000 + 30,000 = (130,000 + 4,000) = 210 cm2

(32.5 Sq. In.) Vertical
Furnace Water Heater Total Input
100,000 + 30,000 = (130,000 + 2,000) = 210 cm 2

(65 Sq. In.) Horizontal

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"

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

An unconfined space or homes with tight construc-
tion may not have adequate air infiltration for proper

combustion and ventilation of flue gases.
Failure to supply additional air by means of ventila-

tion grilles or ducts could result in personal injury

and/or death.

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