ICP GDL050N12A1, GDL075N12A1, GDL075N12A2, GDL075N12A3, GDL100N16A1 Installation Guide

...

NTC7/G N L - Upflow/Horizontal

NDC7/G DL - Downflow

Series

SAFETY CONSIDERATIONS

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. Thesewordsareusedwiththesafety-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 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. Inthe 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.

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 ....................... 8

4.HorizontalVenting ......................... 11

5.MasonryChimneyVenting ................... 12

6.GasSupplyandPiping ...................

7.ElectricalWiring ........................

8,DuctworkandFilter......................

9.ChecksandAdjustments..................

10.FurnaceMaintenance ...................

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.

LP1 7/29/98 441 01 2003 03 Replaces 44t 01 2003 02 (6/97)

15 16

20 22

1.Installation

Safety Rules

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 recre-

ation vehicles or mobile home.

• Upflow and downflow models are approved for installation in buildings constructed on site.

• Do NOT use this furnace as a construction heater or to heat a building 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 LP 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.

• 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.

Your unit is built to provide many years of safe and dependable service providing itis properly installed and maintained. However,

abuse and/or improper use can shorten the life of the unit and create hazards for you, the owner.

A. The U.S. Consumer Product Safety Commission 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 and smoke detectors listed by Underwrit- ers 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.

FreezingTemperatures andYour Structure

NOTE: It is the personal responsibility and obligation of the cus-

tomer to contact a qualified installer to ensure that the installation

is adequate and conforms to governing codes and ordinances.

DualCertified Furnace

This furnace is dual certified. This means that the INLET pipe is optional. See Figure 1 for identification of INLET and OUTLET

pipe. Combustion air can be drawn from outside the structure or inside the structure.

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.

2. Have someone check the structure frequently during cold weather to make sure it is warm enough to prevent pipes

from freezing. Suggest they call qualified service agency, if

required.

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.

Dimensions and Clearances - Upflow/Horizontal Models

Locationand Clearances

Iffurnace is a replacement, it is usually best to install the furnace

where the old one was. Choose the location orevaluate the exist- ing location based upon the minimum clearance and furnace di-

mensions (Figure 1 & Figure 2).

CAUTION

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.

UNIT CAP.

50,000 75,000

100,000 125,000

CONVER-

SION

METRIC

(ram)

25-21-69

CABINET

40 : (1016)

191/8: (486) 15/8: (41) '_'m= m41 223/4= (578) 15/8= (41) 11/2= (38) ]b_/8 = t4241

281/2= (724)

ELECTRICAL CONNECTIONS

SUPPLY AIR

181/2: (47t) 171/2: (446) 211/4=(539)

235/32= (588)

MINIMUM CLEARANCES TO

COMBUSTIBLE

MATERIALS FOR ALL UNITS

REAR 0 FRONT 3" (75ram)*

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.

ALL DIMENSIONS IN INCHES (mm)

RETURN AIR GAS CONNECTIONS FLUE

BOTTOM SIDE LEFTSD. OUTLET

143/4= 375)

183/4= (476)

227/16= (571)

143/8: (366)

307/t6 = (773) 283/16= (716)

23 = (584)

AIR INLET

55/32= (t32)

65/8 = (t69)

31/16= (78)

121/2: 319) 151/8= (384) 55/t6 : (135)

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UNIT

CAPACITY

50,000 75,000 40

t00,000 40 t25,000 40

CONVERSION

METRIC(mm)

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CABINET

A B C

40 t91/8 281/2

t91/8 281/2 223/4 281/2 223/4 281/2

40=(1016)

191/8=(486)

223/4 =(578)

281/2=(724)

jJq"" .

_ 33/4 25-21-68

ELECTRICALCONNECTIONS

TOP SIDE LOWVOLT

D E DD EE F G 15/8 15/8 15/8 11/2 37t8 253/4 15/8 15/8 15/8 11/2 37t0 253/4

15/8 15/8 15/8 11/2 37/8 253/4 15/8 15/8 15/8 11/2 37/8 253/4

15/8=(41) 11/2= (42) 37/8= (99)

253/4=(654)

RETURNAIR

TOP

H I 181/2 175/8 181/2 175/8

181/2 211/4 181/2 211/4

181/2=(471)

17518=(448)

211/4=(540)

Minimum Cabinet Clearances to

Combustible Materials for all Units

TOP BOT RH LH BACK FRNT FLUE

6" *0" O" 0" 0" 3" 6"

* Can not beinstalled directly on combustibleflooring. Supply plenum must have 1" clearance for first 6' from

furnace.

ALL DIMENSIONS IN INCHES (mm)

SUPPLYAIR

BOTTOM

J K Z t65/8 175/8 5/8 t65/8 175/8 5/8

t65/8 213/8 5/8 t65/8 213/8 5/8

165/8=(421) t75/8=(449)

213/8=(540)

5/8= (18)

GASCONNECTIONS

RIGHTSD. LEFTSD.

M P MM P 12_8 24 103/8 24 12_8 24 103/8 24

12_8 24 103/8 24 12_8 24 103/8 24

125/8=(319)

24 = (584)

103/8=(264)

AIRINLET

T Y 5%2 31t4 5%2 31t4

65/8 31/4

55/32 31/4

5%2=(13t) 65/8= (169)

31/4=(83)

FLUE

OUTLET

W V 121_ 5_16 121_ 5_16

151_ 5_16 151_ 5_16

121/2=(3t9) 151/8=(384)

58/16=(135)

Installation Requirements

1. Install furnace level.

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

3. Install furnace as centralized as practical with respect to the heat distribution system.

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

Combustion Air Piping section).

For downflow installations, do NOT install furnace directly on

combustible floors unless using a special noncombustible subbase. See Ductwork and Filter section later inthis manu-

al.

Fire Hazard. If installing horizontally, place furnace on

noncombustible cement board or sheet metal. For counterflow furnaces 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.

6. Maintain clearance for fire safety and servicing. A front clear- ance of 30" (760mm) is recommended for access to the

burner, controls and filter.

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

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.

HorizontalFurnace Installation

Poison carbon monoxide gas, fire, and/or explosion hazard.

Make certain model installed is certified for use in multiple configurations.

Failure to install unit in configuration for which it is certified can result in property damage,

personal injury and/or death.

IMPORTANT

NOTE: Inspect unit rating plate to be certain model number be- gins with "NTC7" or "GNL'. This identifies unit as horizontally

mountable. If unit does NOT bear this designation, you may NOT mount this unit horizontally. Horizontal furnace must 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-to-left or left-to-right airflow position. See Figure 4.

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Typical Horizontal Installation

25-21-70

furnace and the combustible wood floor and extend 12" (300mm) beyond the front of the furnace louver door.

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

PressureSwitch Relocation

Ifthe furnace is installed in a left to right airflow position (right side of furnace facing down), the pressure switch will remain in the

same position as installed by the factory (see Figure 5). Ifthe fur- nace is installed in a right to left airflow position (left side of fur-

nace facing down), the pressure switch MUST be relocated to the right side of the furnace using the holes provided on the side of the furnace. Position the pressure switch in the same orientation as

the original location.

The following minimum clearances (Figure 1 and Figure 2) to combustibles MUST be maintained. As shown in Figure 3, ONLY

the corner ofthe cabinet is allowed to contact the rafters. All other clearances MUST be observed as shown in Figure 1 and

Figure 2.

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.

If the furnace is to be installed in a crawl space, consult local codes. A concrete pad 1" to 2" (25 to 50mm) thick is recom-

mended for crawl space installation on the ground.

Thirty (30) inches(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.

The horizontal furnaces may be installed directly on combustible wood flooring or supports for added fire protection it is recom-

mended that cement board or sheet metal is placed between the

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Pressure Switch Relocation

25-21-80a

To reposition switch, remove the two screws that secure the pres- sure switch to the blower partition. Attach the pressure switch in the location shown. It may be necessary to shorten the tube length. To prevent possible kinking of the pressure switch hose, trim the hose to remove excess.

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

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 codes, or in the absence of local codes, the applica-

ble national codes.

Contaminated CombustionAir

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 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.

• Permanentwavesolutionsforhair.

• Chlorinatedwaxesandcleaners.

• Chlorinebasedswimmingpoolchemicals.

• Watersofteningchemicals.

• De-icingsaltsorchemicals.

• Carbontetrachloride.

• Halogentyperefrigerants.

• Cleaningsolvents(suchasperchloroethylene).

• Printinginks,paintremovers,varnishes,etc..

• Hydrochloricacid.

• SulfuricAcid.

• Solventcementsandglues.

• Antistaticfabricsoftenersforclothesdryers.

• Masonryacidwashingmaterials.

ConfinedSpace Installation

Air Openings and Connecting Ducts

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. Whenscreensareusedtocoveropenings,theyMUSTbe no less than 1/4" (6mm) 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 combus- tion and ventilation of flue gases using horizontal or vertical

ducts or openings.

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-

)liances installed in the area.

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

This installation NOT approved in Canada

GasVent . GableVent,)

- OptionalInletAir (t)

SoffitVent

Inlet Air(1)

MinimumOneInletand OneOutletAirSupply is Required

Maybe in andCombinationShown

InletAir OpeningMustbe Within12"(300mm)offloor OutletAir OpeningMust be Withint2"(3OOmm)of ceiling

(1) 1SquareInch (6cm2) per4000BTUH (2) 1SquareInch (6cm2) per2000BTUH

I ' ' n so%lit' eot

ut'et''II L

I _ .L[ II I Outlet

• "1 I I I _ I I t Air(2)

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

one outlet, are required.

Inlet Air (t)

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

4. Size openings and ducts per Table 1.

/3#

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).

Vertical duct openings or openings directly to outside require

1square inch(6.5mm ) of free area per 4,000 BTUH for com- bined input of all gas appliances in area (see Table 1).

FreeArea

MinimumFreeArea Requiredfor Each Opening

BTUH

input HorizontalDuct

Rating (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 cm2 (62.5 sq. in.)

150,000 484 cm 2 (71 sq. in.)

VerticalDuctoropenings

to outside

(4,000BTUH)

81 cm2(12.5 sq.in.)

121cm2 (18.75sq. in.)

161 cm 2 (25 sq. in.)

202 cm 2 (31.25 sq. in.)

242 cm 2 (37.5 sq. in.)

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 cm2

(65Sq. In.) Horizontal

Unconfined Space Installation

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 personal

injury and/or death.

Round

Duct

(4,000

BTUH)

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.

DirectVent Installations

Combustion air is obtained from outside the structure. Ventilation air must be obtained from the following:

Ina closet or utility room installation, itwill be necessary to provide

ventilation air from an area of adequate air supply. Any restricted installation requires two openings in the door or

single wall of the closet or utility room. One opening should be lo- cated within 12" (305ram) of the top and the other within 12"

(305mm) of the bottom of the enclosure. (see Figure 6).

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Closet or Utility Room Installation

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

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

sealed vapor barrier. Openings are gasketed or sealed and

The following minimum free area is required for these openings:

a. Openings to interior space-Each opening to interior space

must have a free area at least 1 square inch per 1,000 BTU per hour input rating, but not less than 100 square inches.

b. Openings to outdoors-Each opening to the outdoors must

have a free area at least 1 square inch per 2,000 BTU per hour input rating if horizontal air ducts are used.

Air openings in the casing front, return air grilles, and warm air registers must not be obstructed.

In all instructions provisions for adequate combustion air must be made in accordance with Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1-1988, or

applicable provisions of the local building codes.

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