ICP H9MPT050F12A1, H9MPT050F12B1, H9MPT075F12A1, H9MPT075F14A2, H9MPT075F14B1 Installation Guide

...

Page 1

*9MPT *9MPV

Four Position 2- Stage Condensing Gas Furnace

SAFETY REQUIREMENTS

Recognize safety information. This is the safety-alert symbol/X X. When you see this symbol on the furnace and in instructions or 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 inminor personal injury or 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 (N FGC) NFPA

No. 54/ANSIZ223.1. In Canada, refer to the current edition of the 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 requre these instructions as a minimum for a safe installation.

Table of Contents

1.SafeInstallationRequirements................. 4

2.Installation................................ 5

3.Combustion&VentilationAir .................. 8

4.Vent& CombustionAirPiping ................ 10

5.GasSupplyandPiping ...................... 20

6.ElectricalWiring ........................... 24

Manufactured by:

International Comfort Products Corporation (USA)

Lewieburg, TN USA 87091

7.DuctworkandFilter(Upflow/Horizontal)......... 25

8. ChecksandAdjustments.................... 29

9.FurnaceMaintenance ....................... 31

10.SequenceofOperation&Diagnostics.......... 31

11.ConcentricVentTermination................. 37

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.

Printed in U.S.A. LP1 9/4/2001 440 01 2010 04

Page 2

2-Stage Gas Furnaces

*9MPT - Multispeed PSC Blower Motor

*9MPV - Variable Speed Motor

*Denotes Brand

Brand Brand Identifier

8 = Non-Condensing, 80+% Gas Furnace 9 = Condensing, 90+% Gas Furnace

Installation Configuration UP = Upflow

DN = Downfiow UH = Upflow/Horizontal

HZ = Horizontal DH = Downfiow/Horizontal

MP = Multiposition, Upflow/Downflow/Horizontal

Major Design Feature

= One (Single) Pipe 2 = Two Pipe D=I or2Pipe

L = Low NOx

* Denotes Brand

N = Single Stage P = PVC Vent

T = Two Stage V = Variable Speed

MP T 0 75 B 12 A

Engineering Rev.

Denotes minor changes

MarketingDigit

Denotes minor change

Cooling Airflow

08 = 800 CFM

12 = 1200 CFM 14 = 1400 CFM

16 = 1600 CFM 20 = 2000 CFM

Cabinet Width

B = 15.5" Wide

F = 19.1" Wide J = 22.8" Wide

L = 24.5" Wide

Input (NominalMBTUH)

Printed in U.S.A. LP1 9/4/2001 440 01 2010 04

Page 3

Dealer Name:

START-UP CHECK SHEET

For 90+ Furnace

(Keep this page for future reference)

Address:

City, State(Province), Zip or Postal Code:

Phone: Owner Name:

Address:

City, State(Province), Zip or Postal Code:

Model Number:

Serial Number:

Type of Gas: Natural: _1 LP: _1

Which blower speed tap is used?

High Fire __ Low Fire or (Cooling)

Temperature of SupplyAir: High Fire (°F) or (°C)__

Low Fire (°F).__or (°C)__

Business Card Here

Manual Gas Shut-Off Upstream

of Furnace/Drip-Leg?

Condensate Drain Connected?

Condensate Drain Trapped? YES [_

Transition Pressure switch hose relocated for U/D/H Application? YES _1 NO _1

Blower Speed Checked? YES _1 NO _1

All Electrical Connections Tight? YES _1 NO _1

Gas Valve OK? YES _1 NO _1

Measured Line Pressure When Firing Unit:

Calculated Firing Rate:(See Checks andAdjustments Sec- tion), (Lo) & (Hi)

YES _1 NO _1

NO_1

Temperature of Return Air: (°F)__ or (°C)__

Temp, Rise Hi Fire (Supply - Return ): (°F) or (°C).__

Lo Fire (Supply - Return ): (°F) or (°C).__

Filter Type and Size:

Fan "Time ON" Setting:

Fan "Time OFF" Setting:

Dealer Comments:

44001 2010 04

Temperature Rise (supply-return temperature):(°F)__

Measured Manifold Gas Pressure: (Lo) __ & (Hi) __

Static Pressure (Ducts): Supply Air Return

Date of Start-Up:

CO ?

0O2 ?

Page 4

1. Safe Installation Requirements

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 Canadian Stan-

dards Association (CSA) for installation in the United States and Canada. Refer to the appropriate codes, along with Figure 1 or

Figure 2 and 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. (Fur- naces can be converted to LR 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 around 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 protected from direct contact with water.

NOTE: It is the personal responsibility and obligation of the end user to contact a qualified installer to ensure that the installation is adequate and conforms to governing codes and ordinances.

Safety Rules

Your unit is built to provide many years of safe and dependable service provided it is properly installed and maintained. However, abuse and/or improper use can shorten the life of the unit and create hazards for you, the owner.

A. The U.S. Consumer Product Safety Commission 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). 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.

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 de-

tectors 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.

FreezingTemperaturesand YourStructure

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 it from op- erating if sensors detect abnormal conditions such as clogged ex-

haust flues.

If your unit remains shut off during cold weather the water pipes

could freeze and burst, resulting in serious water damage.

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.

Winter Shutdown

If you go away during the winter months and do not leave the heat

on in your home, the plastic transition box and the condensate

44001 2010 04

Page 5

traponthefurnacemustbeprotectedfromfreezedamage.(See

Figure8troughFigure11)

1. Disconnectthe5/8,ODrubberhosefromtheventdrainfit- tingthatislocateddownstreamofthecombustionblower.

Insertafunnelintothehoseandpourfour(4)ouncesof sanitarytype(RV)antifreezeintothecondensatetrap.Re- connectthe5/8,ODrubberhosetothestubonthevent drainfitting.Securewiththehoseclamp.

2. Installation

Poison carbon monoxide gas Hazard.

This furnace can NOT be common vented or

connected to any type B, BW or L vent or vent connector, nor to any portion of a factory-built or masonry chimney. If this furnace is replacing a previously common-vented furnace, it may be necessary to resize the existing vent and chimney to prevent oversizing problems for the other remaining appliance(s). See Venting and

Combustion Air Check in Gas Vent Installation section. This furnace MUST be vented to the outside.

Failure to properly vent this furnace or other appliances can result in death, personal injury and/or property damage.

2. Disconnect the 3/4,,OD rubber hose from the condensate trap. Insert a funnel into the hose and and pour four(4)

ounces of sanitary type (RV) antifreeze into the plastic Transition box. Squeeze the hose together near the end and quickly reconnect the 3/4" OD rubber hose to the stub

on the condensate trap. Secure with the hose clamp.

When you return home, your furnace will be ready to start, as it is not necessary to drain the antifreeze from the furnace.

Typical Upflow Installation

AIuminumornon-rustingshietdrecommended. (SeeVentTerminationShieldingfordimensions).

•8" Min. _ I_ 20' Max. rq _ InletPipe Ooup%gonendsoi

atmospheric Single Pipe pipe& couplingout-

in same <_ (_ _-_ (notusedon exhaustpipe.Total zone model) sidestructure= 8"

VentPipes MUSTbe supported Horizontallyand

Vertically

Min. Max.

zone

LocationandClearances

Refer to Figure 1 or Figure 2 for typical installation and ba-

sic connecting parts required. Refer to Figure 4 for typical

horizontal direct vent installation and basic connecting parts required. Supply and return air plenums and duct are

also required.

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

furnace where the old one was. Choose the location or evaluate the existing location based upon the minimum

clearance and furnace dimensions (Figure 3).

CAUTION

Special precautions MUST be made if installing

furnace in an area which may drop below freezing. This can cause improper operation or damage to equipment. Iffurnace environment has the potential of

freezing, the drain trap and drainline must be

protected. The use of electric heat tape or RV

antifreeze is recommended for these installations.

(See "Condensate Trap Freeze Protection Section")

* Increaseminimumfrom8" to 18" forcold climates (sustainedtemperatures

below0 oF). 25-23-33

Typical Downflow Installation

SeeVentTermination ShieldinginVentSection.

I_ "8" Min.

InletPipe _:_ _] 20' Max. (notusedon _ in same SinglePip_ _,_J_ atmospheric

model) _ zone

Vent PipesMUSTb supportedHorizonta andVertically

\_ _ "//////////////////////////J_

Couplingon inside andoutsideofwait

torestrainventpipe

Min. Max.

same

Do NOT operate furnace in a corrosive atmosphere

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

section, Contaminated Combustion Air.

44001 2010 04

* Increaseminimumfrom8" to 18" for coldclimates(sustainedtemperatures

below0°F).

25-23-33a

Page 6

Dimensions and Clearances

AIR iNTAKE (Dual Certified or

Cabinet to Combustible Clearances

I I I I1" 0 ' 0" 0 ' 0 ' 3 ' 0"

r i

TRAP (DOWNFLOW) _

21/4

131/4

• THERMOSTAT _T_ 7 _

i 17/8

I I

I I I I

[

TOP _

LEFT SIDE 6"/_6_

VEN_ _J_ @ _

_ 413/16

TRFALPoW/HOR,ZONTAL_ _

215/8 1 47/8

I I

BOTTOM i

231,'8

I I

/ I

11,,4

/ ELECTRICAL

11,,16 I

-- 13/8

283/4

175/16 297,,8

241/1_

111/16 3111/16

_-_ 37/8

1311/18

1913/16

FRONT

45/16 __

23/8

11,,16

GAS

113,,16 413/16

297/8

3311/16 /

1918/16 273,,16 175/16

215/_

ALL DIMENSIONS IN INCHES

281/2

-- 181/2 -- TYP.

r 1

RIGHT SIDE

" ,_ ) / TRAP (DOWNFLOV_

( O ELECTRICAL

_ ! _,/_ VENT

I _16 (UPFLOW/HORIZONTAL)

7 _HTHERMOSTAT

-- 2_/4

TRAP

1/2

13114

111,,11

Unit Cabinet

Capacity A B

*gMPTO50F12A 191/8 178/8 *gMPTO75F12A 191/8 178/8

*9MPT1O0J16A 223/4 211/4 *9MPT125L20A 241/2 23

*9MPV050F12A 191/8 178/8 *9MPV075F12A 191/8 178/8

*9MPVlOOJ20A 223/4 211/4 *9MPV125L2OA 241/2 23

47/8 [

BoSom Top

D E F G H

143/4 43/8 41_ 21_ 91_ 143/4 43/8 41_ 21_ 91_

183/4 43/8 41_ 28/8 113/8

23 43/8 41_ 21/4 121/4 143/4 43/8 41_ 21_ 91_ 143/4 43/8 41_ 21_ 91_

183/4 43/8 41_ 28/8 113/8

23 43/8 41_ 21/4 121/4

215/8

17/8

25-23-36A

[_ 440 01 2010 04

Page 7

InstallationRequirements

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.

4. Install the vent pipes as short as practical. (See Vent and Combustion Air Piping section).

5. Maintain clearance for fire safety and servicing. A front clearance of 30" is recommended for access to the burner, controls and filter.

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

For downflow installations, non combustible subbase must be used under the furnace unless installation is on a non

combustible floor surface. This requirement applies even when a coi! box or cabinet is used.

Fire Hazard. Place furnace on noncombustible subbase on

downflow applications, unless installing on non-combustible flooring.

Failure to install unit on noncombustible subbase can result in death, personal injury

and/or property damage.

For horizontal installations, line contact is permissible only between lines formed by intersection of back and two sides

of furnace jacket, and building joists, studs or framing.

Residential garage installations require:

Burners and ignition sources installed at least 18" above

the floor.

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

10. Local codes may require a drain pan under the entire fur- nace and condensate trap when the furnace is installed in

attic application.

InstallationPositions

This furnace can be installed in an upflow, horizontal (either left or

right) or downflow airflow position. DO NOT install this furnace on

its back. For the upflow position, the return air ductwork can be attached to either the left or right side panel and/or the bottom. For horizontal and downflow positions, the return air ductwork must

be attached to the bottom. The return air ductwork must never be attached to the back of the furnace.

quired for the condensate trap. Downward slope of the conden- sate drain line from the condensate trap to the drain location must

be provided. Adequate freeze protection of the drain trap and the drain line must be provided. See "Condensate Drain Trap"section

for further details.

Leveling

Proper leveling of the furnace must be provided to insure proper drainage of the condensate from the furnace. The furnace must be level to within 1/4" from front to back and from side to side for

upflow and downflow installations or top to bottom for horizontal installations.

Vent and Combustion Air Connections

On the Dual Certified furnace, the vent and combustion air pipes attach to the furnace through the top panel for the upflow and hori- zontal installations. For the downflow installation, the vent and combustion air pipes attach to the furnace through the alternate

locations on the furnace side panels. Note: On the Direct Vent furnace, the vent pipe attaches to the fur-

nace through the side panels. The combustion air pipe attaches to the top panel or to the alternate location on the side panel. On the Single Pipe furnace, the vent pipe attaches to the furnace

through the furnace side panels. Note: Repositioning of the combustion blower is required for the

vent pipe connection to the furnace through the "right side" panel. See "Vent and Combustion Air Piping" section for further details.

HorizontalFurnaceInstallation

This furnace can be installed horizontally in an attic, basement, crawl space, alcove, or suspended from a ceiling in a basement or utility room. See Figure 4. Do not install furnace on its back or in

the reverse airflow positions as safety control operation will be ad- versely affected.

Typical Horizontal Installation

Inlet Pipe (notusedonSinglePipemodel)

Vent

Pipe

Condensate Trap

FurnaceInstallationConsiderations

The installation of the furnace for a given application will dictate the position of the furnace, the airflow, ductwork connections,

vent and combustion air piping. Consideration must be given to the following:

CondensateTrap and Drain Lines

The supplied condensate trap must be attached to the furnace side panel on either the left or right side. For horizontal installa- tions, the drain trap is vertically attached to the side panel below

the furnace. A minimum clearance of 5" below the furnace is re- 44001 2010 04

25-23-34

NOTE: 5" bottom clearance required for condensate trap.

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 ridgely attach the furnace to pre- vent movement. These straps should be attached to the furnace

with sheet metal screws and to the rafters or joists with bolts. The preferred method isto use an angle iron frame bolted to the rafters or joists. (Take caution to allow door panels to be removed for maintenance)

Page 8

If the furnace is to be installed in a crawl space, consult local

codes. A suitable concrete pad or blocks are recommended for crawl space installation on the ground.

NOTE: 5" bottom clearance required for condensate trap.

Thirty (30) inches 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.

3. Combustion & Ventilation Air

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 death and/or

personal injury.

Ventingand CombustionAir Check

NOTE: The following information is supplied to allow the installer

to make adjustments to the setup of existing appliances, IF

REQUIRED, based on good trade practices, local codes, and

good judgement of the installer. Manufacturer does NOT take re- sponsibility for modifications made to existing equipment.

NOTE: If this installation replaces an existing furnace from a commonly vented system, make sure there is adequate combus- tion 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 hor-

izontal pitch to ensure there is no blockage or restriction, leakage, 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 maximum speed. Do not operate a summer exhaust fan.

Close fireplace dampers.

Followthe lighting instructions for each appliance being in- spected. Adjust thermostat so appliance(s) will operate continuously.

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 5).

The horizontal furnaces may be installed directly on combustible wood flooring or supports as long as all required furnace clear-

ances are met. See Figure 3.

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

ports.

For horizontal installation over a finished living space. A field fab-

ricated auxiliary drain pan with drain pipe is recommended to pre- vent damage by overflow due to blocked condensate drain.

Vent Check

Vent Pipe--_ I A/ Draft Hood

Typical Gas

WaterHeater / Matc.

I I

I 1

7. After it has been determined that each appliance vents properly, return doors, windows, appliances etc. to their

normal condition.

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

rected using the appropriate tables in code books of coun-

try having jurisdiction.

NOTE: if flame pulls towards draft hood, this indicates sufficient venting.

NOTE: Non direct vent appliances occupying same enclosed space as furnace MUST have enough air for proper combustion and ventilation. All duct or openings for supplying combustion and

ventilation air must comply with the gas and electrical codes of the country having jurisdiction.

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.

Air Openingsand ConnectingDucts

1. Total input rating for all non direct vent gas appliances MUST be considered when determining free area of open-

ings.

2. Connect ducts or openings directly to outside.

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

4. The minimum dimension of rectangular air ducts MUST

NOT be less than 3".

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.

Confined SpaceInstallation

NOTE: A confined space is defined as an area with less than 50 cubic feet per 1,000 BTUH input rating for all gas appliances

installed in the area.

Requirements

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

44001 2010 04

Page 9

Figure 6 illustrate how to provide combustion and ventila-

tion air. A minimum of two permanent openings, one inlet and one outlet, are required.

One opening MUST be within 12" of the floor and the se-

cond opening within 12" of the ceiling.

Size openings and ducts per Table 1.

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

ThisinstallationNOTapprovedinCanada

GableVent_b.J

- OptionalInletAir (t)

I II I -- I

SoffitVent

_Air (t)

wate_

5. Horizontal duct openings require 1" square offree area per 2,000 BTUH of combined input for all gas appliances in

area (see Table 1).

6. Vertical duct openings or openings directly to outside re- quire 1" square of free area per 4,000 BTUH for combined

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

Gable Vent

Air (t)

Inlet

Air (t]

Soffit Vent

MinimumOne Inlet and One OutletAir Supply is Required

InletAir Opening Must beWithin12"of floor OutletAir OpeningMustbeWithin12" of ceiling

(t) t SquareInch per4000 BTUH (2)t SquareInch per2000 BTUH

BTUH

input HorizontalDuct

Rating (2,000 BTUH)

50,000 25 sq.in. 75,000 37.5sq. in.

100,000 50sq.in. 125,000 62.5sq. in. 150,000 75sq. in.

EXAMPLE: Determining Free Area Appliance 1 Appliance 2 Total Input

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

Appliance 1 Appliance 2 Total Input

100,000 + 30,000 = (130,000 + 2,000) = 65 Sq. In. Horizontal

May beinandCombinationShown

Inlet

Air(t)

MinimumFree Area Requiredfor Each Opening

VerticalDuctoropenings Round

to outside Duct

(4,000BTUH) (4,000

12.5sq.in. 4"

18.75sq. in. 5" 25sq. in. 6"

31.25sq, in. 7"

37.5sq. in. 7"

BTUH)

Inlet

Air (2)

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 infiltration for proper combustion and ventilation

of flue gases. Failure to supply additional air by means of

ventilation grilles or ducts could result in death

and/or personal injury.

An unconfined space is defined as an area having a minimum vol- ume of 50 cubic feet per 1,000 Btuh total input rating for all gas

appliances in area. Refer to Table 2 for minimum area required.

One permanent opening, commencing within 12" of the top of the enclosure, shall be permitted where the equipment has clear-

ances of at least 1" from the sides and back and 6" 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 communi- cate with the outdoors, and shall have a minimum free area of:

• 1sq. in per 3000 Btu per hr. 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.

44001 2010 04

I Unconfined Space

Minimum Area in Square Feet

BTUH Input

Rating

50,000

78,000

114,000

155,000

EXAMPLE: NOTE: Square feet is based on 8 foot ceilings,

28,000BTUH X 50CubicFt. = 1,400 = 175Sq. Ft.

1,000 8' Ceiling Height

Minimum Area in Square Feet

312 490

712 968

Page 10

NOTE:Referto definitionsin sectiontitledUnusually Tight

Construction. If any one of the conditions apply, the space MUST be considered confined space regardless of size.

1. Adjoining rooms can be considered part of an unconfined area if there are openings without doors between rooms.

2. An attic or crawl space may be considered an unconfined space provided there are adequate ventilation openings di-

rectly to outdoors. Openings MUST remain open and NOT have any means of being closed off. Ventilation openings to

outdoors MUST be at least 1" square of free area per 4,000

BTUH of total input rating for all gas appliances in area.

3. Install air intake a minimum of 12" above maximum snow

level and clear of any obstruction. Duct or ventilation open- ing requires one square inch of free area per 4,000 BTUH

of total input rating for all gas appliances in area.

4. Air inlet MUST be screened with not less than 1/4" mesh screen.

UnusuallyTight Construction

In unconfined spaces, infiltration may be adequate to provide air

for combustion, ventilation and dilution of flue gases. However, in

4. Vent and Combustion Air Piping

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.

DualCertified (*9MPT&*9MPV Models)

This furnace is certified as a category IV appliance. This furnace can be installed as a direct vent furnace using outside air for com-

bustion or the furnace can use air from inside the structure for combustion. The INLET air pipe is optional. If combustion air

comes from inside the structure, adequate make up air MUST be provided to compensate for oxygen burned. See Confined

Space Installation in the Combustion and Ventilation Air chapter. If combustion air is drawn from outside the structure, it

MUST be taken from the same atmospheric pressure zone as the

vent pipe.

Contaminated Combustion Air

installations in certain areas or types of structures will increase

the exposure to chemicals or halogens that may harm the fur- nace.

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.

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

Walls and ceilings exposed to the outside have a continu- ous, sealed vapor barrier. Openings are gasketed or

sealed and

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 or flue gases will condense in the heat exchanger. This will shorten the life of the heat exchanger and possibly void your warranty.

• Chlorinated waxes and cleaners.

• Chlorine based swimming poo! chemicals.

• Water softening chemicals.

• De-icing salts or chemicals.

• Carbon tetrach!oride.

• 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.

Ventand Combustion Air PipingGuidelines

NOTE: All vent piping MUST be installed in compliance with local

codes or ordinances, these instructions, good trade practices, and codes of country having jurisdiction.

1. Determine the best routing and termination for the vent pipe and air inlet pipe by referring to all of the instructions and guidelines in this Section.

2. Determine the size required for the vent pipe and air inlet pipe.

3. Loosely assemble all venting parts without adhesive (pipe joint cement) for correct fit before final assembly.

4. Use of vertical piping is preferred because there will be some moisture in the flue gases that may condense as it

leaves the vent pipe (See Special Instruction For Horizon-

tal Vents).

5. The vertical vent pipe MUST be supported so that no weight is allowed to rest on the combustion blower.

6. Exhaust vent piping or air inlet piping diameter MUST NOT be reduced.

[_ 44001 2010 04

Page 11

7. Allexhaustventpipingfromthefurnacetotermination

MUST slope upwards. A minimum of 1/4" per foot of run is required to properly return condensate to the furnace drain

system.

8. Use DWV type long radius elbows whenever possible, as they provide for the minimum slope on horizontal runs and

they provide less resistance in the vent system. If DWV el-

bows cannot be used, use two, 45 ° elbows when possible. On horizontal runs the elbows can be slightly misaligned to

provide the correct slope.

All horizontal pipe runs MUST be supported at least every five feet with galvanized strap or other rust resistant materi-

al. NO sags or dips are permitted.

10. All vertical pipe runs MUST be supported every six feet where accessible.

11. The maximum pipe length is 40' total in the inlet or outlet side of the system. Up to five, 90 ° elbows can be used on

the inlet or the outlet. With the Concentric Vent Termination

Kits (NAHA001CV or NAHA002CV), the maximum pipe length is 35' with 4 90 ° elbows. If more elbows are required,

reduce the length of both the inlet and exhaust pipes 5' for

each additional elbow used. (See Table 3 or Table 4).

12. The minimum pipe run length is 2'.

13. The piping can be run in the same chase or adjacent to sup-

ply or vent pipe for water supply or waste plumbing. It can

also be run in the same chase with a vent from another 90+ furnace.

NOTE: In NO case can the piping be run in a chase where

temperatures can exceed 140 ° E or where radiated heat from adjacent surfaces would exceed 140 ° F.

14. The vent outlet MUST be installed to terminate in the same atmospheric pressure zone as the combustion air inlet.

15. The vent system can be installed in an existing unused chimney provided that:

• Both the exhaust vent and air intake run the length ofthe chimney.

• No other gas fired appliance or fireplace (solid fuel) is vented into the chimney.

• The top of the chimney MUST be sealed flush or crowned up to seal against rain or melting snow so ONLY the piping protrudes.

• The termination clearances shown in Figure 7 are main- tained.

16.

Furnace applications with vertical vents requiring vent di-

ameter increaser fittings must have increaser fittings

installed in vertical portion of the vent. Condensate will be

trapped in the vent if the vent diameter is increased prior to

having an elbow turned upward. This could cause nui-

sance tripping of the pressure switch.

PipingInsulation Guidelines

NOTE: Use closed cell, neoprene insulation or equivalent. If Fi-

berglass or equivalent insulation is used it must have a vapor bar-

rier. Use R values of 7 up to 10', R- 11 if exposure exceeds 10'. If Fiberglass insulation is used, exterior to the structure, the pipe

MUST be boxed in and sealed against moisture.

.When the vent or combustion air pipe height above the roof exceeds 30", or if an exterior vertical riser is used on a

horizontal vent to get above snow levels, the exterior por- tion MUST be insulated.

2. When combustion air inlet piping is installed above a sus- pended ceiling, the pipe MUST be insulated with moisture

resistant insulation such as Armaflex or other equivalent

type of insulation.

3. Insulate combustion air inlet piping when run in warm, hu- mid spaces such as basements.

Sizing Combustion Air and VentPipe

Consult Table 3 or Table 4 to select the proper diameter exhaust and combustion air piping. Exhaust and combustion air piping is

sized for each furnace Btuh size based on total lineal vent length

(on inlet or outlet side), and number of 90 ° elbows required.

1. Double Pipe Installation-If installing as a direct-vent ap- pliance, consult Table 4 to select the proper diameter ex- haust and combustion air piping. Exhaust and combustion

air piping is sized for each furnace Btuh size based on total

lineal vent length (on inlet or outlet side), and number of 90 °

elbows required.

2. Single Pipe Installation-if installing as a non-direct vent appliance, (single outlet pipe and no inlet pipe) refer to

Table 3. The table shows the maximum number of elbows allowed with any given pipe diameter and length of run.

3. Use of Elbows-Two 45 ° elbows can be substituted for one 90 ° elbow. The elbow or elbows used for vent termination

outside the structure ARE counted, including elbows need- ed to bring termination above expected snow levels.

Pipe Diameter Table

Single Piping ONLY

50,000 & 75,000 Btuh Furnaces

40' & (5) 90 ° elbows with 2" PVC pipe or

100,000 Btuh Furnace

40' & (5) 90 ° elbows with 3" PVC pipe

125,000 Btuh Furnace

40' & (5) 90 ° elbows with 3" PVO pipe

Elbows are DWV Long Radius Type for 2" and 3" vents.

If more than five elbows are required, reduce the length of both the inlet and exhaust pipes 5' for each additional elbow

used. NOTE: It is allowable to use larger diameter pipe and fitting than

shown in the tables but not smaller diameters than shown.

Pipe Diameter Table

Dual Piping ONLY

50,000 & 75,000 Btuh Furnaces

40' & (5) 90 ° elbows with 2" PVC pipe or

100,000 Btuh Furnace

40' & (5) 90 ° elbows with 3" PVC pipe

125,000 Btuh Furnace

40' & (5) 90 ° elbows with 3" PVO pipe

Elbows are DWV Long Radius Type for 2" and 3" vents.

If more than five elbows are required, reduce the length of both the inlet and exhaust pipes 5' for each additional elbow

used.

* Feet of pipe is whichever pipe run is the longest, either inlet or outlet side.

44001 2010 04 [_

Page 12

For "Concentric Termination Kit" Venting table, see "Section 10" in this manual.

VentTermination Clearances

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

Inlet and outlet pipes may NOT be vented directly above each other.

Failure to properly vent this furnace can result in death, personal injury and/or property damage.

1. Determinetermination locations based on clearances spe- cified in following steps and as shown in Figure 7,

Figure 13, through Figure 20.

For "Concentric Termination Kit" clearances, see Figure 40, Figure 41, Figure 42, Figure 43 and Figure 44 in "Section 10"

in this manual.

2. The vent termination must be located at least 12" above ground or normally expected snow accumulation levels.

3. Do NOT terminate over public walkways. Avoid areas where condensate may cause problems such as above

planters, patios, or adjacent to windows where steam may

cause fogging.

4. The venttermination shall be located at least 4' horizontally from any electric meter, gas meter, regulator, and any relief equipment. These distances apply ONLY to U.S. installa-

tions. The vent termination is to be located at least 3' above any

forced air inlet located within 10' ; and at least 10' from a combustion air intake of another appliance, except another

direct vent furnace intake.

6. In Canada, the Canadian Fuel Gas Code takes prece- dence over the preceding termination instructions.

Vent Termination Clearances (United States Only)

In Canada See Canadian Fuel Gas Code

OtherThan

Other Than

DirectVent

Terminal

CondensateDrainTrap

This furnace removes both sensible and latent heat from the prod- ucts of combustion. Removal of the latent heat results in con-

densation of the water vapor. The condensate is removed from the furnace through the drains in the plastic transition and the vent

fitting. The drains connect to the externally mounted condensate drain trap on the left or right side of the furnace.

The condensate drain trap supplied with the furnace MUST be used. The drain line between the condensate drain trap and the drain location may be constructed of 3/4" PVC, CPVC pipe or oth-

er suitable material.

The drain line must maintain a 1/4" per foot downward slope to- ward the drain.

DO NOT trap the drain line in any other location than at the con-

densate drain trap supplied with the furnace.

Frozen water pipe hazard. When activated an auxiliary safety switch will

cause a furnace not to operate. During freezing temperatures the water pipes in

your home could freeze and burst causing water damage to the home.

Do not leave the home unattended during freezing temperatures, or shut off the water supply and

drain the pipes before leaving.

If possible DO NOT route the drain line where it may freeze. The drain line must terminate at an inside drain to prevent freezing of the condensate and possible property damage.

1. A condensate sump pump MUST be used if required by lo- cal codes, or if no indoor floor drain is available. The con-

densate pump must be approved for use with acidic condensate.

A plugged condensate drain line or a failed condensate pump will allow condensate to spill. If the furnace is

installed where a condensate spill could cause damage, it is recommended that an auxiliary safety switch be installed

to prevent operation of the equipment in the event of pump failure or plugged drain line. If used, an auxiliary safety

switch should be installed in the R circuit (low voltage)

ONLY.

CondensateDrainTrapFreezeProtection

DirectVent

Terminal

50,000Btuh

orless

OtherThan Direct Vent Forced Air

Terminal 12" Inlet

DirectVentTerminal

MoreThan 50,000 Btuh

[_ 44001 2010 04

10-11-36

Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper op-

eration or damage to the equipment. If the the furnace environ- ment has the potential of freezing, the drain trap and drain line must be protected. Use 3 to 6 watt per foot at 115 volt, 40 ° F self- regulating shielded and waterproof heat tape. Wrap the drain trap

and drain line with the heat tape and secure with the ties. Follow the heat tape manufacturer's recommendations.

Page 13

Upflow Installations (Dual Certified *gMPT & *gMPV Models)

LEFT Side Venting

Combustion

Air Pipe (optional)

Air Intake Coupling

PlasticCaps

Pressure Switch Hose, Blower

Pressure Switch Hose,

F Transition

Pressure Switch, Blower (Hi Fire)

Return Air

RIGHT Side Venting

Drain Tube

Rubber

UpflowInstallations- (DualCertified*9MPT &

Mount the condensate drain trap in a vertical position to either the

left or right side of the furnace using the two screws and gasket that are provided. If needed, remove the hole plugs from the fur- nace side panel and relocate to the open set of holes in the oppo-

site side panel. Drill two /64' diameter holes in the casing using the condensate trap as the template.

Ensure that the vent fitting and the 90 ° elbow is securely attached to the combustion blower.

This configuration allows left side venting from the furnace. If right side venting is required, the combustion blower must be relocated

on the plastic transition box. Remove the four(4) screws that se- cure the blower to the transition. Rotate the blower 180 ° and se-

cure with the four(4) screws. Use caution to not over tighten the screws to prevent stripping out of the plastic mounting holes.

For right side venting, remove vent fitting assembly from combus- tion blower. Remove 90 ° elbow and rubber tubing from the vent fitting by loosening the clamp on the vent fitting. Securely attach

vent fitting directly to combustion blower.

NOTE: The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe, with the drain stub at a 20 ° to

30 ° downward slope.

Plug the right drain stub of the vent fitting with the rubber plug. Use a blunt pointed screwdriver to push the plug into the stub.

7 ,

DRAIN SIDE VII_

_ward

t030°

*9MPV) (See Figure 8)

For left side mounted condensate trap, connect the 3/4" OD rub-

ber hose with the 90 ° bend to the drain stub on the bottom of the plastic transition box and secure with a 3/4" clamp.

Route the hose to the large drain stub on the condensate trap. Cut

off excess hose and discard. Connect the hose to the drain stub on the trap and secure with a 3/4" clamp.

For right side mounted condensate trap, the rigid plastic drain tube MUST be used. Cut two 2" long sections from the 3/4" OD

rubber hose. Connect the plastic drain tube to the drain stub on the bottom of the plastic transition box and to the stub on the con-

densate trap using the two hose sections and 3/4" clamps. NOTE: The support leg on the plastic drain tube MUST be posi- tioned on the blower partition.

Connect the 5/8" OD rubber hose with the 90° bend to the left drain stub on the vent fitting and secure with a 5/8" clamp,

Route the hose to the small drain stub on the condensate trap, Cut

off excess hose and discard, Connect the hose to the drain stub on the trap and secure with a 5/8" clamp.

NOTE: Ensure hoses maintain a downward slope to the conden- sate trap with no kinking or binding for proper condensate drain-

age.

25-23-53b

44001 2010 04 [_1

Page 14

Horizontal Left Installations (Dual Certified *9MPT & *9MPV)

Supply

Air

Vent Pipe_ Grommet

DRAIN SIDE VIEW

Combustion Air Pipe, (optional) Transition Box

Air intake Coupling

Vent Fitting & Clamps

Gas Pipe Grommet

Rotatedownward Rubber Coupling 20° to 30° & Clamps

90 ° Elbow

Trap & Gasket

5/8" Hose & Clamps

Drain Line

Pressure Switch Hose,

Pressure Switch,

(Lo Fire)

Blower

Combustion Blower Mounting Screws

(4)

Pressure Switch Hose, Transition

' Hose & Clamps

Return

Air

HorizontalLeftInstallations- (DualCertified*9MPT & *9MPV)(See Figure 9)

Relocate the plastic caps and clamps on the condensate drain trap from the vertical drain stub to the horizontal drain stubs. Se- cure the clamps tightly to prevent condensate leakage,

Mount the condensate drain trap in a vertical position to the left side of the furnace using the two screws and gasket that are pro- vided. Note: The condensate trap will be located under the fur-

nace in a vertical position when the furnace is placed horizontally on the left side, If needed, remove the hole plugs from the furnace side panel and relocate to the open set of holes in the opposite side panel. Drill two 7/64" diameter holes in the casing using the

condensate trap as the template.

Ensure that the vent fitting and the 90° elbow is securely attached to the combustion blower.

NOTE: The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe, with the drain stub at a 20 ° to 30° downward slope.

Plug the upper drain stub on the vent fitting with the rubber plug,

Use a blunt pointed screwdriver to push the plug into the stub. Connect the 3/4" OD rubber hose with the 90° bend to the drain

stub on the bottom of the plastic transition box and secure with a 3/4" clamp.

Route the hose to the large drain stub on the condensate trap. Cut

off excess hose and discard, Connect the hose to the drain stub on the trap and secure with a 3/4" clamp,

Connect the 5/8" OD rubber hose with the 90° bend to the small drain stub on the trap and secure with a 5/8" clamp,

Route the hose to the lower drain stub on the vent fitting, Cut off

excess hose and discard. Connect the hose to the drain stub on the vent fitting and secure with a 5/8" clamp,

NOTE: Ensure hoses maintain a downward slope to the conden- sate trap with no kinking or binding for proper condensate drain-

age.

dwg 25-23-54a

[_ 44001 2010 04

Page 15

iiiiiiiiiiiiiiiiii!:iii i i!i!! ; i!!!JJJJJiiiii; iiiiiiiii¸

Horizontal Right Installations (Dual Certified *9MPT & *9MPV)

Return

Air

Vent Fitting Vent Pipe

Rubber Coupling & Clamps go°Elbow & Clamps\

_ \_ Gas Pipe

5 Plastic Caps _ N Rubber Plug \ Grommet

/s"H°se & C'amp_-. _ _ X _' X_ _ U.I

\ \

Blower _ _

tom--on

Combustion Blower -__ Mounting _

Pressure Switch Hose,Transition

Screws (4) _ _

Pressure Switch,Transition (Lo Fire)

_Bl° \ \Pressure Switch DRAIN_

PressureSwitch, Hose, Blower ;IDE VIEW

Plastic Caps_

wer (Hi Fire) __e

Air Intake Coupling

downward

Combustion Air Pipe

J (Optional)

Supply

Air

Drain Line _ >

HorizontalRight Installations- (DualCertified

Relocate the plastic caps and clamps on the condensate drain trap from the vertical drain stub to the horizontal drain stubs. Se-

cure the clamps tightly to prevent condensate leakage.

Mount the condensate drain trap in a vertical position to the right side of the furnace using the two screws and gasket that are pro-

vided. Note: The condensate trap will be located under the fur- nace in a vertical position when the furnace is placed horizontally

on the right side. If needed, remove the hole plugs from the fur- nace side panel and relocated to the open set of holes in the oppo- site side panel. Drill two 7/64" diameter holes in the casing using the condensate trap as the template.

Ensure that the vent fitting and the 90 ° elbow is securely attached to the combustion blower.

NOTE: The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe, with the drain stub at a 20 °

downward slope.

Plug the upper drain stub on the vent fitting with the rubber plug.

Use a blunt pointed screwdriver to push the plug into the stub.

Remove the pressure switch hose from the upper stub on the plastic transition box.

dwg 25-23-55a

*9MPT& *9MPV)(See Figure 10)

Relocate the plastic caps on the stubs of the plastic transition box

from the lower stubs to the upper stubs and secure tightly with the clamps.

Route the pressure switch hose to the lower stub on the plastic

transition box. Cut off excess hose and discard. Connect the pres- sure switch hose to the lower stub on the plastic transition box.

NOTE: Failure to correctly install the pressure switch hose to the transition can adversely affect the safety control operation.

Connect the 3/4" OD rubber hose with the 90 ° bend to the drain stub on the bottom of the plastic transition box and secure with a

3/4" clamp.

Route the hose to the large drain stub on the condensate trap. Cut

off excess hose and discard. Connect the hose to the drain stub on the trap and secure with a 3/4" clamp.

Connect the 5/8" OD rubber hose with the 90 ° bend to the lower drain stub on the vent fitting and secure with a 5/8" clamp.

Route the hose to the smaller drain stub on the condensate trap.

Cut off excess hose and discard. Connect the hose to the drain stub on the trap and secure with a 5/8" clamp.

NOTE: Ensure hoses maintain a downward slope to the conden- sate trap with no kinking or binding for proper condensate drain-

age.

44001 2010 04 [_

Page 16

Downflow Installations (Dual Certified *gMPT & *gMPV Models)

LEFT Side Venting

<Z>

Return Air

Combustion Blower Mounting Screws (4)

Pressure Switch, Transition

(Lo Fire)

Pressure Switch Hose, Transition _

Pressure Switch, Blower

(HI Fire)

Pressure Switch Hose,

3/4 & Clamps

5/8° Clamps

RIGHT Side Venting

Combustion Blower (Rotate 180° for Left Side)

Transition

Box

Air Intake Coupling

Combustion Air Pipe, (Optional)

Drain Line

Vent Fitting

Vent Pipe

/_ Grommet

-Plastic Caps

Condensate

Trap & Gasket

Grommet

Supply Air

DownflowInstallations- (DualCertified*9MPT &

Mount the condensate drain trap in a vertical position to either the right or left side of the furnace using the two screws and gasket

that are provided. If needed, remove the hole plugs from the fur- nace side panel and relocated to the open set of holes in the oppo- site side panel. Drill two 7/64" diameter holes in the casing using

the condensate trap as the template.

Ensure that the vent fitting is securely attached to the combustion

blower using the clamp.

NOTE: The vent fitting MUST be installed with the airflow marking arrow pointed toward the vent pipe, with the drain stub at a 20° to 30° downward slope.

For right side venting, remove vent fitting assembly from combus- tion blower. Remove 90 ° elbow and rubber tubing from the vent

fitting by loosening the clamp on the vent fitting. Securely attach vent fitting directly to combustion blower.

This configuration allows right side venting from the furnace. Ifthe

left side venting is required, the combustion blower must be relo- cated on the plastic transition box. Remove the three(4) screws

that secure the blower to the transition. Rotate the blower 180 ° and secure with the three(3) screws. Use caution to not over tight-

en the screws to prevent stripping out of the plastic mounting holes.

Plug the upper drain stub on the vent fitting with the rubber plug.

Use a blunt pointed screwdriver to push the plug into the stub.

dwg 25-23-56a

*9MPV Models)(See Figure 11)

Remove the pressure switch hose from the upper stub on the

plastic transition box.

Relocate the plastic caps on the stubs of the plastic transition box

from the lower stubs to the upper stubs and secure tightly with the clamps.

Route the pressure switch hose to the lower stub on the plastic transition box. Cut off excess hose and discard. Connect the pres- sure switch hose to the lower stub on the plastic transition box.

NOTE; Failure to correctly install the pressure switch hose to the transition box can adversely affect the safety control operation.

Connect the 3/4" OD rubber hose with the 90 ° bend to the drain stub on the bottom of the plastic transition box and secure with a

3/4" clamp.

Route the hose to the large drain stub on the condensate trap. Cut off excess hose and discard. Connect the hose to the drain stub

on the trap and secure with a 3/4" clamp. Connect the 5/8" OD rubber hose with the 90 ° bend to the lower

stub on the vent fitting and secure with a 5/8" clamp.

Route the hose to the smaller stub on the condensate trap. Cut off excess hose and discard. Connect the hose to the drain stub on

the trap and secure with a 5/8" clamp. NOTE" Ensure hoses maintain a downward slope to the conden-

sate trap with no kinking or binding for proper condensate drain- age.

[_ 44001 2010 04

Page 17

ConnectingVentand CombustionAir Piping

Proper Sealing Procedure for

Combustion Blower

Poison carbon monoxide gas hazard. Cement or mechanically seal all joints, fittings,

etc. to prevent leakage of flue gases. Failure to properly seal vent piping can result in

death, personal injury and/or property damage.

Refer to the Figure 8 through Figure 11 that corresponds to the installation position of the furnace for the application.

Preassemble the vent and combustion air piping from the furnace to the vent termination. Do not cement the pipe joints until the pipe preassembly process is complete.

CombustionAir Pipe Connection (Dual Certified or

Direct Vent)

Install the air intake coupling and gasket to the furnace with the four(4) screws. (See Figure 8 through Figure 11)

Note: For the upflow and horizontal installations, the air intake coupling and gasket must be installed to the top panel of the fur-

nace.

For downflowinstallation, the air intake coupling and gasket must

be installed to the alternate air intake location on either the left or

right side panels. Remove the 3" hole plug from the side panel and relocate to the air intake hole inthe top panel. Use the four screws to seal the four(4) mounting holes inthe top panel next to the hole plug. Drill four(4) 7/64" diameter holes in the casing using

the air intake coupling as the template.

The air intake coupling is sized for 2" PVC pipe.

Install the combustion air pipe to the air intake coupling using RTV sealant to provide for future serviceability.

Vent Pipe Connection

Install the vent pipe grommet to the furnace panel. Locate the grommet in the furnace panel at a location directly away from the

vent fitting on the combustion blower. The grommet snaps into the 3" hole plug from the furnace panel. NOTE: Depending on the

installation position, the vent pipe grommet will be installed to the top panel or to the alternate location on the side panels. If needed,

remove the 3" hole plug from the furnace panel and relocate tothe open hole in the furnace panel. See Figure 8 through Figure 11.

The vent pipe grommet is sized for 2" PVC pipe.

Install the vent pipe to the vent fitting on the combustion blower using the clamp.

Note: The vent fitting MUST be installed with the air flow marking arrow pointed toward the vent pipe. (See Figure 12) Some installations require the vent fitting to be installed with a 20 to 30 ° downward slope. (See Figures 8 - Figure 11)

VentFitting

90° Elbow...... _//F

&Clamps__/

VentPipe _ (Sidepanetex.it)._

Vent Fitting J & Clamps /

DRAIN SIDE VIEW

jVent Pipe (Top panelexit)

Rubber Coupling & Clamps

Combustion

_ __,.ower

Rotate

downward 20° to 30°

25-23-35

Joining Pipeand Fittings

Fire hazard. Provide adequate ventilation and do NOT

assemble near heat source or open flame. Do NOT smoke while using solvent cements and avoid contact with skin or eyes.

Observe all cautions and warnings printed on material containers to prevent possible death, personal injury and/or property damage.

This furnace is approved for venting with Schedule 40 PVC, CPVC, ABS, Cellular Core pipe fittings and SDR-26 PVC.

NOTE: All PVC, CPVC, ABS, and Cellular Core pipe fittings, sol- vent cement, primers and procedures MUST conform to Ameri-

can National Standard Institute and American Society for Testing and Materials (ANSI/ASTM) standards.

• Pipe and Fittings - ASTM D1785, D2241, D2466, D2661, D2665, F-891, F-628

• PVC Primer and Solvent Cement - ASTM D2564

• Procedure for Cementing Joints - Ref ASTM D2855

NOTE: Inorder to create a seal that allows future removal of pipe, RTV sealant MUST be used on the inlet pipe where itjoins to

the furnace. PVC, CPVC, ABS, and Cellular Core pipe and ce- ment may be used on all other joints.

CAUTION

Do NOT use solvent cement that has become curdled,

lumpy or thickened and do NOT thin. Observe precautions printed on containers. For applications

below 32 ° R, use only low temperature type solvent

cement.

1. Cut pipe end square, remove ragged edges and burrs. Chamfer end of pipe, then clean fitting, socket and pipe joint of all dirt, grease, or moisture.

44001 2010 04 [_1

Page 18

NOTE:Stirthesolventcementfrequentlywhileusing.Useanatu- ralbristlebrushorthedaubersuppliedwiththecement.Theprop-

er brush size is one inch.

2. After checking pipe and socket for proper fit, wipe socket and pipe with cleaner-primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe. Do NOT al-

low primer to dry before applying cement.

3. Apply a thin coat of cement evenly in the socket. Quickly apply a heavy coat of cement to the pipe end and insert

pipe into fittings with a slight twisting movement until it bot-

toms out.

NOTE: Cement MUST be fluid while inserting pipe. If NOT, recoat

pipe.

4. Hold the pipe in the fitting for 30 seconds to prevent the ta-

pered socket from pushing the pipe out of the fitting.

5. Wipe all excess cement from the joint with a rag. Allow 15

minutes before handling. Cure time varies according to fit,

temperature and humidity.

Connecting VentPipesand Termination

NOTE: Combustion air intake and vent MUST terminate in the

same atmospheric pressure zone. If installation is in a cold cli- mate (sustained temperatures below 0°F), increase the minimum

distance between vent pipe and air intake from 8" to 18".

CAUTION

Maintain a minimum of 36" between combustion air inlet and clothes dryer vent, Terminate the combustion

air intake as far as possible from any air conditioner,

heat pump, swimming pool, swimming pool pumping,

chlorinator or filtration unit.

Poison carbon monoxide gas hazard.

Inlet and outlet pipes may NOT be vented directly above each other

Failure to properly vent this furnace can result in death, personal injury and/or property damage.

Install all couplings, nipples and elbows using proper pro-

cedures for Joining Pipe and Fittings and maintain spac-

ing between vent and combustion air piping as indicated in Figure 13 through Figure 20.

iiiiiiiiiiiiii_i;!i:ii:ii:ii!;i:;!ii!iiiiiililiiiiii!i_i:i_I!¸_i!_i_i!_!_ii_ii_ii!_!ii_i_ii_ii_ii_ii_iiiiii_iii_ii_ii_ii_iiiiiiiiiiiiii_iiii!_!i_i!i!_i_i!iii_!_ii_i_i_i_i_i_i_i_i_i_i_ii_i

_ig_ _ Sidewall Termination 12" or More

.............................................................................Above Snow Level or Grade Level

"18" Minimum for cold climates

(substained below 0° F)

HorizontalTermination

Cut two holes. 21/2" for 2" pipe, 3" for 21/2" pipe, or 31/2" for 3" pipe. Do NOT make the holes oversized, or it will be nec-

essary to add a sheet metal or plywood plate on the outside with the correct size hole in it.

2. Check hole sizes by making sure it is smaller than the cou- plings or elbows that will be installed on the outside. The couplings or elbows MUST prevent the pipe from being

pushed back through the wall.

3. Extend vent pipe and combustion air pipe through the wall 3/4" to 1" and seal area between pipe and wall.

4. install the couplings, nipple and termination elbows as shown and maintain spacing between vent and combus-

tion air piping as indicated in Figure 13 and Figure 14.

A metal shield is recommended 18" x 18" min. or 18" min. diame- ter around the vent termination at the exterior wall to protect the

house exterior materials from flue product or condensation

(freezing) damage.

Using Exterior Risers

1. InstallelbowsandpipetoformriserasshowninFigure 14.

2. Secure vent pipe to wall with galvanized strap or other rust

resistant material to restrain pipe from moving.

3. insulate pipe with Armaflex or equivalent moisture resis- tant closed cell foam insulation or Fiberglass insulation if

boxed in and sealed against moisture.

[_ 44001 2010 04

Page 19

Sidewall Termination with Exterior

Risers to Get Above Snow Level or

Grade Level

j. "18" Minimumfor coldciimates

8"* _ (substainedbelow 0° F)

S MIN. /

20' /_W

MAX /

MultiVent TerminationClearances

When two (2) or more furnaces are vented near each other, each furnace must be individually vented.

Two (2) vent terminations may be installed as shown in Figure 16, Figure 17, Figure 18, Figure 19, Figure 20 and

Figure 21, but the next vent termination must be at least 36" away from first 2 terminations. It is important that vent terminations be made as shown to avoid recalculation of flue gases.

Concentric Vent and Combustion-

Air Roof Termination

SNOW LEVEL 2_-00-04F

VerticalTermination

1. Figure 15 shows the proper installation and clearances for vertical vent termination. The vertical roof termination

should be sealed with a plumbing roof boot or equivalent flashing. The inlet of the intake pipe and end of the exhaust

vent must be terminated no less than 12" above the roof or snow accumulation level, and 12" away from a vertical wall

or other protrusion.

2. If the vent system is installed in an existing chimney make sure clearances shown in Figure 15 are maintained. Hori-

zontal section before the termination elbow can be ex- tended on the inlet air to provide necessary clearance.

Rooftop Termination

12"

or Snow Level

Dimension "A" is touching or 2" maximum separation.

Dimension 'W' is touching or 2" maximum separation.

Combustion

Air

Concentric Vent and Combustion- Air Sidewall Termination

Vent 25-22-02d

Exhaust

Sidewall Inlet Vent and Exhaust- Air Termination

A = 12" Above roof or snow accumulation level B = 8" Min., 20' Maximum, except in areas with extreme

cold temperatures (sustained below 0°F), the 18" Min.

8" Min,

VentTermination Shielding

Under certain wind conditions some building materials may be af-

fected by flue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a cor-

rosion resistant material (such as aluminum sheeting) may be re-

quired to prevent staining or deterioration. The protective material should be attached and sealed (if necessary) to the building be- fore attaching the vent terminal.

44001 2010 04 [_

12" Min.Grade //

or Snow Level

__D mension "A" is touchin_ or 2" maximum separation.

18" Min, for

Cold Climates

(Sustained Below 0°F)

Page 20

18" Min. for Cold Climates

(Sustained Below 0° F)

iiiiiiii¸i¸iiiiiiiiiiiiii!!;JJJi!iiii!iiiiiiiiiiiiiiiiii¸iiiiiiiiiiiiiii

18" Min. for Cold Climates

(Sustained Below 0 ° F)

ls°°wao°,Von,andExhau°,ArTermination with Exterior Risers

8" Min.

12" Min. Grade or

Inlet Snow Level

Dimension "A" is touching or 2" maximum separation.

Rooftop Inlet Vent and Exhaust-

Air Termination

Inlet 20' Max.

8" Min. \

_:_;;;;;;;;;;;;;;_iii_i_ii_ii_i_ii_i_i_iilii_i_iiiiiiiiiiiiiiiiiii_iiii_iiiiiiiiii_i_iiiiiiii_iiiiiiiiiiiiiiiiiiiiiiiii_Recommended Alternate Installa-

tion for Sustained Cold Weather

-0 ° F & below)

INLET

12"MIN, GroundLevel

_OR__ "_ SnowLevel

FRONT VIEW

SIDE VIEW

12" MIN.

25-23-73

12" Min. Grade or Snow Level

Exhaust

25-22-43

5. Gas Supply and Piping

Poison carbon monoxide gas, fire and explosion hazard.

Models designated for Natural Gas are to be used with Natural Gas Only, unless properly converted to use with LP gas.

Failure to properly vent this furnace can result in death, personal injury and/or property damage.

NOTE: The rating plate is stamped with the model number, gas

type and gas input rating. In addition, models manufactured for sale in Canada have orifice size information stamped on the rat-

ing plate.

SameJoist

Space

SupplyPressure

Fire hazard. Do NOT set input rating above that shown on

rating plate.

Failure to properly set input pressure can result in

death, personal injury and/or property damage.

1. Supply pressure can be checked using the 1/8" NPT port on the supply side of the gas valve.

2. Gas input to burners MUST NOT exceed the rated input shown on rating plate.

3. Do NOT allow minimum gas supply pressure to vary down- ward, Doing so will decrease input to furnace. Refer to

Table 5 for normal gas supply and manifold pressures.

[_ 44001 2010 04

Page 21

Gas Pressures Below 2000 Ft.

Gas

Type

Natural 7"

LP 11"

With Propane gas, the rated input is obtained when the

BTU content is 2,500 BTU per cubic foot and manifold pressure set at 10" W.C.

• If Propane gas has a different BTU content, orifices MUST be changed by licensed Propane installer.

• Measured input can NOT exceed rated input.

• Combustion Air Box Cover MUST be removed when adjust-

ing manifold pressure.

• Any major change in gas flow requires changing burner orifice size.

Recom-

mended

(1.7 kPa)

(2.7 kPa)

Supply Pressure

Max. Min.

14" 4.5"

(3.5 kPa) (1.1 kPa)

14" 11"

(3.5 kPa) (2.7 kPa)

Important Notes

Manifold

Pressure

Hi Fire Lo Fire

3.5" 1.7"

(0.9 kPa) (0.5 kPa)

10" 4.9"

(2.5 kPa) (1.3 kPa)

MANIFOLDPRESSURE AND ORIFICE SIZE FORHIGH ALTITUDE APPLICATIONS

High Altitude Pressure Chart

i i i!iii! !i!i !i!i!i!i!i!i!i!iI

Heat Value

Btu/Ou.Ft.

80O 85O 90O

95O 1000 1050

1100

Orifice Size

0-1999

High Low

3.5 1.7

3.2 1.6

2.9 1.4 #42

2000-2999

High Low

3.5 1.7

3.4 1.7

3.1 1.5

2.8 1.4 #42

3000-3999

High Low

3.5 1.7

3.3 1.6

3.0 1.5

2.7 1.3

2000-8000 ft. (Natural Gas)

Elevation Above Sea Level

4000-4999

High Low

3.5 1.7

3.2 1.5

2.9 1.4

2.6 1.3

#42

5000-5999

High Low

3.5 1.7

3.3 1.6

3.0 1.5

2.7 1.3

2.5 1.2 #42

6000-6999

High Low

3.5 1.7

3.2 1.6

2.9 1.4

2.6 1.3

2.4 1.2 #42

7000-7999

High Low

3.5 1.7

3.4 1.7

3.1 1.5

2.8 1.4

2.5 1.2

2.3 1.1 #42

GasSupplyPressure

Gas supply pressure should be within minimum and maximum values listed on rating plate. Pressures are usually set by gas sup- pliers.

ManifoldGasPressureAdjustment(Hi&LoFire)

NOTE: Make adjustment to manifold pressure with burners oper-

ating.

Fire or explosion hazard.

Turn OFF gas at shut off before connecting

manometer. Failure to turn OFF gas at shut off before

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

1. Remove the burner compartment door.

2. Connect manometer to the tapped opening on the outlet side of gas valve. Use a manometer with a 0 to 12" mini-

mum water column range.

3. Turn gas ON. Operate the furnace on high fire by using a jumper wire on the R to Wl & W2 thermostat connections on the fan board.

4. Remove the adjustment cover on the gas valve. Turn ad- justing screw counterclockwise to decrease the manifold pressure and clockwise to increase. See Figure 38.

5. Set the manifold pressure to value shown in Table 5 or

Table 6.

6. Operate the furnace on low fire by using a jumper wire on the R to Wl thermostat connections on the fan board.

Note: The fourth (4th) DIP switch should be in the on posi-

tion to set the low fire manifold pressure. (See wiring di- gram)

7. Repeat steps 4 and 5 for low fire operation.

8. When the manifold pressures are properly set, replace the adjustment screw covers on the gas valve.

9. Remove the jumper wires from the thermostat connections on the fan board. Remove manometer and replace plug in gas valve.

10. Reture fourth (4th) DIP switch to previous setting.

11. Replace the burner compartment door.

44001 2010 04 [_

Page 22

GeneralDerating Rules

1. For operation with natural gas at altitudes above 2,000', orifice change and/or manifold pressure adjustment may

be required to suit gas supplied. Check with gas supplier. If

orifice sizing is needed, it should be based on reducing the

input rating by 2% (natural) or 4% (LP) for each 1,000'

above sea level. See Table 6 and Figure 22 for required

pressure change and/or orifice change for high altitudes.

2. For operation with LP gas at altitudes above 2,000', gas ori- rices MUST be changed and manifold pressure MUST be

maintained as per Table 5. Orifice sizes for 0-2000' above sea level are #54. 2000-7000' above sea level, use #55. 7000-8000' above sea level, use #56 orifices. Orifices can

be ordered through your distributor. (See Figure 22)

NOTE: The derating of these units at 2% (Natural) and 4% (L P.)

has been tested and approved by CSA.

HighAltitudeAir PressureSwitch

Altitudes over 4,000' require a different air pressure switch than the one installed at the factory. Check parts listfor pressure switch

and consult your distributor for part number and availability. In Canada, provincial codes may govern installation of switch. Check with governing authorities.

ChangingOrificesfor HighAltitude

NOTE: Main burner orifices can be changed for high altitudes.

1. Disconnect gas line from gas valve.

2. Remove manifold from furnace.

3. Remove the orifices from the manifold and replace them with properly sized orifices.

4. Tighten orifices so it is seated and gas tight, (See

Figure 22)

Changing Orifices

Measure from face of orifice

( 1,. j to the_ back side of the

11/8" to 13/16"_

Electrical shock, fire or explosion hazard.

Turn OFF electric power (at disconnect) and gas

supply (at manual valve in gas line) when installing orifices. Installation of orifices requires a qualified service technician.

Failure to properly install orifices can result in death, personal injury and/or property damage.

5. Reinstall manifold. Ensure burners do NOT bind on new orifices.

[_ 44001201004

Page 23

_i_ _23 Typical Gas Piping for Upflow

Drip Leg and Union, Union* should cabinet. Manual shut-off valve MUST be

Gas Pipe Grommet (Single

of dripleg, union, and furnace.

Use elbows and 3" pipe nip! piping when using right

side gas pipe entry.

3" pipe

LP Low pressure

switch. Optional on some models.

25-23-84

* Union may be installed inside the cabinet when necessary because of clearances.

NaturalGas Input RatingCheck Example

NOTE: The gas meter can be used to measure input to furnace. Natural Gas No,of Seconds TimePer Cubic

Rating is based on a natural gas BTU content of 1,000 BTU's per BTUContent Per Hour Footin Seconds

cubic 1,000

meter. Check with gas supplier for actual BTU content.

Turn OFF gas supply to all appliances and start furnace.

Use jumper wire on R to Wl and W2 for Hi fire.

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

ample.

Repeat steps 1 and 2 with jumper wire on R to W2 for low

fire.

NOTE: Fourth (4th) dip switch must be in "ON" position. (See Furnace Wiring Diagram). Return fourth (4th) dip

switch to previous setting after check.

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

NOTE: If meter uses a 2 cubic foot dial, divide results (seconds) by two.

3,600 48 75,000

1,000 x 3,600 + 48 = 75,000 BTUH

25-23-37

Hour

t BTU Per

44001 2010 04 [_

Page 24

iiiiiil;iii!¸i¸!!!!!i¸iiiiiiii;¸i¸ii¸i¸¸i¸¸i¸¸i¸¸i¸¸ii;¸i i¸i i!! ¸ii;¸i¸

Typical Gas Piping for Downflow

Use elbows and 3" pipe nipl valve to piping when using left side gas pipe entry.

LP Low pressure switch. Optional LP

conversion.

Drip Leg and Union, Union* should be outside

the cabinet. Manual shut-off valve MUST be

upstream of dripleg, union, and furnace.

*Union may be installed inside the cabinet when necessary because of clearances.

Gas Pipe Grommet (Single Pipe)

25-23-39

GasPiping Requirements

vice technician in accordance with all building codes, (In the state of Massachusetts, gas supply connections MUST be performed

NOTE: The gas supply line must be installed by a qualified ser- 1.

by a licensed plumber or gas fitter). 2.

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

Refer to NFGC and ANSI Z223.1 for proper gas pipe size.

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

3. Measure pipe length from gas meter or LP second stage regulator.

NOTE: Refer to Figure 23 or Figure 24 for the general layout at

the furnace. The rules listed apply to natural and LP gas pipe

installations.

NOTE: On the Dual Certified or Direct Vent models, install the gas pipe grommet to the furnace side pane! with the gas pipe entry. If needed, remove the 2" hole plug and re!ocate to the open hole in

the furnace side panel.

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

I OTE: The use of copper tubing for gas piping is NOT approved

by the state of Massachusetts.

5. Use ground joint unions and install a drip leg no less than 3" long to trap dirt and moisture before it can enter gas valve. 4.

6. Use two pipe wrenches when making connections to pre-

vent gas valve from turning. 5.

7. Install a manual shut-off valve external to furnace casing 6.

and tighten all joints securely.

Additional LP Connection Requirements

Have a licensed LP gas dealer make all connections at

storage tank and check all connections from tank to fur- nace.

Ifcopper tubing is used, it MUST comply with limitation set in National Fuel Gas Code or CGA codes.

3. Two-stage regulation of LP gas is recommended.

FinalCheck

1. The furnace and its individual shut-offvalve must be discon- nected from the gas supply piping system during any pres- sure testing of that system at test pressures in excess of

1/2" PSIG.

The furnace must be isolated from the gas supply piping system by closing its individual manual shut-off valve dur-

ing any pressure testing of the gas supply piping system at

test pressures equal to or less than 1/2" PSIG.

2. Test all pipes for leaks.

3. Gas pressure MUST NOT exceed t/2" PSIG to gas valve. Checking gas piping above 1/2" PSIG requires the furnace

and manual shut-off valve to be disconnected during test-

ing.

Apply soap suds (or a liquid detergent) to each joint,

Bubbles forming indicate a leak.

Correct even the smallest leak at once.

If orifices were changed, make sure they are checked for leakage.

[_ 44001 2010 04

Page 25

6. Electrical Wiring

Electrical shock hazard.

Humidifier/ElectronicAir Cleaner

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

Turn OFF electric power at fuse box or service

panel before making any electrical connections and ensure a proper ground connection is made before connecting line voltage.

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

PowerSupplyWiring

The furnace MUST be electrically wired and grounded in accor- dance with local codes, or in the absence of local codes with the

latest edition of The National Electric Code, ANSI NFPA 70 and/or

The Canadian Electric Code CSA C22.1.

Field wiring connections must be made inside the furnace con-

nection box. A suitable strain relief should be used atthe point the wires exit the furnace casing.

Copper conductors must be used. Line voltage wires should be sized for the inputamps stated on the rating plate. Furnace should

be connected to its own separate circuit.

Thermostat

The 2- stage furnace control will operate with either a single stage or a two stage heating thermostat and will provide 2-stage heat-

ing operation. For single stage thermostat installations, the R and

W wires from the thermostat connect to the R and Wl connec- tions on the furnace control. Note: The fourth (4th) DIP switch

must be in the off position, failure to change DIP switch will result

in Lo Fire ONLY operation. (See furnace wiring digram) See "Fur- nace Wiring Diagram" for switch settings. Failure to set DIP switch will result in Lo fire operation ONLY with single stage thermostat.

During operation, the furnace will operate on low fire for 12 minu- teslf the heat request exists for more than 12 minutes. If the heat

request exists for more that 12 minutes, the furnace will automati- cally shift to the high fire mode for the remaining duration of the

heating cycle. For two stage thermostat installations, the R, Wl and W2 wires from the thermostat connect to the R, Wl and W2

connections on the furnace control. During operation, the furnace will shift from low fire to high fire as requested by the thermostat. The thermostat heat anticipators should be adjusted to a .10 set-

ting for both types of thermostats.

Low voltage connections to furnace must be made on terminal board to fan control.

OptionalEquipment

All wiring from furnace to optional equipment MUST conform to

local codes or, in the absence of local codes with the latest edition of The National Electric Code, ANSI NFPA 70 and/or The Cana-

dian Electric Code CSA C22.1. install wiring in accordance with manufacturer's instructions. The wiring MUST have a minimum

temperature rating of 105 ° C. codes or, in the absence of local codes, the applicable national codes. Install wiring in accordance

with manufacturer's instructions.

CAUTION

Do NOT exceed 115V/0,8 amp, maximum current load

for both the EAC terminal and the HUM terminal combined,

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 air circulating blower is energized during the heat mode. However, the electronic air cleaner is NOT energized during continuous fan operation controlled by the elec-

tronic fan control.

Electrical Connections

NOTE: Junction Box can be mounted to either the left or

right side.

Connection

Box

25-23-42

Dehumidification- Variable Speed ONLY (*9MPV)

The fan control is wired for 24 VAC normally open (N/O) dehumi- distat connection. Connect dehumidistat to the R terminal and the

1/4" male quick connect Y2 terminal on the fan control (See Figure 26 and "Furnace Wiring Diagram"). A 20% reduction of

cooling airflow will occur when the Y2 dehumidistat terminal is en- ergized during a call for cooling from the thermostat.

Fan Control

The fan control is preset at the factory with a fixed blower ON delay of 30 seconds in the heating mode. The blower OFF timing

is preset at 140 seconds, if desired, the fan OFF delay can be re- set to obtain the longest delay times while still maintaining comfort levels. See "Furnace Wiring Diagram".

44001 2010 04 [_

Page 26

ControlCenterFuse

The 24V circuit contains a 5-amp, automotive-type fuse located on fan timer board. (See Figure 26) 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.)

7. Ductwork and Filter

Fan Timer Connections

Dip Switch See "Wiring

Diagram" for switch settings

FUSE

25-22-44a

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

utility room. Return air duct MUST be sealed to furnace casing.

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

Installation

NOTE: Design and install air distribution system to comply with

Air Conditioning Contractors of America manuals and/or NFPA pamphlets 90A and 90B or other approved methods that conform to local codes and good trade practices.

When furnace supply ducts carry air outside furnace area, seal return air duct to furnace casing and terminate duct outside furnace space.

Install air conditioning cooling coil (evaporator) on outlet

side of furnace.

For furnaces installed without a cooling coil it is recom- mended that the outlet duct be provided with a removable

access panel. This panel should be accessible when the furnace is installed so the exterior of the heat exchanger can be viewed for inspections. The access panel MUST be

sealed to prevent leaks.

If separate evaporator and blower units are used, install good sealing dampers for air flow control. Chilled air going through the furnace could cause condensation and shorten

the furnace life.

NOTE: Dampers (field supplied) can be either automatic or manual. Manually operated dampers MUST be equipped with a

means to prevent furnace or air conditioning operation unless damper is in the full heat or coo! position.

Poison carbon monoxide gas hazard. Cool air passing over heat exchanger can cause

condensate to form resulting in heat exchanger failure.

This could result in death, personal injury and/or property damage.

Connections

NOTE: On upflow installations, return air can enter through either

side, both sides, or the bottom. On horizontal or downflowinstalla- tions the return air must enter through the knockout opening in the lower panel of the furnace. Return air can not enter through rear

of the furnace. When the furnace is located in an area near or ad- jacent to the living area, the system should be carefully designed

with returns to minimize noise transmission through the return grille. Any blower moving a high volume of air will produce audible

noise which could be objectionable to when the unit is located very close to living areas. It is advisable to route the return air

ducts under the floor or through the attic.

[_ 44001 2010 04

Page 27

Forsideconnectionsusinga16"x25"filter,cutouttheem- bossedareashowninFigure27.Thiswil!providea141/2"

x221/2"approximateopening.

Side Return Air Cutout

A = 141/2" Height of Cutout for 16" x 25" Filter B = 221/2" Width of Cutout for 16" x 25" Filter

Embossed Area on Side of Furnace

Use either filter type:

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

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

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.

Side Mounted Filter Rack

Furnace Bottom

NOTE: Furnaces with 5 TONS cooling rating require two(2) side

returns or one side return with bottom return.

2. Bottom returns can be made by removing the knockout panel in the furnace base. Do NOT remove knock-out ex-

cept for a bottom return.

3. Installation of locking-type dampers are recommended in

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

4. Non-combustible, flexible duct connectors are recom- mended for return and supply connections to furnace.

5. If air return grille is located close to the fan inlet, install at least one, 90 ° air turn between fan and inlet grille to reduce

noise.

NOTE: To further reduce noise, install acoustical air turning

vanes and/or line the inside of duct with acoustical material.

Sizing

Existing or new ductwork MUST be sized to handle the correct amount of airflow for either heating only or heating and air condi- tioning.

Insulation

°I / jJ

25-20-90

FilterInstallation using FilterRack

When installing or removing abottom mounted filter, slide the two side filter clips to the back of the furnace BEFORE installing or re- moving. This will allow the filter to clear the front raised edge of the furnace. Insert filter into side clips first and push filter back until it is fully engaged into back clip. When filter is in place, slide clips back

into place midway on filter as shown in Figure 29.

Bottom Mounted Filter Rack

1. Insulate ductwork installed in attics or other areas exposed to outside temperatures with a minimum of 2" insulation

and vapor barrier.

2. Insulate ductwork in indoor unconditioned areas with a minimum of 1" insulation with indoor type vapor barrier.

Slide filter clips towards back before removing

AW3192

Filters

A Filter must be used:

Filters are not supplied with these furnaces, but can be purchased

from dealer.

44001 2010 04 [_

Refer to Figure 30 and for guidelines to install filters. Furnaces

which require larger filter media and have limited clearances on one side of furnace, require a standoff filter rack, see Figure 30,

available from your distributor.

Page 28

StandoffFilter Rack

Note: The three(3) screws in the top panel of the furnace next to the duct flange MUST be removed to provide serviceability of the

primary heat exchangers in the downflow installation

1. Position plenum through the floor and 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.

Using Optional

Standoff Filter

Rack

25-21-45a

CAUTION

If filters are only suitable for heating application,

advise homeowner that filter size may need to be

increased if air conditioning is added.

AdditionOf Air Conditioning

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

densation on the heat exchanger. The coi! installation instructions must be consulted for proper coil location and installation proce-

dures. With a parallel flow arrangement, dampers must be

installed to prevent chilled air from entering the furnace. If manu- ally operated dampers are used, they must be equipped with a means to prevent operation of either unit unless the damper is in

full heat or full cool position. A 3" clearance is required on the right side of the furnace in order

to run the condensate drain line. Copper, iron or plastic tubing may be used for the condensate drain line.

DownflowFurnaceInstallation

Non-Combustible FloorInstallation

Fabricate a plenum to the dimensions given in Figure 3, for the furnace outlet. Plenum should be flanged, approximately 3/4" for support.

CombustibleFloorInstallation

Fire Hazard. Place furnace on noncombustible subbase on

downflow applications, unless installing on non-combustible flooring.

Failure to install unit on noncombustible subbase can result in death, personal injury

and/or property damage.

Subbase for Combustible Floor

NOTE: The three(3) screws in the top panel of the furnace next to

the duct flange MUST be removed to provide serviceability of the primary heat exchangers in the downflow installation

Note: When using the subbase for combustible floors, the dis- charge air duct flanges on the furnace MUST be broken down to provide proper fit up to the subbase. Use duct pliers to bend the

duct flanges flat onto the furnace casing. DO NOT bend the duct flanges inward (toward the heat exchangers) as air flow restric- tions may occur.

The Subbase for Combustible Floors MUST be used when a downflow furnace is set on a combustible floor, even when the fur-

nace is installed on a coil box.

Cut the opening in the floor according to Table 7. The hole

in the floor must be cut to the dimensions listed in Table 7

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

The opening in the base is 1t/4" shorter and 11/8" narrower than the recommended size of the opening in the floor. This is done to

maintain clearance between the floor and the plenum.

2. Fabricate the plenum to the dimensions given in Table 7. Note that the dimensions given are outside dimensions.

[_ 44001 2010 04

Page 29

Subbases for Combustible Floors Dimensions

Subbase for Combustible

Floors Part Number

Subbase for Combustible

Floor Dimensions

H* J* K**

Furnace Subbaee

NAHH001SB NAHH002SB

NAHH003SB NAHH010SB

1511/16 283/4 149/16 16

195/16 283/4 183/16 16

225/16 283/4 2113/16 16

243/4 209/I6 239/16 161/4

Subbase for Coil Cabinets

NAHH004SB NAHH005SB

NAHH006SB NAHH009SB

1511/t6 209/I6 149/16 161/4

195/16 209/16 183/16 161/4

23 209/16 2113/16 161/4

2411/t6 283/4 239/16 16

* Outside Dimension ** Base Spacer Side To Side

3. Set the base over the opening in the floor, centering it over the opening. Fasten the base to the floor with screws or

nails. See Figure 31, Figure 32 and Figure 33.

Furnace Subbase

Opening In Floor

M N

161/4 145/8 181/4 18t/4

181/4 217/8 161/4 235/8

161/4 145/8 181/4 18t/4

181/4 217/8 161/4 235/8

Opening In Base

Typical Plenum

For Plenum

P R

15 131/2 15 171/8

15 193/4 15 221/2

15 131/2 15 171/8

15 193/4 15 221/2

Coil Cabinet Subbase

Plenum

Dimensions

S T

15 131/2 15 17t/8

15 193/4 15 221/2

15 131/2 15 17t/8

15 193/4 15 221/2

A = 41/4" Minimum clearance from back of hole to wall or other obstruction.

Plenum

Combustible

Floor Base

25-20-46

25-20-46b

A = 4 1/4" Minimum clearance from back of hole to wail or other obstruction,

4. Drop the plenum through the opening in the base. The flange of the plenum should rest on top of the subbase.

5. Position furnace or coil cabinet and furnace on subbase so

it aligns between the locating tabs.

Setting the Subbase

Furno

Insulation of Combustible Floor Bas

___ _"_/W_dood Floor

Wood Scre_ _/_ _ Plenum 25-20-46a

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

allow easy installation of the condensate drain. See Figure 34.

44001 2010 04 [_

Page 30

Condensate Line Raised by Base

25-20-52

8. Checks and Adjustments

Startup

NOTE: Refer to the start-up procedures in the "User's Informa-

tion Manual" or to the "Operating Instructions Label" on the fur- nace.

CAUTION

If any sparks, odors or unusual noises occur, immediately shut OFF power to furnace. Check for

wiring errors or obstruction to blower.

GasSupplyPressure

Gas supply pressure should be within minimum and maximum values listed on rating plate. Pressures are usually set by gas sup-

pliers.

ManifoldGasPressureAdjustment

NOTE: Make adjustment to manifold pressure with burners oper-

ating.

Fire or explosion hazard.

Turn OFF gas at shut off before connecting

manometer. Failure to turn OFF gas at shut off before

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

1. Remove the burner compartment door.

2. With gas OFE connect manometer to tapped opening on gas valve. Use manometer with a 0 to 15" water column

range.

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

clockwise to increase.

4. For altitudes up to 2000', set pressure to value shown in Table 5, ± 0.3" (8mm) water column. For altitudes of 2000'

to 8000', see Section 5 for correct pressure setting.

Adjust PilotBurner

The furnace has a pilot flame to light the main burner. The flame should surround 3/8"to t/2" ofthe flame sensor. See Figure 35. To

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

flame as required. Replace adjusting screw cap.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiil;iiiiiii_il¸!I¸!I¸!i¸i!iiiiiiiiii;i;i;i;i;i;iiii!!i;i¸i¸iiiii;;i¸iii:;il;iiiiiiiiil;ii

Pilot Burner

Proper Flame _ Flame Sensor Adjustment _

3/8" to 1/2" /_

_ / _"_ Hot Surface

10-11-65

MainBurnerFlameCheck

Allow the furnace to run approximately 10 minutes then inspect the main burner and pilot flames. See Figure 36.

Check for the following (Figure 36):

• 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.

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

essary to adjust gas pressures, or check for drafts.

[_ 44001 2010 04

Page 31

Main Burner

Refer to Furnace Wiring Diagram for location of the heating

and cooling speed taps located on the electronic fan con- trol as well as location of unused blower motor speed

leads. Use the chart (Table 8) to determine the blower mo-

tor speed settings.

Blower Speed Chart

10-10-78

TemperatureRiseCheck

The blower speed MUST be set to give the correct air temperature

rise through the furnace as marked on the rating plate for both

high fire and low fire operation. Temperature rise is the difference between supply and return air temperatures.

To check temperature rise,use the following procedure:

1. Place thermometers in supply and return air registers as close to furnace as possible, avoiding direct radiant heat from heat exchangers.

2. Operate furnace on high fire for 10 minutes with all the reg- isters and duct dampers open by using a jumper wire on R

to Wl and W2 thermostat connections on the fan board.

Note: The fourth (4th) DIP switch should be in the on posi-

tion. (See furnace wiring digram)

3. Take readings and compare with range specified on rating plate.

4. If the temperature rise is not in the correct range, the blower

speed must be changed. A higher blower speed will lower the temperature rise. A lower blower speed will increase the temperature rise.

5. Repeat steps 2 thru 4 with the furnace operating on low fire

for 10 minutes by using a jumper wire on the R to W1 ther-

mostat connections on the fan board.

6. Remove the jumper wire after the adjustments are com- plete. Return fourth (4th) to previous setting.

ChangingBlowerSpeed (*9MPTModels)

Electrical shock hazard.

Wire Color

Black

Orange*

Blue Red

Motor Speed

High

Med-High

Medium

Low

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

2. Change the heat or cool blower motor speed by removing the motor lead from the "Heat" or "Cool" terminal and re-

place it with the desired motor speed lead from the "Un- used Motor Lead" location. Connect the wire previously

removed from the "Heat" or "Cool" terminal to the vacated "Unused Motor Lead" terminal.

3. If the same speed must be used for both heating and cool-

ing, 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. Attach a jumper between the "Heat" and "Cool" terminals and the

remaining motor speed lead.

Note: For 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 atthe "Unused Mo- tor 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.

Turn OFF power to furnace before changing speed taps.

Failure to do so can result in death and/or personal in-

jury.

NOTE: The speed taps that the manufacture sets from the factory

for this product are based on a nominal 400 CFM per ton cooling and the basic mid range on the temperature rise for heating.

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 applica- tion when the unit is installed.

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

44001 2010 04 E_

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 ContinuousBlowerSpeed the Same

If it is necessary to operate the heating speed and continuous

blower speed using the same blower speed, connect a jumper 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.

Page 32

ChangingBlowerSpeed (*9MPVModels)

Electrical shock hazard.

Turn OFF power to furnace before changing speed taps,

Failure to do so can result in personal injury and/or

property damage.

NOTE: The blower speeds that the manufacturer sets from the

factory for this product are based on a nominal 400 CFM per ton cooling and the mid range on the temperature rise for heating.

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 applica-

tion when the unit is installed.

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

1. The 115 VAC power supply to the furnace must be turned OFF before making adjustments to the motor.

Blower Motor Control

The heating, cooling and continuous blower speeds can be adjusted by changing the switch settings that are located

on the motor control (see Figure 37). Switches #1 and #2 adjust the continuous blower speeds. Switches #3, #4 and

#5 adjust the heating speeds. Switches #6, #7 and #8 ad- just the cooling speed. See the "TechnicalSupportManual" for the switch settings for the desired airflow rates for the

installation.

45678

oN 1 l

; I_6; INPUT

OFF O THERMOSTAT

DIP CONNECTIONS

SWITCHES

9. Furnace Maintenance

CAUTION

It is recommended that the furnace be inspected and

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

See "User's Information Manual" and the "Service

Manual".

10. Sequence of Operation & Diagnostics

DDDDD

SIGNAL OR

25-23-10

010

*EXAMPLE Cooling Airflows Switches

6_7&8: 000 3.5 Ton

001 3.0 Ton 010 2,5 Ton 011 2,0 Ton

*See "Technical Support

Manual" for correct airflow rates.

The following is the normal operating sequence for the 2-stage control system.

Cooling(Y) Request:

24 VAC signals applied to Y & G terminals of EFT (electronic fan timer) control.

• Coo! motor speed energized after 5 second Coo! Fan On Delay time.

Y & G signals removed from EFT.

• Cool motor speed de-energized after 60 second Cool Fan Off Delay time,

[_ 44001 2010 04

Page 33

Cooling(Y)anddehumidification(Y2)requests:

• 24VACsignalsappliedtoY,Y2&GterminalsofEFT(electronicfantimer)control.

• Sameoperationasthecooling(Y)request,exceptthecoolingspeedisreduced20%tocompensateforhighhumidityconditionsduring

coolingoperation.ThecoolingspeedreturnstothenormalsettingaftertheY2signalisremoved.

CirculatingFan (G) Request:

24 VAC signals applied to G terminals of EFT control.

• Low motor speed energized without delay.

G signal removed from EFT.

• Low motor speed de-energized without delay.

NOTE1) Furnaces with DC blower motors run a low circulating fan speed in response to G request. NOTE2) Furnaces with PSC blower motors de-energize the Low Heat fan speed during the heat exchanger warm-up period on a

call for Heating that occurs during a G request.

NOTE3) Heating or Cooling requests received during a Fan request cause the fan speed to change to the appropriate heat or cool

speed after the selected Fan On Delay time expires. The fan returns to circulating speed after the selected Fan Off Delay time expires following loss of the Heating or Cooling request.

Heating(Wl) Request (single stage thermostatoperation, 4th DIP switch must be in off position)(see furnace

wiring diagram):

24 VAC signals applied to Wl terminal of EFT control.

• Inducer motor turns on at high speed.

• The high fire solenoid energizes.

• Following a 3 second prepurge delay, the pilot valve opens and the ignitor begins to warm up.

• After the pilot lights, the main burners energize and light (burners now at high fire rate).

• Timed from the opening of the main gas valve, the control will delay the selected Heat Fan On Delay time before switching the inducer to low speed, de-energizing the high fire solenoid and the fan switches to Low Heat speed.

• Timed from initial application of the Heating request, if the Wl request is still present after the selected Low Fire Delay time expires (12 minutes), the inducer switches to high speed, the high fire solenoid energizes and the fan switches to High Heat speed.

Wl signal removed from EFT.

• The gas valve de-energizes and the main burners go out.

• The inducer runs at its present speed for a 5 second postpurge period.

• The fan switches to (or stays at) Low Heat speed.

• Timed from the gas valve de-energizing, the Low Heat fan speed de-energizes after the selected Heat Fan Delay time expires.

NOTE4) If a new Heating request arrives while the control is waiting in the Heat Fan Off Delay time, the fan speed switches to High Heat until the Heat Fan Off Delay expires or the Heat Fan On Delay expires for the new Heating request.

Heating Request(two stage thermostat operation,4th DIP switch must be in on position) (see furnace wiring

diagram):

24 VAC signals applied to Wl terminal of EFT control.

• Same response as single stage thermostat operation described above except the control will not go to high fire, High Heat fan speed unless a W2 signal is applied.

24 VAC signals applied to Wl and W2 terminals of EFT control.

• Same light-off routine as described for the signal stage thermostat operation except that at the end of the selected Heat Fan On Delay, the inducer remains on high fire, the high fire solenoid remains energized and the High Heat fan speed energizes.

NOTE5) The EFT control responds without delay to the presence or loss of W2 (with Wl constant). W1 & W2 results in high inducer,

high fire and High Heat fan speed. Wl only results in low inducer, low fire and Low Heat fan speed.

44001 2010 04 [_

Page 34

Heating Requestwith Gas Supply LineShut Off:

24 MAC signals applied to Wl terminal of EFT control.

• Inducer motor turns on at high speed.

• The high fire solenoid energizes.

• Following a 3 second prepurge delay, the pilot valve opens and the ignitor begins to warm up.

• The ignitor glows red-hot for 30 seconds, then turns oft.

• The igniter stays oft for 25 seconds, then begins to warm-up again.

• The igniter glows red-hot for 30 seconds, then turns off.

• The pilot valve closes 3 seconds after the igniter de-energizes.

• The inducer de-energizes 5 seconds after the pilot valve closes.

• The SmartValve proceeds to soft lockout and flashes error code 6.

• The control exits soft lockout after 5 minutes and begins another ignition sequence.

GasValveDiagnosticCodes(SeeFigure38)

OFF = Control not powered

Heartbeat = Normal Operation (Standby or call for heat)

1Flash 2Flashes 3Flashes

4 Flashes = 5 Flashes =

6 Flashes + 1 Note 1 = 6 Flashes + 2 Notes 1,2 =

6 Flashes + 3 Notes 1,2 =

6 Flashes + 4 Notes !,2 = 7 Flashes =

8 Flashes = 9 Flashes =

= Not used = Low Pressure switch closed when should be open

Low Pressure switch circuit was still sensed as open 30 seconds after the inducer was energized. System is in 5 minute delay mode, with inducer off. After 5-minute delay, a new ignition sequence will be initiated.

(Note: SV9541Q On/Oft switch in off position during a call for heat wil! generate this diagnostic code) Limit switch string open Flame sensed out of sequence - Flame signal still present.

Soft Lockout -Maximum retry count exceeded (failed to light within 4 trials for ignition)

Soft Lockout - Maximum recycle count exceeded - Last failure was Flame Sense Lost During Run, Cycling Pressure Switch or Blocked Condensate.

Soft Lockout -Maximum recycle count exceeded - Last failure was Airflow Proving Circuit Opened

During Run Soft Lockout -Maximum recycle count exceeded - Last failure was Limit Circuit Opened During Run Soft Lockout Due to Limit Trips Taking Longer than 2 minutes to Reset; Auto Reset After 1 Hour if

Call for Heat Still Present. Reset by Cycling Call for Heat at Any Time.

High Pressure Switch closed when sould be open.

High Pressure Switch open when sould be closed.

NOTE 1 :The 6 + X designation indicates a combination of flash codes: 6 flashes shows the control is in soft lockout, followed by X flashes

to indicate the reason the control went into soft lockout. When the 6+ X code is flashing, the SV9541 will attempt a new ignition sequence after a five minute delay period, if the call for heat is still present. Reset of the thermostat wil! initiate a new ignition sequence immediately.

NOTE 2: Any combination of 5 'abnormal' events during a single call for heat will result in soft lockout. An 'abnormal' event is a Flame Sense Failure During Run, Airflow Proving Circuit Open During Run, or Limit Circuit Open During Run. The flash code wil! indicate which was the last 'abnormal' event that put the system into the soft lockout state based on the table above.

[_ 44001 2010 04

Page 35

Typical Gas Valve Honeywell

On/Off Switch

INLET

Manifold Adjustment

(Hi._

Diagnostic Light (on some models)

Pilot

Adjustment

OUTLET

25-22-25a

OUTLET

Manifold Pressure

LO Adjustment

INLET

25-22-49a

44001 2010 04

Page 36

HONEYWELL SV9541Q "SMART VALVE" Sequence of Operation

POWERAPPLIEDTOAPPLIANCE

THERMOSTATCALLSFORHEAT

I HIAND LOWAIR PROVINGSWITCHESPROVEDOPEN?

COMBUSTIONAIR BLOWER

ONHIGHSPEED

HIAND LOWAIR PROVINGSWITCHES

PROVEDCLOSEDWITHIN30 SECONDS?

YES

I PRE-PURGE

PILOTVALVEOPENS:

IGNITORPOWERED

PILOTLIGHTSANDFLAMEISSENSED

DURING90 SECONDTRAILFOR

IGNITION? (1)

MAINVALVEOPENSONHIGH,

IGNITER"OFF"

CIRCULATINGFAN"ON"AND

COMBUSTIONAIR BLOWERONLOW

SPEED.MAINVALVEON LOWFIRE

AFTERDELAY (2)

FLAMESENSELOST?

_1_ WAtTFOR PRESSURESWITCHESTOOPEN J

COMBUSTIONBLOWERDE-ENERGIZEDJ__

THREESECONDFLAME L,,

FAILURERECYCLEDELAY

PILOTVALVECLOSES;

PILOTIGNITOROFF

YES

PILOTANDMAINVALVECLOSE

FIVEMINUTEWAITPERIOD

CIRCULATINGAIRFANOFF

AFTERDELAY

THERMOSTATCALLFORHEAT ENDS

FLAMESENSELOSTMORETHANFIVE _NTIMESINTHIS CALLFORHEAT?

PILOTANDMAINVALVECLOSE

COMBUSTIONBLOWER"OFF"AFTER

POSTPURGE

CIRCULATINGAIR FAN"OFF"AFTER

DELAY

WAIT FOR NEXT CALL FOR HEAT I

[_ 44001 2010 04

(1) Ignitorturns"OFF"about30secondsintothe trialfor ignition.Ifthe pilotflamehas

notlit,it turnsback"ON"forthefinal 30secondsof the90 secondtrialforignition. Thepilotvalveis energizedduringtheentiretrialfor ignition.Thisis normalopera- tionfor thegasignitionsystem.

(2) Ifa W2callfor heatispresent,circulatingfan onhighspeed.Combustionairblow-

erandmainvalveremainon high.

NOTE:If mainlimitstringopensandtakeslongerthan2 minutesto close,system

goesinto1hourwaitperiod.

YES

COMBUSTIONAIR BLOWEROFFAFTER

POSTPURGE

Page 37

HONEYWELL SV9541Q "SMART VALVE" Trouble shooting

The 6 + X designation indicates a combination of flash codes: 6 flashes shows the control is in soft lockout, followed by X flashes to

indicate the reason the control went into soft lockout. Last status code indicates repair to address first

LED

STATUS

Off No power to system control. Low voltage (24V) power at 24 VAC and COM terminals on ST9162A

Heartbeat Normal indication whenever the system is powered, unless some Bright - Dim abnormal event has occurred. Not Applicable - Normal Operation (stand by or call for heat)

2 Flashes open).

3 Flashes

4 Flashes

5 Flashes

6 Flashes + 1 Flash

INDICATES CHECK/REPAIR

Line voltage input at L1 and Neutral connectors on ST9162A Fan Timer.

System wiring harness is in good condition and securely connected.

Low pressure switch closed when it should be open Pressure switch stuck closed (system will wait for pressure switch to (i.e. when call for heat begins).

(Combustion blower is not energized until pressure switches opens) Pressure switch miswired orjumpered.

Low pressure switch, open when it should be closed (i.e. longer than 30 seconds after combustion blower!inducer is energized).

System goes into 5-minute delay period, with combustion blower/ inducer off. At end of the 5-minute delay, another cyclewill begin.

Main Umit or Roll Out Switch is open.

Combustion blower is energized, Circulating blower is energized heat speed.

Flame signal sensed out of proper sequence. Combustion blower is energized, Circulating blower is energized

heat speed after the "ON" delay. Soft Lockout.

Failed to light pilot during 90 sec. trial for ignition

Combustion air blower is de-energized, Circulating blower is de- energized after the "OFF" delay.

After 5-minute delay time, control system will reset and initiate a new ignition sequence,

Ignition system control switch must be in the ON position. Pressure switch operation, tubing, and wiring.

Restrictions in furnace air intake or vent piping.

Main limit switch. Manual reset burner rollout switch.

Limit and rollout switch wiring is in good condition and securely connected.

Flame at pilot burner.

Gas supply off or pressure too low or high for appliance to operate. Damaged or broken HIS element

Line voltage HOT lead wire not connected to L1 terminal on ST9162A. Furnace not properly earth grounded.

Flame sense rod contaminated or in incorrect position. Pilot burner located in incorrect position. Pilot burner lead wires are in good condition and popery connected. Pressure switches operation, tubing, and wiring.

SoftLockout.

Gas supply off or pressure too low or high for appliance to operate. Line voltage HOT lead wire not connected to L1 terminal on ST9162A.

Furnace not properly earth grounded. Flame sense rod contaminated or in incorrect position. Pilot burner located in incorrect position. Pilot burner lead wires are in good condition and properly connected. Cycling, pressure switch

Condensate drain blocked Pressure switches operation, tubing, and wiring.

6 Flashes + 2 Flashes

Last failure was Flame Sense lost during run.

Maximum recycle count exceeded

Combustion air blower is de-energized, Circulating blower is de-energized after the "OFF" delay.

After 5-minute delay time, control system will reset and initiate a new ignition sequence,

44001 2010 04 [_

Page 38

HONEYWELL SV9541Q "SMART VALVE" Trouble shooting continued

Soft Lockout.

Last failure was pressure switch

Ignitionsystemcontrolswitchmustbein theONposition.

6 Flashes + 3 Flashes

Maximum recycle count exceeded

Combustion air blower is de-energized, Circulating blower is de- energized after the "OFF" delay.

After 5-minute delay time, control system will reset and initiate a new ignition sequence,

Soft Lockout.

Pressureswitchesoperation,tubing,andwiring. Restrictionsinfurnaceairintakeorventpiping. Highwindsblowingagainstvent.

6 Flashes + 4 Flashes

7 Flashes

8 Flashes

9 Flashes

Lastfailurewaslimitcircuitopenedduringrun.

Combustion air blower is de-energized, Circulating blower is de-energized after the "OFF" delay.

After5-minute delaytime,controlsystemwillresetandinitiatea newignitionsequence,

Soft Lockout.

Blowerfailure(typical) Limittrip tooklongerthan2 minutesto reset.

System will start a new ignition sequence after 1 hour, if call for heat still present.

High Pressure closed when should be open. (i.e., when call for heat begins).

(Combustion blower is not energized until pressure switches open)

High Pressure openwhen should be closed. (i.e., longer than 30 seconds after combustion/inducer is energized).

Systemgoesintoa5minutedelayperiodwithcombustionblower/ inducer"OFF'.Atendofthe5 minutedelayanothercyclebegins.

Mainlimitswitch. Limitand rolloutswitchwiringisin goodconditionandsecurely

connected. Restrictioninduct work.

Dirtyfilter

Deadblower. Blockedductwork.

Pressure switches stuck closed (system will wait for pressure switch to open).

Pressure switch miswired or jumpered. Ignition system control switch must be in the "ON" position.

Pressure switch operation, tubing and wiring.

Restrictions in furnace air intake or vent piping.

[_ 44001 2010 04

Page 39

11. Concentric Termination

VentTermination Clearances

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

Inlet and outlet pipes may NOT be vented directly above each other (standard vent terminals).

Failure to properly vent this furnace can result in death, personal injury and/or property damage.

Figure 39 Kit Components

Kit Contents:

3" Rain Cap or 2" Rain Cap 3" Diameter SDR-26 Pipe, 191/2" Long or 4" Diameter SDR-26 Pipe, 371/8" Long, 2" Diameter SDR-26 Pipe, 315/8" Long or

21/2" Diameter SDR-26 Pipe, 24" Long, 3" Y Concentric Fitting or 2" Y Concentric Fitting

3" or 4" Dia.

SDR-26 Pipe

1. Determinetermination locations based on clearances spe- cified in following steps and as shown in Figure 7,

Figure 39 through Figure 44.

2. The vent termination must be located at least 12" above ground or normally expected snow accumulation levels.

Do NOT terminate over public walkways. Avoid areas

where condensate may cause problems such as above

planters, patios, or adjacent to windows where steam may

cause fogging.

The venttermination shall be located at least 4' horizontally from any electric meter, gas meter, gas regulator, and any

relief equipment. These distances apply ONLY to U.S. installations.

The vent termination is to be located at least 3' above any forced air inlet located within 10' ; and at least 10' from a

combustion air intake of another appliance, except another direct vent furnace intake.

6. In Canada, the Canadian Fuel Gas Code takes prece- dence over the preceding termination instructions.

2" or 3" Dia. 2 or 21/2" Dia.

Y Concentric Fitting SDR-26 Pipe

Vertical& Horizontal Termination

Determine the pipe diameters required for the installation

from Table 9 and Figure 41.

Determine the best location for the termination kit. See

Figure 40 for vertical termination or Figure40 and Figure 44 for horizontal termination. Roof termination is

preferred since it is less susceptible to damage, has re- duced intake contaminants and less visible vent vapor. For

side wall termination, consideration should be given to: 1) possible damage from the vapors to plants/shrubs, other

equipment and building materials, 2) possible damage to the terminal from foreign objects, 3) wind effects that may cause recirculation of flue products, debris or light snow

and 4) visible vent vapor.

Figure 40 Concentric Vent Roof Installation

Vent/_ Maintain 12" rain. clearance

above highest anticipated snow level. Max. of 24"

Combustion Air

Roof Boot/ Flashing (Field

above roof.

2" or 3" Dia. Rain Cap

25-22-03

ConcentricVentTermination- Kit# NAHAOO1CV& NAHAOO2CV

These kits are for vertical or horizontal termination of the combus- tion air inlet and the exhaust vent pipes on Category IV gas-fired

condensing furnaces. The NAHA001CV kit can be used for 3" di- ameter pipe systems. The NAHA002CV kit can be used for 2" diameter pipe system. Refer to Table 9 for the correct pipe size

for the furnace. Both the combustion air inlet and the exhaust vent pipes must attach to the termination kit. The termination kit must

terminate outside the structure and must be installed per the

instructions outlined below for vertical or horizontal termination.

Vertical termination is preferred. Field supplied pipe and fittings are required to complete the installation.

44001 2010 04 [_

Note:

Support must be field installed to secure termination kitto structure.

3. Cut one 5" diameter hole through the structure for the NAHA001CV Kit or one 4" diameter hole for the

NAHA002CV Kit.

Vent

Support

(Field Supplied)

j45 Elbow

(Field Supplied)

Combustion Air 25-22-02

Page 40

4.DimensionDmaybelengthenedto60"max.orshortenedby cuttingthepipesto12"min.DimensionAwillchangeaccord- ingtoDdimension.(SeeFigure41)

Figure 41 Concentric Vent Dimensional

11/2"-- : _

Model A* B C NAHA002CV 333/8 2 3t/2 NAHA001CV 387/8 3 41/2

* = Dimension will change accordingly as dimension D is

lengthened or shortened.

**= Dimension D may be lengthened to 60" may also be short- ened

by cutting the pipes provided in the kit to 12" minimum

NAHAOO2CV- 35' & (4)90° elbows with 2" PVC pipe

NAHAOOlCV - 35' & (4) 90° elbows with 3" PVCpipe

1. Do not include the field supplied 45°elbow inthe total elbow

count.

2. If more than four elbows are required, reducethe length of both the inlet and the exhaust pipes five feet for each

additional elbow used.

3. Elbows are DWV long radius type for 2" and 3" vents.

If more than four elbows are required, reduce the length of both the inlet and exhaust pipes 5' for each additional elbow

used. * Feet of pipe iswhichever pipe run is the longest, either inlet

or outlet side.

If assembly needs to be extended to meet height or side wall

thickness requirement, the two pipes supplied in the kit may be

replaced by using the same diameter solid, single (no coupling

connections) field supplied SDR-26 PVC (ASTM D2241) pipes.

Do not extend dimension D more than 60". (See Figure 41)

Do not use field supplied couplings to extend the pipes. Airflow restriction will occur and the furnace

pressure switch may cause intermittent operation.

Drawing

B PVC Vent/Exhaust

PVC Intake/Combustion Air

A -_

Concentric Termination Kit

NAHA001 CV & NAHA002VC Venting

Table Dual Piping ONLY

50,000 & 75,000 Btuh Furnace

100,000 & 125,000 Btuh Furnace

25-22-03

D**

167/8

211/8

Partially assemble the concentric vent termination kit.

Clean and cement the parts using the procedures for Join-

ing Pipe and Fittings section of the manual. A) Cement the

Y Concentric fitting to the 4" diameter kit pipe. (See

Figure 42) B) Cement the 3" rain cap to the 21/2" diameter

kit part. (See Figure 42) NOTE: A field supplied stainless steel screw may be used to secure the rain cap to the pipe

instead of cementing when field disassembly is desired for

cleaning (See Figure 42)

iiiiiiiiiiii_ii_i!i_i_i_;i;!!i!iii_iiiiiiiii_i_!_!_:_ii_;_l_;;i;i_!_i!_i_ii_ii_i_iiiiiiiiiiiiiiiilil_iiiiiiiii_iiiiiiiii_iiii_;_i!i!_i!!i

25-22-02

Rain Cap to Vent Pipe Assembly

Drill clearance hole in rain cap and pilot hole in vent pipe.

Stainless steel screw (Field supplied)

Poison carbon monoxide gas hazard.

When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may

cause cracking of the PVC components, allowing flue gases to be recirculated.

Failure to follow this warning could result in

death, personal injury and/or property damage.

Poison carbon monoxide gas hazard.

Do not operate the furnace with the rain cap removed as recirulation of the flue gases may occur. Water may also collect inside the larger combustion air pipe and flow to the burner

enclosure.

Failure to follow this warning could result in death, personal injury and/or property damage.

6. Install the Y concentric fitting and the pipe assembly through the structure's hole. For vertical termination, install

the parts through the field supplied roof boot/flashing.

NOTE; Do not allow insulation or other materials to accu-

mulate inside the pipe assembly when installing through the structure's hole.

7. Secure the assembly to the structure as shown in

Figure 40 or Figure 44 using field supplied metal strap-

ping or equivalent material.

[_ 44001 2010 04

Page 41

NOTE: Ensure the termination height isabove the roof sur-

face or anticipated snow level as shown in Figure 40 for vertical termination. Ensure the termination location clear-

ance dimensions are as shown in Figure 43 and Figure 44 for horizontal termination.

iiiiiiiiiiiiiiii'i!iii!!i_!i:il¸;i_i_i_i_iiiiiii_lilil_l_l;l;l;l;l;l;_:l:l:l:l;_;_;!_:_l_l_;ii_iii!_!!i!_i_li;_;_i_i_i_iiiiiiiiiiiiiii_iiiiiiiiiiiiiiiiiiii

_ig_ 43...........................................................................Air Side Termination

J-1" max

Concentric Vent and Combustion-

Roof Overhang

Maintain 12" clearance above high- est anticipated snow level or grade whichever is greater. 25-22-02

Figure 44

Vent _ _V

Combustion \ iiiiii 1" max.

Air 45 ° Elbow ;;;;;;

Note:

Securing strap must be field installed to prevent movement of ter- mination kit in side wall.

8. install the rain cap and the small diameter pipe assembly in the Y concentric fitting and the large pipe assembly. Ensure

that the small diameter pipe is bottomed out and securely cemented in the Y concentric fitting.

9. Cement the furnace combustion air and vent pipes to the concentric vent termination assembly. See Figure 40 or

Figure 44 for proper pipe attachment.

10. Operate the furnace through one heat cycle to ensure com- bustion air and vent pipes are properly connected to the

concentric termination connections.

Concentric Vent Sidewall

Attachment

Strap

(Field Supplied) X _ AirC°mbusti°n

ent

_ _-_ Flush to

(Field Supplied)

25-22-02

44001 2010 04 [_

ICP H9MPT050F12A1, H9MPT050F12B1, H9MPT075F12A1, H9MPT075F14A2, H9MPT075F14B1 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual