ICP NAHA00601WK Installation Instructions Manual

INSTALLATION INSTRUCTIONS
TWINNING KIT
NAHA00601WK
Please read these instructions completely before starting the installation.
SAFETY CONSIDERATIONS
! WARNING
Failure to follow this warning could result in personal injury, death and/or property damage.
Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, other conditions, which could result in personal injury or death. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factoryauthorized kits or accessories when modifying this product.
!
Failure to follow this warning could result in dangerous operation, personal injury, death, or property damage.
Furnaces shall NOT be twinned (i.e. tandem or staged operation) unless approved in factory technical specifications literature for the furnace. A factory authorized, fieldsupplied Twinning Kit MUST be used. Consult furnace pre−sale literature for specific models approved for twinning and the correct twinning kit. Twinned furnaces must be installed on both a common supply AND a common return duct system as shown in the Twinning Kit Installation Instructions. Only two furnaces can be twinned on a common supply and return duct system using a factory authorized twinning kit.
WARNING
gloves. Have a fire extinguisher available during start−up, adjustment steps, and service calls. Recognize safety information. This is the safetyalert symbol
. When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safetyalert symbol. DANGER identifies the most serious hazards which will result
in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 1................................
TABLE OF CONTENTS 1.....................................
INTRODUCTION 2..........................................
DESCRIPTION AND USAGE 2................................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTION 4..........
MULTIPOISE SINGLE−SPEED AND TWOSPEED
NONCONDENSING HSI FURNACE MODELS 4................
INSTALL FURNACES 5......................................
DIMENSIONS 5.............................................
CONNECT ELECTRICAL COMPONENTS—HEATING 11..........
CONNECT ELECTRICAL COMPONENTSCOOLING 15..........
VENTING 15................................................
GAS SUPPLY PIPING 15......................................
ELECTRICAL SUPPLY CONNECTIONS 15......................
STARTUP AND ADJUSTMENT 16.............................
SEQUENCE OF OPERATION 19...............................
Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and
qualified personnel should install, repair, or service heating equipment. Untrained 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 literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply. These instructions cover the minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation. Follow all safety codes. In the United States, follow all safety codes including the current edition of the National Fuel Gas Code (NFGC) NFPA No. 54/ANSI Z223.1. In Canada, refer to the current edition of the National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC), CAN/CSAB149.1 and .2. Wear safety glasses and work
! WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal injury, death, and/or property damage.
Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any installation or modification. Follow the operating instructions on the label attached to the furnace.
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing and gloves when handling parts.
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INTRODUCTION
IMPORTANT: Only the furnace sizes listed in Table 2 can be
twinned. Both furnaces must have the same product number, including heating and cooling sizes, to achieve correct operation.
This furnace twinning kit permits connection to the following furnaces to operate as a single unit on the same duct work:
S Two multipoise, 33.3 inch (846 mm), single−speed,
noncondensing furnaces (See Figure 1, Figure 2 and Table 2)
S Two multipoise, 33.3 inch (846 mm), two−stage,
noncondensing furnaces (See Figure 1, Figure 14, and Table 2)
!
UNIT AND PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in unit and property damage.
A noncondensing furnace shall NOT be twinned with a condensing furnace. Twostage condensing or noncondensing furnaces shall not be twinned with any single stage furnace. Do not twin furnaces that have a different number of blower motor speed taps together. Furnaces shall only be twinned in the positions shown. Variablespeed furnaces shall not be twinned.
WARNING
DESCRIPTION AND USAGE
Refer to the appropriate section for your furnaces. SECTION I: Models N8MSN & N8MSL Multipoise
SingleSpeed Non−Condensing HSI Furnaces
S SingleStage Heat with SingleStage GasHeat Thermostat S TwoStage Heat with Twostage GasHeat Thermostat
Models F8MTL & G8MTL Multipoise Two−Stage NonCondensing HSI Furnaces
S TwoStage Heat with SingleStage GasHeat Thermostat S TwoStage Heat with TwoStage GasHeat Thermostat
DUCT CONNECTIONS
All furnaces must have a common supply plenum attached to the furnaces or evaporator coils prior to any branch supply trunk or takeoff. The height of the plenum should be at least as high (upflow/downflow) or as long (horizontal) as the width of one furnace. Supply air dampers, when used should be installed in the branch ducts, not in the common plenum. Fire or smoke dampers, when required by code may be installed in the common plenum. Refer to the damper manufacturer’s ratings installation instructions for proper application. The damper should not create undue restriction in the open position.
All furnaces must be installed to ensure sufficient return air to both furnaces:
S For upflow furnaces: A combination of one full side of each
and bottom inlet plenum or bottom only inlet plenum shall be used for return air to each furnace. The preferred method is to have all return air brought into the bottom of the furnaces through a common bottom plenum. The bottom returnair plenum shall be at least as high as the width of the furnace bottom returnair opening. When there are height limitations, the bottom returnair plenum height can be reduced to 8 in. minimum (203mm) if one entire side returnair opening of each furnace is used in conjunction with the bottom return opening. Rear inlet plenums shall not be used. (See Figure 1) Connect all return trunks or branch return ducts to common return plenum.
S For downflow and horizontal furnaces: All return air must
be brought into the bottom opening of the furnace through a common return air plenum. The returnair plenum shall be at least as long (horizontal) or tall (downflow) as the width of the furnace returnair opening. (See Figure 2) Connect all return trunks or branch return ducts to common return plenum.
S For all furnaces: Fire or smoke dampers, when required by
code may be installed in the common return plenum. Refer to the damper manufacturer’s ratings installation instructions for proper application. The damper should not create undue restriction in the open position.
!
FIRE HAZARD
Failure to follow this warning could result in improper auxiliary limit operation, fire, personal injury or death.
Do not remove the center return−air partitions between the furnaces.
Staged heating operation is permitted only with this twinning kit. With the singlespeed, noncondensing furnaces, the lefthand furnace is used for first−stage heat, and both furnaces are used for secondstage heat. With the two−stage, noncondensing furnaces, lowgas heat in both furnaces is used for first−stage heat, and high−gas heat in both furnaces is used for secondstage heat. This kit ensures both furnace blowers operate simultaneously so air flows through the duct work rather than recirculating in a loop between the furnaces.
WARNING
2
Specifications subject to change without notice.
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Common
A
Supply Air Plenum
Figure 1 Upflow Ductwork Connections
Common
A
Supply Air Plenum
Twinned Furnace
Common Return
A
A
Example 1
Example 1 Notes:
Return duct cannot obstruct access to either furnace Return Air can enter thru any combination of:
a. Left side only b. Right side only c. Bottom only d. Back of platform when height of platform
equal Dimension A as shown
e. Any combination of a, b, c, d
Air Plenum
Figure 2 Downflow/Horizontal Ductwork Connections
Return Air Plenum
B
Example 2 Notes:
When furnaces are installed Back-to-Back (not shown) return duct MUST connect to the common return plenum and side inlet of BOTH furnaces Return duct cannot obstruct access to either furnace
Twinned Furnace
8 MIN
Common Return Air Plenum
Example 2
Return Air Plenum
B
A02223
Common Return Air Plenum
A
A
Twinned Furnaces
Common Supply Air Plenum
Example 3 - Downflow Applications
Example 3 Notes:
Do not connect return air to any side of the furnace Connect return air plenum as shown
A
A
Common Supply Air Plenum
Example 4 Notes:
Do not connect return air to any side of furnace. Do not stack condensing furnaces of top of each other When furnaces are installed Side-by-Side (not shown), return connection is similiar. Depth of plenum Dimension A must equal to the front width of one furnace
Twinned furnaces Stacked* (80% ONLY)
A
Example 4 - Horizonal Applications
A
Common Return Air Plenum
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Specifications subject to change without notice.
3
Table 1 – Kit Contents
DESCRIPTION PART NO. QTY
Sealing tape 2
External extension harness 327962701 1
Main twinning harness 327957701 1
Secondary twinning harness 327959701 1
Twostage furnace wiring diagram 337068101 1
Single stage furnace heat wiring diagram
Single stage furnace/twostage heat wiring diagram
Label 327956101 1
Tape 1
Bag Assembly includes:
Snap bushing 2
Screws (HEX HD 6B X ¾) 10
Screws (flat head) 1
Wire tie 4
Clamps 2
Installation Instructions 1
Auxiliary door switch bracket 1
337070101 1
337069101 1
NOTE: As a result of staged heating with single−speed furnaces, the air temperature distribution in the supply plenum may be uneven when only 1 furnace is heating.
NOTE: Refer to the Installation, Start−Up, and Operating Instructions supplied with each furnace for information on venting, clearances, startup, maintenance, and other information not covered in this publication.
See Table 1 for kit contents.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTION
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit and component damage.
Failure to follow this caution could result in unit and component damage. Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.
CAUTION
A02224
1. Disconnect all power to the furnace. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.
3. After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity (for example; DO NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).
4. If you touch ungrounded objects (recharge your body with static electricity), firmly touch furnace again before touching control or wires.
5. Use this procedure for installed and uninstalled (ungrounded) furnaces.
6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 5 before bringing the control or yourself into contact with the furnace. Put all used AND new controls into containers before touching ungrounded objects.
7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.
SECTION I: MULTIPOISE SINGLESPEED AND
TWOSPEED NONCONDENSING HSI FURNACE
MODELS
SINGLE−STAGE TWOSTAGE
N8MSN F8MTL
N8MSL G8MTL
NOTE: Throughout these instructions, when the furnace installed side−by−side, the lefthand (LH) side will be referred to as the LH furnace, and the furnace installed on the righthand (RH) side as the RH furnace. When the furnaces are installed back−to−back, the lefthand (LH) side will be referred to as the LH furnace, and the furnace installed on the righthand (RH) side as the RH furnace when viewed from the side with the extension harness installed.
4
Specifications subject to change without notice.
443 06 2403 01
Figure 3 Dimensional Drawing
FLUE
PROCEDURE 1 — INSTALL FURNACES
A. Upflow/Downflow, Side−by−Side Position
Refer to Figure 3 and Table 2 for appearance and dimensional drawing of twinned furnaces and their connection locations.
1. Select 2 identical heating and airflow furnaces. (See Table 2.)
2. Remove outer door and blower access door.
3. For upflow and downflow applications: a. For upflow applications: Bottom return air usage is
required as part of any upflow return air configuration. If additional return air is to enter 1 side of each furnace, in addition to bottom return air, cut open 1 entire returnair opening in appropriate side of each furnace. (See Figure 1)
UNIT DAMAGE AND FIRE HAZARD
Failure to follow this warning could result in fire, personal injury or death.
DO NOT use the back of the furnace for returnair duct connections, as limit cycling will occur.
b. For downflow applications:
!
Return air can only be connected to bottom opening of furnace. A common return air plenum is required for proper auxiliary limit switch operation. (See Figure 2)
Table 2 – Dimensions − in. (mm) for Single Stage and TwoStage with PSC Blower
A B C D
CABINET WIDTH
Model Numbers
0451408 143/16 (360) 129/16 (319) 95/16 (237) 1211/16 (322) 4 (102) 104 (47) 0451412 143/16 (360) 129/16 (319) 95/16 (237) 1211/16 (322) 4 (102) 107 (49) 0701408 143/16 (360) 129/16 (319) 95/16 (237) 1211/16 (322) 4 (102) 111 (50) 0701412 143/16 (360) 129/16 (319) 95/16 (237) 1211/16 (322) 4 (102) 115 (52) 0701716 171/2 (445) 157/8 (403) 119/16 (294) 16 (406) 4 (102) 126 (57) 0901714 171/2 (445) 157/8 (403) 119/16 (294) 16 (406) 4 (102) 127 (58) 0902116 21 (533) 193/8 (492) 135/16 (338) 191/2 (495) 4 (102) 140 (64) 0902120 21 (533) 193/8 (492) 135/16 (338) 191/2 (495) 4 (102) 146 (66) 1101712 171/2 (445) 157/8 (403) 119/16 (294) 16 (406) 4 (102) 135 (61) 1102116 21 (533) 193/8 (492) 135/16 (338) 191/2 (495) 4 (102) 146 (66) 1102122 21 (533) 193/8 (492) 135/16 (338) 191/2 (495) 4 (102) 152 (69) 1352116 21 (533) 193/8 (492) 135/16 (338) 191/2 (495) 4 (102){ 149 (68) 1352422 241/2 (622) 227/8 (581) 151/16 (383) 23 (584) 4 (102){ 163 (74) 1552420 241/2 (622) 227/8 (581) 151/16 (383) 23 (584) 4 (102){ 170 (77)
*5in. or 6in. (127 or 152 mm) vent connector may be required in some cases.
{135 and 155 size furnaces require 5 or 6in. (127 or 152 mm) vents. Use a vent adapter between furnace and vent stack. See Installation Instructions for complete
installation requirements
in (mm)
OUTLET WIDTH
in (mm)
TOP AND BOTTOM FLUE
COLLAR in (mm)
WARNING
BOTTOM INLET WIDTH in (mm)
COLLAR*
in (mm)
SHIP WT (KG)
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Specifications subject to change without notice.
5
!
UNIT DAMAGE AND FIRE HAZARD
Failure to follow this warning could result in unit damage, fire, personal injury or death.
DO NOT use the back or sides of the furnace for returnair duct connections in downflow position, as limit switch cycling will occur.
4. Remove bottom closure panels from both furnaces. (See Figure 4)
a. Lay furnaces on back or sides. b. Remove 2 screws from bottom front panel. c. Pull front panel forward to remove. d. Remove bottom closure panel and discard. e. Reinstall bottom front panel.
f. Stand furnaces upright.
5. Apply 2 factorysupplied foam strips to mating side of each furnace. Locate strips equal distance from top and bottom as shown in Figure 5. Trim off excess material.
6. Remove 7/8in. diameter accessory hole knockouts in blower compartment from mating sides of furnaces. (See Figure 3)
Bottom Closure Panel
Bottom Filler Panel
WARNING
8. Bend or remove the supply flanges as required for upflow or downflow installation. Refer to the furnace installation instructions for complete details.
9. Position furnaces against each other on return air plenum, supply air plenum or evaporator coil casing. Adjust and shim each furnace to align 7/8in. diameter holes in both furnaces.
10. Drill two 1/8in. holes, approximately 1 in. (25 mm)below discharge flange, from inside top of discharge opening and through both furnaces. (See Figure 6) Drill two 1/8in. holes, approximately 1 in. (25 mm)below return air flange, from inside top of return air opening and through both furnaces. (See Figure 7 as an example.)
11. Drive 1 factorysupplied screw through each hole and tighten until furnaces are secure and foam strips have sealed gap between furnaces.
12. Connect return and supplyair ducts to furnaces. Seal duct connections to prevent air leakage.
13. Move 115v junction box JB in RH furnace (as viewed from the upflow position) from lefthand side to righthand side. Refer to furnace installation instructions for complete details.
14. Go to PROCEDURE 2A for Single Stage Furnaces or PROCEDURE 2B for TwoStage Furnaces.
B. Upflow/Downflow, Back−to−Back Position
Refer to Figure 3 and Table 2 for appearance and dimensional drawing of twinned furnaces and their connection locations.
1. Select 2 identical heating and airflow furnaces. (See Table 2)
2. Remove outer door and blower access door.
3. Remove bottom closure panels from both furnaces. (See Figure 4)
a. Lay furnaces on back or sides. b. Remove 2 screws from bottom front panel. c. Pull front panel forward to remove. d. Remove bottom closure panel and discard. e. Reinstall bottom front panel.
f. Stand furnaces upright.
4. Applications
Figure 4 Removing Bottom Closure Panel
Figure 5 Location of Foam Strips
7. Insert a plastic snap bushing through the 7/8−in. knockout from the outside of the casing.
6
Specifications subject to change without notice.
A02232
Figure 6 Attaching Furnaces Together at Discharge
Opening
a. For upflow applications:
Bottom return air usage is required as part of any upflow return air configuration. If additional return air is to enter 1 side of each furnace, in addition to bottom return air, cut open 1 entire return−air
443 06 2403 01
opening in appropriate side of each furnace. (See Figure 2)
!
UNIT DAMAGE AND FIRE HAZARD
Failure to follow this warning could result in unit damage, fire, personal injury or death.
DO NOT use the side of the furnace for returnair duct connections, as limit cycling will occur.
b. For downflow applications:
Return air can only be connected to bottom opening of furnace. A common return air plenum is required for proper auxiliary limit switch operation. (See Figure 3)
5. Apply 2 factorysupplied foam strips to the back of each furnace. Locate strips equal distance from top and bottom as shown in Figure 5. Trim off excess material.
6. Determine which side of furnace will be used to route external extension harness. Remove 7/8in. diameter accessory hole knockouts in blower compartment side selected to attach harness to. (See Figure 3)
7. Bend or remove the supply flanges as required for upflow or downflow installation. Refer to the furnace installation instructions for complete details.
8. Position furnaces back−to−back on returnair plenum, supply air plenum or evaporator coil casing. Adjust and shim each furnace to align both furnaces.
NOTE: External extension harness cannot be used on the same side of the furnace that the return air ducts connect to. Locate harness on opposite side of furnace when side return air is used.
9. Drill two 1/8in. holes, approximately 1 in. (25 mm)below discharge flange, from inside top of discharge opening and through both furnaces. (Similar to Figure 6) Drill two 1/8in. holes, approximately 1 in. (25 mm)below return air flange, from inside top of return air opening and through both furnaces. (Similar to Figure 7)
10. Drive 1 factorysupplied No. 6 X 3/4in. LG screw through each hole and tighten until furnaces are secure and foam strips have sealed gap between furnaces.
11. Connect return and supplyair ducts to furnaces. Seal duct connections to prevent air leakage.
WARNING
A02219
Figure 7 Attaching Furnaces Together at Return Air
Opening
12. Move 115v junction box JB in either furnace from lefthand side to right−hand side if required. Refer to furnace installation instructions for complete details.
13. Go to Step 2A for Single Stage Furnaces or Step 2B for TwoStage Furnaces.
C. Horizontal, Back−to−Back Position
When twinning furnaces in the horizontal position, consideration must be made to the type of building construction. Attic floors should be constructed to support normal live and dead loads of the furnaces and the person(s) servicing them.
Trusses, wood and metal are engineered for specific applications, and may not support the weight of two (2) furnaces suspended from the top chords or the bottom chords of the trusses. Long horizontals spans may flex or sag, resulting in damage to the building. Contact the truss manufacturer for additional design and engineering assistance.
Do not suspend furnaces with straps or suspend furnaces from roof decking.
For attic installations on a platform (See Figure 8):
1. Construct a platform from 3/4in. (76 mm) (nominal plywood), extending out 30 inches (762 mm) from the front of each furnace.
2. Maintain all clearances to combustibles per the furnace Installation, Start−up and Operating Instructions.
3. Follow all additional building codes.
4. Long truss spans may require additional support along the bottom chord of the truss. Consult the truss manufacturer’s guidelines for engineering assistance.
5. Long rafter or attic joist spans may require additional support along the bottom of the rafter or joist. Consult local or regional building codes for design and loading requirements.
443 06 2403 01
Specifications subject to change without notice.
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