ICP NTC7/GNL, NDC7/GDL Installation Instructions Manual
NTC7/G N L - Upflow/Horizontal
NDC7/G DL - Downflow
Series
SAFETY CONSIDERATIONS
/X
Recognize safety information. This is the safety-alert symbol _. When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
UnderstandthesignalwordDANGER, WARNING, orCAUTION. Thesewordsareusedwiththesafety-alertsymbol. DANGERidenti-
ties the most serious hazards will result in severe personal injury or death. WARNING signifies a hazard that could result in personal
injuryor death. CAUT__Nisusedt_identifyunsafepracticeswhichw_u_dresu_tinmin_rpers_na_injury_rpr_ductandpr_pertydam-
age.
Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified person-
nel should install, repair, or service heating equipment.
Untrained service personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working on heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety precautions that may apply.
Follow all safety codes. Inthe United States, follow all safety codes including the current edition National Fuel Gas Code (NFGC) NFPA
No. 54/ANSIZ223.1. In Canada, refer to the current edition ofthe National Standard Canada CAN/CGA-Bt 49.1 - and .2-M91 Natural
Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Havefire extinguisher available during start-
up and adjustment procedures and service calls.
These instructions cover minimum requirements and conform to existing national standards and safety codes, in some instances,
these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential
construction practices. We require these instructions as a minimum for a safe installation.
Design Certified
byAGA
Manufactured by:
International Comfort Products Corporation (USA)
Lewisburg, TN USA 37091
Table of Contents
1.Installation............................... 2
2,Combustion&VentilationAir ................. 5
3,GasVentInstallation ....................... 8
4.HorizontalVenting ......................... 11
5.MasonryChimneyVenting ................... 12
6.GasSupplyandPiping ...................
7.ElectricalWiring ........................
8,DuctworkandFilter......................
9.ChecksandAdjustments..................
10.FurnaceMaintenance ...................
13
15
16
20
22
This furnace is not designed for use in mobile
homes, trailers or recreational vehicles. Such
use could result in property damage, bodily in-
jury and/or death.
LP1 7/29/98 441 01 2003 03
Replaces 44t 01 2003 02 (6/97)
1.Installation
Installation or repairs made by unqualified
persons can result in hazards to you and others.
Installation MUST conform with local codes or, in
the absence of local codes, with codes of the
country having jurisdiction.
The information contained in this manual is
intended for use by a qualified service technician
familiar with safety procedures and equipped
with the proper tools and test instruments.
Failure to carefully read and follow all instruc-
tions in this manual can result in furnace
malfunction, property damage, personal injury
and/or death.
NOTE: This furnace is design certified by the American Gas
Association and the Canadian Gas Association for installation in
the United States and Canada. Refer to the appropriate codes,
along with this manual, for proper installation.
• This furnace is NOT approved for installation in recre-
ation vehicles or mobile home.
• Upflow and downflow models are approved for installation
in buildings constructed on site.
• Do NOT use this furnace as a construction heater or to heat
a building under construction.
Use only the Type of gas approved for this furnace (see
Rating Plate on unit). Overfiring will result in failure of heat
exchanger and cause dangerous operation. (Furnace can
be converted to LP gas with approved kit.)
• Do NOT use open flame to test for gas leak.
• Ensure adequate combustion and ventilation air is pro-
vided to the furnace.
• Seal supply and return air ducts.
• The vent system MUST be checked to determine that it is
the correct type and size.
• Install correct filter type and size.
• Unit MUST be installed so electrical components are pro-
tected from direct contact with water.
• It is the suggestion of this manufacturer to install fire and
carbon monoxide detectors.
Safety Rules
Your unit is built to provide many years of safe and dependable
service providing itis properly installed and maintained. However,
abuse and/or improper use can shorten the life of the unit and
create hazards for you, the owner.
A. The U.S. Consumer Product Safety Commission recom-
mends that users of gas-burning appliances install carbon
monoxide detectors. There can be various sources of car-
bon monoxide in a building or dwelling. The sources could
be gas-fired clothes dryers, gas cooking stoves, water
heaters, furnaces, gas-fired fireplaces, wood fireplaces,
and several other items. Carbon monoxide can cause seri-
ous bodily injury and/or death. Therefore, to help alert
people of potentially dangerous carbon monoxide levels,
you should have carbon monoxide detectors listed by a na-
tionally recognized agency (e.g. Underwriters Laborato-
ries or International Approval Services) installed and
maintained in the building or dwelling (see Note below).
B. There can be numerous sources of fire or smoke in a build-
ing or dwelling. Fire or smoke can cause serious bodily in-
jury, death, and/or property damage. Therefore, in order to
alert people of potentially dangerous fire or smoke, you
should have fire and smoke detectors listed by Underwrit-
ers Laboratories installed and maintained in the building or
dwelling (see Note below).
Note: The manufacturer of your furnace does not test any detec-
tors and makes no representations regarding any brand or
type of detector.
C. To ensure safe and efficient operation of your unit, you
should do the the following:
1. Thoroughly read this manual and labels on the unit.
This will help you understand how your unit operates and
the hazards involved with gas and electricity.
2. Do not use this unit if any part has been under water.
Immediately call a qualified service technician to inspect
the unit and to replace any part of the control system and
any gas control which has been under water.
3. Never obstruct the vent grilles, or any ducts that pro-
vide air to the unit. Air must be provided for proper com-
bustion and ventilation of flue gases.
Carbon monoxide or "CO" is a colorless and odorless gas
produced when fuel is not burned completely or when the
flame does not receive sufficient oxygen.
FreezingTemperatures andYour Structure
NOTE: It is the personal responsibility and obligation of the cus-
tomer to contact a qualified installer to ensure that the installation
is adequate and conforms to governing codes and ordinances.
DualCertified Furnace
This furnace is dual certified. This means that the INLET pipe is
optional. See Figure 1 for identification of INLET and OUTLET
pipe. Combustion air can be drawn from outside the structure or
inside the structure.
Freeze warning.
Turn off water system.
If your unit remains shut off during cold weather
the water pipes could freeze and burst, resulting
in serious water damage.
Your unit is equipped with safety devices that may keep itfrom op-
erating if sensors detect abnormal conditions such as clogged ex-
haust flues.
G3
Ifthe structure will be unattended during cold weather you should
take these precautions.
1. Turn off main supply water into the structure and drain the
water lines if possible. Open faucets in appropriate areas.
2. Have someone check the structure frequently during cold
weather to make sure it is warm enough to prevent pipes
from freezing. Suggest they call qualified service agency, if
required.
Poison carbon monoxide gas hazard.
If this furnace is replacing a previously
common-vented furnace, it may be necessary to
resize the existing vent line and chimney to
prevent oversizing problems for the other
remaining appliances(s). See applicable codes
and Venting and Combustion Air Check in Gas
Vent Installation section.
Failure to properly vent this furnace or other
appliances can result in property damage,
personal injury and/or death.
Locationand Clearances
Iffurnace is a replacement, it is usually best to install the furnace
where the old one was. Choose the location orevaluate the exist-
ing location based upon the minimum clearance and furnace di-
mensions (Figure 1 & Figure 2).
CAUTION
Do NOT operate furnace in a corrosive atmosphere
containing chlorine, fluorine or any other damaging
chemicals. Refer to Combustion & Ventilation Air sec-
tion, Contaminated Combustion Air.
Dimensions and Clearances - Upflow/Horizontal Models
v
K
Z
25-21-69
MINIMUM CLEARANCES TO
COMBUSTIBLE
MATERIALS FOR ALL UNITS
REAR 0
FRONT 3" (75ram)*
For Service 30" (760mm)
ALL SIDES Of SUPPLY PLENUM 1" (25mm)
SIDES 0
VENT
Single Wall Vent 6" (150mm)
Type B-1 Double Wall Vent 1" (25mm)
TOP OF FURNACE 6" (150mm)
* 6" with accessory Masonry Chimney drafthood kit installed.
ALL DIMENSIONS IN INCHES (mm)
UNIT
CAP.
CABINET
ELECTRICAL CONNECTIONS
SUPPLY AIR
RETURN AIR GAS CONNECTIONS FLUE
AIR INLET
BOTTOM SIDE LEFTSD. OUTLET
50,000
75,000
100,000
125,000
CONVER-
SION
TO
METRIC
(ram)
40 : (1016)
191/8: (486) 15/8: (41) '_'m= m41
223/4= (578) 15/8= (41) 11/2= (38) ]b_/8 = t4241
281/2= (724)
181/2: (47t)
171/2: (446)
211/4=(539)
235/32= (588)
143/4= 375)
183/4= (476)
227/16= (571)
143/8: (366)
307/t6 = (773)
283/16= (716)
23 = (584)
55/32= (t32)
65/8 = (t69)
31/16= (78)
121/2: 319)
151/8= (384)
55/t6 : (135)
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_ 33/4 25-21-68
Minimum Cabinet Clearances to
Combustible Materials for all Units
TOP BOT RH LH BACK FRNT FLUE
6" *0" O" 0" 0" 3" 6"
* Can not beinstalled directly on combustibleflooring.
Supply plenum must have 1" clearance for first 6' from
furnace.
ALL DIMENSIONS IN INCHES (mm)
UNIT
CAPACITY
50,000
75,000 40
t00,000 40
t25,000 40
CONVERSION
TO
METRIC(mm)
CABINET
A B C
40 t91/8 281/2
t91/8 281/2
223/4 281/2
223/4 281/2
40=(1016)
191/8=(486)
223/4 =(578)
281/2=(724)
ELECTRICALCONNECTIONS
TOP SIDE LOWVOLT
D E DD EE F G
15/8 15/8 15/8 11/2 37t8 253/4
15/8 15/8 15/8 11/2 37t0 253/4
15/8 15/8 15/8 11/2 37/8 253/4
15/8 15/8 15/8 11/2 37/8 253/4
15/8=(41) 11/2= (42) 37/8= (99)
253/4=(654)
RETURNAIR
TOP
H I
181/2 175/8
181/2 175/8
181/2 211/4
181/2 211/4
181/2=(471)
17518=(448)
211/4=(540)
SUPPLYAIR
BOTTOM
J K Z
t65/8 175/8 5/8
t65/8 175/8 5/8
t65/8 213/8 5/8
t65/8 213/8 5/8
165/8=(421)
t75/8=(449)
213/8=(540)
5/8= (18)
GASCONNECTIONS
RIGHTSD. LEFTSD.
M P MM P
12_8 24 103/8 24
12_8 24 103/8 24
12_8 24 103/8 24
12_8 24 103/8 24
125/8=(319)
24 = (584)
103/8=(264)
AIRINLET
T Y
5%2 31t4
5%2 31t4
65/8 31/4
55/32 31/4
5%2=(13t)
65/8= (169)
31/4=(83)
FLUE
OUTLET
W V
121_ 5_16
121_ 5_16
151_ 5_16
151_ 5_16
121/2=(3t9)
151/8=(384)
58/16=(135)
Installation Requirements
1. Install furnace level.
2. This furnace is NOT to be used for temporary heat of build-
ings or structures under construction.
3. Install furnace as centralized as practical with respect to the
heat distribution system.
Install the vent pipes as short as practical. (See Vent and
Combustion Air Piping section).
7.
8.
Use a raised base if the floor is damp or wet at times.
Residential garage installations require:
• Burners and ignition sources installed at least 18" (457mm)
above the floor.
• Located or physically protected from possible damage by a
vehicle.
HorizontalFurnace Installation
4.
5.
For downflow installations, do NOT install furnace directly on
combustible floors unless using a special noncombustible
subbase. See Ductwork and Filter section later inthis manu-
al.
Fire Hazard.
If installing horizontally, place furnace on
noncombustible cement board or sheet metal.
For counterflow furnaces place furnace on
noncombustible cement board or sheet metal.
Failure to install unit on noncombustible cement
board or sheet metal can result in property
damage, personal injury and/or death.
6. Maintain clearance for fire safety and servicing. A front clear-
ance of 30" (760mm) is recommended for access to the
burner, controls and filter.
Poison carbon monoxide gas, fire, and/or
explosion hazard.
Make certain model installed is certified for use
in multiple configurations.
Failure to install unit in configuration for which it
is certified can result in property damage,
personal injury and/or death.
IMPORTANT
NOTE: Inspect unit rating plate to be certain model number be-
gins with "NTC7" or "GNL'. This identifies unit as horizontally
mountable. If unit does NOT bear this designation, you may NOT
mount this unit horizontally. Horizontal furnace must not be
mounted on its back.
If you purchased a horizontally mountable furnace, it can be
installed horizontally in an attic, basement, crawl space, alcove,
or suspended from a ceiling in a basement or utility room in either
a right-to-left or left-to-right airflow position. See Figure 4.
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Typical Horizontal Installation
25-21-70
The following minimum clearances (Figure 1 and Figure 2) to
combustibles MUST be maintained. As shown in Figure 3, ONLY
the corner ofthe cabinet is allowed to contact the rafters. All other
clearances MUST be observed as shown in Figure 1 and
Figure 2.
If the furnace is to be suspended from the floor joists in a crawl
space or the rafters in an attic, it is necessary to use steel pipe
straps or an angle iron frame to attach the furnace. These straps
should be attached to the furnace with sheet metal screws and to
the rafters or joists with bolts. The preferred method is to use an
angle iron frame bolted to the rafters or joists.
If the furnace is to be installed in a crawl space, consult local
codes. A concrete pad 1" to 2" (25 to 50mm) thick is recom-
mended for crawl space installation on the ground.
Thirty (30) inches(760mm) between the front of the furnace and
adjacent construction or other appliances MUST be maintained
for service clearance.
Keep all insulating materials clear from Iouvered door. Insulating
materials may be combustible.
The horizontal furnaces may be installed directly on combustible
wood flooring or supports for added fire protection it is recom-
mended that cement board or sheet metal is placed between the
furnace and the combustible wood floor and extend 12" (300mm)
beyond the front of the furnace louver door.
This furnace MUST NOT be installed directly on carpeting or tile
or other combustible material other than wood flooring or sup-
ports.
PressureSwitch Relocation
Ifthe furnace is installed in a left to right airflow position (right side
of furnace facing down), the pressure switch will remain in the
same position as installed by the factory (see Figure 5). Ifthe fur-
nace is installed in a right to left airflow position (left side of fur-
nace facing down), the pressure switch MUST be relocated to the
right side of the furnace using the holes provided on the side of the
furnace. Position the pressure switch in the same orientation as
the original location.
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Pressure Switch Relocation
25-21-80a
To reposition switch, remove the two screws that secure the pres-
sure switch to the blower partition. Attach the pressure switch in
the location shown. It may be necessary to shorten the tube
length. To prevent possible kinking of the pressure switch hose,
trim the hose to remove excess.
Note: Care MUST be taken not to cut the tube too short.
2. Combustion& VentilationAir
Poison carbon monoxide gas hazard.
Contaminated CombustionAir
Use methods described here to provide
combustion and ventilation air.
Failure to provide adequate combustion and
ventilation air can result in personal injury
and/or death.
Furnaces require ventilation openings to provide sufficient air for
proper combustion and ventilation of flue gases. All duct or open-
ings for supplying combustion and ventilation air must comply
with the gas codes, or in the absence of local codes, the applica-
ble national codes.
Installations in certain areas or types of structures will increase
the exposure to chemicals or Halogens which may harm the fur-
nace. These instances must use only outside air for combustion.
The following areas or types of structures may contain or have ex-
posure to the substances listed below. The installation must be
evaluated carefully as it may be necessary to provide outside air
for combustion.
• Commercial buildings.
• Buildings with indoor pools.
• Furnaces installed in laundry rooms.
• Furnaces installed in hobby or craft rooms.
• Furnaces installed near chemical storage areas.
• Permanentwavesolutionsforhair.
• Chlorinatedwaxesandcleaners.
• Chlorinebasedswimmingpoolchemicals.
• Watersofteningchemicals.
• De-icingsaltsorchemicals.
• Carbontetrachloride.
• Halogentyperefrigerants.
• Cleaningsolvents(suchasperchloroethylene).
• Printinginks,paintremovers,varnishes,etc..
• Hydrochloricacid.
• SulfuricAcid.
• Solventcementsandglues.
• Antistaticfabricsoftenersforclothesdryers.
• Masonryacidwashingmaterials.
ConfinedSpace Installation
NOTE: A confined space is defined as an area with less than 50
cubic feet(1.4m 3) per 1,000 BTUH input rating for all gas ap-
)liances installed in the area.
Air Openings and Connecting Ducts
1. Total input rating for all gas appliances MUST be considered
when determining free area of openings.
2. Connect ducts or openings directly to outside.
3. Whenscreensareusedtocoveropenings,theyMUSTbe no
less than 1/4" (6mm) mesh.
4. The minimum dimension of rectangular air ducts MUST NOT
be less than 3" (75mm).
5. When sizing grille or louver, use the free area of opening. If
free area is NOT stamped or marked on grill or louver, as-
sume a 20% free area for wood and 60% for metal.
Requirements
1. Provide confined space with sufficient air for proper combus-
tion and ventilation of flue gases using horizontal or vertical
ducts or openings.
2. Figure 5 illustrates how to provide combustion and ventila-
tion air. A minimum oftwo permanent openings, one inlet and
one outlet, are required.
Outside Air (This is ONLY a guide. Subject to codes of country having jurisdiction.)
This installation NOT approved in Canada
GasVent . GableVent,)
- OptionalInletAir (t)
SoffitVent
/1
MinimumOneInletand OneOutletAirSupply is Required
Maybe in andCombinationShown
InletAir OpeningMust be Within12"(300mm)of floor
OutletAirOpeningMust be Withint2"(3OOmm)of ceiling
(1) 1SquareInch (6cm2) per4000BTUH
(2) 1SquareInch (6cm2) per2000BTUH
Inlet
Air(1)
I ' ' n so%lit' eot
ut'et''II L
I _ .L[ II I Outlet
• "1 I I I _ I I t Air(2)
Inlet
Air (t)
3.
One opening MUST be within 12" (300mm) of the floor and
the second opening within 12" (300mm) of the ceiling.
4. Size openings and ducts per Table 1.
5.
6.
Horizontal duct openings require 1 square inch(25sq, mm) of
free area per 2,000 BTUH of combined input for all gas ap-
pliances in area (see Table 1).
Vertical duct openings or openings directly to outside require
3
1square inch(6.5mm ) of free area per 4,000 BTUH for com-
bined input of all gas appliances in area (see Table 1).
/3#
FreeArea
MinimumFreeArea Requiredfor Each Opening
BTUH
input HorizontalDuct
Rating (2,000BTUH)
50,000 161cm2(25 sq. in.)
75,000 242cm2(35.5sq.in.)
100,000 323 cm 2 (50 sq. in.)
125,000 403 cm2 (62.5 sq. in.)
150,000 484 cm 2 (71 sq. in.)
VerticalDuctoropenings
to outside
(4,000BTUH)
81 cm2(12.5 sq.in.)
121cm2 (18.75sq. in.)
161 cm 2 (25 sq. in.)
202 cm 2 (31.25 sq. in.)
242 cm 2 (37.5 sq. in.)
Round
Duct
(4,000
BTUH)
4"
5"
6"
7"
7"
EXAMPLE: Determining Free Area
Furnace Water Heater Total Input
100,000 + 30,000 = (130,000 + 4,000) =210 cm2
(32.5 Sq. In.) Vertical
Furnace Water Heater Total Input
100,000 + 30,000 = (130,000 + 2,000) =210 cm2
(65Sq. In.) Horizontal
Unconfined Space Installation
Poison carbon monoxide gas hazard.
Most homes will require additional air,
An unconfined space or homes with tight
construction may not have adequate air infiltra-
tion for proper combustion and ventilation of
flue gases,
Failure to supply additional air by means of ven-
tilation grilles or ducts could result in personal
injury and/or death.
An unconfined space is defined as an area having a minimum vol-
ume of 50 cubic feet(1.4m 3) per 1,000 Btuh total input rating for all
gas appliances in area.
Adjoining rooms can be considered part of an unconfined area if
there are no doors between rooms.
An attic or crawl space may be considered an unconfined space
provided there are adequate ventilation openings directly to out-
doors. Openings MUST remain open and NOT have any means
of being closed off. Ventilation openings to outdoors MUST be at
least 1 square inch (25mm 2) of free area per 4,000 BTUH of total
input rating for all gas appliances in area.
In unconfined spaces, infiltration should be adequate to provide
air for combustion, ventilation and dilution of flue gases. However,
in buildings with unusually tight construction, additional air MUST
be provided using the methods described in section titled Con-
fined Space Installation:
Unusually tight construction is defined as: Construction with
1 . Walls and ceilings exposed to the outside have a continuous,
sealed vapor barrier. Openings are gasketed or sealed and
2. Doors and openable windows are weather stripped and
Other openings are caulked or sealed. These include joints
around window and door frames, between sole plates and
floors, between wall-ceiling joints, between wall panels, at
penetrations for plumbing, electrical and gas lines, etc.
VentilationAir
Some provincial codes and local municipalities require ventilation
or make-up air be brought into the conditioned space as replace-
ment air. Whichever method is used, the mixed return air temper-
ature across the heat exchanger MUST not fall below 60°F (15° c)
or flue gases will condense in the heat exchanger. This will short-
en the life of the heat exchanger and possibly void your warranty.
DirectVent Installations
Combustion air is obtained from outside the structure. Ventilation
air must be obtained from the following:
Ina closet or utility room installation, itwill be necessary to provide
ventilation air from an area of adequate air supply.
Any restricted installation requires two openings in the door or
single wall of the closet or utility room. One opening should be lo-
cated within 12" (305ram) of the top and the other within 12"
(305mm) of the bottom of the enclosure. (see Figure 6).
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Closet or Utility Room Installation
The following minimum free area is required for these openings:
a. Openings to interior space-Each opening to interior space
must have a free area at least 1 square inch per 1,000 BTU
per hour input rating, but not less than 100 square inches.
b. Openings to outdoors-Each opening to the outdoors must
have a free area at least 1 square inch per 2,000 BTU per
hour input rating if horizontal air ducts are used.
Air openings in the casing front, return air grilles, and warm air
registers must not be obstructed.
In all instructions provisions for adequate combustion air must be
made in accordance with Section 5.3, Air for Combustion and
Ventilation, of the National Fuel Gas Code, ANSI Z223.1-1988, or
applicable provisions of the local building codes.
[33
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