ICP NTP6/TNESeries, NDP6/TDESeries, NTP6050FB, TNE050B12, NTP6075GF Installation Instructions Manual

...

NTP6/TNESeries

Two-Stage Upflow/Horizontal

NDP6/TDESeries

Two-Stage Downflow

Non-condensing Furnace

SAFETY REQUIREMENTS

Recognize safety information. This is the safety-alert symbol _. When you see this symbol on the furnace and in instructions 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 in minor 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 (NFGC) NFPA No. 54/ANSIZ223.1. In Canada, refer tothe current edition ofthe 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 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 ....................... 7

4.HorizontalVenting ......................... 8

5.GasSupplyandPiping ...................... 9

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

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

8.DuctworkandFilter(Downflow).............

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

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

lt. SequenceofOperation& Diagncstic........

12 14

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 6/4/99 441 01 2007 00

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 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 American Gas

Association and the Canadian Gas Association for installation in the United States and Canada. Refer to the appropriate codes,

along with this manual, for proper installation.

• This furnace is NOT approved for installation in mobile

homes, trailers or recreation vehicles.

• Do NOT use this furnace as a construction heater 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. (Furnace can

be converted to L.E 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.

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 extinguisher and smoke detectors listed

by Underwriters 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.

FreezingTemperaturesand Your Structure

• 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.

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.

Safety Rules

Your unit is equipped with safety devices that may keep itfrom op- erating if sensors detect abnormal conditions such as clogged ex-

haust flues.

Your unit is built to provide many years of safe and dependable service providing 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.

/SJ

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.

44101 200700

Havesomeonecheckthestructurefrequentlyduringcold

weathertomakesureitiswarmenoughtopreventpipes fromfreezing.Suggesttheycallaqualifiedserviceagency,

ifrequired.

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 death, personal injury and/or property damage.

Locationand Clearances

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

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

mensions (Figure 1).

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.

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Dimensions and Clearances (NTP6/TNE)

" min. _

25-22-28

DIMENSIONAL INFORMATION

MINIMUM CLEARANCES TO

COMBUSTIBLE MATERIALS FOR ALL UNITS

REAR 0 FRONT 3" (75mm)

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)

NOTE: Evaporator "A" coil drain pan dimensions may vary from furnace duct opening size. Always consult evaporator specifications for duct size requirements.

Unit is designed for bottom return or side return.

Return air through back of unit is NOT allowed.

UnitCapacity

NTP6050FB

TNE050B12

NTP6075GF

TNE075F14

NTP6100GF

TNE100F14

NTP6100HKJ

TNE10OJ20 NTP6125KJ TNE125J20

Cabinet

A B C

40 151/2 281/2

40 191/3 281/2

40 223/4 281/2

ElectricalConnections

Top Left/RightSide LowVolt

D E D E R P

11/2 11/2 11/2 11/2 41/2 175/16

Supp_Air

O N

181_ 14

17_8181t2

181/2 211/4

ReturnAir

Bottom Side

F G J H

231/8 t25/8 22112 121/4

231/8 t43/4 221/2 141/2

231/8 t83/4 22112 14112

GasConnections

RightSide LeftSide

M K L K

237/8 281/4 26 281/,

23718 281/4 26 2811,

mm Equivalents 40"= 1016 151/2"= 394 191/8,_486 223/4=578 281/2_724 11/2"= 38 41/.2" =1t4 175/16=440 181/2"= 470

14"= 365 175/8"= 448 211/4"= 540 231/8 = 587 125/8"= 321 143/4 = 375 18_/4"= 476 22_/2"= 572 121/4 = 311 141/2"= 368

237/8" = 606 281/4" = 718 26" = 660 ALL DIMENSIONSININCHES(millimeters)

441 01 2007 O0 [_

Dimensions and Clearances (NDP6/TDE)

IIIIIIIII©

_ _ : 3/4(19) _-21-47b

' min.

MIMUM CLEARANCES TO

COMBUSTIBLE

MATERIALS FOR ALL UNITS

REAR 0 FRONT 3" (75ram)

For Service 30" (760ram)

ALL SIDES Of I" (25ram) SUPPLY PLENUM

SIDES 0 VENT

Single Wall Vent 6" (150mm)

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

TOP OF FURNACE 6" (150mm)

DIMENSIONAL INFORMATION

Unit Dimensions

Cabinet

A D

ElectricalConnections

Top LeftSide

D E

C D

281/2 11/2

(724) (38)

28112 11/2

(724) (38)

281/2 11/2

(724) (38)

Return

(356)

17%

(448) 211/4

(540)

Left

Supply

LowVoltage

Right

(F) (G) (F)

316116 253/4 313116

(99) (654) (96)

316116 253/4 313116

(99) (654) (96)

316116 253/4 313116

(99) (654) (96)

H I

(G)

NDP6050/075FB 40 151/2 11/2 15/8 11/2 243/4 14 165/8 TDE050/075Bt2 (1.02M) (394) (38) (4t) (38) (629) (356) (422)

NDP6100HF 40 19118 1112 1518 11/2 243/4 175/8 16618 TDE100F16 (1.02M) (486) (38) (4t) (38) (629) (448) (422)

NDP6125KJ 40 22314 1112 1518 11/2 243/4 211/4 165/8 TDE125J20 (1.02M) (578) (38) (4t) (38) (629) (540) (422)

GasConnections Flue

Unit Dimensions

J K L N P R

NDP6050/075FB 91/2 261/16 237/8 181/2 37/8 51/4 TDE050/075Bt2 (239) (662) (606) (470) (123) (132)

NDP6100HF 91/2 261/16 23718 181/2 55116 51/4 TDE100F16 (239) (662) (606) (470) (150) (132)

NDP6125KJ/ 9112 261116 23718 181/2 71/2 51/4 TDE125J20 (239) (662) (606) (470) (196) (132)

ALL DIMENSIONS IN INCHES (mm)

Installation Requirements

1. Install furnace level.

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

controls and filter.

Install furnace as centralized as practical with respect to the

heat distribution system.

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

Installation section).

Do NOT install furnace directly on carpeting, tile or other

combustible material other than wood flooring.

Fire Hazard. Place furnace on noncombustible cement board

or sheet metal on downflow applications. Failure to install unit on noncombustible cement

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

441 01 2007 00

6. 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.

• Furnace must be located or physically protected from pos- sible damage by a vehicle.

Horizontal FurnaceInstallation

IMPORTANT

NOTE: Inspect unit rating plate to be certain model number be-

gins with "NTP6 or TNE". This identifies unit as horizontally

mountable. If unit does NOT bear this designation, you may NOT mount this unit horizontally. Horizontal furnace may not be

mounted on its back.

The following minimum clearances to combustibles MUST be maintained between the furnace and adjacent construction. As

shown in Figure 1, ONLY the corner of the cabinet is allowed to contact the rafters Figure 3. All other clearances MUST be ob- served as shown in Figure 1.

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 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 or left airflow position. See Figure 3.

Thirty inches (30")(760mm) between the front of the furnace and adjacent construction or other appliances MUST be maintained

for service clearance.

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II II II

Typical Horizontal Installation

Keep all insulating materials clear from Iouvered door. Insulating

materials may be combustible.

It is recommended for further fire protection 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 fur- nace louver door. (This is a recommendation only, not a require-

ment).

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

2. Combustion&VentilationAir

Contaminated Combustion Air

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

tion and ventilation air.

Failure to provide adequate combustion and

ventilation air can result in death and/or personal

injury.

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.

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.

Installations in certain areas or types of structures will increase the exposure to chemicals or halogens that 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.

• Permanent wave solutions for hair.

• Chlorinated waxes and cleaners.

• Chlorine based swimming pool chemicals.

• Water softening chemicals.

• De-icing salts or chemicals.

• Carbon tetrachloride.

• Halogen type refrigerants.

• Cleaning solvents (such as perchloroethylene).

• Printing inks, paint removers, varnishes, etc..

441 01 2007 00 [_

• Hydrochloric acid.

• Sulfuric Acid.

• Solvent cements and glues.

• Antistatic fabric softeners for clothes dryers.

• Masonry acid washing materials.

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-

pliances 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. When screens are used to cover openings, the openings MUST be no smaller 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 4 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

_ L_ "Optional Inlet Air (1)

SoffitVent

Inlet

Air (1)

MinimumOne Inlet and OneOutletAirSupply isRequired

May bein andCombinationShown

InletAir OpeningMustbe Withint2"(300mm)of floor OutletAirOpeningMustbe Withint2"(300mm)of ceiling (1) 1SquareInch(6cm2) per4000BTUH

(2) 1SquareInch(6cm2) per2000BTUH

I ' ' n Sot fflit ent

i1 ¢ etAir''ii L

I _ J-L II I Outlet

i N iii

.......I g%l r-_l"_" lulet

I_'l I I I _ _ Air(2)

Inlet Air (t)

3. One opening MUST be within 12" (300mm) of the floor and • Not less than the sum of the areas of ai]vent connectors in the the second opening within 12" (300mm) of the ceiling, confined space.

Size openings and ducts per Table 1.

Horizontal duct openings require 1 square inch(25sq, mm) of free area per 2,000 BTUH of combined input for all gas ap- pliances in area (see Table 1).

Vertical duct openings or openings directly to outside require

1square inch(6.5mm 3) of free area per 4,000 BTUH for com- bined input of all gas appliances in area (see Table 1).

One permanent opening, commencing within 12" (30 cm) of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1" (2.5 cm) from the sides and back and 6"

(16 cm) 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 communicate with the outdoors, and shall have a mini-

mum free area of:

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

/SJ

Free Area

MinimumFreeAreaRequiredforEachOpening

BTUH

Input HorizontalDuct

Rating (sq. in./2,000BTUH)

50,000 25sq. in. (161cm2) 75,000 35.5 sq. in.(242cm2)

100,000 50sq. in.(323cm2) 125,000 62.5sq. in.(403 cm2)

VerticalDuctor openings Duct

to outside (sq.in.

(sq. in./4,000BTUH) /4,000

BTUH)

12.5sq. in.(81cm2) 4"

18.75sq. in.(121cm2) 5" 25sq. in. (161cm2) 6"

31.25sq.in. (202cm2) 7"

EXAMPLE: Determining Free Area

Furnace Water Heater Total Input

100,000 + 30,000 = (t30,000 + 4,000) = 32.5 Sq. In. Vertical

(210 cm2)

Furnace Water Heater Total Input 100,000 + 30,000 = (t30,000 + 2,000) = 65 Sq. In. Horizontal

(419 cm2)

441 01 2007 00

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 death and/ or personal injury.

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.

3. GasVent Installation

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

4. Keep vertical Category [ vent pipe or vent connector runs as

short and direct as possible.

Read and follow all instructions in this section. Failure to properly vent this furnace can result in

death, personal injury and/or property damage.

Install the vent in compliance with codes of the country having ju- risdiction, local codes or ordinances and these instructions.

Vertical outdoor runs of type B or ANY single wall vent pipe below the roof line are NOT permitted.

Slope all horizontal runs up away from furnace a minimum of

1/4" (6mm) per foot.

Support all horizontal vent pipe every 6' (2m) using proper clamps and metal straps.

Check existing gas vent or chimney to ensure they meet clearances and local codes.

These fan assisted combustion furnaces have been classified as

Category [ appliances which means that they MUST operate with

a negative vent pressure.

Category! Safe Venting Requirements

The furnace MUST be connected to a factory built chimney or vent complying with a recognized standard. Venting into a masonry or concrete chimney is only permitted as out-

lined in the United States National Fuel Gas Code vent- ing tables or Masonry Chimney section in these

instructions.

NOTE: The following instructions comply with the United States National Fuel Gas Code. Based on the highest input rate on the

furnace rating plate.

If a Category [ vent passes through an attic, any concealed space or floor, use ONLY Type B or Type L double wall vent pipe. If vent pipe passes through interior wall, use type B vent

pipe with ventilated thimble ONLY.

2. Do NOT vent furnace into any chimney serving an open fire- place or solid fuel burning appliance.

3. Use the same diameter Category [ connector or pipe as per- mitted by the United States National Fuel Gas Code vent- ing tables.

44101 2007 00

Poison carbon monoxide gas hazard. If this furnace is replacing a previously

common-vented furnace, it may be necessary to resize the existing chimney liner or vent to prevent over sizing problems for the other remaining appliances(s). See codes of country having jurisdiction.

Failure to properly vent this furnace or other

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

EZ3

+ 14 hidden pages

ICP NTP6/TNESeries, NDP6/TDESeries, NTP6050FB, TNE050B12, NTP6075GF Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual