ICP NUGM100EHB1 Installation Guide

• Safety Rules

• Installation

• Ventilation Air

• Vent & Combustion Piping

• Gas Supply & Piping

• Wiring

• Ductwork Connections

• Start-Up

• Maintenance

q

Design Certified

Printed in U.S.A.

Manufactured by:

Inter-City Products Corporation (USA)

Lavergne, TN USA 37086

by AGA.

NUGMSeries

CondensingGasFurnace

LP1 1008854 3J8/94

_ Condensing Gas Furnace Installation Instructions I

Table of Contents

1. Safety Labeling andSignalWords .............. 3

Danger, Warning and Caution .................. 3

Danger Label ............................... 3

Warning Label .............................. 3

Caution Label .............................. 3

2. Safe Installation Requirements ................ 4

3. Installation ................................ 6

Dual Certified Furnace ......................... 6

Location and Clearances ....................... 6

Installation Requirements ...................... 6

False Floor Closet Installation ................... 9

4. Combustion & Ventilation Air .................. 10

Venting and Combustion Air Check ............... 10

Air Openings and Connecting Ducts .............. 10

Confined Space Installation ..................... 10

Requirements ....................... . ...... 10

Unconfined Space Installation ................... 12

Unusually Tight Construction ................... 12

Ventilation Air ............................... 12

5. Vent and Combustion Air Piping ................ 13

Dual Certified Furnace ......................... 13

Contaminated Combustion Air ................... 13

Vent and Combustion Air Piping Guidelines ........ 13

Piping Insulation Guidelines ................... 14

Sizing Combustion Air and Vent Pipe ............. 14

Vent Termination Clearances .................. 16

Condensate Drain Trap and Neutralizer ........... 16

Connecting Furnace and Piping ................. 16

Vent Pipe Connection ........................ 17

Air Inlet Pipe Connection ...................... 17

Joining Pipe and Fittings ...................... 18

Connecting Vent Pipes and Termination ........... 18

Vertical Termination .......................... 18

Horizontal Termination ....................... 18

Using Extedor Risers ......................... 19

Optional Vent Screens ........................ 19

Vent Termination Shielding .................... 19

6. GasSupplyand Piping ....................... 20

Supply Pressure .............................. 20

General U.S. Derating Rules ................... 20

General Canadian Derating Rules ............... 20

Manifold Gas Pressure Adjustment ............... 20

High Altitude Air Pressure Switch ................ 21

Changing Orifices for High Altitude ............... 21

Natural Gas Input Rating Check ................. 21

Gas Piping Requirements ...................... 22

Connections ................................ 22

Additional LP Connection Requirements .......... 22

Final Check ................................. 23

Startup ..................................... 23

7. Electrical Wiring ............................ 24

Grounding .................................. 24

Polarizing ................................... 24

Labeling .................................... 24

Power Supply ................................ 24

Thermostat ................................. 24

Heat Anticipator ............................. 24

Optional Equipment .......................... 25

Humidifier/Electronic Air Cleaner ................ 25

Wiring for Air Conditioning ..................... 25

Fan Control ................................. 25

S. Ductwork and Filter ......................... 26

Installation .................................. 26

Connections ................................ 26

Sizing ..................................... 26

Insulation .................................. 26

Filters ..................................... 26

Filter Installation ............................. 27

Addition Of Air Conditioning .................... 27

9. Checks and Adjustments ...................... 2g

Main Burner Flame Check ..................... 29

Pilot Burner Flame Check ...................... 29

Limit Control Check .......................... 29

Fan Control Check ........................... 30

Temperature Rise Check ...................... 30

Continuous Fan Operation ..................... 31

Separate speed selections for Heat, Cool, and

Continuous Fan ............................. 31

Heating and Continuous BLower Speed the Same ... 31

10. Furnace Maintenance ....................... 32

Filters ..................................... 32

Replacement ............................... 32

Blower Motor ................................ 32

Furnace Inspection ........................... 32

Vent Pipe .................................. 32

Return Air Duct .............................. 32

Furnace Base ............................... 32

Furnace Intedor ............................. 33

Pilot Burners ................................ 33

Main Burners ............................... 33

Condensate Disposal ......................... 33

11. CleaningHeat Exchangers.................... 34

Primary Heat Exchanger ....................... 34

Accessing .................................. 34

Cleaning ................................... 34

Secondary Heat Exchanger .................... 34

Accessing .................................. 34

Extedor Cleaning ............................ 34

Accessing Intedor of Secondary Heat Exchanger ... 34

Interior Cleaning ............................. 34

Cleaning Burners ............................ 35

Reassembly ................................ 35

12. Glossary of Terms ........................... 36

13. Appendix of Helpful Information ............... 37

Canadian Codes ............................. 37

Applicable Natural Gas and Propane Codes ....... 37

Applicable Electrical Codes .................... 37

United States Codes .......................... 37

Applicable Natural Gas and Propane Codes ....... 37

Applicable Electrical Codes .................... 37

I.Condensing Gas Furnace

1, SafetyLabelingandSi0nalWords

Installation Instructions I

Danger,Warning and Caution

The signal words DANGER, WARNING and CAUTION are used to identify levels of hazard seriousness. The signal word
DANGER isonly used on product labels to signify an immediate hazard. The signal words WARNING and CAUTION will

be used on product labels and throughout this manual and other manuals that may apply to the product.

DangerLabel

White lettering on a black background except the word
DANGER which is white with a red background.

DANGER

Immediate hazards which WILL result in severe personal
injury or death.

WarningLabel

WARNING

Hazards or unsafe practices which COULD result in

severe personal injury or death.

White _ettering on a black background except the word
WARNING which is black with an orange background.

!

The signal word WARNING is used throughout this manual
in the following manner:

CAUTION

Hazards or unsafe practices which COULD result in minor

personal injury or product or property damage.

The signal word CAUTION is used throughout this manual
in the following manner:

CAUTION

CautionLabel

White lettering on a black background except the word
CAUTION which is black with a yellow background.

_ Installation Instructions Condensin_l Gas Furnace I

2. SafeInstallationRequirements

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. See Appendix.

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 in-
stallation in the United States and Canada. Refer to the ap-

propriate 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.

• 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 op-

eration.

• Ensure adequate combustion and ventilation air is
provided 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
protected from direct contact with water.

NOTE; It is the personal responsibility and obligation of the
customer to contact a qualified installer to ensure that the
installation is adequate and conforms to governing codes

and ordinances.

Carbon Monoxide Poisoning 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 line and
chimney to prevent oversizing problems for the
other remaining appliance(s). See applicable
codes in appendix and 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 property damage,

personal injury and/or death.

• Do NOT use open flame to test for gas leak.

I Condensing Gas Furnace

installation Instructions

START-UP CHECK SHEET

(Keep this page for future reference)

Dealer Name:

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

Business Card Here

Manual Gas Shut-Off Upstream
of Furnace/Drip-Leg?

Drip-Leg Upstream of Gas Valve?

Condensate Drain Connected? YES _1 NO [_

Blower Speed Checked? YES CI NO [_1

All Electrical Connections Tight? YES _1 NO {_1

YES 1_1 NO [_1

YES {_1 NO _1

!

Blower Motor H.P.:

Supply Voltage:.

Limit Opens at...(°F) or(°C)__

Limit Closes at...(°F) or(°C).__

Which blower speed tap is used?
(Heating). (Cooling)

Temperature of Supply Air: (°F) or(°C).__

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

Rise (Supply Temp - Return Temp): (°F) or(°C)__

Filter Type and Size:

Fan "Time ON" Setting:.

Fan 'q'ime OFF" Setting:

Gas Valve OK? YES CI NO[_I

Measured Line Pressure When Firing Unit:

Calculated Firing Rate:(See ChecksandAdjustmentsSec-
tion).

Measured Manifold Pressure:

Thermostat OK?

Subbase Level?

Anticipator Set?

Breaker On? YES [_1

Date of Installation:

Date of Start-Up:

YES O NO

YESI_I NOel

YES_I NO _1 Set At?:

NO _1

Dealer Comments:

_ Installation Instructions Condensin_l Gas Furnace I

3. Installation

!

NOTE: Installation MUST conform with local building
codes and local plumbing and waste water codes, or inthe

absence of local codes, with codes of the country having

jurisdiction. See Appendix.

DualCertified Furnace

This furnace is dual certified. This means that the INLET

pipe is optional. See Figure "1for identification of INLET
and OUTLET pipe. Combustion air can be drawn from out-

side the structure or inside the structure. If drawing com-
bustion air 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.

LocationandClearances

1. Referto Figure 1 fortypicaldirectventornon_:lirect

vent installation and basicconnecting parts required.

Supply and return air plenums and duct are also re-
quired.

2.

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

the furnace where the old one was. Choose the loca-
tion or evaluate the existing location based upon the

minimum clearance and furnace dimensions
(Figure 2).

Installation Requirements

1. Install furnace level.

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

3. Install furnace as centralized as practical with re-
spect 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" (762mm) is recommended for
access to the burner, controls and filter.

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. If furnace environment has the potential of

freezing, the drain trap and blower must be protected

with antifreeze. Disconnect the rubber coupling on top
of furnace and pour 8 onces of sanitary type (RV)
antifreeze into the vent pipe to protect the blower and
drain trap from freeze damage.

Do NOT operate furnace in a contaminated

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

Ventilation Air section, Contaminated Combustion

Air,

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

7. Residential garage installationsrequire:

• Burners and ignition sources installed at least 18
inches(457mm) above the floor.

• Located or physically protected from possible dam-
age by a vehicle.

61ZJ

I Condensing Gas Furnace Installation Instructions

Figure I Typical Installation

* 8"(200ram) Min.

20'(6m) Max.

in same atmospheric zone

--q

ipe is

Optional

Vent Pipes MUST be
supported Horizon-
tally and Vertically

!

Tee to prevellt a_rlc<tk

Tee for overflow

I NLE:T

Inlet Pipe is

\

* Increase minimum from 8" to 18" for cold climates

(substained temperatures below 0 °F),

7LZ.J

_ Installation Instructions Condensin_lGas Furnace J

Figure 2 Dimensions and Clearances

|

I' 10 7_"

\

BACK
DRAIN

CONNECTION

Cabinet Clearances

TOP BOT RH LH BACK FRNT FLUE
1" 0 0 0 0" 3 0"

93/16.

A

L

U_IT

CAPACPTY

S00CO
7SCO0

_00.000
125CC_

_O

/CONWnSION

G,_S¢ON_ECTIO_S ORAIN CONNE¢ n_

AIG_T SIDE L_" SIO_ RdGH_SlOE

N I P N _, n s

t/2" i 2_-_B" :_,___- _.1_16. t _,_- 4._t_

i

ze 1_"=724

lt2-=$s

1o 7_.=_76

_.1F_=_7o

LEm" SlO_

S • V

7r_-_

c

nETURNApR

_)TTOM SIDE

J L I M

2_.tm. 23 IFZ" 22.1_2" I _ lrZ"

_LUE O,_TL_T

_" 2 _I_S" _.7_16_

231_'_7

14_'_'=375 2.V_.=S 4

2_._

I Condensing Gas Furnace

False FloorClosetInstallation

NOTE: This type of installation is in a closet with the fur-

nace placed over an opening in a false floor raised above

the regular floor (Figure 3). False floor closet installation

MUST be made in accordance with local building and fire

codes.

1. If an existing closet is being reworked, shorten and
frame the door so the door bottom is above, or flush

with the location of false floor.

2. Construct a level framework of 2 x 4's or 2 x 6's

around the inside of the closet. Make the top of the
false floor at least 12 inches(30Omm) above existing

floor.

3. Cut a piece of plywood (for the false floor) to fit tightly
inside the closet, but do NOT install yet.

NOTE: Plywood MUST be A-C exterior glued or approved

for underlayment use, with a minimum 3/4inch thickness.

Maximum size is 4' x 4' unless supported by adequate

bracing with any joints in the false floor tightly sealed.

Installation Instructions I

4.

Set the furnace on the plywood in proper position.
Open front access panel and mark inside of bottom

opening on plywood. Cut opening in the plywood.

5,

Unless existing floor is concrete, place a piece of

sheet metal on existing floor under position of open-

ing in false floor. Sheet metal should be 2 inches

wider in both directions than opening and centered

under opening.

6,

Apply silicone or butyl rubber caulking around top of
frame work and install false floor. Seal around edge
of false floor and any joints.

7,

Apply a bead of caulking around opening in false
floor and set furnace over opening so the bottom is

sealed.

8.

Cut return air openings and box them in so they are
sealed from the wall and open ONLY into the area

below the false floor and the return air opening in bot-

tom of furnace.

g,

Direct vent models de NOT require ventilation air.

10.

Adequate combustion air openings MUST be pro-
vided if piping unit as non-direct vent (one pipe). See

Combustion and Ventilation Air chapter.

|

Figure3 I Typical Closet False Floor Installation

Min. 3/4 inch
A-C exterior

glued plywood

Sheet metal
pan centered

under furnace

J

Cross Supports
to prevent sagging

Seal bottom of
furnace and edge

of wood floor

Return Air

Return Air

S22

I Installation Instructions Condensin_lGas Furnace J

4. Combustion& VentilationAir

NOTE: Ifflame pulls towards draft hood, this indicates suf-

ficient infiltration air.

Carbon monoxide Poisoning Hazard.
Use methods described here to provide com-

bustion and ventilation air.

Figure 4 _ Vent Check

Failure to provide adequate combustion and

ventilation air can result in personal injury

and/or death.

!

VentingandCombustionAir Check

NOTE: This section ofthe manual applies to this furnace IF
venting as a non-direct vent (single pipe) appliance.

The following information is supp[iedto allow the installer
to make adjustments to the setup ofexisting appliances, IF

NEEDED. These instructions are presented to be used for

reference ONLY IF NEEDED, based on good trade prac-
tices, local codes, and good judgment of the installer.

Manufacturer does NOT take responsibility for modifica-
tions made to existing equipment.

NOTE: If this installation removes an existing furnace from
a venting system serving one or more other appliances,

and to make sure there is adequate combustion air for all
appliances, MAKE THE FOLLOWING CHECK.

1,

Seal any unused openings in the venting system.

2.

Visually inspect the venting system for proper size
and horizontal pitch to ensure there is no blockage or
restriction, leakage, corrosion or other deficiencies

which could cause an unsafe condition.

3. Insofar as is practical, close all doors and windows
and all doors between the space in which the appli-
ance(s) remaining connected to the venting system
are located and other spaces of the building.

4. Turn on clothes dryers and any appliance not con-
nected 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 oper-
ate asummer exhaust fan. Close fireplace dampers.

Vent Pipe --_1 I A/ DraftHood

Typical Gas

Water Heate_l_l _ _,P_._ Match

NOTE: Non-direct vent appliances occupying same en-
closed space as furnace MUST have enough air for proper
combustion and ventilation. All duct or openings for supply-
ing combustion and ventilation air must comply with the
gas and electrical codes of the country having jurisdiction.
See Appendix.

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 Connecting Ducts

1. Total input rating for all non direct vent gas appli-
ances, includingfurnace, 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, they
MUST be no less than 1/4inch(6mm) mesh.

4. The minimum dimension of rectangular air ducts
MUST NOT be less than 3 inches(75mm).

5. When sizing grille or louver, use the free area of
opening. If free area is NOT stamped or marked on
grillor louver, assume a 20% free area for wood and

60% for metal.

ConfinedSpaceInstallation

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 appliances installed in the area.

5. Follow the lighting instructions for each appliance be-
ing inspected. Adjust thermostat so appliance(s) will
operate continuously.

6. 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 4).

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

corrected using the appropriate tables in code books
of country having jurisdiction. See Appendix for list-

ing of applicable codes.

Requirements

1. Provide confined space with sufficient air for proper
combustion and ventilation of flue gases using hori-
zontal or vertical ducts or openings.

2. Figure 6, Figure 7, and Figure 8 illustrate how to
provide combustionand ventilation air. A minimum
of two permanent openings, one inletand one outlet,

are required.

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

inches(300mm) of the ceiling.

4. Size openings and ducts per Figure 5.

5. Horizontal duct openings require 1 square

inch(25sq, mm) offree area per 2,000 BTUH ofcorn-

I Condensing Gas Furnace

Installation Instructions

bined input for all gas appliances in area (see

Figure 5).

,

Vertical duct openings or openings directly to outside
require I square inch(6.Smm 3)of free area per 4,000
BTUH for combined input of all gas appliances in
area (see Figure 5).

Free Area

Figure 5

STUH

Input

Rating

50,000
75,000

100,000

. 125,000

150,000

Minimum Free Area Required for Each Opening

Horizontal Duct

(2,000 BTUH)

25 sq. in.(161 cm 2)

35.5 aq. in.(242 cm 2

50 sq. in.(323 cm2I

62.5 sq. in.(403 cm z
71 sq. in.(484 cm 2)

(other appliances)

Vertical Duct or

openings to outside

(4,000 BTUH)

12.5 sq, in.(81 em2)

15.75 sq. in.(121 cm 2

25 sq. in.!161 cm 2)

31.25 sq. in.(202 cm2)

37.5 sq. in.(242 cm 2)

EXAMPLE: Determining Free Area

Appliance 1 Appliance 2 Total Input

100,000 + 30,000 = (130,000 + 4,000) 2210cm 2

Appliance 1 Appliance 2 Total Input

100,000 + 30,000= (130,000 + 2,000)= 4tgcm 2

(32.5 Sq. In.) Vertical)

(65 Sq. In.) Horizontal)

Round

Duct

(4,000

BTUH I

4"

5-

6 _

7"

7,,

Figure 7

Gas Vent

NOTE:Drawing air from attic is

NOT allowed in Canada.

Minimum One Inlet and One Outlet Air Supply is Required

May be in any Combination Shown

Inlet Air Opening Must be Within 12" (3O0mm) of floor
Outlet Air Opening Must be Within 12" (300mm) of ceiling

(1) 1 Square ineh(6cm2) per 4000 Btuh

Providing Combustion &

Ventilation Air (Except Canada)

Soffit Vent

(1)

!

I Providing Combustion &Figure 6 Ventilation Air

Gas Vent

f

Outlet
Air (1) Outlet

tn II liAr'2'

I Ilpels I I_-I II It

ptional

Air (1) _ilre_2)

Minimum One Inlet and One Outlet Air Supply is Required

Inlet Air Opening Must be Within 12" 130Omm) of floor
Outlet Air Opening Must be Within 12 (300ram) of ceiling

May be in any Combination Shown

(1) 1 Square inch(6cm2) per 4000 Btuh
(2) 1 Square inch(6cm2) per 2000 atuh

Figure 8 Ventilation Air

Minimum One Inlet and One Outlet Air Supply is Required

Inlet Air Opening Must be Within 12" 1,300mm) of floor

Outlet Air Opening Must be Within 12 (300ram) of ceiling

(1) 1 Square inch(6cm2) per 4000 Btuh
(2) 1 Square inch(6cm2) per 2000 Btuh r

I Providing Combustion &

Gas Vent _ Gable Vent

Ventilated Attic_

Top Above Insulatioif_

t Air (1) ! Soffit

I Vent

May be in any Combination Shown

I Installation Instructions

Condensing]Gas Furnace I

!

Unconfined SpaceInstallation

Carbon Monoxide Poisoning Hazard.

Most homes will require additional air,

An unconfined space or homes with tight con-
struction may not have adequate air infiltration

for proper combustion and ventilation of flue
gases,

Failure to supply additional air by means of venti-
lation grilles or ducts could result in personal in-
jury and/or death•

An unconfined space is defined as an area having a mini-

mum volume of 50 cubic feet(1.4m 3)per 1,000 Btuh total
input rating for all gas appliances in area. Refer to Figu re 9

for minimum area required.

NOTE: Refer to definitions in section titled Unusually Tight
Construction and the Appendix. If any one of the conditions

apply, the space MUST be considered confined space re-
gardless of size.

1. Adjoining rooms can be considered part of an uncon-
fined area if there are openings without doors be-
tween rooms.

2,

An attic or crawlspace may be considered an uncon-
fined space provided there are adequate ventilation
openings directly to outdoors. Openings MUST re-
main 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.

4. Air inlet MUST be screened with not less than 1/4
inch(6mm) mesh screen.

UnusuallyTightConstruction

In unconfined spaces, infiltration may be adequate to pro-

vide air for combustion, ventilation and dilution of flue
gases. However, in buildings with unusually tight construc-

tion, additional air MUST be provided using the methods
described in section titled Confined Space Installation:

If any one of the following conditions are present, the

space MUST be treated as confined space.

1. Walls and ceilings exposed to the outside have a
continuous, sealed vapour barrier. Openings are

gasketed or sealed.

2. Doors and openable windows are weather stripped.

3,

Other openings are caulked or sealed. These include
joints around window and door frames, between sole

plates and floors, between wall-ceiling joints, be-
tween wall panels, at penetrations for plumbing,

electrical and gas lines, etc.

Figure 10

Screen /
Area

This _,_

Min 12" /

Fresh Air Duct

F Inlet Air Fresh

f

Air Duct

Figure 9 Unconfined Space

BTUH Input Minimum Area 1 Sq. Inch

Rating in Square Feet per 4,000 BTUH

50,000 312(29m 2) 4"(100ram)

78,000 490(46m 2) 5"(127mm)

114,000 712(66m _) 6"(152m m)

155,000 968(90m=) T'(178m m)

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

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

1,000 8' Ceiling Height

3.

Install air intake a minimum of 12" (300mm) above
maximum snow level and clear of any obstruction.

Duct or ventilation opening requires one square inch
of free area per 4,000 BTUH of total input rating for all
gas appliances in area. Refer to Figure 10 for typical

fresh air duct installation.

Minimum Area in Square Feet

Round Duct Size

Furnace

6"(150mm) Min.

18"(460mm) Max.

Ventilation Air

Some provincial codes and local municipalities require
ventilation or make-up air be brought into the conditioned
space as replacement air.Whichever method is used, the
mixed return air temperature across the heat exchanger
MUST not fall below 60°F (15° c) or flue gases will con-
dense in the heat exchanger. This will shorten the life of the
heat exchanger and possibly void your warranty.

Condensing Gas Furnace

5. VentandCombustionAirPiping

Carbon monoxide poisoning, fire and explosion
hazard.

Read and follow all instructions in this section

Failure to properly vent this furnace can result in

property damage, personal injury and/or death.

DualCertified Furnace

Installation Instructions,

• Carbon tetrachtoride.

• 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.

This furnace is certified as a category IV appliance and is
dual certified as a direct vent furnace using outside air for

combustion or it 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 at-
mospheric pressure zone as the vent pipe.

ContaminatedCombustionAir

Installations in certain areas or types of structures will in-
crease the exposure to chemicals or Halogens which may

harm the furnace.

The following areas or types of structures may contain

chemicals or Halogens. Inspect structure carefully to en-
sure listed chemicals or substances are NOT present.

• Commercial buildings.

• Buildings with indoorpools.

• Furnaces installed in laundry rooms.

• Furnaces installed in hobby or craft rooms.

• Furnaces installed near chemical storage areas.

Exposing the furnace to the following substances will dam-
age the furnace. Do NOT situate air inlet near any of the
following chemicals or their source.

CAUTION

Terminate the combustion air intake as far as possible
from any air conditioner, heat pump, swimming pool,
swimming pool pumping, chorlinator or filtration
units, or dryer vent.

• Permanent wave solutions for hair.

• Chlorinated waxes and cleaners.

• Chlorine based swimming pool chemicals.

• Water softening chemicals.

• De-icing salts or chemicals.

Vent andCombustionAirPipingGuidelines

!

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 (when used) by referring

to all of the instructions and guidelines in Section 6.

2. Determine the size required for the vent pipe and air
inlet pipe (when used).

3. Looselyassemble allventing parts without adhesive

(pipe joint cement) for correct fit before final assem-
bly.

4. Use of vertical piping is preferred because there will
be some moisture in the flue gases that may con-
dense as it leaves the vent pipe (See Special Instruc-

tion For Horizontal Vents),

5. The vent MUST exit the furnace at the top left side.

6. The vertical vent pipe MUST be supported so that no

weight is allowed to rest on the combustion blower.

7. Exhaust vent piping diameter MUST NOT be re-

duced.

8. All piping from the furnace to termination MUST
slope upwards, away from furnace, a minimum of

U4" per foot of run (6mm per 300mm).

9. Use DWV type long radius elbows whenever possi-

ble, as they provide for the minimum slope on hori-
zontal runs and they provide less resistance in the
vent system. If DWV elbows cannot be used, use
two, 45 degree elbows when possible. On horizontal
runs the elbows can be slightly misaligned to provide
the correct slope.

10. All horizontal pipe runs MUST be supported at least
every five feet with metal pipe strapping. NO sags or

dips are permitted.

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

12. The maximum pipe length is40 total feet (12m) in the

inlet or outlet side of the system. Up to five, 90 de-

gree elbows can be used on the inlet orthe outlet,
(See Vent Tables).

13. The minimum pipe run length is 5 feet (1.5m).

14. Venting thr°ugh acrawl space is permitted °nly as di-

rected by your distributor or factory representative.

Condensing Gas Furnace Installation Instructions

15.

The piping can be run in the same chase or adjacent
to supply or vent pipe for water supply or waste

plumbing. Itcan 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° F. or where ra-
diated heat from adjacent surfaces would exceed

140° F.

16. If installing as a direct-vent appliance, the vent outlet
MUST be installed to terminate in the same atmos-

pheric pressure zone as the combustion air inlet.

17. The vent system can be installed in an existing un-
used chimney provided that:

Both the exhaust vent and air intake run the length of

the chimney.

No other gas fired appliance or fireplace 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 16 are
maintained.

Piping Insulation Guidelines

NOTE: In general, chimneys on an outside wall and attics

are exposed to cold conditions which can cause the vent
pipe to sweat from condensation. This can lead to moisture
damage to living spaces. It is highly recommended that pip-

ing in these cases be insulated to insure proper protection
from condensation damage.

Use 1/2" (50mm) wall, closed cell, neoprene insulation or

equivalent. If Fiberglas or equivalent insulation is used it

must have a vapor barrier. Use Rvalues of 7 up to 10 feet,
R-11 ifexposure exceeds 10 feet. If Fiberglas insulation is

used, exterior to the structure, the pipe MUST be boxed in

and sealed against moisture.

1. Insulate pipe when the exhaust vent passes through
an unconditioned space or raceway.

2. If situations require pipe to be run on the exterior wall
to reach a suitable termination point, it MUST be

properly insulated.

3. If it is necessary to insulate piping when an inactive
chimney is used as a chase, the top of the chimney
MUST be sealed flush or crowned up to seal against
rain or melting snow so ONLY the piping protrudes.

4. When the vent or combustion air pipe height above
the roof exceeds 30 inches(760mm), or if an exterior
vertical riser is used on a horizontal vent to get above
snow levels, the exterior portion MUST be insulated.

5. When combustion air inlet piping is installed above a
suspended ceiling, the pipe MUST be insulated with

moisture resistant insulation such as Armaflex or
other equivalent type of insulation.

6. Insulate combustion air inlet piping when run in
warm, humid spaces such as basements.

SizingCombustionAirandVentPipe

1. Single Pipelnstallation-lf installing as anon-direct
vent appliance, (single outlet pipe and no inlet pipe)

refer to Table 1. The table shows the maximum

number of elbows allowed with any given pipe di-

ameter and length of run.

2. Double Pipe Installation-If installing as a direct-
vent appliance, consult Table 2 to select the proper

diameter exhaust and combustion air piping. Ex-

haust and combustion air piping is sized for each fur-
nace Btuh size based on total lineal vent length (on

inlet or outlet side), and number of 90° elbows re-
quired.

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, in-

cluding elbows needed to bring termination above

expected snow levels. When the vent system
length used is borderline with the next size com-

bination category, always use the next larger
size.

EXAMPLE: Refer to, 75,000 Btuh Furnace, Table 2.

• A vent system uses 25 feet of Inlet pipe and 24 feet

of Outlet pipe. Use the maximum length found in your
system, so 25 ft. is the lengthto use in these tables. The

25-30 column should be used.

• There are 4 elbows on the Outlet and 2 elbows on the
Inlet. Use the 4 elbows row because that is the maxi-

mum number of elbows on any one side (Inlet or Ex-
haust).

• In this example, combinations C or F are allowed.
Using the legend at the bottom of the table, combination

C is 3" Inlet with a 21/2" Exhaust. Combination F is a 3"

Inlet with a 3" Exhaust. Either combination is allowed to-

gether, but they can NOT be mixed. Inother words, part
of a C combination can NOT be used with part of an F

combination just because they are listed together in the

same block.

J Condensing Gas Furnace Installation Instructions

Pipe Diameter Table

Table I Single Piping ONLY

50,000 & 75,000 Btuh Furnaces

Max No. Of

Elbows in One

Side3

UP TO 5 All combinations use "A" a 2" Exhaust

Max No. Of Feet of Pipe*

Elbows in One

Side _ 0-9 10-14 15-1 €. 20-24 25-29 30-3_ 35-40

1 A A A A A A B,C

2 A A A A A B,C B,C

3 A A A A B,C B,C B,C

4 A A A B,C B,C B,C B,C

5 A A B,C B,C B,C B,C B,C

Max No. Of Feet of Pipe*

Elbows in One

Side _ 0-9 10-14 15-19 20-24 25-2_ 30-3, 35-4(_

1 A A B,C B,C B,C B,C C

0-,1,0-t,lt5-,o120-2,125-,930- 3 0

100,000 Btuh Furnace

125 000 Btuh Furnace

Feet of Pipe*

Table 2 Pipe Diameter Table

50,000 Btuh Furnace

Max No. Of Feet of Pipe*

Side _ 0-9 10-14 15-19 20-24 25-29 30-3 35-4(

E,hows,oonsI I I I

UP TO 5 All combinations use "A" a 2" Exhaust

Max No. Of Feet of Pipe*

Elbows in One

Side _ 0-9 10-14 15-19 20-24 25-2c. 30-34 35-4C

1 A A A A D,B E,B E,B

2 A A A D,B E,B E,B C,F

3 A A D,B E,B E,B C,F C,F
4 A D,B E,B E,B C,F C,F C,F

5 D,B E,B E,B C,F C,F C,F C,F

Max No. Of Feet of Pipe*

Elbows in One

Side _ 0-9 10-14 15-19 20-24 25-20 30-34 35-4(1

1 A A A D,B E,B E,B C,F

and 2" Air Inlet Pipe

75,000 Btuh Furnace

100,000 Btuh Furnace

Dual Piping ONLY

!

2 A B,C B,C B,C B,C C C

3 B,C B,C B,C B,C C C C
4 R,C B,C B,C C C C C
5 B,C B,C C C C C C

Possible combination legend:
A = 2" Exhaust

B = 2_/z" Exhaust
C = 3" Exhaust

Elbows are DWV Long Radius Type for 2" and 3"vents.
Schedule 40 (sharp radius) for 2V2"

3 - Signifies the maximum number of elbows, includ-

ing the termination elbow(s), on any one part of the

system. Example: 4 elbows on the exhaust and 5 el-

bows on the inlet would use the chart showing 5 el-

bows, because 5 is the maximum number on any one
side,

* Feet of pipe is whichever pipe run is the longest,

either inlet oroutlet side,

2 A A D,B E,B E,F C,F C,F
3 A D,B E,B E,F C,F C,Fi C,F
4 D,B E,B E,F C,F C,F C,F C,F
5 E,B E,F C,F C,F C,F C,F C,F

125,000 Btuh Furnace

Max No. Of

Elbows in One

Side

UP TO 5

Possible combination legend:

A = 2" Inlet with a 2" Exhaust

B = 3" Inlet with a 2" Exhaust

C = 3" Inlet with a 2112" Exhaust

D = 2V2"Inlet with a 2" Exhaust
E = 2V2"Inlet with a 2V2"Exhaust

F = 3" Inlet with a 3" Exhaust
Elbows are DWV Long Radius Type for 2" and 3" vents.

Schedule 40 (sharp radius) for 2V="

0-,110-14115-t01 0- ,1 5- 0130- 5-49

All combinations use "F" a a- Ex-

haust and 3" Air Inlet Pipe

Feet of Pipe*

Condensing Gas Furnace

Installation Instructions

Vent TerminationClearances

Carbon monoxide poisoning, fire and explosion
hazard.

Inlet and outlet pipes may NOT be vented

directly above each other.

Failure to properly vent this furnace can result in

property damage, personal injury and/or death.

1,

Determine termination locations based on clear-
ances specified in following steps and as shown in

Figure 11, Figure 14, Figure 15 and Figure 16.

The vent termination must be located at least 12

inches(300mm) above ground or normally expected

snow accumulation levels.

3. Do NOT terminate over public walkways. Avoid ar-
eas where condensate may cause problems such as
above planters, patios, or adjacent to windows where
steam may cause fogging.

4. The vent termination shall be located at least 4
feet(1220mm) horizontally from any electric meter,

gas meter, regulator, and any relief equipment.
These distances apply ONLY to U.S. installations.

5. The vent termination is to be located at least 3
feet(914mm) above any forced air inlet located within

10 feet(3m) ;and at least 10 feet(3m) from a combus-

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

.

In Canada, the Canadian Fuel Gas Code takes
precedence over the preceding termination instruc-

tions. See Appendix.

Figure 11

I ent Termination Clearances

(United States Only)

See text for Canadian Requirements

/

CondensateDrainTrapand Neutralizer

This furnace removes both sensible and latent heat from
the combustion flue gases. Removal of latent heat results

in condensation of flue gas water vapor. This condensed

water vapor drains from the secondary heat exchanger,
through a built-in drain trap transition, and out of the unit.

Condensate piping or tubing can exit from the right side,

left side, or rear of the cabinet.

NOTE: The 90 ° compression fitting elbow(provided), re-
quires the drain line and overflow line are to be 1/2
inch(13mm) copper tube. CPVC. 5/8"(16mm) I.D. vinyl tub-

ing may be used outside the furnace cabinet to connect to
the drain line. Internal trap assembly provides the required
4 inches water column, so no additional trap is required.

1.

Do NOT put a loop in the drain piping. This would
cause an extra water column pressure in addition to
the pressure inside the built-in drain trap.

2,

Drains must terminate at an inside drain to prevent
freezing of condensate and possible property dam-
age.

3.

Consideration MUST be given to type of filter being
installed. 125,000 Btuh furnace require 2-16x25x1
filters(one on each side of furnace). This configura-

tion does NOT allow the condensate drain line to be
run out the side of furnace. If line MUST be run out
the side, an optional standoff filter rack with one

20x25x1 filter is needed. Install optional filter rack on
side of furnace opposite the side where condensate

drain line will exit.

4,

A condensate or sump pump MUST be used if local
codes require, or if no inside floor drain is available, if

pump is approved for use with acidic condensate, a
neutralizer cartridge is not needed. If using a neutral-
izer cartridge, it MUST be installed in the drain line in
a horizontal position ONLY.

NOTE: Recommended service time for replacing neutral-
izer cartridge is one year.

5. A condensate pump MUST have an auxiliary safety
switch to prevent operation of furnace and resulting

overlow of condensate in the event of pump failure.
The safety switch MUST be wired through the R cir-
cuit ONLY (low voltage) to provide operation in either

heating or cooling modes.

6. Install an overflow line if routing to floor drain or sump
pump. See Figure 1 for example of proper routing

and installation of overflow line.

Connecting Furnace and Piping

Carbon monoxide poisoning hazard.

Cement or mechanically seal all joints, fittings,
etc. to prevent leakage of flue gases.

Failure to properly seal vent piping can result in
personal injury and/or death.

1. Preassemble the exhaust and combustion air piping
from the furnace to the vent termination. Do NOT ce-

I Condensing Gas Furnace Installation Instructions

ment any joints together until the preassembly proc-
ess is complete.

Vent Pipe Connection

1. Install the ABS supplied piece of vent pipe to the
combustion blower using RTV sealant ONLY. This

provides for future serviceability.

CAUTION

Do NOT cement pipe into combustion blower. When
inserting vent pipe into combustion blower, use a
bead of RTV sealant that is at least 3/8" (10mm) from
the edge of the pipe. Too much sealant can cause the
condensate drain to clog. See Figure 12.

2.

Install the flexible connector (provided) on the ABS
pipe from the combustion blower. This will be used to
connect to the rest of the vent system, See

Figure 13.

Air Inlet Pipe Connection

NOTE: Air Inlet Collar issized for 3" PVC pipe. If 2" (50mm)
or 2,,V2"(64mm) combustion air piping is used, a 3" (75m m)

to 2 (50mm) or 3 (75mm) to 21/2 (64mm) reducer fitting is
required.The reducing section can be before the 90° el-

bow in a horizontal section.

1. Install pipe section or pipe/reducer fitting (as re-
quired) to the inlet collar using RTV sealant ONLY to

provide for future serviceability.

NOTE: On single pipe installation, using combustion air

from inside the structure, it is recommended that a screen

be placed inside the Combustion Air Inlet. A 3" plastic
screen is available for this purpose. Itwill prevent small ob-

jects from falling into the combustion chamber. Use RTV

sealant ONLY to provide for future serviceability.

Figure 12 Proper Sealing Procedure for

Combustion Blower

ABS pipe (supplied)
MUST be used
SeaE to Combustion

blower with RTV

_ea]enl

I

Figure 13 ! Vent Trap and Furnace Connections

Flexible coupling and clamps
(supplied) are installed out-

side the cabinet.

ABS pipe (supplied) MUST be
installed between

tion blower and coupling.

RTV sealant used to join com-
bustion blower and ABS pipe

and Air Inlet Pipe to Combus-

tion Air Inlet.. See Figure 12.

Air Intake Pipe
(Direct-Vent Installation only)

Place a 3" Plastic Screen (Op-

tional) inside the Air Inlet Collar
when Combustion Air comes

from inside the structure.

Condensate compression

fitting can be turned to exit out
the left side, right side, or rear

of cabinet, If piping is exiting
out the right side of cabinet, it
is necessary to use an elbow to
run pipe In front of electronic

module. Cabinet entrance hole
is offset enough to allow ade-

quate clearance.

25-20-71

I Condensing Gas Furnace

installation instructions

JoiningPipeand 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 personal
injury and/or death.

NOTE: All PVC, CPVC, ABS, and Cellular Core pipe fit-

!

tings, solvent cement, primers and procedures MUST con-
form to American National Standard Institute and

American Society for Testing and Materials (ANSI/ASTM)

standards. Schedule 40 is the ONLY approved wall thick-
ness.

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

• PVC Primer and Solvent Cement - ASTM D2564

• Procedure for Cementing Joints - Ref ASTM D2855

NOTE: In order to create a seal that allows future removal
of pipe, RTV sealant MUST be used on both the inlet and
the exhaust pipes where they join to the furnace. PVC,
CPVC, ABS, and Cellular Core pipe and cement 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 precau-

tions printed on containers. For applications below 32
degrees F., use only low temperature type solvent ce-
ment.

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.

NOTE: Stir the solvent cement frequently while using. Use
a natural bristle brush or the dauber supplied with the ce-
ment. The proper 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 allow 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 bottoms 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 tapered socket from pushing the pipe out of the

fitting.

5. Wipe all excess cement from the joint with a rag. Al-
low 15 minutes before handling. Cure time varies ac-
cording to fit, temperature and humidity.

ConnectingVent PipesandTermination

NOTE: Combustion air intake and vent MUST terminate in

the same atmospheric pressure zone. If installation is in a
cold climate (substained temperatures below 0°F), in-
crease the minimum distance between vent pipe and air in-

take from 8"to 18".

CAUTION

Maintain a minimum of 36 inches(Ira) between com-
bustion 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, chorlinator or filtration unit.

Carbon monoxide poisoning, fire and explosion
hazard.

Inlet and outlet pipes may NOT be vented

directly above each other.

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

1.

install all couplings, nipples and elbows using proper
procedures for Joining Pipe and Fittings and main-
tain spacing between vent and combustion air piping
as indicated in Figure 14 through Figure 16.

Vertical Termination

1. Figure 16 shows the proper installation and clear-
ances 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"(300mm) above the roof or snow ac-
cumulation level, and 12"(300mm) away from a verti-
cal wall or other protrusion.

2. If the vent system is installed in an existing chimney
make sure clearances shown in Figure 16 are main-

tained. Horizontal section before the termination el-
bow can be extended on the inlet air to provide
necessary clearance.

Horizontal Termination

1,

If installing as a direct-vent appliance, cut two holes.
21/2" (67mm) for 2" (50mm) pipe, 3"(75mm) for 2 _/2"

(67mm) pipe, or 31/2"(90mm) for 3"(75mm) pipe. Do
NOT make the holes oversized, or it will be neces-

sary to add a sheet metal or plywood plate on the out-
side with the correct size hole in it. If venting as a
single pipe appliance, cut only one hole.

I Condensing Gas Furnace

Installation Instructions I

2. Check hole sizes by making sure it is smaller than the
couplings or elbows that will be installed on the out-
side. 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 3/4to 1"(19 to 25mm) and seal area between
pipe and wall.

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

combustion air piping as indicated in Figure 14
through Figure 16.

UsingExteriorRisers

1. install elbows and pipe to form riser as shown in

Figure 15.

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
resistant closed cell foam insulationor Fiberglass in-

sulation ifboxed in and sealed against moisture.

Optional Vent Screens

To prevent unwanted pests or foreign material from enter-

ing terminated pipes, plastic vent screens are available in

2" and 3" sizes. Use of these screens is recommended ex-
cept in cold climate areas where ice is likely to form on

them. Glue the screen inside the termination elbow using
pipe cement. Screens should be inspected monthly for
blockage and cleaned yearly prior to startup.

Sidewall Termination

12 Inches or More Above

Snow Level or Grade Level

• 18" Minimum for cold climates

8"* _ (substainedbel°wO_F)

MIN

A metal shield is recommended 18" x 18"(457mm x
457mm) min. or 18"(457mm) min. diameter around the
vent termination at the exterior wall to protect the house ex-

terior materials from flue product or condensation (freez-

ing) damage.

Figure 15 Exterior Risers to Get Above

J Sidewall Termination with

Snow Level or Grade Level

18" Minimum for cold clirnate_

(substained below O°F)

I' MN

25-00-04F

Inlet is ]

optional

I

EXHAUST i

optionallnletis] !i/// _ _.Nj//

SNOW LEVEL

25_O,,35F

Vent Termination Shielding

Under certain wind conditions some building materials may
be affected by flue products expelled in close proximity to

unprotected surfaces. Sealing or shielding of the exposed
surfaces with a corrosion resistant material (such as alumi-

num sheeting) may be required to prevent staining or dete-
rioration. The protective material should be attached and

sealed (if necessary) to the building before attaching the
vent terminal.

FigMrei6 ;I Rooftop Termination

Inlet is
optional ]

A = f2" Above roof or snow accumulation level
B = 8" M_n., 2(_"Maximum, except in areas with extreme

cold temperatures (substamed below 0 F), then 18 Mw .

• o . =n

25-00-06

Installation Instructions Condensing Gas Furnace ]

6. Gas

Fire and explosion hazard.

Natural Gas

Models designated for Natural Gas are to be used
with Natural Gas ONLY.

LP Gas

LP gas models have orifices sized for commer-

cially pure propane gas. Furnace MUST NOT be

used with butane or a mixture of butane unless
properly sized orifices are installed by a licensed

LP installer.

Failure to follow these instructions can result in

property damage, personal injury and/or death.

!

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

gas type and gas input rating. In addition, models manufac-
tured for sale in Canada have orifice size information

stamped on the rating plate.

General U.S. Derating Rules

1.

For operation with natural gas at altitudes 2,000 feet
and above, 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 4

percent for each 1,000 feet above sea level. See

Figure18 and Figure 19 for required pressure
change and/or orifice change for high altitudes.

2.

For operation with LP gas, gas orifices MUST be
changed and manifold pressure MUST be

maintained as per Figure 17. Orifice sizes for
0-2000 ft. above sea level are #54. 2000-7000 ft.

above sea level, use #55. 7000-8000 ft. above sea
level, use #56 orifices. Orifices can be ordered

through your distributor.

General Canadian DeraUng Rules

3.

In Canada, to derate both Natural and LP gas, the in-
put MUST be decreased 10% for altitudes
2,000-4,500 ft. above sea level. The orifice MUST be

sized as shown on the rating plate, NOT as shown in

these instructions. Installations above 4,500 ft.

MUST consult provincial authorities.

SupplyPressure

Fire hazard.

Do NOT set input rating above that shown on

rating plate.

Failure to properly set input pressure can result in
property damage, personal injury and/or death.

1. Supply pressure can be checked using the

1/8"(3.2mm) 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

downward. Doing so will decrease input to furnace.

Refer to Figure "17for normal gas supply and mani-

fold pressures.

Figure 17 Gas Pressures Below 2000 Ft.

Gas
Type

Natural 3.5 inches

LP 10 inches

Recommended Max.

7 inches 14 inches

11 inches 14 inches

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 inches 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 ad*

justing manifold pressure.

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

Supply Pressure

Min.

4.5 inches

11 inches

Important Notes

Manifold
Pressure

Manifold Gas PressureAdjustment

NOTE: Gas suppty pressure MUST be within minimum and
maximum values listed on rating plate. Pressures are usu-

ally set by gas suppliers.

Make adjustment to manifoldpressure with burners oper-

ating and combustion air box cover removed.

Condensing Gas Furnace

installation instructions

1. Remove combustion air box cover.

2. Connect U-Tube manometer to the tapped opening
on the outlet side of gas valve. Use manometer with a

O-12 inches water column range.

3. Turn gas ON, fire the furnace and remove adjust-

ment screw cover on gas valve.

4. Turn counterclockwise to decrease pressure and
clockwise to increase.

5. Set pressure to value shown in Figure 17. Refer to

Important Notes in Figure 17. Pressure is also
listed on furnace rating plate.

6. When pressure is set, replace adjustment screw
cover on gas valve.

7. Replace combustion air box cover.

NOTE: Adjustment screw cover MUST be replaced on gas
valve BEFORE reading manifold pressure and operating

furnace.

HighAltitudeAirPressureSwitch

Altitudes over 4,000 ft. require a different air pressure
switch than the one installed at the factory. Consult your

distributor for part number and availability. In Canada, pro-

vincial codes may govern installation of switch. Check with

governing authorities.

ChangingOrificesfor HighAltitude

5. Reinstall manifold and combustion air box cover. En-
sure burners de NOT bind on new orifices.

High Altitude Pressure Chart

Figure 18 2000-4999 ft. (Natural Gas)

Heat Value ;

Btu/Cu,Ft.

800
850

9O0

95O

1000

1050

1100

Figure 19

Heat Value'

Btu/Cu.Ft.

800
85O

900

950

1000
1050

1100

0-1999 2000-2999 3000-3999 4000_499. (

-I Shaded box requires orifice change to a #44.
No Shading indicates factory installed orifice and

manifold pressure change only.

J Shaded box requires odfice change to a #44.

No Shading indicates factory installed orifice and

manifold pressure change only.

Elevation Above Sea Level

3.5 3,5 3.5 3,5

3.5

3.5

3.5

3.5

3.2

2.9

3,5 3,5 3.2

3.2 3.2 2.9

3.1 2.8 2.6

2.8 2.5 2.3

2.5 2.3 3.5

2.3 3.5 3.3

High Altitude Pressure Chart

5000-7999 ft. (Natural Gas)

Elevation Above Sea Level

5000-6999

3.2

2,9

2.6

2.3

3.5

3.3

3.0

6000-6999 7000-7999

2.9 2.7

2.6 2.3
2,3 3.5

3.5 3.3

3.3 3.0

3.0 2.7

2.7 2.4

!

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
property damage, personal injury and/or death.

NOTE: Main burner orifices can be changed for high alti-
tudes.

1. Disconnect gas line from gas valve.

2,

Remove combustion box front cover and manifold

from furnace.

3.

Remove the orifices from the manifold and replace

them with properly sized orifices.

4.

Tighten orifices so there is 1_/_6" (27mm) from the
faces of the orifices to the back side of the manifold,

Figure 20.

Figure 20

Changing Orifices

Measure tlh6" (27ram)

from face of orifice to

the back side of the
manifold.

NaturalGasInputRatingCheck

NOTE: The gas meter can be used to measure input to fur-

nace. Rating is based on a natural gas BTU content of

1,000 BTU's per cubic meter. Check with gas supplier for

actual BTU content.

1. Make sure combustion air box cover is in place and
closed before performing the following steps.

Installation Instructions Condensing Gas Furnace J

2.

Turn OFF gas supply to all appliances and start fur-

nace.

3.

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

fer to Example,

Example

Natural Gas No. of Seconds Time Per Cubic BTU Per

BTU Content Per Hour Meter in Seconds Hour

1,000 3,600 48 75,000

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

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

4. Relight all appliances and ensure all pilots are oper-
ating.

GasPiping Requirements

!

1. Determine the minimum pipe size from the tables in
Figure 22 and Figure 23, basing the length of the

run from the main line, gas meter or source to the fur-
nace.

2.

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

3.

Install correct pipe size for run length and furnace rat-
ing.

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

Connections

NOTE: Refer toFigure 21 for the general layout at the fur-

nace. The rules listed apply to natural and LP gas pipe in-
stallations.

1. Use black iron or steel pipe and fittings or other pipe
approved by local code.

2.

Use ground joint unions and install a drip leg no less

than 3 inches long to trap dirt and moisture before it
can enter gas valve.

3.

Use two pipe wrenches when making connections to

prevent gas valve from turning.

4.

Install a manual shut-off valve and tighten all joints

securely.

Figure 21

Drip Leg and
Union, Union*
should be outside

the cabinet. Man-
ual shut-off valve

MUST be up-
stream of dripleg,

union, and fur-
nace.

LP Low

switch.
Optional
on some

models.

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

Typical Gas Piping

Air Intake Pipe
(Direct-Vent Use elbows to
Installation connect valve
only) to piping when

using right
side gas pipe

Additional LPConnectionRequirements

1. Have a licensed LP gas dealer make all connections
at storage tank and check all connections from tank

to furnace.

2. If copper tubing is used, it MUST comply with limita-
tion set in National Fuel Gas Code or CGA codes,

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

I Condensing Gas Furnace

Figure 22 Natural Gas Pipe Sizes/Capacity

Natural Gas Capacity

BTU Per Hour Input

(in Thousands)

Pipe Pipe Size I.D.
Length

(Feet) 3/6" 1/2" 3/4" 1" 11/4" 1112'

10 72 132 278 520 1,05C 1.600

20 49 92 190 350 730 1,100

30 40 73 152 285 590 890

40 34 63 130 245 500 760

Installation Instructions I

• ANSI Z21.24a-1983, Metal Connectors for Gas
Appliances

• ANSIZ21.45b-1983, FlexibleConnectorsofOther

Than All-Metal Construction for Gas Appliances.

2. Use pipe joint compound on external (male) threads
ONLY, Joint compound MUST be resistant to any

chemical action of LP gases (Figure 24),

/

Figure 24 / Proper Piping

&

Contro] Use Moderate Amount

Practice

of Compound

50 30 56 115 215 440 670

60 27 50 105 195 400 610

NOTE: Piping that is too small will prevent the proper
amount of gas from reaching the furnace.

Figure 23 LP Gas Pipe Sizes/Capacity

LP Gas Capacity

BTU Per Hour Input

(InThousands)

Pipe Copper Tubing O.D. Iron Pipe I,D.
Length

(Feet) 3/8" 1/2'1 518" 3141" 11211 3tt4" 1"

10 39 92 199 329 275 567 1,071

20 26 62 131 216 189 393 732

30 21 50 107 181 152 315 590

40 19 41 90 145 129 267 504

%

Leave 2 End

Thread Pipe Right Length

Final Check

1,

This furnace MUST be isolated from the gas supply

piping system by closing its individual manual shut-
off valve during any pressure testing of the gas sup-

ply system at pressures equal to or less than V2"
PSIG (3.5 kPa).

2. Test all pipes for leaks.

,

Gas pressure MUST NOT exceed 1/2"PSIG to gas
valve. Checking gas piping above _/2"PSIG requires
the furnace and manual shut-off valve to be discon-

nected during testing.

4. Apply soap suds (or a liquid detergent) to each joint.
Bubbles forming indicate a leak.

5. Correct even the smallest leak at once.

Threads Bare

!

50 -- 37 79 131 114 237 448

60 -- 35 72 121 103 217 409

NOTE: Copper tubing for gas supply MUST comply with limita-
tions in National Fuel Gas code, reference 2.6.3 Metallic Tub-

ing

NOTE: If a gas connector is used, it MUST be acceptable
to local authority. Connector may NOT be used inside the
furnace or be secured or supported by the furnace or
ductwork. Connectors MUST comply with one of the fol-
lowing standards or a superseding standard.

6. If orifices were changed, make sure they are

checked for leakage.

Startup

NOTE: Refer to Starting The Unit in the Users Informa-

tion Manual

CAUTION

If any sparks, odors or unusual noises occur, immedi-
ately shut OFF power to furnace. Check for wiring er-

rors or obstruction to blower.

_ Installation Instructions Condensin_ Gas Furnace ]

7. ElectricalWiring

a

Electrical shock hazard.

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 property damage,
personal injury and/or death.

Grounding

NOTE: The furnace MUST be electrically wired and

grounded in accordance with local codes or, inthe absence
of local codes, with the electrical codes of the country hav-

ing jurisdiction. Electronic controls and furnace will NOT

operate unless properly grounded. A ground lug wire is
provided for ground connection. Use an approved copper

connector from furnace to service panel or properly driven
ground rod. See Appendix.

I

5. Complete linevoltage connections insideconnection
box. See Figure 25.

Figure 25

115V 6OHz.

Electrical Connections

Air Intake Pipe

(Direct-Vent Installation only)

0

Polarizing

NOTE: To insure safe, reliable operation, unit MUST be

polarized. Proper polarity is shown in Figure 25. The white
wire is neutral and the black wire is hot.

Labeling

CAUTION

Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dan-
gerous operation.

Power Supply

NOTE: Line voltage circuit is completely factory wired.

Make all line voltage connections inside furnace junction
box. ALL electrical work MUST conform with local codes,

ordinances and the national electrical code, NFPA
70-1990 or current edition.

1. Run #14 AWG hot and neutral wires from a 15 amp
circuit breaker. Ground wire gauge MUST meet or

exceed codes.

2. Do NOT connect furnace to existing lighting or other
circuit.

3,

Do NOT complete line voltage connections until fur-
nace is permanently grounded.

4.

Make all line voltage and ground connections with
copper wires.

_ THERMOSTAT

25 2O-72

Thermostat

NOTE: Thermostat location has an important effect on the

operation of the unit. Follow instructions included with ther-
mostat for correct mounting and wiring.

Heat Anticipator

• Set thermostat heat anticipator in accordance with

thermostat instructions and actual measured value.
To measure heat anticipator, do the following:

1,

Wrap 10 loops of single strand, insulated thermostat
wire around the prongs of an amp meter. Set the

scale on the amp meter to measure no more than 10

amps.

2.

Connect the uninsulated ends of this wire jumper
across terminals R and W on the subbase. (Multi-
stage thermostats use RH and W) Do NOT attach

thermostat to subbase.

3, Fire the thermostat for about one minute. Read the

amp meter. Divide the amp reading by 10 and set an-
ticipator to this number.

Condensing Gas Furnace

Installation Instructions

4. Remove wires from subbase and attach thermostat
to subbase.

OptionalEquipment

NOTE: All wiring (except thermostat) from furnace to op-

tional equipment MUST conform to the temperature limita-
tions of local codes or, in the absence of local codes, with

the electrical codes of the country having jurisdiction. See
Appendix. Install wiring in accordance with manufacturer's

instructions.

Humidifier/ElectronicAirCleaner

The furnace is pre-wired for humidifier and/or electronic air

cleaner connection.

CAUTION

Do NOT exceed 115V/0.8 amp maximum currrent load

for both the EAC terminal and the HUM terminal com-
bined.

1,

For connection of a humidifier, break the designated

tabs ("HUM" and "N") on the electronic fan control

located in the circulating blower compartment
(Figure 26). This will expose the terminals required

for connection to the 115v power supply.

FanControl

The fan control is preset at the factory with a fixed blower
ON delay of 60 seconds in the heating mode. The blower

OFF timing is preset at 120 seconds. If desired, the fan
OFF delay can be reset to obtain the longest OFF time
while still maintaining comfort levels. See Figure 26 and

Figure 27.

I

Figure

"EAC" And "N" 7\

26 I Fan Timer Connections

i

Breakouts _

I
I

|

2. For connection of an electronic air cleaner, break the
designated tabs ("EAC" and "N") on the electronic

fan control located in the circulating blower compart-

ment (Figure 26). This will expose the terminals re-

quired for connection to the 115v power supply.

NOTE: The humidifier willbe powered when the combus-
tion blower is energized. The electronic air cleaner will be
powered anytime the thermostat calls. However, the elec-

tronic air cleaner is NOT energized during continuous fan
operation controlled by the electronic fan control.

Wiring for Air Conditioning

1. Replace heating only thermostat and cable with heat/
cooling thermostat and 4-wire thermostat cable if re-
quired.

2. Connect from W, G, R and Y on thermostat to W, G,
R and Yon furnace low voltage terminal board.

3. Connect wires from contactor on condensing unit to

Y and C on furnace low voltage terminal board.

4. Follow all instructions with condensing unit and

evaporator coil.

"_-Dip

Switch 10-11-44

Figure 27 Fan OFF Delay DIP switch Settings

1 2 1 2

60 Sec. 90 Sec.

1 2 1 2

NOTE: The furnace electronic fan control will change fan

speeds automatically as heat and cool are selected at the
thermostat.

120 Sec. t50 Sec.

_ Installation instructions Condensing Gas Furnace I

8, Ductw0rk andFilter

Connections

NOTE: Return air can enter through either side, both sides,

Carbon monoxide poisoning hazard.
Do NOT draw return air from inside a closet or util-

ity room. Return air duct MUST be sealed to fur-
nace casing.

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

Installation

NOTE: Design and install air distribution system to comply
with Air Conditioning Contractors ofAmerica manuals and/

or NFPA pamphlets 90A and 90B or other approved meth-
ods that conform to local codes and good trade practices.

1. When furnace supply ducts carry air outside furnace
area, seal return air duct to furnace casing and termi-

nate duct outside furnace space.
Install air conditioning cooling coil (evaporator) on

outlet side of furnace,
Ifseparate evaporator and blower units are used, in-

stall good sealing dampers for air flow control.
Chilled air going through the furnace could cause

condensation and shorten the furnace life.

4,

it is recommended for furnaces installed without a

cooling coil that the outlet duct be provided with a re-

movable access panel. This panel should be acces-

sible when the furnace is installed so that the heat
exchanger can be viewed for inspections. The ac-

cess panel MUST be sealed to prevent leaks.

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 opera-

tion unless damper is in the full heat or cool position.

or the bottom. When the furnace is located in an area near
or adjacent to the living area, the system should be care-

fully 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 objection-
able 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.

1. For side connections using a 16" x 25" filter, cut out
the embossed area shown in Figure 28. This will

provide a 14Y2" x 22Y2" approximate opening.

NOTE: A 125,000 Btuh furnace requires two side returns
or a bottom return for 5tons cooling. If two side returns are

used it does NOT allow the condensate drain line to be run
out the side of furnace. If line MUST be run out the side, an
optional standoff filter rack with one 20x25x1 filter is

needed. Install optional filter rack on side of furnace oppo-
site the side where condensate drain line will exit.

.

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

knock-out except for a bottom return. A 20" x 25" fil-
ter can be used for abottom return for a100,000 Btuh
furnace. A 25" x 25" filter is required for 125,000

Btuh furnaces.

3.

An optional 20" x 25" duct standoff is available to be
used in lieu of one filter on each side of furnace, or

optional 16" x 25" external filter racks are available.

4.

Installation of locking-type dampers are recom-
mended in all branches, or in individual ducts to bal-

ance system's air flow.

5.

Non-combustible, flexible duct connectors are rec-
ommended for return and supply connections to fur-
Race.

6.

If air return grille is located close to the fan inlet, in-
stall at least one, 90 degree air turn between fan and
inlet grille to reduce noise.

NOTE: To further reduce noise, install acoustical air turn-
ing vanes and/or line the inside of duct with acoustical ma-

terial.

Carbon monoxide poisoning hazard.

Cool air passing over heat exchanger can
cause condensate to form resulting in heat ex-

changer failure.

This could result in personal injury and/or
death.

Sizing

Existing or new ductwork MUST be sized to handle the cor-
rect amount of airflow for either heating only or heating and

air conditioning.

Insulation

1. Insulate ductwork installed inattics or other areas ex-
posed to outside temperatures with a minimum of 2

inch insulation and vapor barrier.

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

barrier.

i Condensing Gas Furnace Installation Instructions

Filters

NOTE: The size and type(s) of filter supplied with the fur-

nace will handle the airflow required if central air condition-
ing is used with the furnace.

Use either filter type:

• Washable, high velocity filter based on a maxi-
mum air flow rating of 600 FPM.

• Disposable, low velocity filter based on a maxi-
mum 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 listed in Table 3. Washable, high ve-

locity filters can be replaced ONLY with same type and

size.

Filter Installation

When installing or removing a bottom mounted filter, slide
the two side filter clips to the back of the furnace BEFORE

installing or removing. 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 mid-
way on filter as shown in Figure 30.

AdditionOfAir Conditioning

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

avoid condensation on the heat exchanger. The coil instal-

lation instructions must be consulted for proper coil loca-

tion and installation procedures. With a pararlel flow
arrangement, dampers must be installed to prevent chilled

air from entering the furnace. If manually operated damp-
ers are used, they must be equipped with a means to pre-

vent operation of either unit unless the damper is infull heat
or full cool position.

A 3" (75mm) 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.

Figure 29

Refer to Figure 31 through Figure 32 for guidelines to in-
stall filters. Furnaces which require larger filter media and

have limited clearances on one side of furnace, require a

standoff filter rack, see Figure 31, available from your dis-
tributor. Refer to Table 3 for filter media needed.

CAUTION

If filters are only suitable for heating application, ad-
vise homeowner that filter size may need to be in-

creased if air conditioning is added.

Figure 28

Embossed Area I H I
on Side of Furnace ] _" L

Side Return Air Cutout

A = 14112" Height of Cutout for
16" x 25" Filter

B = 221/2"Width of Cutout for .J
16,, x 25- Filter

!

25-20-90

Figure 30 I Bottom Mounted Filter Rack

AW3192

Slide filter clips towards back before removing

I Installation Instructions

Condensin_lGas Furnace I

Figure 31 / Standoff Filter Rack

.L

Using Optional

Standoff Filter

Rack

AW 3191

Figure

UsingTwo

FilterRacks

/ Filters Installed on Two Sides

32

±

Filter Filter

AW 3181

!

Table 3 Recommended Filter Area

Airflow

m3/hr CFM m_ Sq. In. mm Inches

375 800 .25 384 510 x 635 20 x 25

425 900 .28 432 510 x 635 20 x 25

470 1000 .30 480 510 x 760 20 x 30

520 1100 .34 528 510 x 760 20 x 30

565 1200 .37 576 355 x 635 14 x 25

615 1300 .40 4624 355 x 635 14 x 25

660 1400 .43 672 405 x 635 16 x 25

710 1500 .46 720 405 x 635 16 x 25

755 1600 .50 768 510 x 635 20 x 25

800 1700 ,53 816 510 x 635 20 x 25

850 1800 ,56 864 510 x 635 20 x 25

Disposable Low Velocity (300 FPM Air Flow)

Min, Surface Area Recommended Nominal Size

Washable High Velocity (600 FPM Air Row)

Min. Surface Area Recommended Nominal Size

Qty. m= Sq, In. mm Inches Qty.

1 0,23 350 355 x 635 14 x 25 1

1 0,23 350 355 x 635 14x 26 1

1 0.23 350 355 x 635 14 x 25 1

1 0.23 350 355 x 635 14 x 25 1

2 0,23 350 355 x 635 14 x 25 1

2 0,23 360 355 x 635 14 x 25 1

2 0.23 350 355 x 635 14 x 25 1

1 0.26 400 406 x 635 16 x 25 1

2 0.26 400 406 x 635 16 x 28 1

2 0.32 500 508 x 635 20 x 25 1

2 6,32 500 508 x 635 20x 25 1

895 1900 ,59 912 510 x 760 20 x 30

945 2000 .62 960 510 x 760 20 x 30

2 0.32 500 508 x 635 20 x 25 1

2 0,32 500 508 x 635 20 x 25 1

I Condensing Gas Furnace

9. ChecksandAdjustments

Installation Instructions

Main BurnerFlameCheck

NOTE: The main burner flames can be observed through

the sight glass in the combustion box in most instances.

1. Check for the following (Figure 33):

, Stable, blue flames

• Flames do NOT touch sides of heat exchanger

NOTE: Dust may cause orange tips or wisps of yellow, but
MUST NOT have solid, yellow tips.

2. Check main burner flames monthly.

3. If any problems with main burner flames are noted, it
may be necessary to clean burners or adjust gas

pressures. This procedure is to be done by a quali-
fied service technician.

Pilot BurnerFlameCheck

NOTE: The pilot burner flames can be observed through
the sight glass in the combustion box. If view is not ade-

quate, you may need to remove combustion box cover.
Check for the following :

• Stable blue flame

• Flame iscompact and points toward the burners

The pilot flame should envelop 3/8"to V2"(10-13ram) of the
tip of the igniter sensor. See Figure 34. If flame is NOT cor-

rect, do the following:

Figure 34 Pilot Burner

Proper Flame
Adjustment ×_/;'_ "

' I

Flame Rod

Hot Surface

Igniter

10-11-65

1. Remove the combustion box cover. See Cleaning LimitControl Check

Burners in Cleaning Heat Exchangers chapter.

2. Remove pilot adjustment cover screw on gas valve.

3. Turn inner adjustment screw clockwise to decrease
or counterclockwise to increase pilot flame.

4. Replace cover screw and combustion cover.

I

Figure 33 I Main Burner

Burner Face

Fire hazard.

Limit control is factory preset and can NOT be ad-

justed. Use ONLY manufacturer's authorized re-
placement pads.

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

death.

1. Operate furnace continuously for 15 minutes.

2. Block return air grille(s) and check that main burners
go out and blower continues to run.

3. Remove material blocking return air grille(s). Check
that main burners relight after a short cool down pe-
riod.

I

I Installation Instructions Condensin_l Gas Furnace I

Fan ControlCheck

Figure 35 Fan OFF Delay DIP switch Settings

1 2 1 2

60 Sec. 90 Sec.

1 2 1 2

120 Sec. 150 Sec.

1. The fan OFF control switch is preset at the factory,
but, if necessary can be adjusted to obtain asatisfac-

tory comfort level.

NOTE: The fan control is preset to turn ON 60 seconds af-
ter the burners light, it can be adjusted to turn OFF at 60,

90, 120, and 150 seconds. Refer to Figure 35.

2. Operate the furnace and ensure that the blower
turns ON and OFF at the appropriate time to provide

the desired comfort level.

TemperatureRiseCheck

NOTE: Temperature rise is the difference between supply

and return air temperature.

!

1. Place thermometers in supply and return air registers

as close to furnace as possible, avoiding direct radi-

ant heat from heat exchangers.

2. Operate furnace continuously for 15 minutes with all
registers and duct dampers open.

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

4. If the correct amount of temperature rise is NOT ob-

tained, it may be necessary to change blower speed.
A higher blower speed will lower the temperature

rise. A lower blower speed will increase the tempera-
ture rise.

NOTE: The blower speed MUST be set to give the correct

air temperature rise through the furnace as marked on the

rating plate.

Electrical shock hazard.

Turn OFF power to furnace before changing speed

taps.

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

death,

Note: Theblowerisfactoryset for heating and cooling. If it

is necessary to change speeds, refer to steps below.

5. Refer to Figure 37 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 (Figure 36) to determine the
blower motor speed settings.

6.

Change the heat or cool blower motor speed by re-
moving the motor lead from the "Heat" or "Cool" ter-

minal and replace it with the desired motor speed tap

from the "Unused Blower Speed Tap" location.

Connect the wire previously removed from the "Heat"
or "coor' terminal to the vacated "Unused Blower

Speed Tap" terminal.

Figure 36 Blower Speed Chart

Wire Color Motor Soeed

Black High
Orange Med-High

Blue Medium-Low

Red Low

7.

If the same speed must be used for both heating and

cooling, remove the undesired motor speed lead
from the "Heat" or "Cool" terminal and connect that

lead to the open terminal at "Unused Blower Speed

Tap" location. Attach a jumper between the "Heat"
and "Cool" terminals and the remaining motor speed

lead.
Note: For motors with (4) speed leads, it may be nec-

essary to tape off the terminal of the motor speed
lead removed from the "Heat" or "Cool" terminal with

electrical tape if an open terminal is not available at
the "Unused Blower Speed Tap" location.

Condensing Gas Furnace

Installation Instructions

Figure 37 Blower Speed Taps

Unused Blower Blower Speed

"EAC" And "N"

Breakouts _,

I L

Speed Taps Taps

"HUM" And "N"

\_Dip

Switch 10-11-44

ContinuousFanOperation

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 operation.

Separatespeedselectionsfor Heat, Cool,and
ContinuousFan

Connect low speed lead from circulating motor to the
"Cont" terminal at the electronic fan control. The appropri-

ate motor leads should already be connected to the "Heat"
and "Cool" terminals.

Note: See next section "Heating and Continuous Blower

Speedthe Same" if low speed is required for heating to ob-

tain desired temperature rise.

Heating and Continuous Blower Speed the Same

If it is necessary to operate the heating speed and continu-
ous blower speed using the same blower speed, connect a

jumper between the "Heat" and "Cont" terminals on the

electronic fan control.
Note: There should be only ONE motor lead going to the

"Heat" and "Cont" terminals.

I

I Installation Instructions Condensin_ Gas Furnace J

10. FurnaceMaintenance

CAUTION • Filter type must be same unless replacing a dis-

It is recommended that the furnace be inspected and
serviced on an annual basis (before the heating sea-

son) by a qualified service technician.

If you perform maintenance on the furnace yourself, re-

member that certain mechanical and electrical skills, plus
specialized tools are required to properly perform mainte-

nance. Personal injury or death may result if you are NOT

properly trained. You should carl your installing dealer or
place of purchase if you are uncertain about your ability to
perform maintenance.

Electrical shock hazard.

Turn OFF power to furnace before performing

any maintenance or removing panels.

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

Blower Motor

posable low-velocity type with a washable high-
velocity type.

Turn OFF electric power at circuit breaker or discon-

1.

nect switch.

2.

Inspect filter then replace or clean washable type. If

filter is aluminum mesh type, coat it with filter coating
spray.

3.

Ensure all panels are tightly closed before restoring

power.

• If oil ports are provided on the motor, pedodic lubri-
cation is recommended. If no oil ports are pro-
vided, the motor is considered permanently

lubricated and no lubrication is required.

• When oil ports are provided, lubricate by adding 1/2
teaspoon (2cc) of SAE #10W30 motor oil to each

motor bearing. (This applies to motors with oil

tubes or cap plugs in motor end bells ONLY.)

• Combustion Air Blower Motor does NOT require

oiling.

Filters

NOTE: Dirty filters are the most common cause of inade-

quate heating or cooling performance.

• Inspect filters monthly

• Replace disposable type filters before they be-
come clogged.

• Use water and mild detergent to clean washable
type filters.

• Replace filters with same size and type

NOTE: Some filters are marked with an arrow to indicate

the proper direction of air flow through the filter. The arrow

MUST point in the direction of air flow. Refer to section on

filters in this manual.

Replacement

NOTE: The filter rack will normally be found outside the fur-

nace blower compartment, but alternate locations may be
somewhere in the return air duct, a remote filter rack at-

tached to the outside of the furnace, or a remote filter grille.

• Remote filter grilles and return air cabinets will
usually have a hinged door or removable panel to

access filter.

• Filter racks attached to the furnace will usually be
made so the filter simply slides out one side. Use

ONLY the same size filter.

CAUTION

Do NOT over oil or use 3 in 1oil, penetrating oil, WD40
or similar oils. Use of these may damage motors.

FurnaceInspection

NOTE: A properly adjusted gas furnace will NOT require
frequent cleaning. Inspect furnace regularly to ensure safe
and efficient operation. A brief monthly inspection that
does NOT require disassembly is recommended. Have fur-

nace inspected and cleaned (if required) by a qualified

service technician annually.

VentPipe

• Ensure vent pipe and combustion air intake are
clear and free of obstructions.

• Check vent pipe for tight joints, secure attachment
to furnace and sagging pipe.

• Horizontal sections of vent pipe MUST slope up-
ward, away from furnace, 1/4 inch per foot (6 mm

per 300mm).

ReturnAir Duct

• Check that return air ducts are sealed to furnace
casing and that duct is in good physical condition.

• Duct MUST terminate outside the space with NO

holes or inlets in furnace space.

Furnace Base

• The floor or furnace base MUST be in good physi o
cal condition.

I Condensing Gas Furnace Installation Instructions I

Furnace Interior

• Remove the front panel and use a flashlight to in-
spect the visible part of the heat exchanger, burn-
ers and spark igniter, or pilot.

• Remove the access panel on the outlet supply
duct so you can see the top of the heat exchanger.

Remove combustion air box cover and shine a

b right light into the heat exchanger sections where
the burners are and observe for any leaks of light
from the access panel in the supply duct. If leaks of
light are observed do NOT operate furnace, call a
qualified service technician.

• Check for loose soot and give particular attention
to deterioration from corrosion or other sources.

• If soot or deterioration is found inside furnace do

NOT operate furnace and call a qualified service

technician.

Carbon monoxide poisoning hazard.
If any leaks are observed or if soot or

deterioration is found inside furnace do NOT

operate furnace. Call a qualified service
technician.

Failure to do so can result in personal injury

and/or death.

Pilot Burners

• Periodically check pilot burner for flame character-
istics. Flame should be stable, blue, and envelop

the tip of the sensor.

Main Burners

• Allow the furnace to run approximately 10 minutes

then inspect the main burner flames.

• Contact a qualified service agency at once if an ab-
normal flame develops.

• Replace burners if extremely rusted, crushed, or if
burner ports have collapsed.

CondensateDisposal

NOTE: A condensate neutralizer cartridge, if used in the

drain line, will require some maintenance.

• Disassemble and clean cartridge prior to each

heating season, or if drain line become plugged.
Inspect the drain line and overflow line at least

monthly, if the condensate neutralizer cartridge
becomes plugged, the condensate will flow
through the overflow line. If this happens, clean
both cartridge and drain lines.

To clean, disconnect the drain line cartridge and
unscrew end cap from cartridge. Pour the neutrar-
izer out and thoroughly flush neutralizer and inside
of cartridge with water, Pour neutralizer back into
cartridge, adding neutralizer if cartridge is less

than 3/+full.
Reassemble and seal threaded connections with

silicone rubber (bathtub caulk) or pipe dope ap-
proved for plastic pipe. See repair parts sections in
the parts list to order replacement neutralizer.

Condensate is acidic, do NOT use for any pur-
pose.

B

I Installation Instructions

11. CleaningHeatExchangers

Condensin_l Gas Furnace I

Seconda HeatExchanger

Electrical shock, fire or explosion hazard.

Turn OFF electric power at disconnect and gas
supply at manual shutoff valve. Have qualified

service technician perform the following proce-
dures.

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

If filters are inadequate or NOT maintained, it may be nec-

essary to clean the exterior surface of the secondary heat

exchanger to obtain proper airflow. If the primary heat ex-
changer requires cleaning, itcan be completed without re-
moving or cleaning the secondary heat exchanger.

The ONLY time it should be necessary to disassemble and
clean the interior of both the primary and secondary heat

exchangers would be due to a sooting condition caused by
abnormal combustion. If heavy sooting condition is ob-
served, heat exchangers need replacement. Repair cause
of sooting.

PrimaryHeat Exchanger

Accessing

NOTE: The following parts and assemblies MUST be re-

moved before the heat exchanger can be cleaned.

1. Disconnect electric power.

2.

Disconnect gas supply line at union and at gas valve
and remove gas pipe from furnace. Disconnect elec-
trical leads at gas valve.

Remove screws from the perimeter of the combus-
tion box. Remove combustion box with care to avoid

damage.

4.

Remove four (4) screws that hold combustion blower
and remove combustion blower.

5. Remove screws around collector box and remove
collector box.

Accessing

NOTE: The following parts and assemblies MUST be re-
moved before the heat exchanger can be cleaned.

1. Disconnect electric power.

2. Remove the wiring quick connects on blower parti-
tion.

3. Remove the two retaining screws holding blower in
position on the slide rails.

4. Blower can now be removed by pulling assembly
from furnace. Support blower next to furnace to avoid
having to disconnect wiring.

ExteriorCleaning

1. Using a stiff bristle brush and a vacuum cleaner,
clean dirt and lint build-up from bottom side of secon-
dary heat exchanger. Brush strokes must be with the
fin surface to avoid damage to the fins. Use a fin
comb to straighten fins.

2. Inspect and clean blower wheel using brush and vac-
uum. Be careful NOT to dislodge balance weights
(clips) that may be on the blower wheel.

3. Reassemble in reverse order unless you are going to
clean the interior. If so, see next section.

CAUTION

Fins on secondary heat exchanger have sharp edges.

Wear gloves to prevent possible cuts.

Failure to do so can result in personal injury.

Accessing Interior of Secondary Heat Exchanger

NOTE: The following parts and assemblies MUST be re-

moved before the heat exchanger can be cleaned. These
steps assume you have already accessed the exterior of

the secondary heat exchanger as outlined above.

1. Remove screws holding combustion airblowerto the

front partition and remove combustion blower.

2. Remove screws holding collector box and remove
collector box.

Cleaning

1. Use a long flexible handle brush and vacuum cleaner
with long narrow attachment.

2.

Insert long handle brush into heat exchanger and

clean. If any large particles are observed, be careful

not to dislodge them and push them further into heat

exchanger.

3. Use long narrow vacuum attachment to clean any re-
maining particles.

4. Reassemble in reverse order,

Interior Cleaning

1. Using agarden hose, flush interior of secondary heat
exchanger from inlet side located behind the lower

part of the collector box. Flush until water is clear

2. Remove drain line from bottom of transition box lo-
cated in the blower compartment.

3. Remove two(2) screws holding transition box in

place and remove transition box.

4. Back flush transition assembly with garden hose,
Shake to loosen any particles and flush again until

water is clear.

I Condensing Gas Furnace

Installation Instructions

5. Inspect interior passages of secondary heat ex-
changer for heavy soot. If heavy soot is indicated, an

abnormal condition exists or has existed. Correct ab-
normal condition and see you distributor about re-

placement of heat exchangers.

6. Reassemble in reverse order.

CleaningBurners

1. Follow steps 1-3 in Accessing Primary Heat Ex-

changer.

2. Remove screws holding front cover of combustion
box and remove cover and gasket.

3. Remove three(3) screws holding manifold and re-

move manifold.

4.

Remove igniter assembly and sensor (if applicable)

from burners and carefully lay in bottom of combus-
tion box.

CAUTION

Igniter assembly is fragile. Extreme care must be taken
to protect igniter from damage.

,

Remove two(2) screws holding burner tray and re-
move burner assembly.

6.

Gently strike orifice end of burners on ablock of wood

to remove any dirt or lint build up in the tube.

7.

Use a brush to clean any visible soot or scale.

8.

Vacuum burners and combustion box.

Reassembly

NOTE: Reassemble all parts in reverse order as removed,

with the following instructions.

1. Replace any torn or defective insulation.

2. Replace all gaskets and parts that are broken or de-
teriorated.

3.

Test for gas leaks after reassembly. Use a soapy so-
lution on all joints. ALL leaks MUST be repaired im-

mediately.

4. Perform an operational check of the furnace.

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_ installation Instructions

12. GlossaryofTerms

Condensing Gas Furnace I

Cased cooling coil
A coil assembly which attaches to upflow furnaces ONLY.

A cased cooling coil is unable to support the weight of a
downflow furnace. See Coil box.

Category IV

A direct vent central furnace which operates with a positive
vent pressure and with a vent gas temperature less than

140 ° F. above its dewpoint.

Coil box
A sheet metal box designed to support the weight of a fur-

nace. A coil box requires that a coil be added to complete
the assembly.

Combustible Materials

As defined by the National Fuel Gas Code, "As pertaining

to materials adjacent to or in contact with heat producing
appliances, vent connectors, gas vents, chimneys, steam

and hot water pipes, and warm airducts, shall mean mate-

rials made of or surfaced with wood, compressed paper,
plant fibers, or other materials that are capable of being ig-

nited and burned. Such material shall be considered com-
bustible even though flame-proofed, fire retardant treated,

or plastered."

Combustion air
Air drawn in from indoors or outdoors to supply air for the

combustion process.

tion airand help exhaust combustion air. See Combustion

Air definition.

Gas Connector

The flexible gas hose which connects the gas supply to the
furnace. Gas con nector can NOT be used inside furnace or

be secured or supported by the furnace or ductwork.

Heat anticipator
A variable resistor insidea thermostat which generates a

small amount of heat. The purpose of the anticipator is to
reduce temperature swings. The anticipator must be set to
match the current output by the low voltage transformer.

Horizontal venting

Vent of a gas appliance where vent exits or terminates

through a side wall of a structure.

Manometer

A test gauge for measuring air pressure differentials in
airflows. Calibrated to show in inches of water column.

("w.c.).

Sweep elbows
Elbows used in venting which have a larger turning radius

than standard elbows. Can be 45° or 90° radii.Allow more

latitude in venting because vent runscanbe turnedwithout

the restrictionsnormally found in90 degree elbows.

A confined space is defined as an area with less than 50
Confined space

cubic feet(l.4m 3) per 1,000 BTUH input rating for all gas
appliances installed in the area.

Some structures have unusually tight construction, and
MUST have additional air brought in. See manual for in-

structions concerning unusually tight construction.

Fan assisted appliances
An appliance which uses a motorized fan to pull incombus-

Type FSP

A direct vent central furnace system in which the combus-
tion air connections, the flue gas connections, and the vent
air intake terminal may be specified by the furnace manu-

facturer to be supplied by the installer.

Unconfined space

An unconfined space is defined as an area having a mini-

mum volume of 50 cubic feet(1.4m 3) per 1,000 Btuh total
input rating for all gas appliances in area. Refer to Figure 9

for minimum area required.

I Condensing Gas Furnace

13. Anpendixof HelpfulInformation

Installation Instructions I

CanadianCodes

Applicable NaturalGasand PropaneCodes

National Standards;

Natural Gas Installation Code. CAN/CGA- B149.1-M91

(or current edition),

Propane Installation Code. CAN/CGA - B149.2-M91
(or current edition).

Applicable Electrical Codes

Canadian Electrical Code Part 1.CSA Standard C22.1 -
1990 (or current edition).

UnitedStatesCodes

ApplicableNatural GasandPropaneCodes

National Fuel Gas Code, ANSI Z223.1-1988 (or current

edition).

Applicable Electrical Codes

National Electrical Code

ANSI/NFPA No. 70-1990 (or current edition)

For a nominal charge, these code books can be ordered

from:

Canadian Gas Association
55 Scarsdale Road

Don Mills, Ontario M3B ZR3

Canadian Standards Association

178 Rexdale Boulevard

Rexdale, Ontario M9W IR3

For a nominal charge, these code books can be ordered

from:

American National Standards Institute

1430 Broadway

New York, NY 10018

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