International Comfort Product WFEU Series, WFEU060B048, WFEU040B036, WFEU080C060, WFEU100C060 Installation Instructions Manual
WFEU
ECM Blower Motor
80% Furnaces
Installation Instructions
SAFETY CONSIDERATIONS 2........................
INTRODUCTION 2..................................
CODES AND STANDARDS 4.......................
SAFETY 4......................................
GENERAL INSTALLATION 4......................
COMBUSTION AND VENTILATION AIR 4...........
DUCT SYSTEMS 4...............................
ACOUSTICAL LINING AND FIBROUS GLASS DUCT 5
GAS PIPING AND GAS PIPE PRESSURE TESTING 5...
ELECTRICAL CONNECTIONS 5...................
VENTING 5........................................
ELECTROSTATIC DISCHARGE
(ESD) PRECAUTIONS PROCEDURE 5...............
UPFLOW INSTALLATION 9.......................
DOWNFLOW INSTALLATION 10...................
HORIZONTAL INSTALLATION 11..................
AIR DUCTS 12...................................
GAS PIPING 15..................................
ELECTRICAL CONNECTIONS 18..................
115- V WIRING 18................................
J- BOX RELOCATION 18..........................
24- V WIRING 19.................................
ACCESSORIES 19................................
VENTING 21.......................................
MASONRY CHIMNEY REQUIREMENTS 21..........
APPLIANCE APPLICATION REQUIREMENTS 22.....
ADDITIONAL VENTING REQUIREMENTS 24........
SIDEWALL VENTING 24..........................
START- UP, ADJUSTMENT, AND SAFETY CHECK 26.....
START- UP PROCEDURES 26......................
ADJUSTMENTS 26...............................
CHECK SAFETY CONTROLS 28...................
SERVICE AND MAINTENANCE PROCEDURES 30.......
INTRODUCTION 31..............................
ELECTRICAL CONTROLS AND WIRING 31.........
CARE AND MAINTENANCE 32....................
CLEANING AND/OR REPLACING AIR FILTER 32....
BLOWER MOTOR AND WHEEL 32.................
CLEANING HEAT EXCHANGER 33.................
SEQUENCE OF OPERATION 34....................
FAULT CODE RECALL 35.........................
CLEAR FAULT MEMORY 35.......................
COMPONENT TEST 35...........................
WIRING DIAGRAMS 35...........................
TROUBLESHOOTING 35..........................
SINGLE- ST AG E
INDUCED- COMBUSTION
4- WAY MULTIPOISE FURNACE
PARTS REPLACEMENT INFORMATION GUIDE 38....
Approved for installations up to 2,000 feet (610 meters)
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from current edition
of NFPA 54/ANSI Z223.1E, with permission of National Fire
Protection Association, Quincy, MA 02269 and American Gas
Association, Washington DC 20001. This reprinted material is
not the complete and official position of the NFPA or ANSI on
the referenced subject, which is represented only by the standard
in its entirety.
441 01 7201 00 6/14/2019
SAFETY CONSIDERATIONS
!
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, serious injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use could cause carbon monoxide
poisoning, explosion, fire, electrical shock, or other
conditions which may cause personal injury or property
damage. Consult a qualified service agency, local gas
supplier, or your distributor or branch for information or
assistance. The qualified service agency must use only
factory- authorized and listed kits or accessories when
modifying this product.
!
CAUTION
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory- authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
include in literature and attached to the unit. Consult local
building codes, the current editions of the current edition of
National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the
current edition of National Electrical Code (NEC) NFPA 70.
Recognize safety information. This is the safety-alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING,and
CAUTION. These words are used with the safety- alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is
used to identify unsafe practices which may result in minor
personal injury or product and property damage. NOTE is used
to highlight suggestions which will result in enhanced
installation, reliability, or operation.
!
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing furnaces.
2
Specifi cations are subject to change w ithout noti ce.
.
1. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
2. Install this furnace only in a location and position as
specified in the “Location” section of these instructions.
3. Provide adequate combustion and ventilation air to the
furnace space as specified in “Air for Combustion and
Ventilation” section.
4. Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system only, as
specified in the “Venting” section of these instructions.
5. Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections, as specified
in the “Gas Piping” section.
6. Always install furnace to operate within the furnace’s
intended temperature- rise range with a duct system which
has an external static pressure within the allowable range,
as specified in the “Start- Up, Adjustments, and Safety
Check” section. See furnace rating plate.
7. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space
containing the furnace, the return air shall also be handled
by duct(s) sealed to the furnace casing and terminating
outside the space containing the furnace. See “Air Ducts”
section.
8. A gas- fired furnace for installation in a residential garage
must be installed as specified in the warning box in the
“Location” section (see Fig. 5).
9. The furnace is not permitted to be used for heating of
buildings under construction.
10. These Multipoise Gas- Fired Furnaces are CSA (formerly
A.G.A. and C.G.A). design- certified for use with natural
(see furnace rating plate) and for installation in alcoves,
attics, basements, closets, utility rooms, crawlspaces, and
garages. The furnace is factory- shipped for use with
natural gas.
11. See Fig. 2 for required clearances to combustible
construction.
12. Maintain a 1- in. (25 mm) clearance from combustible
materials to supply air ductwork for a distance of 36
inches (914 mm) horizontally from the furnace. See
current edition of NFPA 90B or local code for further
requirements.
13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than
wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s
approved coil assembly or a manufacturer’s coil casing
box is used. See Fig. 2 for clearance to combustible construction.
INTRODUCTION
This 4- way multipoise Category I fan- assisted furnace is CSA
design- certified. A Category I fan- assisted furnace is an
appliance equipped with an integral mechanical means to either
draw or force products of combustion through the combustion
chamber and/or heat exchanger. The furnace is factory-shipped
for use with natural gas.
This furnace is not approved for installation in mobile homes,
recreational vehicles, or outdoors. The furnace is not permitted to
be used for heating of buildings under construction. This furnace
is designed for minimum continuous return- air temperature of
60_F(16_C)db or intermittent operation down to 55_F(13_C)
db such as when used with a night setback thermostat. Return- air
temperature must not exceed 80_F(27_C) db. Failure to follow
these return- air temperature limits may affect reliability of heat
exchangers, motors, and controls. (See Fig. 3).
For accessory installation details, refer to the applicable
instruction literature.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
441 01 7201 00
SD5507- 4 ULN 80 REV. B
V
VENT
FURNACE SIZE
WFEU040B036
WFEU060B048
WFEU080C060
WFEU100C060
A190257
Fig. 1 - Dimensional Drawing
Table1–Dimensions
A B C D
CABINET
WIDTH
IN. (MM)
17- 1/2 (445) 15- 7/8 (403) 11- 9/16 (294) 16 (406) 4 (102) 118 (54)
17- 1/2 (445) 15- 7/8 (403) 11- 9/16 (294) 16 (406) 4 (102) 126 (57)
21 (533) 19- 3/8 (492) 13 - 5/16 (338) 19- 1/2 (495) 4 (102) 140 (64)
21 (533) 19- 3/8 (492) 13 - 5/16 (338) 19- 1/2 (495) 4 (102) 150 (68)
OUTLET WIDTH
IN. (MM)
Specifi cations are subject to change w ithout noti ce.
TOP FLUE
COLLAR ONLY
IN. (MM)
BOTTOM WIDTH
IN. (MM)
ENT
CONNECTION
SIZE*
IN. (MM)
SHIP WT
(LB / KG)
NOTE: ALL DIMENSIONS IN INCH (MM) U.S. ECCN: Not Subject to Regulation (N.S.R.)
3441 01 7201 00
Fig. 2 - Clearances to Combustibles
A02055
Fig. 3 - Return Air Temperature
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these instructions. The installation must comply with regulations
of the serving gas supplier, local building, heating, plumbing, and
other codes. In absence of local codes, the installation must
comply with the national codes listed below and all authorities
having jurisdiction.
A180239
In the United States, follow all codes and standards for the
following:
Safety
S USA: Current edition of National Fuel Gas Code
(NFGC) NFPA 54/ANSI Z223.1 and the Installation
Standards, Warm Air Heating and Air Conditioning
Systems ANSI/NFPA 90B
General
Installation
S Current edition of the NFGC and the NFPA 90B. For
copies, contact the National Fire Protection Association
Inc., Batterymarch Park, Quincy, MA 02269;
(www.NFPA.org) or for only the NFGC, contact the
American Gas Association, 400 N. Capitol Street,
N.W., Washington, DC 20001 (www.AGA.org).
Combustion and Ventilation
Air
S Current edition of NFGC NFPA54/ANSI Z223.1 Sec-
tion 9.3, Air for Combustion and Ventilation.
Duct
Systems
S Air Conditioning Contractors Association (ACCA)
Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American
Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2005 Fundamentals Hand-
4
Specifi cations are subject to change w ithout noti ce.
441 01 7201 00
book Chapter 35 or 2004 HVAC Systems and Equipment Handbook Chapters 9 and 16.
Acoustical Lining and Fibrous Glass
Duct
S Current edition of SMACNA and NFPA 90B as tested
by UL Standard 181 for Class I Rigid Air Ducts
Gas Piping and Gas Pipe Pressure T
esting
S Current edition of NFGC NFPA54/ANSI Z223.1;
chapters 5, 6, 7, and 8 and National Plumbing Codes.
Electrical
Connections
S Current edition of National Electrical Code (NEC) NF-
PA 70.
V
enting
S Current edition of NFGC NFPA 54 / ANSI Z223.1;
Chapters 12 and 13.
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
!
CAUTION
FURNACE RELIABILITY HAZARD
Improper installation or service of furnace may cause
premature furnace component failure.
Electrostatic discharge can affect electronic components.
Follow the Electrostatic Discharge Precautions Procedure
listed below during furnace installation and servicing to
protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects
maybe required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the
furnace chassis which is close to the control. Firmly touch
the clean, unpainted, metal surface of the furnace chassis
which is close to the control. Tools held in a person’s hand
during grounding will be satisfactorily discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example;
DO NOT move or shuffle your feet, do not touch
ungrounded objects, etc.).
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch a clean, unpainted
metal surface of the furnace again before touching control
or wires.
5. Use this procedure for installed and uninstalled
(ungrounded) furnaces.
6. Before removing a new control from its container,
discharge your body’s electrostatic charge to ground to
protect the control from damage. If the control is to be
installed in a furnace, follow items 1 through 4 before
bringing the control or yourself in contact with the
furnace. Put all used and new controls into containers
before touching ungrounded objects.
7. An ESD service kit (available from commercial sources)
mayalsobeusedtopreventESDdamage.
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
A02097
Fig. 4 - Multipoise Orientations
Specifi cations are subject to change w ithout noti ce.
5441 01 7201 00
LOCATION
GENERAL
This multipoise furnace is shipped in packaged configuration.
Some assembly and modifications are required when used in any
of the four applications shown in Fig. 4.
This furnace must:
S be installed so the electrical components are protected
from water.
S not be installed directly on any combustible material
other than wood flooring for upflow applications.
Downflow installations require use of a factory- approved floor base or coil assembly when installed on
combustible materials or wood flooring (refer to
SAFETY CONSIDERATIONS).
S be located as close to the chimney or vent and attached
to an air distribution system. Refer to Air Ducts section.
S be provided ample space for servicing and cleaning.
Always comply with minimum fire protection clearances shown on the furnace clearance to combustible
label.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death, and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
S Commercial buildings
S Buildings with indoor pools
S Laundry rooms
S Hobby or craft rooms, and
S Chemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
S Permanent wave solutions
S Chlorinated waxes and cleaners
S Chlorine based swimming pool chemicals
S Water softening chemicals
S De- icing salts or chemicals
S Carbon tetrachloride
S Halogen type refrigerants
S Cleaning solvents (such as perchloroethylene)
S Printing inks, paint removers, varnishes, etc.
S Hydrochloric acid
S Cements and glues
S Antistatic fabric softeners for clothes dryers
S Masonry acid washing materials
All fuel- burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return- air duct to
prevent pulling air from the burner area and from draft safeguard
opening.
18-IN. (457.2 mm)
MINIMUM TO BURNERS
A93044
Fig. 5 - Installation in a Garage
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18
inches above the floor. (See Fig. 5) The furnace must be
located or protected to avoid damage by vehicles. When the
furnace is installed in a public garage, airplane hangar, or
other building having a hazardous atmosphere, the furnace
must be installed in accordance with the NFGC.
!
CAUTION
PERSONAL INJURY AND/OR PROPERTY
DAMAGE
Improper use or installation of this furnace may cause
premature furnace component failure.
This furnace is not permitted to be used for heating of
buildings under construction.
6
Specifi cations are subject to change w ithout noti ce.
441 01 7201 00
Table 2 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
TWO O PENINGS OR
VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH)
(550 SQ. MM/KW)
and Duct
Sq. In (mm)
Round Duct
In. (mm) Dia.
FURNACE
INPUT
(BTUH)*
40,000
60,000
80,000
100,000
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH)
(1,100 SQ. MM/KW)
Free Area of Open-
ing and Duct
Sq. In (Sq. mm)
20 (12904) 5 (127) 14 (8696) 5 (127) 10 (6452) 4 (102)
30 (19355) 6 (152) 20 (13043) 5 (127) 15 (9678) 5 (127)
40 (25807) 7 (178) 27 (17391) 6 (152) 20 (12904) 5 (127)
50 (32258) 8 (203) 34 (21739) 7 (178) 25 (16130) 6 (152)
Round Duct
In. (mm)
Dia
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH)
(734 SQ. MM/KW)
Free Area of Open-
ing and Duct
Sq. In (Sq. mm)
Round
Duct
In. (mm)
Dia
Free Area of Opening
* Not all input sizes are available.
EXAMPLE: Determining Free Area
FURNACE WATER HEATER TOTAL INPUT
100,000 + 30,000 = (130,000 divided by 4,000) =
32.5 Sq. In. for each two Vertical Ducts or
Openings
60,000 + 40,000 = (100,000 divided by 3,000) = 33.3 Sq. In. for each Single Duct or Opening
80,000 + 30,000 = (110,000 divided by 2,000) = 55.0 Sq. In. for each two Horizontal Ducts
Table 3 – Minimum Space volumes for 100% combustion, Ventilation, and Dilution from Indoors
OTHER THAN FAN- ASSISTED TOTAL
ACH*
0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300
0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960
0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950
0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600
0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900
0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800
0.00 NP NP NP NP NP NP NP NP
*Air Changes/Hour
(1,000’S BTUH GAS INPUT RATE
30 40 50 44 66 88 110 132
SpaceVolume(ft.3)
FAN- ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return- air ducts to the back of the furnace. (See Fig. 6)
A02054
Fig. 6 - Prohibit Installation on Back
!
CAUTION
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
LOCATION RELATIVE TO COOLING EQUIPMENT
The cooling coil must be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the
furnace. If the dampers are manually operated, they must be
equipped with means to prevent operation of either unit unless
the damper is in the full- heat or full- cool position.
AIR FOR COMBUSTION AND
VENTILATION
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
S U.S. installations: Section 9.3 of the current edition of
NFGC NFPA54/ANSI Z223.1, Air for Combustion
and Ventilation, and applicable provisions of the local
building codes.
Specifi cations are subject to change w ithout noti ce.
7441 01 7201 00
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make- up air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to Carbon
Monoxide Poisoning Hazard warning in venting section of
these instructions to determine if an adequate amount of
make- up air is available.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume
of at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
S Spaces having less than 50 cubic feet per 1,000 Btuh
require the OUTDOOR COMBUSTION AIR
METHOD.
S Spaces having at least 50 cubic feet per 1,000 Btuh
may use the INDOOR COMBUSTION AIR,
STANDARD or KNOWN AIR INFILTRATION
METHOD.
Outdoor Combustion Air
1. Provide the space with sufficient air for proper
combustion, ventilation, and dilution of flue gases using
permanent horizontal or vertical duct(s) or opening(s)
directly communicating with the outdoors or spaces that
freely communicate with the outdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air opening, to the outdoors.
a. Oneopening MU ST commence within 12- in. (300 mm)
of the ceiling and the second opening MUST commence
within 12- in. (300 mm) of the floor.
b. Size openings and ducts per Fig. 7 and Table 2.
DUCTS
TO
O UTDOORS
Method
1 SQ IN.
PER 4000
BTUH*
c. TWO HORIZONTAL DUCTS require 1 square inch of
free area per 2,000 Btuh (1,100 mm
2
/kW) of combined
input for all gas appliances in the space per Fig. 7 and
Tab l e 2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
square inch of free area per 4,000 Btuh (550 mm
2
/kW)
for combined input of all gas appliances in the space per
Fig. 7 and Table 2.
3. ONE OUTDOOR OPENING requires:
a. 1 square inch of free area per 3,000 Btuh (734 mm
2
/kW)
for combined input of all gas appliances in the space per
Tab l e 2 and
b. Not less than the sum of the areas of all vent connectors
in the space.
The opening shall commence within 12” (300 mm) of the ceiling.
Appliances in the space shall have clearances of at least 1” (25
mm) from the sides and back and 6” (150 mm) from the front.
The opening shall directly communicate with the outdoors or
shall communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely communicate with
the outdoors.
Indoor Combustion Air - NFPA & AGA
Standard and Known- Air- Infiltration Rate Methods
Indoor air is permitted for combustion, ventilation, and dilution,
if the Standard or Known- Air-Infiltration Method is used.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in death and/or
personal injury.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
CIRCULATING AIR
DUCTS
VENT THROUGH ROOF
(305mm)
12 ″ MAX
1 SQ IN.
PER 2000
BTUH*
DUCT S
TO
OUTDOORS
1 SQ IN.
PER 2000
BTUH*
(305mm)
*Minimum dimensions of 3 in. (76 mm).
NOTE: Use any of the following combinations of openings:
A&B, C &D, D&E, F&G
B
C IRCULA TING
A
OF COMB USTION AIR
12 ″ MAX
CIRCULA TING AIR DUCT S
CLEARANCE IN FRONT
D
VENT
THR OUGH
R OOF
AIR DUCTS
(76mm)
AT LEAST 3 IN .
OPENINGS SHALL BE
C
DUCT
TO
OUTDOORS
E
12 ″ MAX
(305mm)
F
1 SQ IN .
BTUH*
1 SQ IN .
BTUH*
G
1 SQ IN.
PER 4000
BTUH*
12 ″
MAX
PER
4000
OUTDOORS
PER
4000
12 ″
MAX
(305mm)
(305mm)
A03174
Fig. 7 - Air for Combustion, Ventilation, and Dilution from
Outdoors
8
Specifi cations are subject to change w ithout noti ce.
12" MAX
(305mm)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
INTERIOR
HEATED
SPACE
CIRCULATING AIR DUCTS
*Minimum openin g size is 100 in.2with minimum dimensions of 3 in. (76 mm).
*Minimum of 3 in. (76 mm), when type - B1 vent is used.
UNCONFINED
SPACE
6" MIN
(FRONT)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OPENINGS SHALL BE AT LEAST 3 IN.
OR WALL
CLEARANCE IN FRONT OF COMBUSTION AIR
(152mm)
Ü
12" MA X
(305mm)
A03175
Fig. 8 - Air for Combustion, Ventilation, and Dilution from
Indoors
441 01 7201 00
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40
air changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 3 or Equations 1 and 2.
Determine the minimum required volume for each appliance in
the space and add the volumes together to get the total minimum
required volume for the space.
Table 3 - Minimum Space Volumes were determined by using
the following equations from the current edition of National Fuel
Gas Code ANSI Z223.1/NFPA 54, 9.3.2.2:
1. For other than fan - assisted appliances, such as a draft
hood- equipped water heater:
3
Volume
2. For fan- assisted appliances such as this furnace:
Volume
If:
Iother = combined input of all other than fan-assisted appliances
in Btuh/hr
Ifan = combined input of all fan- assisted appliances in Btuh/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closeable doors between rooms.
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1 in.
mm
in the space, but not less than 100 in.
opening shallcommencewithin 12” (300 mm) of the ceiling and the second opening shall commence within 12”
(300 mm) of the floor. The minimum dimension of air
openings shall be at least 3 in. (80 mm). (See Fig. 8)
c. Combining space on different floor levels. The volumes
of spaces on different floor levels shall be considered as
communicating spaces if connected by one or more permanent openings in doors or floors having free area of
at least 2 in.
rating of all gas appliances.
2. An attic or crawlspace may be considered a space that
freely communicates with the outdoors provided there are
adequate permanent ventilation openings directly to outdoors having free area of at least 1- in.
input rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases.
However, in buildings with unusually tight construction,
Other
Fan
2
/kW) of the total input rating of all gas appliances
21ft
=
ACH
3
15ft
=
ACH
2
/1,000 Btuh (4,400 mm2/kW) of total input
I
other
1000 Btu/hr
I
fan
1000 Btu/hr
2
/1,000 Btuh (2,000
2
(0.06 m2). One
2
/4,000 Btuh of total
A04002
A004003
additional air MUST be provided using the methods describedintheOutdoor Combustion Air Method section.
Unusually tight construction is defined as construction with:
a. Wallsand ceilingsexposed to the outdoors have a contin-
uous, sealed vapor barrier. Openings are gasketed or
sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include
joints around window and door frames, between sole
plates and floors, between wall- ceiling joints, between
wall panels, at penetrations for plumbing, electrical and
gas lines, etc.
Combination of Indoor and Outdoor
1. Indoor openings shall comply with the Indoor
Combustion Air Method below and,
2. Outdoor openings shall be located as required in the
Outdoor Combustion Air Method mentioned previously
and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air
Method below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above.The minimum
dimension of air openings shall be not less than 3 in. (80
mm).
Air
INSTALLATION
UPFLOW INSTALLATION
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return- air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove two screws holding bottom filler panel. (See Fig. 9)
Bottom
Closure Panel
Bottom Filler Panel
A10273
Fig. 9 - Removing Bottom Closure Panel
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return- air opening. This panel MUST be in place when
only side return air is used.
NOTE: Side return- air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return- air
openings in DOWNFLOW configuration.
Specifi cations are subject to change w ithout noti ce.
9441 01 7201 00
Leveling Legs (If Desir
ed)
In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 10) Install field-supplied, 5/16 x 1- 1/2 in. (8 x 38
mm) (max) corrosion-resistant machine bolts, washers and nuts.
NOTE: Bottom closure must be used when leveling legs are
used. It may be necessary to remove and reinstall bottom closure
panel to install leveling legs. To remove bottom closure panel, see
Item 1. in Bottom Return Air Inlet section.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in
each bottom corner of furnace. (See Fig. 10)
5/
16
(8mm)
(8mm)
5/
16
1 3/ 4
(44mm)
3
/ 4
1
(44mm)
(8mm)
5
/ 16
(8mm)
5/
16
1
(44mm)
3/
4
1 3/ 4
(44mm)
DOWNFLOW INSTALLA
TION
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 3
accessories are used:
S Downflow combustible floor subbase
S Manufacturer’s approved Cased Coil or Coil Casing
1. Determine application being installed from Table 4.
2. Construct hole in floor per Table 4 and Fig. 11.
3. Construct plenum to dimensions specified in Table 4 and
Fig. 11.
4. If downflow subbase is used, install as shown in Fig. 12. If
Coil or Coil Casing, install as shown in Fig. 13.
NOTE: It is required that the perforated supply- air duct flanges
be completely folded over or removed from furnace when
installing the furnace on a factory- supplied cased coil or coil box.
To remove the supply-air duct flange, use wide duct pliers or
hand seamers to bend flange back and forth until it breaks off. Be
careful of sharp edges. (See Fig. 14)
Bottom Return Air
These furnaces are shipped with bottom closure panel installed in
bottom return- air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove two screws holding bottom filler panel. (See Fig. 9)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws
Inlet
A89014
Fig. 10 - Leveling Legs
2. For each leg, install nut on bolt and then install bolt and
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install
flat washer if desired.)
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
A
PLENUM
OPENING
B
OPENING
D
FLOOR
C
Fig. 11 - Floor and Plenum Opening Dimensions
A96283
10
Specifi cations are subject to change w ithout noti ce.
441 01 7201 00
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
FLOORING
FURNACE
APPROVED
COIL ASSEMBLY
OR
COIL BOX
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
Fig. 12 - Furnace, Plenum, and Subbase Installed
on a Combustible Floor
Table 4 – Opening Dimensions - In. (mm)
FURNACE
CASING
WIDTH
17–1/2
(445)
21
(533)
Upflow Applications on Combustible or Noncombustible Floor-
Downflow Applications on Noncombustible Flooring
Downflow Applications on Combustible Flooring
Downflow Applications on Combustible Flooring with Cased
Upflow Applications on Combustible or Noncombustible Floor-
Downflow Applications on Noncombustible Flooring
Downflow Applications on Combustible Flooring
Downflow Applications on Combustible Flooring with Cased
APPLICATION
ing (subbase not required)
(subbase not required)
(subbase required)
Coil (subbase not required)
ing (subbase not required)
(subbase not required)
(subbase required)
Coil (subbase not required)
A96285
SHEET METAL
PLENUM
FLOOR
OPENING
Fig. 13 - Furnace, Plenum, and Coil Assembly or
Coil Box Installed on a Combustible Floor
PLENUM OPENING FLOOR OPENING
A B C D
16
(406)
15- 7/8
(403)
15- 1/8
(384)
15- 1/2
(394)
19- 1/2
(495)
19- 3/8
(492)
18- 5/8
(473)
19
(483)
21- 5/8
(549)
19
(483)
19
(483)
19
(483)
21- 5/8
(549)
19
(483)
19
(483)
19
(483)
16- 5/8
(422)
16- 1/2
(419)
16- 3/4
(425)
16- 1/2
(419)
20- 1/8
(511)
20
(508)
20- 1/4
(514)
20
(508)
22- 1/4
(565)
19- 5/8
(498)
20- 5/8
(600)
(508)
22- 1/4
(565)
19- 5/8
(498)
20- 5/8
(600)
(508)
A08556
20
20
HORIZONTAL INSTALLATION
!
WARNING
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return- air ducts to the back of the furnace.
The furnace can be installed horizontally in an attic or crawl space
on either the left-hand (LH) or right- hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a
non- combustible platform, blocks, bricks or pad.
Specifi cations are subject to change w ithout noti ce.
Suspended Furnace
Support
The furnace may be supported under each end with threaded rod,
angle iron or metal plumber’s strap as shown. (See Fig. 15 and
16) Secure angle iron to bottom of furnace as shown.
Heavy-gauge sheet metal straps (plumber’s straps) may be used
to suspend the furnace from each bottom corner. To prevent
screws from pulling out, use 2 #8 x 3/4- in. (19 mm) screws into
the side and 2 #8 x 3/4- in. (19 mm) screws in the bottom of the
furnace casing for each strap. (See Fig. 15 and 16) If the screws
are attached to ONLY the furnace sides and not the bottom, the
straps must be vertical against the furnace sides and not pull away
from the furnace sides, so that the strap attachment screws are not
in tension (are loaded in shear) for reliable support.
Platform Furnace
Support
Construct working platform at location where all required furnace
clearances are met. (See Fig. 2 and 17) For furnaces with 1- in.
(25 mm) clearance requirement on side, set furnace on
noncombustible blocks, bricks or angle iron. For crawl space
11441 01 7201 00
installations, if the furnace is not suspended from the floor joists,
the ground underneath furnace must be level and the furnace set
on blocks or bricks.
Roll- Out Pr
Provide a minimum 17- 3/4 in. x 22 in. (451 mm x 559 mm)
piece of sheet metal for flame roll-out protection in front of
burner area for furnaces closer than 12 inches (305 mm) above
the combustible deck or suspended furnaces closer than 12 inches
(305 mm) to joists. The sheet metal MUST extend underneath the
furnace casing by 1 in. (25 mm) with the door removed.
The bottom closure panel on furnaces of widths 17- 1/2 in. (445
mm) and larger may be used for flame roll- out protection when
bottom of furnace is used for return air connection. See Fig. 17
for proper orientation of roll- out shield.
Bottom Return Air
These furnaces are shipped with bottom closure panel installed in
bottom return- air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove two screws holding bot-
2. Rotate bottom filler panel downward to release holding
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws. Side Return Air
Side Return Air
These furnaces are shipped with bottom closure panel installed in
bottom return- air opening. This panel MUST be in place when
side return air inlet(s) is used without a bottom return air inlet.
FILTER
CARBON MONOXIDE AND POISONING
HAZARD
Failure to follow this warning could result in personal
injury, or death.
Never operate a furnace without a filter or with filter access
door removed.
There are no provisions for an internal filter rack in these
furnaces.
A field- supplied accessory external filter is required.
Refer to the instructions supplied with the external filter rack for
assembly and installation options.
AIR
General Requir
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA)
or American Society of Heating, Refrigerating and Air
Conditioning Engineers (ASHRAE) or consult The Air Systems
Design Guidelines reference tables available from your local
distributor. The duct system should be sized to handle the
required system design CFM at the design external static pressure.
otection
Inlet
tom filler panel. (See Fig. 9)
tabs.
Inlet
Inlet
ARRANGEMENT
!
WARNING
DUCTS
ements
The furnace airflow rates are provided in Table 5 - AIR
DELIVERY- CFM (with filter).
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by duct(s) sealed to
the furnace casing and terminating outside the space containing
the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply- and return- duct connections to furnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration. Ductwork
passing through unconditioned space should be insulated and
sealed to enhance system performance. When air conditioning is
used, a vapor barrier is recommended.
Maintain a 1- in. (25 mm) clearance from combustible materials
to supply air ductwork for a distance of 36 in. (914 mm)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.
Ductwork Acoustical Tr
NOTE: Metal duct systems that do not have a 90 degree elbow
and 10 ft. (3 M) of main duct to the first branch take- off may
require internal acoustical lining. As an alternative, fibrous
ductwork may be used if constructed and installed in accordance
with the latest edition of SMACNA construction standard on
fibrous glass ducts. Both acoustical lining and fibrous ductwork
shall comply with NFPA 90B as tested by UL Standard 181 for
Class 1 Rigid air ducts.
Supply Air
For a furnace not equipped with a cooling coil, the outlet duct
shall be provided with a removable access panel. This opening
shall be accessible when the furnace is installed and shall be of
such a size that the heat exchanger can be viewed for possible
openings using light assistance or a probe can be inserted for
sampling the airstream. The cover attachment shall prevent leaks.
Upflow and Horizontal
Connect supply- air duct to flanges on furnace supply- air outlet.
Bend flange upward to 90_ with wide duct pliers. (See Fig. 14)
The supply- air duct must be connected to ONLY the furnace
supply- outlet-air duct flanges or air conditioning coil casing
(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All accessories
MUST be connected to duct external to furnace main casing.
NOTE: For horizontal applications, the top- most flange may be
bent past 90 degrees to allow the evaporator coil to hang on the
flange temporarily while the remaining attachment and sealing of
the coil are performed.
Downflow
Connect supply- air duct to supply-air outlet on furnace. Bend
flange inward past 90_ with wide duct pliers. (See Fig. 14) The
supply- air duct must be connected to ONLY the furnace supply
outlet or air conditioning coil casing (when used). When installed
on combustible material, supply- air duct must be connected to
ONLY the factory- approved accessory subbase or a factoryapproved air conditioning coil casing. DO NOT cut main furnace
casing to attach supply side air duct, humidifier, or other
accessories. All accessories MUST be connected to duct external
to furnace casing.
Connections
Furnaces
eatment
Furnaces
12
Specifi cations are subject to change w ithout noti ce.
441 01 7201 00
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