iSi North America AMV8, ADV8 User Manual

AMV8/ADV8

GAS

-S

TAGE

FIRED WARM AIR FURNACE

INSTALLATION INSTRUCTIONS

Installer: Affix all manuals adjacent to the unit.

These furnaces comply with requirements embodied in the American National Standard / National Standard of Canada ANSI Z21.47·CSA-2.3 Gas Fired Central Furnaces.

(CA TEGORY 1)

C US

RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.

ATTENTION INSTALLING PERSONNEL

As a professional installer you have an obligation to know the product better than the customer. This includes all

safety precautions and related items.

Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all

safety warnings. Often during installation or repair it is possible to place yourself in a position which is more

hazardous than when the unit is in operation.

Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a

customer in its safe use.

Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good

safety practices...follow them.

The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if

there is a direct conflict between existing practices and the content of this manual, the precautions listed here take

precedence.

*NOTE: Please contact your distributor or our

website for the applicable product data book

referred to in this manual.

IO-316

is a trademark of Maytag Corporation and is used under

www.amana-hac.com

6/06

I. WARNINGS....................................................................................................................................................................... 4

Table of Contents

O THE OWNER ............................................................................................................................................................. 4

TO THE INSTALLER .......................................................................................................................................................... 4

TRANSPORT A TION DAMAGE .................................................................................................................................................. 4

II. SAFETY ........................................................................................................................................................................... 4

ADDITIONAL SAFETY CONSIDERATIONS ................................................................................................................................. 5

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ................................................................................................................. 5

III. PRODUCT APPLICA TION............................................................................................................................................... 5

IV . LOCA TION REQUIREMENTS AND CONSIDERA TIONS.................................................................................................. 6

ENERAL ....................................................................................................................................................................... 6

CLEARANCES AND ACCESSIBILITY ........................................................................................................................................ 7

HORIZONTAL INSTALLATION (AMV MODELS ONLY) ................................................................................................................. 7

FURNACE SUSPENSION ..................................................................................................................................................... 7

EXISTING FURNACE REMOVAL............................................................................................................................................. 8

THERMOST AT LOCATION ..................................................................................................................................................... 8

V . COMBUSTION AND VENTILATION AIR REQUIREMENTS.............................................................................................. 8

VI. CA TEGORY I VENTING (VERTICAL VENTING).............................................................................................................11

VII. EXTERIOR MASONRY CHIMNEYS .............................................................................................................................11

CHECKLIST SUMMARY ..................................................................................................................................................... 12

CHECK 1 - PROPER CHIMNEY TERMINATION........................................................................................................................ 12

CHECK 2 - ANY SOLID OR LIQUID FUEL APPLIANCES VENTED INTO THIS CHIMNEY CHANNEL .......................................................... 13

CHECK 3 - CHIMNEY CROWN CONDITION........................................................................................................................... 13

CHECK 4 - DEBRIS IN CLEANOUT ..................................................................................................................................... 13

CHECK 5 - LINER CONDITION. ......................................................................................................................................... 13

CHECK 6 - DILUTION AIR............................................................................................................................................... 14

CHECK 7 - COMPLETE THE INSTALLATION............................................................................................................................ 14

FIX 1 - LINER TERMINA TION ............................................................................................................................................. 14

FIX 2 -CHANGE VENTING ARRANGEMENTS ............................................................................................................................ 14

FIX 3 - REBUILD THE CROWN .......................................................................................................................................... 14

FIX 4 - RELINING .......................................................................................................................................................... 14

VIII. ELECTRICAL CONNECTIONS.................................................................................................................................... 15

WIRING HARNESS ......................................................................................................................................................... 15

115 VOLT LINE CONNECTIONS ........................................................................................................................................ 15

JUNCTION BOX RELOCATION............................................................................................................................................ 15

24 VOLT THERMOSTAT WIRING ......................................................................................................................................... 16

SETTING THE HEAT ANTICIPA T OR ....................................................................................................................................... 17

SINGLE-STAGE THERMOSTAT APPLICATION........................................................................................................................... 17

24 VOLT DEHUMIDISTAT WIRING ....................................................................................................................................... 17

FOSSIL FUEL APPLICATIONS ............................................................................................................................................ 17

115 VOLT LINE CONNECTION OF ACCESSORIES (HUMIDIFIER AND ELECTRONIC AIR CLEANER) .................................................. 18

24 VAC HUM ................................................................................................................................................................ 18

IX. GAS SUPPLY AND PIPING.......................................................................................................................................... 18

GENERAL ..................................................................................................................................................................... 18

HIGH ALTITUDE DERATE .................................................................................................................................................. 18

PROPAN E GAS CONVERSION ............................................................................................................................................ 20

GAS PIPING CONNECTIONS ............................................................................................................................................. 20

GENERAL ..................................................................................................................................................................... 20

UPFLOW INSTALLA TIONS .................................................................................................................................................. 21

COUNTERFLOW INSTALLATIONS ......................................................................................................................................... 21

GAS PIPING CHECKS ..................................................................................................................................................... 21

PROPANE GAS TANKS AND PIPING .................................................................................................................................... 21

PROPAN E GAS PIPING CHARTS ......................................................................................................................................... 22

X. CIRCULATING AIR AND FILTERS................................................................................................................................. 22

DUCTWORK - AIR FLOW................................................................................................................................................. 22

FILTERS - READ THIS SECTION BEFORE INSTALLING THE RETURN AIR DUCTWORK ................................................................... 22

UPRIGHT INSTALLATIONS .................................................................................................................................................. 22

CIRCULATION AIR FILTERS .............................................................................................................................................. 22

HORIZONT A L INSTALLATIONS ............................................................................................................................................. 23

XI. SEQUENCE OF OPERA TION........................................................................................................................................ 23

WARNING

F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LO SS OF LIF E.

–

O NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUID S IN THE VI CINI TY OF TH IS OR ANY OT HER AP PLIA NCE. –

WHAT TO DO IF YOU SMELL GAS

•

O NOT TRY TO LIGHT ANY AP PLIA NCE.

•

O NOT TOUCH ANY EL ECTR ICAL SW ITCH ; DO N OT USE ANY

PHONE IN YOUR BUILDING.

•

MMEDIATELY CALL YOUR GAS SUPPLIER FR OM A NEIGHBOR’S

PHONE.

OLLOW THE GAS SUPPLI ER’S INSTRUCTIONS.

•

F YOU CANNOT REACH YOUR GAS SUPPLI ER, CALL THE FIRE

DEPARTMENT. –

NSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,

SERVICE AGENCY OR THE GAS SUPPLIER.

Table of Contents

(INTEGRA TED IGNITION CONTROL) ................................................................................................................................. 23

NORMAL HEATING SEQUENCE ........................................................................................................................................... 23

NORMAL COOLING SEQUENCE - INTEGRATED IGNITION CONTROL ............................................................................................ 23

CONST ANT FAN .............................................................................................................................................................. 23

XII. ST ART-UP PROCEDURE AND ADJUSTMENT ............................................................................................................ 24

FURNACE OPERATION ...................................................................................................................................................... 24

FURNACE START-UP ....................................................................................................................................................... 24

FURNACE SHUTDOWN .................................................................................................................................................... 24

GAS SUPPLY PRESSURE MEASUREMENT ............................................................................................................................ 24

GAS MANIFOLD PRESSURE MEASUREMENT AND ADJUSTMENT ................................................................................................ 25

GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) ......................................................................................................... 25

TEMPERATURE RISE ........................................................................................................................................................ 26

CIRCULATOR BLOWER SPEED ADJUSTMENT........................................................................................................................ 26

ADJUST BLOWER HEAT OFF DELAY ................................................................................................................................... 27

CIRCULATOR BLOWER FAN TIMING ADJUSTMENT ................................................................................................................. 28

XIII. OPERA TIONAL CHECKS ........................................................................................................................................... 28

BURNER FLAME ............................................................................................................................................................ 28

AUXILIARY LIMIT CONTROL .............................................................................................................................................. 28

PRIMARY LIMIT .............................................................................................................................................................. 28

XIII. SAFETY CIRCUIT DESCRIPTION ................................................................................................................................... 28

GENERAL ..................................................................................................................................................................... 29

INTEGRATED CONTROL MODULE ....................................................................................................................................... 29

PRIMARY LIMIT .............................................................................................................................................................. 29

AUXILIARY LIMIT ............................................................................................................................................................ 29

ROLLOUT LIMITS ........................................................................................................................................................... 29

PRESSURE SWITCHES .................................................................................................................................................... 29

FLAME SENSOR ............................................................................................................................................................. 29

XV . TROUBLESHOOTING.................................................................................................................................................. 29

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ............................................................................................................... 29

DIAGNOSTIC CHART ........................................................................................................................................................ 29

RESETTING FROM LOCKOUT ............................................................................................................................................ 29

XVI. MAINTENANCE .......................................................................................................................................................... 29

ANNUAL INSPECTION ...................................................................................................................................................... 30

FILTERS ....................................................................................................................................................................... 30

FILTER MAINTENANCE ..................................................................................................................................................... 30

FILTER REMOVAL ........................................................................................................................................................... 30

UPRIGHT FILTER REMOVAL .............................................................................................................................................. 30

INDUCED DRAFT AND CIRCULATOR BLOWER MOTORS ........................................................................................................... 30

FLAME SENSOR (QUALIFIED SERVICER ONLY) .................................................................................................................... 30

IGNITER (QUALIFIED SERVICER ONLY)...............................................................................................................................30

BURNERS .................................................................................................................................................................... 30

XVII. BEFORE LEA VING AN INST ALLA TION .................................................................................................................... 31

XVIII. REP AIR AND REPLACEMENT PARTS .................................................................................................................... 31

OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY

DAMAGE ARISING FROM IMPROPER SERVI CE OR SERVICE PROCEDURES.

F YOU INSTALL OR PERFORM SERVICE ON THIS UNIT, YOU ASSUME RESPONSIBILITY FOR ANY PERSONAL INJURY OR PROPERY DAM AGE WHICH MAY RESULT. SERVICE HEATING AND AIR CONDITIONING EQUIPMENT.

ANY JURISDICTIONS REQUIRE A LICENSE TO INSTALL OR

WARNING

I. WARNINGS

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN

OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

TO THE INSTALLER

Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections, and venting. These furnaces are designed for Category I venting only.

WARNING

O PR EVEN T POSS IBLE P ERSO NAL IN JURY O R DE ATH D UE TO ASPHY XIATIO N,

THIS FURNAC E MUST BE

CATEGORY III VENTING.

ROVISIONS MUST BE MADE FOR VENTING COMBUSTION PRODUCTS

OUTDOORS THROUGH A PROPER VENTING SYSTEM. COULD BE A LIMITING FCTOR IN LOCATING THE FURNACE.

ATEGORY I VENTED. DO NOT VENT USING

HE LENGTH OF FLUE PIPE

CARBON MONOX I DE POISONING H AZARD

Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas

Carbon monoxide producing devices ( such as an aut omobile , space heater, gas water heat er , etc.) should not be operat ed in enclo sed areas such as unventilated garages, utility rooms or parking areas because of the danger of c arbon monoxide (C O ) poisoning re sult ing from the ex ha ust emissio ns. If a furnace or air handler is installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device i s operate d therein, there must be adequa te, direct outside ventilation.

This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon mo noxide producing devic e continues t o operate in the enclosed area. Carb on monoxide emissions can be (re)circulated throughout the structu r e i f t he furnace or ai r handler is o pe r ating in any mode.

CO can cause serious illness including permanent brain damage or death.

B10259-216

WARNING

O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION,

ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL. QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

TO THE OWNER

It is important that you fill out the owner’s registration card and mail it today. This will assist us in contacting you should any service or warranty information change in the future. When filling in the registration card, be sure to include the model, manufacturing, and serial numbers, plus the installation date.

Your warranty certificate is also supplied with the unit. Read the warranty carefully and note what is covered. Keep the warranty certificate in a safe location for future reference.

If additional information or operating instructions are required, contact the dealer where the purchase was made.

Homeowner Notice:

If the residence is left unattended for an extended period of time (i.e., 4 hours or greater), have your heating system periodically checked to ensure proper operation. Potential circumstances beyond our control such as power outages, gas service interruptions, product installation, or component failures could result in heating system operational problems.

TRANSPORTATION DAMAGE

All units are securely packed in shipping containers tested according to International Safe Transit Association specifications. The carton must be checked upon arrival for external damage. If damage is found, a request for inspection by carrier’s agent must be made in writing immediately.

The furnace must be carefully inspected on arrival for damage and bolts or screws which may have come loose in transit. In the event of damage the consignee should:

1. Make a notation on delivery receipt of any visible damage to shipment or container.

2. Notify carrier promptly and request an inspection.

3. With concealed damage, carrier must be notified as soon as possible - preferably within five days.

4. File the claim with the following support documents within a nine month statute of limitations.

• Original or certified copy of the Bill of Lading, or indemnity bond.

• Original paid freight bill or indemnity in lieu thereof.

• Original or certified copy of the invoice, showing trade and other discounts or reductions.

• Copy of the inspection report issued by carrier’s representative at the time damage is reported to carrier.

The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim. The distributor or manufacturer will not accept claims from dealers for transportation damage.

Keep this literature in a safe place for future reference.

II. SAFETY

Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.

WARNING

O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL. QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

OR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A

WARNING

HIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH

MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE

TATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER

REPRODUCTIVE HARM.

WARNING

TO PREVENT POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

DUE TO ELECTRICAL SHOCK, THE FURNACE MUST BE LOCATED TO PROTECT THE ELECTR ICAL COMPO NENTS FROM WA TER.

WARNING

HIS UNIT MUST NOT BE USED AS A "CONSTRUCTION HEATER" DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE. USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TERMPERATURES AND EXPOSURE TO CORROSIVE OR VERY DIRTY ATMOSPHERES.

HIS TYPE OF

WARNING

EATING UNIT SHOULD NOT BE UTILIZED WITHOUT REASONABLE, ROUTINE,

INSPECTION, MAINTENANCE AND SUPERVISION. SUCH DEVICE IS LOCATED WILL BE VACANT, CARE SHOULD BE TAKEN THAT SUCH DEVICE IS ROUTINELY INSPECTED, MAINTAINED AND MONITORED. IN THE EVENT THAT THE BUILDING MAYBE EXPOSED TO FREEZING TEMPERATURES AND WILL BE VACANT, ALL WATER-BEARING PIPES SHOULD BE DRAINED, THE BUILDING SHOULD BE PROPERLY WINTERIZED, AND THE WATER SOURCE CLOSED. I N THE EVENT T HAT THE BUI LDING MA Y BE EX POSED TO F REEZING TEMPERATURES AND WILL BE VACANT, ANY HYDRONIC COIL UNITS SHOULD BE DRAINED AS WELL AND, IN SUCH CASE, ALTERNATIVE HEAT SOURCES SHOULD BE UTI LIZED.

F THE BUILIDNG IN WHICH ANY

ADDITIONAL SAFETY CONSIDERATIONS

• This furnace is approved for Category I Venting only.

• Provisions must be made for venting combustion products outdoors through a proper venting system. The length of flue pipe could be a limiting factor in locating the furnace.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

NOTE: Discharge body’s static electricity before touching unit. An

electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and

servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and non-installed (ungrounded) furnaces.

1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.

2. Firmly touch a clean, unpainted, metal surface of the furnaces near the control. Any tools held in a person’s hand during grounding will be discharged.

3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires.

4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object.

III. PRODUCT APPLICA TION

This furnace is primarily designed for residential home-heating applications. It is NOT designed or certified for use in mobile homes, trailers or recreational vehicles. Neither is it designed or certified for outdoor applications. The furnace must be installed indoors (i.e., attic space, crawl space, or garage area provided the garage area is enclosed with an operating door).

This furnace can be used in the following non-industrial commercial applications:

Schools, Office buildings, Churches, Retail stores,

Nursing homes, Hotels/motels, Common or office areas

In such applications, the furnace must be installed with the following stipulations:

• It must be installed per the installation instructions provided and per local and national codes.

• It must be installed indoors in a building constructed on site.

• It must be part of a ducted system and not used in a free air delivery application.

• It must not be used as a “make-up” air unit.

• All other warranty exclusions and restrictions apply.

This furnace may be used as a construction site heater ONLY if the following conditions are met:

• The vent system is permanently installed per these installation instructions.

• A room thermostat is used to control the furnace. Fixed jumpers that provide continuous heating CANNOT be used.

• Return air ducts are provided and sealed to the furnace.

• A return air temperature range between 60ºF (16ºC) and 80ºF (27ºC) is maintained.

• Air filters are installed in the system and maintained during construction, replaced as appropriate during construction, and upon completion of construction are replaced.

• The input rate and temperature rise are set per the furnace rating plate.

• 100% outside air is provided for combustion air requirements during construction. Temporary ducting can be used.

NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized according to the instructions under Section V, Combustion and Ventilation

Air Requirements, Section 5.3.3.

• The furnace heat exchanger, components, duct system,

air filters and evaporator coils are thoroughly cleaned following final construction clean up.

• All furnace operating conditions (including ignition, input rate, temperature rise and veting) are verified according to these installation instructions.

NOTE: The Commonwealth of Massachusetts requires that the following additional requirements must also be met:

• Gas furnaces must be installed by a licensed plumber or gas fitter.

• A T-handle gas cock must be used.

• If the unit is to be installed in an attic, the passageway to and the service area around the unit must have flooring.

To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product.

WARNING

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,

EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION, OR MAINTENANCE OF THIS PRODUCT.

Additional helpful publications available from the NFPA are, NFPA 90A - Installation of Air Conditioning and Ventilating System and NFPA 90B - Warm Air Heating and Air Conditioning System.

All venting shall be in accordance with PART 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1, or applicable local building and/or air conditioning codes. These publications are available from:

National Fire Protection Association, Inc.

Batterymarch Park

Quincy, MA 02269

The AMV8 and ADV8 series of furnaces meet the California NOx emission standards and California seasonal efficiency standards. ANNUAL inspections of the furnace and its vent system is strongly recommended.

IV . LOCA TION REQUIREMENTS AND CONSIDERA TIONS

GENERAL

WARNING

O PREVENT PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE, DO NOT INSTALL THIS FURNACE IN A MOBILE HOME, TRAILER, OR RECREATIONAL VEHICLE.

To ensure proper furnace operation, install, operate and maintain the furnace in accordance with these installation and operation instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes.

A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1) can be obtained from any of the following:

American National Standards Institute

1430 Broadway

New York, NY 10018

National Fire Protection Association

1 Batterymarch Park

Quincy, MA 02269

CSA International

8501 East Pleasant Valley

Cleveland, OH 44131

A copy of the CAN/CSA B149 Installation Codes can also be obtained from:

CSA International

178 Rexdale Boulevard

Etobicoke, Ontario, Canada M9W 1R3

The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated. The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual J-Load Calculations” published by the Air Conditioning Contractors of America.

In the USA, this furnace MUST be installed in accordance with the latest edition of the ANSI Z223.1 booklet entitled “National Fuel Gas Code” (NFPA 54), and the requirements or codes of the local utility or other authority having jurisdiction. In Canada, this furnace must be installed in accordance with the current CAN/CGA-B149.1 & 2 Gas Installation Codes, local plumbing or waste water codes and other applicable codes.

OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO FIRE,

EXPLOSION, SMOKE, SOOT, CONDENSTAION, ELECTRICAL SHOCK OR CARBON MONOXIDE MAY RESULT FROM IMPROPER INSTALLATION, REPAIR, OPERATION, OR MAINTENANCE OF THIS PRODUCT.

WARNING

O PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in Section V,

Combustion and Ventilation Air Requirements.

• Centrally locate the furnace with respect to the proposed or existing air distribution system.

• Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.

• Provisions must be made for venting combustion products outdoors through a proper venting system. The length of flue pipe could be a limiting factor in locating the furnace.

• Ensure adequate combustion air is available for the furnace. Improper or insufficient combustion air can expose building occupants to gas combustion products that could include carbon monoxide. Refer to Section V,

Combustion and Ventilation Air Requirements.

• The furnace must be level. If the furnace is to be set on a floor that may become wet or damp at times, the furnace should be supported above the floor on a concrete base sized approximately 1-1/2" larger than the base of the furnace.

• Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.

• Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the following substances:

chlorinated waxes or cleaners

chlorine-based swimming pool chemicals

water softening chemicals deicing salts or chemicals

carbon tetrachloride

halogen type refrigerants

cleaning solutions (such as perchloroethylene)

printing inks

paint removers

varnishes

hydrochloric acid

cements and glues

antistatic fabric softeners for clothes dryers

and masonry acid washing materials

• If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit coil. Premature heat exchanger failure will result if the cooling unit coil is placed ahead of the furnace.

• If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor. Protect the furnace from physical damage by vehicles.

• If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the access doors on the “up/top” or “down/bottom” side of the furnace.

• Do not connect this furnace to a chimney flue that serves a separate appliance designed to burn solid fuel.

• On Counterflow Installations, the air conditioning coil must be downstream from the heat exchanger of the furnace.

• Counterflow Installation over a noncombustible floor. Before setting the furnace over the plenum opening, ensure the surface around the opening is smooth and level. A tight seal should be made between the furnace base and floor by using a silicone rubber caulking compound or cement grout.

• Counterflow Installation over a combustible floor. If installation over a combustible floor becomes necessary, use an accessory subbase (see Product Data Book applicable for your model* for details.) A special accessory subbase must be used for upright counterflow unit installations over any combustible material including wood. Refer to subbase instructions for installation details. Follow the instructions with the subbase for proper installation. Do not install the furnace directly on carpeting, tile, or other combustible material other than wood flooring. (Note: The subbase will not be required if an air conditioning coil is installed between the supply air opening on the furnace and the floor.)

CLEARANCES AND ACCESSIBILITY

Unobstructed front clearance of 24" for servicing is recommended.

VENT

B1-VENT SINGLE

1" 6" 1" 3" 0" 1"

SIDES FRONT BA CK

TO P

(PLENUM)

Top clearance for horizontal configuration - 1"

HORIZONTAL INSTALLATION (AMV MODELS ONLY)

Line contact to framing is permitted when installed in the horizontal configuration. “Line contact” is defined as the portion of the cabinet that is formed by the intersection of the top and side.

ACCESSIBILITY CLEARANCE, WHERE GREA TER, SHOULD T AKE PRECEDENCE OVER MINIMUM FIRE PROTECTION CLEARANCE. A gas-fired furnace for installation in a residential garage must be installed so that the ignition source and burners are located not less than eighteen inches (18") above the floor and is protected or located to prevent physical damage by vehicles. A gas furnace must not be installed directly on carpeting, tile, or other combustible materials other than wood flooring.

Vent Pipe C learance to Combustibles 6" using Single Wa ll Connector o r 1 " using B-1 vent.

Top - 1"

Back - 0"

Side Clearance - 1"

Front Clearance - 3"

• Adequate combustion/ combustion air must be supplied to the closet.

• Furnace must be completely sealed to floor or base. Combustion/ ventilation air supply pipes must terminate 12" from top of closet and 12" from floor of closet. DO NOT remove solid base plate for bottom return.

• Return air ducts must be completely sealed to the furnace and terminate outside the enclosure. surfaces.

FURNACE SUSPENSION

If suspending the furnace from rafters or joist, use 3/8" threaded rod and 2”x2”x3/8” angle iron as shown below. The length of rod will depend on the application and the clearances necessary.

PROVIDE 8" MINMUM CLEARANCE BETWEEN

CENTER ROD AND FURNACE CABINET

TO ALLOW FOR CIRCULATOR BLOWER REMOVAL

HOLD DOWN

SUPPORT

NUTS

3/8" DIAMETER

THREADED ROD

(6 PLACES)

NUTS

2"x2"x3/8"

ANGLE IR ON

(3 PLACES)

POSITION AS CLOSE AS POSSIBLE TO BLOWER DECK TO ALLOW FOR

CIRCULATOR BLOWER REMVOAL

Suspended Furnace

ASSURE FURNACE IS LEVEL FROM

END TO END AND HAS A SLIGHT

FORWARD TILT WITH THE FRO NT

OF THE FURNACE 0"-3/4"

BELOW THE BACK OF THE FURNACE

TILT OUTWARD TO ALLOW FOR

DOOR AND CIRCULATOR BLOWER

REMOVAL

EXISTING FURNACE REMOVAL

NOTE: When an existing furnace is removed from a venting system

serving other appliances, the venting system may be too large to properly vent the remaining attached appliances.

HOT

COLD

DRAFTS OR DEAD SPOTS

-BEHIND DOORS

-IN CORNERS

-UNDER CABIN ETS

The following vent testing procedure is reproduced from the

American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47b-2002, CSA-2.3b-2002 Section 1.23.1. The following steps shall be followed with each

appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:

a. Seal any unused openings in the venting system; b. Inspect the venting system for proper size and horizontal

pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the CAN/CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;

c.In so far as practical, close all building doors and windows

and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;

d. Follow the lighting instructions. Place the appliance being

inspected in operation. Adjust thermost at so appliance shall operate continuously;

e.Test for draft hood equipped appliance spillage at the draft

hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle;

f. After it has been determined that each appliance connected

to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;

g. If improper venting is observed during any of the above

tests, the venting system must be corrected.

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CAN/CSA B149 Installation Codes.

If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CAN/CSA B149 Installation Codes.

THERMOSTAT LOCATION

In an area having good air circulation, locate the thermostat about five feet high on a vibration-free inside wall. Do not install the thermostat where it may be influenced by any of the following:

• Drafts, or dead spots behind doors, in corners, or under cabinets.

• Hot or cold air from registers.

• Radiant heat from the sun.

• Light fixtures or other appliances.

• Radiant heat from a fireplace.

• Concealed hot or cold water pipes, or chimneys.

• Unconditioned areas behind the thermostat, such as an outside wall.

Thermostat Influences

Consult the instructions packaged with the thermostat for mounting instructions and further precautions.

V . COMBUSTION AND VENTILA TION AIR REQUIREMENTS

WARNING

O AVOID PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, SUFFICIENT

FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES MUST BE SUPPLIED. FURNACE AREA.

OST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED INTO THE

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air.

House depressurization can cause back drafting or improper combustion of gas-fired appliances, thereby exposing building occupants to gas combustion products that could include carbon monoxide.

If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFP A 54/ ANSI Z223.1 (Section 5.3), or CAN/CSA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

This furnace must use indoor air for combustion. It cannot be installed as a direct vent (i.e., sealed combustion) furnace.

Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces.

The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI

Z223.1 Section 5.3.

5.3.1 General:

(a) The provisions of 5.3 apply to gas utilization equipment

installed in buildings and which require air for combustion, ventilation and dilution of flue gases from within the building. They do not apply to (1) direct vent equipment which is constructed and installed so that all air for combustion is obtained from the outside atmosphere and all flue gases are discharged to the outside atmosphere, or (2) enclosed furnaces which incorporate an integral total enclosure and use only outside air for combustion and dilution of flue gases.

(b) Equipment shall be installed in a location in which the

facilities for ventilation permit satisfactory combustion of gas, proper venting and the maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced.

be provided as required for: cooling of equipment or material, controlling dew point, heating, drying, oxidation or dilution, safety exhaust, odor control, and air for compressors.

(d) In addition to air needed for combustion, air shall be

supplied for ventilation, including all air required for comfort and proper working conditions for personnel.

(e) While all forms of building construction cannot be covered

in detail, air for combustion, ventilation and dilution of flue gases for gas utilization equipment vented by natural draft normally may be obtained by application of one of the methods covered in 5.3.3 and 5.3.4.

(f) Air requirements for the operation of exhaust fans, kitchen

ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.

5.3.2 Equipment Located in Unconfined Spaces:

In unconfined spaces (see definition below) in buildings, infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in 5.3.3b or 5.3.4.

Space, Unconfined.

For purposes of this Code, a space whose volume is not less than 50 cubic feet per 1,000 BTU per hour of the aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, are considered a part of the unconfined space.

5.3.3 Equipment Located in Confined Spaces:

(a) All Air from Inside the Building: The confined space shall

be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of 1 square inch per 1,000 BTU per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure.

NOTE: Ea c h op e ni ng mu st have a free area of not less than one square inch per 1000 BTU of the tot al input rating of all equi pment in the enclosure, but not less than 100 square inches.

Chimney or Gas Vent

Water Heater

Furnace

Opening

Equipment Located in Confined Spaces;

All Air from Inside Building. See 5.3.3-a.

(b) All Air from Outdoors: The confined space shall be provided

with two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

Ventilation louvers (each end of attic)

NOTE: The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total input rati ng of all equipment in the enclosure.

Outlet Air

Water Heater

Alternate air inlet

Furnace

Ventilation louvers for unheated crawl space

Inlet Air

Equipment Located in Confined Spaces; All Air from Outdoors—

Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated

Attic. See 5.3.3-b

2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas V ent

Water Heater

Furnace

Ventilation louvers (each end of attic)

Outlet Air

Inlet ai r d u c t [ends 1 ft (300 mm) above floor]

NOTE : The inlet and outlet air openings must each have a free area of not less than one square inch per 4000 BTU of the total inp u t rating of all equipment in the enclosure.

NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equipment in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.

Chimney or Gas Vent

Water Heater

Furnace

Opening

Alternate Opening Location

Equipment Located in Confined Spaces; All Air from Outdoors

Through Ventilated Attic. See 5.3.3-b.

3. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour of total input rating of all equipment in the enclosure.

Chimney or Gas Vent

NOTE: The air duct openings must have a free area of not less than one square inch per 2000 BTU of the total input rating of all equipment in the enclosure*.

Furnace

Water Heater

Outlet air duct

Inlet air duct

Equipment Located in Confined Spaces;

All Air from Outdoors. See 5.3.3-b.

*If the appliance room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of not less than one square inch per 4,000 BTU per hour of the total input rating of all appliances in the enclosure.

4. When ducts are used, they shall be of the same crosssectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.

Equipment Located in Confined Spaces; All Air from Outdoors -

Single Air Opening. See 5.3.3-b.

5. One permanent opening may be permitted, provided the equipment has clearances of at least 1” from the sides and back and 6” from the front. The opening shall communicate directly with the outdoors and must be located within 12” of the top of the enclosure. The minimum free area of the opening shall be 1 square inch per 3,000 BTU per hour of total input rating of all equipment in the enclosure. The minimum free area shall not be less than the sum of the areas of all vent connectors in the confined space.

5.3.4 Specially Engineered Installations:

The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases.

5.3.5 Louvers and Grilles:

In calculating free area in 5.3.3, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch mesh. If the area through a design of louver or grille is known, it should be used in calculating the size of opening required to provide the free area specified. If the design and free area is not known, it may be assumed that wood louvers will have 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

5.3.6 Special Conditions Created by Mechanical Exhausting or Fireplaces:

Operation of exhaust fans, ventilation systems, clothes dryers, or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment.

VI. CA TEGORY I VENTING (VERTICAL VENTING)

Supply Air

WARNING

NEVER ALLOW THE PRODUCTS OF COMBUSTION, INCLUDING CARBON

MONOXIDE, TO ENTER THE RETURN DUCTWORK OR CIRCULATION AIR SUPPLY.

WARNING

O PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION,

THIS FURNACE MUST BE

ATEGORY

III

VENTING.

ATEGORY I VENTED. DO NOT VENT USING

Category I Venting is venting at a non-positive pressure. A furnace vented as Category I is considered a fan-assisted appliance and the vent system does not have to be “gas tight.” NOTE: Gas furnaces with induced draft blowers draw products of combustion through a heat exchanger allowing, in some instances, common venting with natural draft appliances (i.e. water heaters).

All installations must be vented in accordance with National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest edition. In Canada, the furnaces must be vented in accordance with the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 latest editions and amendments.

NOTE: The vertical height of the Category I venting system must be at least as great as the horizontal length of the venting system.

WARNING

O PREVENT POSSIBLE PERSONAL INJURY OR DEATH DUE TO ASPHYXIATION,

COMMON VENTING WITH OTHER MANUFACTURER'S INDUCED DRAFT APPLIANCS IS NOT ALLOWED.

The minimum vent diameter for the Category I venting system is as shown below:

MODEL

70 4 Inch 4 Inch

90 4 Inch 4 Inch 115 N/A 4 Inch 140 N/A N/A

Under some conditions, larger vents than those shown above may be required or allowed.

When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to

properly vent the remaining attached appliances. Upflow or Horizontal units are shipped with the induced draft

blower discharging from the top of the furnace. (“Top” is as viewed for an upflow installation.) The induced draft blower can be rotated 90 degrees for Category I venting (Figure 3). For horizontal installations, a four inch single wall pipe can be used to extend the induced draft blower outlet 1/2” beyond the furnace cabinet. Vent the furnace in accordance with the National Fuel Gas Code NFP A 54/ANSI Z223.1 - latest edition. In Canada, vent the furnace in accordance with the National Standard of Canada, CAN/CSA B149.1 and CAN/CSA B149.2 - latest editions and amendments.

Venting

THIS FURNACE IS NOT DESIGN CERTIFIED TO BE HORIZONTALL Y VENTED.

MINIMUM VENT

UPFLOW COUNTERFLOW

Upflow Rotated Induced Draft Blower

To rotate the induced draft blwer counterclockwise, proceed as follows:

1. Disconnect electrical power from the furnace.

2. Disconnect the induced draft blower power leads, flue pipe, and pressure switch tubing.

3. Remove the round cutout from the appropriate side of the furnace.

4. Remove and save the four screws that hold the induced draft blower to the flue collector box.

5. Turn the induced draft blower 90 degrees clockwise, or counterclockwise. The gasket is adhered to the back plate and will rotate with the blower assembly.

6. Reinstall the induced draft blower on the flue collector box, using the four screws removed in Step 3. Tighten screws to provide an airtight seal.

7. Reconnect the induced draft blower power leads. NOTE: If the wires are not long enough, pull extra wire from the wire bundle in the blower compartment.

8. Remove and save the screw that holds the pressure switch to the furnace top panel.

9. Relocate the pressure switch to the same side as the flue outlet in the hole provided.

10. Reconnect the draft blower power leads, flue pipe, and pressure switch tubing. Make sure that all wires and the pressure switch tubing are at least one inch from the flue pipe, or any other hot surfaces.

11. Restore power to the furnace.

Counterflow units are shipped with the induced draft blower discharging from the top of the furnace. (“Top” as viewed for a counterflow installation.) Vent the furnace in accordance with the National Fuel Gas Code NFPA 54/ANSIZ223.1 - latest edition. In Canada, vent the furnace in accordance with the National Standard of Canda, CAN/CSA B149.1 and CAN/CSA B149.2 latest editions and amendments.

VII. EXTERIOR MASONRY CHIMNEYS

CA TEGORY I FURNACES ONL Y

An exterior masonry chimney is defined as a “Masonry chimney exposed to the outdoors on one or more sides below the roof line.” The ability to use a clay lined masonry chimney depends on a parameter not associated with interior chimneys. This variable is the geographic location of the installation.

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iSi North America AMV8, ADV8 User Manual

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User Manual