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395CAV
User Manual
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LG 395CAV User Manual

installation instructions
395CAV
and operating instructions
UPFLOW GAS-FIRED INDUCED-COMBUSTION FURNACES
NOTE: Read the entire instruction manual before starting the installation.
This symbol → indicates a change since the last issue. Index Page
SAFETY CONSIDERATIONS.....................................................1
Clearances From Combustible Materials.................................1
Dimensional Drawing...............................................................2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE........................................................................2-3
INTRODUCTION..........................................................................3
LOCATION....................................................................................3
General......................................................................................3
Location Relative to Cooling Equipment ................................3
Hazardous Locations.................................................................3
Unconfined Space.....................................................................4
Confined Space......................................................................4-5
FILTER ARRANGEMENT .......................................................5-6
GAS PIPING...............................................................................6-7
ELECTRICAL CONNECTIONS..................................................7
115-v Wiring.............................................................................7
24-v Wiring...............................................................................7
Accessories................................................................................7
VENTING ......................................................................................7
General...................................................................................7-8
Sequence Of Operation .......................................................8-11
Heating Mode............................................................................9
Cooling Mode......................................................................9-11
Continuous Blower Mode.......................................................11
Heat Pump Mode....................................................................11
Start-Up Procedures................................................................11
Adjustments .......................................................................11-14
Set Gas Input Rate ............................................................11-13
Set Temperature Rise..............................................................13
Set Thermostat Heat Anticipator............................................14
Check Safety Controls .................................................................14
Checklist.......................................................................................14
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified person­nel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply.
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Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No. 54-1992/ANSI Z223.1-1992. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1-
Series G
Cancels: II 395C-40-9 II 395C-40-10
1-96
®
and .2-M95 Natural Gas and Propane Installation Codes (NSC­NGPIC). Wear safety glasses and work gloves. Have fire extin­guisher available during start-up and adjustment procedures and service calls.
Recognize safety information. This is the safety-alert symbol When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury.
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 a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage.
These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residen­tial construction practices. We require these instructions as a minimum for a safe installation.
TABLE 1—MINIMUM CLEARANCES FROM
COMBUSTIBLE MATERIALS (IN.)
UNIT SIZE 045 AND 070 091-155
Sides Single-Wall Vent 1 0
Type B-1 Double-Wall Vent 0 0
Back 00
Plenum Top 11
Vent Single-Wall Vent 6 6
Type B-1 Double-Wall Vent 1 1
Front Single-Wall Vent 6 6
Type B-1 Double-Wall Vent 3 3 Service 30 30
NOTES:
1. Provide 30-in. front clearance for servicing. An open door in front of the unit can meet this requirement.
2. A minimum clearance of 3 in. must be provided in front of the unit for combustion air and proper operation.
ama
CANADIAN GAS ASSOCIATION
APPROVED
R
.
—1—
39 7⁄8″
28 1⁄2″
FLUE COLLAR
7
⁄8-IN. DIA HOLE
POWER ENTRY
7
⁄8-IN. DIA
ACCESSORY
1 3⁄4-IN. DIA HOLE
GAS ENTRY
1
⁄2-IN. DIA HOLE
THERMOSTAT
WIRE ENTRY
2 1⁄16″ 1″
5 3⁄8″
5 13⁄16″
2 3⁄8″
12 5⁄16″
AIRFLOW
A D
13
⁄16″
5 3⁄8″
5 13⁄16″
2 3⁄8″
2 11⁄16″
2 1⁄16″
1″
7
⁄8-IN. DIA
POWER ENTRY
1 1⁄2-IN. DIA R.H. GAS ENTRY
7
⁄8-IN. DIA ACCESSORY
1
⁄2-IN. DIA THERMOSTAT
WIRE ENTRY
19″
OUTLET
13
⁄16″
SIDE INLET
TYP 1″
11
11
⁄16″
24 5⁄16″
AIR INLET
3″
NOTES:
11
⁄16″
E
1. Two additional 7⁄8-in. dia knockouts are located in the top plate.
⁄16″
5
TYP
⁄8″
SIDE INLET
231⁄4″
SIDE RETURN
DUCT LOCATION
2. Minimum return-air opening at furnace: a. For 800 CFM–16-in. round or 141⁄2 x 12-in. rectangle. b. For 1200 CFM–20-in. round or 141⁄2 x 191⁄2-in. rectangle. c. For 1600 CFM–22-in. round or 141⁄2 x 231⁄4-in. rectangle. d. For airflow requirements above 1800 CFM, use both side inlets, a combination of 1 side inlet and the bottom, or the bottom only.
Fig. 1—Dimensional Drawing
TABLE 2—DIMENSIONS (IN.)
UNIT SIZE A D E VENT CONN SHIP. WT (LB)
024045 14-3/16 12-9/16 12-11/16 4 122 036045 14-3/16 12-9/16 12-11/16 4 124 024070 14-3/16 12-9/16 12-11/16 4 132 036070 14-3/16 12-9/16 12-11/16 4 134 042091 17-1/2 15-7/8 16 4 150 048091 21 19-3/8 19-1/2 4 154 036110 17-1/2 15-7/8 16 4 160 048111 21 19-3/8 19-1/2 4 166 060111 24-1/2 22-7/8 23 4 184 048135 21 19-3/8 19-1/2 5 178 060135 24-1/2 22-7/8 23 5 194 060155 24-1/2 22-7/8 23 5 204
141⁄2″
3
⁄4″
1
1″
A88367
PROCEDURE
CAUTION: Electrostatic discharge can affect electronic
components. Take precautions 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 electro-
static potential.
1. Disconnect all power to the furnace. 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 a 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 that recharges your body with static electricity (for example; DO NOT move or shuffle your feet, DO NOT touch un­grounded objects, etc.).
—2—
4. If you touch ungrounded objects (recharge your body with static electricity), firmly touch 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 5 before bringing the control or yourself into 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) may also be used to prevent ESD damage.
INTRODUCTION
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The Model 395CAV, Series G Furnace is available in sizes 45,000 through 155,000 Btuh input capacities.
Installation must conform to the regulations of the serving gas supplier and the local building, heating, and plumbing codes in effect in the area in which the installation is made, or in the absence of local codes with the requirements of the NFGC.
CAUTION: Application of this furnace should be in­doors with special attention given to vent sizing and material, gas input rate, air temperature rise, and unit sizing. Improper installation or misapplication of the furnace can require excessive servicing or cause prema­ture component failure.
This furnace is designed for a minimum continuous return-air temperature of 60°F db or an intermittent operation down to 55°F db such as when used with a night setback thermostat. Return-air temperature must not exceed a maximum of 85°F db.
WARNING: Improper installation, adjustment, alter­ation, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this product. Failure to follow this warning can cause electrical shock, fire, personal injury, or death.
For accessory installation details, refer to the applicable instruction literature.
NOTE: Remove all shipping brackets and materials before operating the furnace.
I. LOCATION A. General
CAUTION: 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.
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CAUTION: Do not use this furnace during construction when adhesives, sealers, and/or new carpets are being installed. If the furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine when burned with combustion air form acids which cause corrosion of the heat exchangers and metal vent system. Some of these compounds are found in paneling and dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction pro­cess. Excessive exposure to contaminated combustion air will result in safety and performance related problems.
This furnace must be installed so the electrical components are protected from water. This furnace shall not be installed directly on carpeting, tile, or any combustible material other than wood flooring.
Locate furnace as close to the chimney/vent and as near the center of the air distribution system as possible. The furnace should be installed as level as possible.
When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.
Provide ample space for servicing and cleaning. Always comply with the minimum fire protection clearances shown on the unit rating plate.
B. 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 a furnace, dampers or other means used to control the flow of air must prevent chilled air from entering the unit. 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.
C. Hazardous Locations
When the furnace is installed in a residential garage, it must be installed so that the burners and ignition source are located at least 18 in. above the floor. The furnace should be protected from physical damage by vehicles. When a furnace is installed in public garages, airplane hangars, or other buildings having hazardous atmospheres, the unit must be installed in accordance with the recommended good practice requirements of the National Fire Protection Association, Inc.
II. AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3 of the NFGC, Air for Combustion and Ventilation, or applicable provisions of the local building codes.
Canadian installations must be installed in accordance with NSC­NGPIC and all authorities having jurisdiction.
—3—
CAUTION: Air for combustion must not be contami­nated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.
SUPPLY
AIR
VENT THROUGH ROOF
All fuel-burning equipment must be supplied with air for combus­tion of the fuel. Sufficient air MUST be provided to ensure there will not be a negative pressure in the equipment room or space. In addition, a positive seal MUST be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and draft safeguard opening.
CAUTION: The operation of exhaust fans, kitchen ven­tilation fans, clothes dryers, 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.
The requirements for combustion and ventilation air depend upon whether the furnace is located in an unconfined or confined space.
A. Unconfined Space
An unconfined space must have at least 50 cubic ft for each 1000 Btuh of input for all the appliances (such as furnaces, clothes dryer, water heaters, etc.) in the space.
For Example:
395CAV FURNACE
INPUT BTUH
44,000 293 66,000 440
88,000 587 110,000 733 132,000 880 154,000 1026
MINIMUM SQ FT WITH
7-1/2 FT CEILING
If the unconfined space is constructed unusually tight, air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the outdoors. Combustion and ventilation openings must be sized the same as for a confined space. A minimum opening with a total of at least 1 sq in. per 5000 Btuh of total input rating for all equipment must be provided. Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room.
B. Confined Space
A confined space has volume less than 50 cu ft per 1000 Btuh of the total input rating for all appliances installed in that space. A confined space MUST have 2 permanent openings, 1 within 12 in. of the ceiling and the other within 12 in. of the floor. (See Fig. 2.)
NOTE: In determining the free area of an opening, the blocking effect of the louvers, grilles, and screens must be considered. If the free area of a louver or grille design is unknown, it may be assumed that wood louvers have a 20 percent free area, and metal louvers or grilles have a 60 percent free area. Screens, when used, must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed.
The size of the openings depends upon whether the air comes from inside or outside of the structure.
1. All air from inside the structure: a. Each opening MUST have at least 1 sq in. of free area
per 1000 Btuh of the total input for all equipment within the confined space, but not less than 100 sq in. per opening. (See Fig. 2.)
12″ MAX
1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL
INTERIOR
HEATED
SPACE
RETURN AIR
* Minimum opening size is 100 square in. with minimum dimensions of 3-In.
†
Minimum of 3-In. when type-B1 vent is used.
UNCONFINED SPACE
CONFINED
SPACE
6″ MIN (FRONT)
1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL
12″ MAX
A89012
Fig. 2—Air For Combustion and Ventilation (Inside Air)
For Example:
395CAV FURNACE
INPUT BTUH
44,000 100 66,000 100
88,000 100 110,000 110 132,000 132 154,000 154
FREE AREA PER OPENING
(SQ IN.)
b. If the building is constructed unusually tight, a perma-
nent opening directly communicating with the outdoors should be provided. This opening shall have a minimum free area of 1 sq in. per 5000 Btuh of total input rating for all equipment in the enclosure.
c. If the furnace is installed on a raised platform to provide
a return-air plenum, and return air is taken directly from the hallway or space adjacent to the furnace, all air for combustion must come from outdoors.
2. All air from outside the structure: a. If combustion air is taken from outdoors through vertical
ducts, the openings and ducts MUST have at least 1 sq in. of free area per 4000 Btuh of the total input for all equipment within the confined space. (See Fig. 3.)
b. If combustion air is taken from the outdoors through
horizontal ducts, the openings and ducts MUST have at least 1 sq in. of free area per 2000 Btuh of the total input for all equipment within the confined space.
†
—4—
For Example:
395CAV FURNACE
INPUT BTUH
44,000 11.0 4 66,000 16.5 5
88,000 22.0 6 110,000 27.5 6 132,000 33.0 7 154,000 38.5 7
FREE AREA PER OPENING
(SQ IN.)
For Example:
395CAV FURNACE
INPUT BTUH
44,000 22.0 6
66,000 33.0 7
88,000 44.0 8 110,000 55.0 9 132,000 66.0 10 154,000 77.0 10
FREE AREA PER OPENING
(SQ IN.)
c. When ducts are used, they must be of the same cross-
sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular ducts must not be less than 3 in. (See Fig. 3.)
ROUND PIPE
(IN. DIA)
ROUND PIPE
(IN. DIA)
WARNING: Do not install the furnace on its back;
safety control operation will be adversely affected. Never connect return-air ducts to the back of the furnace. A failure to follow this warning can cause a fire, personal injury, or death.
III. FILTER ARRANGEMENT
The factory-supplied filter(s) is shipped in the blower compart­ment. Determine location for the filter and relocate filter retaining wire if necessary. See Fig. 4 for side return application and Fig. 5 for bottom return application. See Table 3 to determine correct filter size for desired filter location. Table 3 indicates filter size, location, and quantity shipped with the furnace.
WASHABLE
FILTER
FILTER RETAINER
DUCTS
A
B
TO
SUPPLY
AIR
D
VENT THROUGH ROOF
CONFINED
C
DUCT
TO
OUTDOORS
OUTDOORS
12″ MAX
1 SQ IN. PER 2000 BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN. PER 2000 BTUH*
12
″ MAX
RETURN AIR
*Minimum dimensions of 3-In.
Use any of the following
NOTE:
combinations of openings: A & B C & D D & E F & G
Fig. 3—Air For Combustion and Ventilation
(Outside Air)
SPACE
E
12″ MAX
1 SQ IN. PER 4000 BTUH*
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
A89013
A93045
Fig. 4—Side Filter Arrangement
(Control Removed for Clarity)
For bottom air-return applications, filter may need to be cut to fit some furnace casing widths. A bottom closure panel is factory installed in the bottom of the furnace. When bottom return inlet is desired, remove and discard the bottom closure panel. Remove side clip(s) and install in hole. Two sets of hardware are needed for furnaces in 24-1/2-in. wide casings using 2 filters for bottom return. All hardware is provided for filter installation.
NOTE: Furnaces with a 17-1/2-in. wide casing require an addi­tional procedure when locating the filter for bottom return-air application. Field fabricate a sheet metal filler strip1X3X24-1/2 in. and install it along side of the filter as shown in Fig. 5. Drive 2 screws through the casing side and into the filler strip to secure it in place. Filter should rest on the top of the filler strip when installed.
WARNING: Never operate unit without a filter or with filter access door removed. Failure to follow this warning can cause fire, personal injury, or death.
IV. LEVELING LEGS (IF REQUIRED)
When the furnace is used with side inlet(s) and leveling legs are required, refer to Fig. 6, and install field-supplied, corrosion­resistant 5/16-in. machine bolts and nuts.
NOTE: The maximum length of the bolt should not exceed 1-1/2 in.
1. Lay furnace on its back. Locate and drill 5/16-in. diameter hole in each bottom corner of furnace as shown in Fig. 6.
2. Install nut on bolt and 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.)
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