Napoleon 9600 B, 9700 B Installation And Operating Instructions Manual

IOM

W415-1241 / A / 03.18.15

UM
PG
59

$10.00

INSTALLER: PLEASE FAMILIARIZE YOURSELF WITH VENTING/DRAINING SECTIONS OF

THIS MANUAL BEFORE PROCEEDING WITH THE INSTALLATION. LEAVE
THIS MANUAL WITH THE APPLIANCE FOR FUTURE REFERENCE.

CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.

INSTALLATION AND

OPERATING INSTRUCTIONS

Wolf Steel Ltd., 24 Napoleon Rd., Barrie, ON, L4M 0G8 Canada /

103 Miller Drive, Crittenden, Kentucky, USA, 41030

Phone [phone] • Fax [phone] • www.napoleonheatingandcooling.com • [e-mail]

SAFETY INFORMATION

ELECTRICAL SHOCK, FIRE OR

EXPLOSION HAZARD

Failure to follow safety warnings exactly
could result in serious inquiry, death or
property damage.

Improper servicing could result in
dangerous operation, serious injury, death
or property damage.

- Installation and service must be performed by a
qualifi ed installer, service agency or the gas supplier.

- Before servicing, disconnect all electrical power to
furnace.

- When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.

- Verify proper operation after servicing.

-

Do not store or use gasoline or other fl ammable

vapors and liquids in the vicinity of this or any other
appliance.

- WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use
any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a
neighbour’s phone. Follow the gas supplier’s
instructions.

• If you cannot reach your gas supplier, call the fi re
department.

!

WARNING

!

MANUFACTURER RESERVES THE RIGHT TO DISCONTINUE, OR CHANGE
AT ANY TIME, SPECIFICATIONS OR DESIGNS WITHOUT NOTICE AND

WITHOUT INCURRING OBLIGATIONS.

Patent Pending

H1.25A

CERTIFIED TO ANSI Z21.47-2012 / CSA 2.3-2012

9600 - B SERIES

TWO STAGE MULTI POSITION HIGH EFFICIENCY
(CONDENSING) FORCED AIR GAS FURNACE

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TABLE OF CONTENTS

1.0 INTRODUCTION 3

2.0 SAFETY SYMBOLS AND WARNINGS 4

2.1 SAFETY RULES 5

2.2 CODES 6

3.0 FURNACE SIZING 8

4.0 LOCATION OF UNIT 9

4.1 GENERAL GUIDELINES 9

4.2 OTHER CONSIDERATIONS 9

4.3 INSTALLATION IN UPFLOW, DOWNFLOW OR HORIZONTAL POSITIONS 10

4.4 AIR CONDITIONING 11

5.0 COMBUSTIBLE CLEARANCES 11

6.0 DUCTWORK 12

6.1 DUCTWORK STEPS 13

7.0 VENTING AND COMBUSTION PIPING 14

7.1 ACCEPTABLE MATERIALS IN CANADA 14

7.2 ACCEPTABLE MATERIALS IN UNITED STATES 14

7.3 VENT DRAIN OPTION 15

8.0 NON-DIRECT VENT FURNACE INSTALLATIONS USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM) 16

8.1 DETERMINING COMBUSTION AIR 17

8.1.1 CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE 17

8.1.2 CASE 2: FURNACE LOCATED IN A CONFINED SPACE 17

8.1.3 CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR FROM ATTIC OR CRAWL SPACE 18

8.1.4 CASE 4: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR DUCTED HORIZONTALLY 19

8.1.5 CONNECTION TO FURNACE NON-DIRECT VENT 19

9.0 VENTING GUIDELINES 20

9.1 VENT TERMINATION 21

9.2 IN CANADA 22

9.3 IN UNITED STATES 22

9.4 FURNACE VENTING INSTALLATIONS 23

9.4.1 NON-DIRECT VENT INSTALLATION USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM) 23

9.4.2 DIRECT VENT INSTALLATION USING OUTDOOR COMBUSTION AIR (TWO PIPE SYSTEM) 23

9.4.3 COMBUSTION AIR 23

10.0 TERMINATIONS 24

10.1 COMBUSTION AIR 24

10.2 EXHAUST 24

10.3 CONCENTRIC VENTING KIT 24

10.4 CONCENTRIC VENT TERMINATION INSTALLATION INSTRUCTIONS 24

10.5 LOCATION 24

10.6 MULTIPLE VENTING 25

11.0 ROUTING OPTIONS 28

11.1 EXHAUSTER ROTATION INSTRUCTIONS & PRESSURE SWITCH MOUNTING 28

11.2 CONDENSATE DRAINS 29

11.3 PREPARATIONS FOR VENT AND DRAINING OPTION 29

11.4 DRAIN HOSE INSTALLATION 33

11.4.1 DRAIN PIPING 33

11.4.2 PRIMING CONDENSATE TRAP 34

11.5 ALTERNATE CONDENSATE DRAIN PIPING INSTALLATION USING 1/2” PVC OR 3/4” CPVC 34

11.6 CONDENSATE NEUTRALIZERS 35

12.0 GAS SUPPLY AND PIPING 36

12.1 GAS SUPPLY 36

12.2 GAS PIPING 36

12.3 GAS INLET PRESSURE 37

12.4 LEAK TESTING 37

12.5 PURGING GAS LINES 37

13.0 CONVERSIONS 38

13.1 HIGH ALTITUDE CONVERSION 38

13.2 NATURAL TO LP GAS 38

13.3 CONVERSION STEPS 38

13.4 CHECKING THE INLET GAS PRESSURE 38

13.5 SETTING THE MANIFOLD GAS PRESSURE 39

13.6 CHECKING FURNACE INPUT 40

14.0 ELECTRICAL SPECIFICATIONS 41

14.1 ELECTRICAL WIRING AND CONNECTIONS 41

14.2 FURNACE CONNECTION 42

15.0 LOW VOLTAGE WIRING 43

15.1 SINGLE STAGE THERMOSTAT 43

15.2 TWO STAGE THERMOSTAT 43

15.3 THERMOSTAT LOCATION 43

16.0 OPTIONAL ACCESSORIES (FIELD SUPPLIED/INSTALLED) 44

16.1 ELECTRONIC AIR CLEANER 44

16.2 POWER HUMIDIFIER 44

16.3 EMERGENCY HEAT MODE 44

17.0 INITIAL STARTUP PROCEDURES 45

17.1 TO START THE FURNACE 45

17.2 TO SHUT DOWN THE FURNACE 45

17.3 SEQUENCE OF OPERATION 46

17.4 PROGRAMMABLE THERMOSTAT (OPTION) 46

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1.0 INTRODUCTION

NOTE: Changes, other than editorial, are denoted by a vertical line in the margin.

18.0 AIR FLOW 47

18.1 TEMPERATURE RISE CHECK 47

18.2 CALCULATING AIR FLOW 48

18.3 ADJUSTING BLOWER SPEEDS ON MODELS EQUIPPED WITH ECM 2.3 / EON BLOWER MOTORS 48

18.4 DEHUMIDIFICATION - ECM 2.3 / EON 49

18.5 SETTING BLOWER “ON” AND “OFF” TIMINGS - ECM 2.3 / EON MODELS ONLY 49

18.6 CONTINUOUS FAN OPERATION 49

19.0 MAINTENANCE AND TROUBLESHOOTING 50

19.1 AIR FILTER 50

19.2 LUBRICATION 50

19.3 TROUBLESHOOTING FLOWCHART 51

19.4 DIAGNOSTIC CODES FOR STATUS LED 52

19.5 FAULT CODE HISTORY 52

20.0 WIRE DIAGRAM FOR TWO STAGE FURNACE 53

20.1 TWO STAGE FURNACE WITH ECM 2.3 / EON 53

20.2 TWO STAGE FURNACE WITH X13 54

21.0 WARRANTY 55

22.0 REPLACEMENT PARTS LIST 56

23.0 SERVICE HISTORY 58

H1.22

IMPORTANT:
PLEASE READ THIS MANUAL CAREFULLY
AND KEEP IN A SAFE PLACE FOR FUTURE
REFERENCE BY A SERVICE TECHNICIAN.

ATTENTION:
UPFLOW VENTING RIGHT, MUST DRAIN ON
LEFT SIDE.

H4.0.5

This high effi cient gas fi red two stage condensing furnace is an upfl ow, downfl ow, horizontal left and right war

m

air furnace suitable for residential and light commercial heating applications with inputs from 40,000 to 120,000
Btu/hr.

This high effi cient furnace series is CSA certifi ed as a Category IV indirect or direct vent central forced air
furnace. When installed as a direct vent furnace, all combustion air is supplied to the furnace burners through the

air intake system. (See Section 7, “Ventilation and Combustion Piping.”)

All models may be fi red by natural or LP gas (propane), and may be fi eld converted from natural gas to LP gas
using Conversion Kit W370-0018.

The furnace is shipped completely assembled except for the condensate drain trap assembly. Please inspect
for damage when the furnace is unpacked.

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2.0 SAFETY SYMBOLS AND WARNINGS

H3.3.1

Understand and pay particular attention to the words DANGER, WARNING, and CAUTION and the following
defi ned symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.

DANGER

! !

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL

RESULT IN DEATH OR SERIOUS INJURY.

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED,

COULD RESULT IN DEATH OR SERIOUS INJURY.

WARNING

!

!

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY

RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT

AGAINST UNSAFE PRACTICES.

CAUTION

!

!

H6.0

IMPORTANT:
READ THE FOLLOWING INSTRUCTIONS COMPLETELY BEFORE INSTALLING!

H3.3

WARNING

!

!

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE

OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR

LOSS OF LIFE.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS, OR
OTHER COMBUSTIBLE MATERIALS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WHAT TO DO IF YOU SMELL GAS

• DO NOT TRY TO LIGHT ANY APPLIANCE.

• DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR
BUILDING.

• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE, OR A CEL­LULAR PHONE FROM A LOCATION WELL AWAY FROM THE BUILDING. FOLLOW THE
GAS SUPPLIER’S INSTRUCTIONS.

• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.

• DO NOT RE-ENTER THE BUILDING UNTIL AUTHORIZED TO DO SO BY THE GAS
SUPPLIER OR THE FIRE DEPARTMENT.

PROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN

CAUSE INJURY, PROPERTY DAMAGE OR LOSS OF LIFE. REFER TO THIS MANUAL.

INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,

SERVICE AGENCY OR THE GAS SUPPLIER.

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2.1 SAFETY RULES

H3.4

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE

PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF

THIS FURNACE. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING

INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY

RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE,

POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE

POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

!

!

H6.1

1. Use this furnace only with type of gas approved for this furnace. Refer to the furnace rating plate.

2. Install this furnace only in dry indoor locations (protected from weather).

3. Provide adequate combustion and ventilation air to the furnace space as specifi ed in Section 7 of this

manual, “Ventilation and Combustion Piping.”

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only,

as specifi ed in Section 7 of this manual, “Venting and Combustion Piping.”

5. Never test for gas leaks with an open fl ame. Use a commercially available soap solution made specifi cally

for the detection of leaks to check all connections as specifi ed in Section 12 of this manual, “Gas Supply

and Piping.”

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, listed on the furnace rating plate, and as

specifi ed in Sections 3, 6, and 18 of this manual, “Furnace Sizing,” “Ductwork,” and “Airfl ow.”

7. 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. (Furnace for heating the home located in the attached
garage, for example).

8. A gas-fi red furnace for installation in a residential garage must be installed so that the burners and ignitor
are no less than 18” (457 mm) above the fl oor. The furnace must be located, or protected to avoid physical

damage by vehicles. (See safety warning).

9. This furnace may be used for heating of buildings or structures under construction provided that:

• The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed per
these installation instructions.

• A room thermostat must control the furnace. The use of fi xed jumpers that will provide continuous
heating is not allowed.

• The return air duct must be provided and sealed to the furnace casing, and terminate outside the
space containing the furnace.

• Return air temperature range between 55°F (13°C) and 80°F (27°C) must be maintained.

• Air fi lters must be installed in the system and must be maintained during construction.

• Air fi lters used to clean the circulating air during the construction process must be either replaced or
thoroughly cleaned prior to occupancy.

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

• One hundred percent (100%) outdoor air must be provided for combustion air requirements during
construction. This is to minimize the corrosive effects of adhesives, sealers and entrainment of
drywall dust into combustion air, which can cause fouling and plugging of furnace components.

• The furnace heat exchanger, components, duct system, and evaporator coils must be thoroughly
cleaned following fi nal construction clean-up.

• All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be
verifi ed according to these installation instructions.

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2.2 CODES

H6.2

1. This furnace must be installed:
a. In accordance with all local codes, by-laws and regulations by those authorities having jurisdiction.

b. In Canada, this furnace must be installed in accordance with the current CAN/CGA -B149.1 and .2

Natural Gas and Propane, and the National Electric Code (NEC) NFPA 70.

c. In the United States, this furnace must be installed in accordance with the current ANSI Z223.1 (NFPA

54) National Fuel Gas Code.

2. Electrical connections must be made in accordance with:
a. Any applicable local codes, by-laws and regulations.

b. Canada: current edition of CAN/CSA C22.1 and C22.2, Canadian Electrical Code (Part 1 and 2).
c. United States: current edition of ANSI/NFPA 70, National Electrical Code.

Codes and additional information may be obtained from:

Canadian Standards Association American Gas Association
5060 Spectrum Way 400 North Capitol Street, NW, Suite 450
Mississauga, Ontario, L4W 5N6 Washington DC, 20001
Phone: [phone] Phone: [phone]
website: www.csa.ca website: www.aga.org

National Fire Protection Association
1 Batterymarch Park
Quincy, MA, 02169-7471
Phone: [phone]
website: www.nfpa.org

H3.5

DO NOT INSTALL THIS FURNACE IN A MOBILE HOME! THIS FURNACE IS NOT

APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE,

PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

THE FURNACE CONTAINS FOIL COVERED FIBERGLASS INSULATION. INHALATION OF

FIBERGLASS PARTICLES IS ASSOCIATED WITH RESPIRATORY DISEASE INCLUDING

CANCER.

NATURAL GAS AND PROPANE ARE NORMALLY ODORIZED BY THE FUEL SUPPLIER. IN

SOME CASES, THE ODORANT MAY NOT BE PERCEIVABLE. INSTALLATION OF UL AND

ULC RECOGNIZED FUEL GAS DETECTORS INSTALLED IN ACCORDANCE WITH THEIR

MANUFACTURER’S INSTRUCTIONS IS RECOMMENDED AS AN ADDITIONAL MARGIN OF

SAFETY.

THE EXHAUST GASES FROM THIS FURNACE CONTAIN CHEMICALS WHICH ON
SOME OCCASIONS MAY INCLUDE CARBON MONOXIDE. CARBON MONOXIDE IS AN
ODORLESS, TASTELESS, CLEAR COLORLESS GAS WHICH IS HIGHLY TOXIC. EVEN

LOW CONCENTRATIONS ARE SUSPECTED OF CAUSING BIRTH DEFECTS AND OTHER

REPRODUCTIVE HARM.

UL AND ULC RECOGNIZED CO DETECTORS ARE RECOMMENDED FOR ALL BUILDINGS

EQUIPPED WITH FOSSIL FUEL BURNING APPLIANCES. ALL CO DETECTORS SHOULD

BE INSTALLED IN ACCORDANCE WITH THEIR MANUFACTURER’S INSTRUCTIONS AND

APPLICABLE LOCAL BUILDING CODES.

FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD!

FAILURE TO REPLACE WITH PROPER CONTROL COULD RESULT IN FIRE, EXPLOSION

OR CARBON MONOXIDE POISONING.

REPLACE GAS VALVE ONLY WITH THE SAME MODEL NUMBER OR AS SPECIFIED BY THE

MANUFACTURER.

WARNING

!

!

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FIGURE 1 - FURNACE DIMENSIONS AND CLEARANCE TO COMBUSTIBLES

TOP LEFT SIDE RIGHT SIDE

0"

Top

NOTES:
S - Service clearance 24 inches (610mm) or more.
C - Combustible oor (but not carpet or non-ceramic tile).
All models approved for closet installation.

Plenum
1/2" (13mm)
on all sides

0"

0"

0"

0"

H3.6A

WARNING

!

!

WHEN THIS FURNACE IS INSTALLED IN A STORAGE GARAGE, IT MUST BE INSTALLED

SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18” (457 mm)
ABOVE THE FLOOR TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH

MAY BE PRESENT IN THE GARAGE.

THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY

VEHICLES.

FAILURE TO HEED THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING

IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

TABLE A - FURNACE DIMENSIONS

INPUT

OUTPUT

HIGH

INPUT

LOW

OUTPUT

LOW Width Depth Height Supply Air Return Air

K/Btu/hr K/Btu/hr K/Btu/hr K/Btu/hr A B C (F x G) (D x E)

40 38 24 23

17 1/2"

(445mm)

29 1/2"

(749mm)

32 7/8"

(835mm)

16 1/2" x 19 5/8"

(419mm x 499mm)

14" x 23"

(356mm x 584mm)

60 57 36 34

80-3*

77 48 46

80-4**

22 1/2"

(572mm)

21 1/2" x 19 5/8"

(546mm x 499mm)

100 96 60 58

120 115 72 69

NOTE: * 3 TON, ** 4 TON

H12.11.2

UPFLOW DOWNFLOW HORIZONTAL

TOP 0 0 0

PLENUM TOP 1/2" (13mm) 0 1/2" (13mm)

FRONT 0* 0* 0*

BACK 0 0 0

SIDES 0 0 0**

BOTTOM 0*** 0 0

FLUE PIPE 0 0 0

ENCLOSURE CLOSET CLOSET CLOSET

TABLE B - MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

*24" (610mm) REQUIRED FOR SERVICE
**SUPPLY AIR OUTLET / 1/2" (13mm) RETURN AIR INLET

*** CERTIFIED FOR CLOSET INSTALATION ON COMBUSTIBLE FLOORING.

TABLEAU B - DÉGAGEMENTS MINIMAUX AUX MATÉRIAUX COMBUSTIBLES

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3.0 FURNACE SIZING

H7.0.3

The maximum hourly heat loss for each heated space shall be calculated in accordance with the procedures

described in the manuals of the Heating, Refrigeration and Air Conditioning Institute of Canada (HRAI), or

by any other method which is suitable for local conditions, provided the results obtained are in substantial
agreement with, and not less than those obtained using the procedure described in their manuals.

In the United States, “Manual J - Load Calculation,” published by the Air Conditioning Contractors of America,

describes a suitable procedure for calculating the maximum hourly heat loss.

If the installation is a retrofi t application, do not rely on the capacity of the existing heating equipment as a
method to size the new furnace. Many of the heat transfer multiples listed in earlier versions of load calculation
manuals were much higher than those listed in more recent editions. It is possible that energy saving
measures have been completed since the installation of the existing furnace. This might include additional
insulation in the attic or walls, the application of sprayed foam insulation, the addition of storm windows and
doors, weather-stripping, caulking, etc.

Many of the older furnaces were equipped with large belt drive blower systems, operating at low RPM’s. If
replacing an existing furnace, be sure that the existing ductwork can handle the amount of airfl ow necessary
for a reasonable temperature rise. Most older gas furnaces operated with a system temperature rise of 70 ­100°F (39 - 56°C). This furnace is designed to be operated with a system temperature rise (∆T) of High Fire
35 - 65°F (20 - 36°C), Low Fire 25 - 55°F (14 - 31°C). If
the furnace selected has an identical output capacity as the
original furnace, a substantial increase in system air fl ow will
be necessary. See Table 1 and the airfl ow characteristics in

Section 18 of this manual, “Airfl ow”.

Existing ductwork should be assessed for its air handling
capabilities.

The “Equal Friction Chart,” as published by ASHRAE and HRAI, is the basis for the various air duct

calculators available through heating supply companies. Following the air velocity guide lines, according to

the “Equal Friction Chart,” or a slide rule air duct calculator, a typical 6" (152mm) round duct has a capacity of

approximately 100 cfm.

NOTE:

The return air system is equally as important as the supply air system. An under-sized return air system
will prevent suffi cient quantities of air from reaching the supply air system and will consequently reduce
the service life of the furnace and its components.

TABLE 1 - RANGE OF TEMPERATURE RISE

Furnace Models Temperature Rise

ALL

High Fire (HF) 35 - 65°F (20 - 36°C)

Low Fire (LF) 25 - 55°F (14 - 31°C)

H12.15.3

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4.0 LOCATION OF UNIT

4.1 GENERAL GUIDELINES

FIGURE 3 - SUGGESTED METHOD FOR SUSPENDING HORIZONTAL FURNACE

RETURN AIR PLENUM

ALLOW ENOUGH ANGLE
IRON OVERHANG TO PERMIT
OPENING THE BLOWER DOOR.

• 3/8” THREADED ROD

• 2” ANGLE IRON

• JAM NUTS

• LOCK WASHER

• FLAT WASHER

SUPPLY AIR PLENUM

4.2 OTHER CONSIDERATIONS

H8.1.2

1. Select a location where the exhaust and combustion air piping can be routed between the furnace and
their terminations with a minimum of lengths and fi ttings. Be sure to check that the proposed termination

location will meet code requirements with respect to location and minimum clearances. (See venting

section for minimum and maximum limits.)

2. Select a location as near as possible to the existing or proposed duct system.

3. The furnace location must have provisions for condensate drainage. If a suitable drain is unavailable near
the furnace, a condensate pump must be used. The condensate pump drain tubing must not terminate
outdoors; similar to some air conditioning condensate installations. Be sure to select a condensate pump
that has been approved for furnace condensate applications.

4. The furnace location must permit access for servicing and be within the clearance to combustibles
guidelines as marked on the appliance rating plate.

5. The furnace must be installed on a level surface. It is recommended that the rear of the furnace be
elevated 1/4" (6mm) higher than the front to facilitate proper condensate drainage.

6. If the furnace is being installed so that the return air will enter through the bottom, the perimeter of the
furnace must be properly supported.

7. When installed in the horizontal position, the furnace may be supported from the bottom, or suspended.

(Figure 3)

8. In upfl ow right venting confi guration, furnace must drain on the left side.

1. If the furnace is to be located in an area where the combustion air is laden with chemical compounds such
as bromine, chlorine or fl uorine, as may be found in swimming pool chemicals, laundry detergents, etc.,
use outdoor air for combustion. These compounds when exposed to fl ame, form acids which attack the
heat exchanger and other components.

Exposure to the following substances in the combustion air supply (but not limited to the following) will also
require OUTDOOR AIR for combustion:

• Aerosols, particularly CFC based or propelled aerosols

• Air fresheners

• “Airplane Glue” and similar adhesives and cements

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4.3 INSTALLATION IN UPFLOW, DOWNFLOW OR HORIZONTAL POSITIONS

H8.2

• Ammonia, as commonly found in permanent wave solutions used in hair dressing salons

• Anti-static fabric softeners used in clothes dryers

• Carbon tetrachloride

• Chlorinated cleaners and waxes

• Chlorine and bromine based swimming pool chemicals

• De-icing salts or chemicals (rock salt, etc.)

• Dry cleaning fl uids such as perchloroethylene

• Fumes from curing polyurethane and similar substances

• Halogen based refrigerants including R-12 and R-22

• Hydrochloric acid, muriatic acid and other acid based masonry washing and curing materials

• Printer’s inks, paint removers, varnishes, varsol, toluene, etc.

• Water softener salt and chemicals

2. If this furnace is to be installed in an area over a fi nished ceiling or living area, install a fi eld fabricated
auxiliary drain pan under the furnace to protect that area from accidental condensate spills. The auxiliary
pan should be large enough to collect accidentally spilled condensate from the air conditioning evaporator
coil assembly if applicable.

3. If the furnace is installed in an area where freezing may occur, a garage, an attic, a crawl space or any
unconditioned space, steps must be taken to protect the condensate trap and drain line from freezing.

H8.3.2

UPFLOW INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed in

accordance with instructions in the appropriate sections of this manual.
HORIZONTAL INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed in

accordance with instructions in the appropriate sections of this manual.
NON-SUSPENDED INSTALLATION: Maintain clearances to combustibles as outlined in Table B. The furnace

must be supported in such a way as to not allow twisting or sagging of the cabinet.
SUSPENDED INSTALLATION: Maintain clearances to combustibles as outlined in Table B. The furnace may

be suspended by fi eld fabricating a cradle of angle iron and threaded rod. Secure the furnace with 2” (51mm)
minimum slotted angle or equivalent as shown in Figure 3. The furnace must be supported in such a way as to
not allow twisting or sagging of the cabinet. Position the supports so as to not interfere with accessing the burner
and blower compartments.

DOWNFLOW INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed
in accordance with instructions in the appropriate sections of this manual.

The opening in the fl oor must provide adequate clearances to the combustible material according to the
clearance to combustible as outlined in Table B.

IMPORTANT:

• THE FURNACE MUST BE INSTALLED ON A LEVEL SURFACE. IT IS RECOMMENDED
THAT THE REAR OF THE FURNACE BE ELEVATED 1/4” (6mm) HIGHER THAN THE
FRONT TO FACILITATE PROPER CONDENSATE DRAINAGE.

• IF THE FURNACE AND AIR CONDITIONER IS LOCATED ABOVE A FINISHED SPACE,
INSTALL A DRAIN PAN UNDERNEATH THE UNIT.

NOTE

This furnace is approved for installation in attics, alcoves, utility rooms, closets and crawl spaces. If this
furnace is to be installed in a utility room, be sure that it is located in such a way as to allow access for
servicing or the removal of other appliances installed in the room (hot water heater, for example). It is not
permissible to use a rear return on this appliance. Use only side and bottom returns.

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4.4 AIR CONDITIONING

5.0 COMBUSTIBLE CLEARANCES

H8.4.3

This furnace may be used as part of an air conditioning system. The furnace wiring and control system is “air
conditioning ready.” There are the following factors to consider:

The air conditioning evaporator coil must be downstream of the
heat exchanger. The cooled air passing over the warmer heat
exchanger tubes can cause condensation inside the tubes,
resulting in corrosion and premature failure.

A parallel duct system can be installed to direct the air from the
furnace through the evaporator coil only. Use dampers or other
means to bypass the heat exchanger. If (summer/winter) dampers
are used, they should be interlocked to prevent system operation
unless the dampers are in the full open or full closed position.

NOTE

If installing a two stage air
conditioning system, clip the JW38
jumper wire between Y (low cool)
and Y2 (high cool) on the furnace
control board.

Control defaults to Y2 (high cool) if
JW38 jumper wire is NOT cut.

H9.0

Table B provides the certifi ed clearances to combustibles information. Also see the appliance rating plate
affi xed to the furnace for specifi c model number, serial number and clearance to combustibles information.

IMPORTANT:
THIS FURNACE REQUIRES A MINIMUM OF 24" (610mm) OF FRONT CLEARANCE FOR
SERVICE PURPOSES. FOR THIS PURPOSE, SERVICE CLEARANCE TAKES PRECE­DENCE OVER CLEARANCE TO COMBUSTIBLES.

H3.7

THIS FURNACE IS CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORS. THIS

SHALL BE INTERPRETED AS A WOOD FLOOR ONLY.

THE FURNACE MUST NOT BE INSTALLED DIRECTLY ON CARPETING, OR OTHER

COMBUSTIBLE MATERIAL EXCEPT WOOD.

INSTALLATION ON COMBUSTIBLE MATERIAL CAN RESULT IN FIRE, CAUSING PROPERTY

DAMAGE, PERSONAL INJURY OR DEATH.

THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL

COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS

AND LIQUIDS.

THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE

USED AS A CLOSET OR FOR ANY OTHER STORAGE PURPOSE.

WARNING

! !

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6.0 DUCTWORK

H10.0

Proper airfl ow is required for the correct operation of this furnace. Insuffi cient airfl ow may cause erratic
operation, could cause the furnace to cycle on the high temperature limit, and may damage the heat
exchanger. Excessive airfl ow may result in an excessively noisy duct system and may result in undesirable
consequences such as creating uncomfortable drafts.

If air conditioning is to be used with the furnace, the duct system must be capable of delivering the correct
amount of airfl ow for each system.

The ductwork should be sized and constructed in accordance with accepted industry standards. Duct sizing
and construction information may be obtained from:

• A.C.C.A. (Air Conditioning Contractors of America)

• A.S.H.R.A.E. (American Society of Heating, Refrigeration and Air Conditioning Engineers)

• H.R.A.I. (Heating, Refrigerating and Air Conditioning Institute (Canada)

• S.M.A.C.N.A. (Sheet Metal and Air Conditioning Contractors’ National Association (United States)

All of the above professional organizations have duct sizing manuals available.

The total static pressure drop of the air distribution system (including fi lters) should not exceed 1.0” w.c.

H3.8

DO NOT ALLOW GAS PIPING TO BE ROUTED THROUGH JOIST SPACES THAT ARE

USED FOR RETURN AIR PURPOSES. DO NOT USE JOIST SPACES FOR RETURN AIR

PURPOSES IF THE JOIST SPACE ALREADY CONTAINS PLUMBING STACKS, CHIMNEY

COMPONENTS, ETC. UNLESS THE PORTION USED FOR RETURN AIR PURPOSES CAN

BE COMPLETELY ISOLATED FROM PORTIONS WITH OTHER USAGES.

NEVER ALLOW THE PRODUCTS OF COMBUSTION FROM THE FLUE TO ENTER THE

RETURN AIR OR SUPPLY AIR DUCTWORK.

ALL RETURN AIR DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO

THE FURNACE WITH SHEET METAL SCREWS. TAPE THE SHEET METAL SEAMS IN THE

VICINITY OF THE FURNACE WITH DUCT TAPE OR SIMILAR MATERIAL.

WHEN THE FURNACE IS MOUNTED ON A PLATFORM WITH RETURN AIR THROUGH THE

BOTTOM, IT MUST BE SEALED AIR TIGHT BETWEEN THE FURNACE AND THE RETURN

AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT

OF THE FURNACE WITHOUT SAGGING OR GAPS AROUND THE BASE. IT MUST ALSO

BE SEALED BETWEEN THE SUPPORT AND THE BASE.

FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO

THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING

CARBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR

DEATH.

WARNING

!

!

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6.1 DUCTWORK STEPS

H10.1

1. Position the furnace to minimize ductwork length and fi ttings.

2. Cut open a return air inlet. The choices are furnace bottom, either side, or any combination thereof (i.e.,
two sides or a side and the bottom).In all cases, cut the return air opening the full width of the return air
markers on the side panel.

NOTE: If the airfl ow requirements exceed 1800 cfm, models will require air openings and fi lters on:

• both sides, OR

• one side and the bottom, OR

• just the bottom

3. Connect the return air duct or fi lter fi tting to the furnace. The connection should be sealed air tight to prevent
entraining combustion gases from an adjacent fuel burning appliance, or entraining combustion air for this
furnace or adjacent fuel burning appliances.

4. Ensure that there is adequate space and accessibility for air fi lter removal.

5. If an air conditioning evaporator coil is required, position it on the supply air side of the furnace. Ensure
that no air can bypass the evaporator coil.

6. Connect the supply air plenum to the supply air outlet.

FLEXIBLE DUCT CONNECTORS are an effective device to prevent the telegraphing of mechanical noise from
the furnace to other parts of the home via the ductwork. If using fl exible connectors, ensure that the adjoining
duct is independently supported.

H3.9

DO NOT USE THE REAR PANEL AS A RETURN AIR INLET. THERE IS INSUFFICIENT

ROOM TO PERMIT ADEQUATE AIRFLOW.

DAMAGES, DEFECTS OR FAILURES CAUSED BY CONDITIONED AIR (RETURN AIR)

SUPPLIED TO THE FURNACE BEING GREATER THAN 20% FROM OUTDOORS (55°F/13°C

MIN. RETURN AIR TEMPERATURE).

SOME HEATING AIR FLOW VALUES MAY BE HIGHER THAN THOSE REQUIRED FOR

COOLING. BE SURE TO SIZE DUCT SYSTEM FOR HIGHEST POSSIBLE VALUES.

WARNING

!

!

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7.2 ACCEPTABLE MATERIALS IN UNITED STATES

7.0 VENTING AND COMBUSTION PIPING

7.1 ACCEPTABLE MATERIALS IN CANADA

H3.10

READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO

PROPERLY VENT OR SUPPLY COMBUSTION AIR TO THIS FURNACE CAN CAUSE CAR-

BON MONOXIDE POISONING, OR AN EXPLOSION OR FIRE, RESULTING IN PROPERTY

DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

WARNING

!

!

H11.1A

Effective August 1, 2007, all vent piping materials and fi ttings for fl ue gas venting must be ULC S636 listed
and identifi ed as such on the material. The fi rst 3ft. (900mm) of venting must be readily available for visual
inspection. Specifi ed primers and glues of the certifi ed vent system must be from a single system manufacture,
and not intermixed with other system manufacture’s vent system parts. The components of the certifi ed vent
system must not be interchanged with other vent systems, or unlisted pipe, and or fi ttings. Follow the venting
manufacturers instructions on installation, cutting, de-burring, cementing, curing and supporting of the venting
system.

Furnace must be vented with ULC S636 certifi ed PVC manufactured by IPEX, or ULC S636 certifi ed PPE
manufactured by M&G Duravent.

PVC vent terminations may use concentric kits listed in section 10.3 - or terminate using 45 and 90 degree
elbows.

PPE venting must terminate using 45 and 90 degree elbows.

Minimum rating of 149 degrees F (65°C).

H11.2A

Furnace venting may be comprised of:

• Schedule 40 PVC, ASTM D1785 or CSA B137.3

• PVC-DWV, ASTM D2665 or CSA B181.2

• Schedule 40 CPVC, ASTM F441 or CSA B137.6

• PVC PRIMER AND SOLVENT CEMENT: ASTM D2564

• PPE ULC S636 Manufactured by M&G Duravent - must terminate using 45 and 90 degree elbows.

Follow piping manufacturers instructions on proper installation of piping and fi ttings including cutting, deburring

,

priming, cementing, curing and supporting.

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7.3 VENT DRAIN OPTION

H11.3

A vent drain is recommended when vent passes through any unconditioned space such as an attic or crawl
space in order to prevent the accumulation of excess condensate in the inducer housing during operational
cycles, refer to images for Vent Drain Option.

To install the vent drain, complete the following steps:

IMPORTANT: Tee, reducer and nipple must be properly
cemented together using the appropriate method
and materials specifi ed in section 7.0 Venting and
Combustion Piping; 7.1 Acceptable Materials in Canada
and 7.2 Acceptable Materials in United States.

1. Place a tee of the proper diameter for the vent system
being installed 2" (51mm) or 3" (76mm) in the horizontal run
or vertical riser closest to the furnace.

2. Place a reducer bushing of proper diameter in the stem
portion of the tee. The recommended size for the reducer is
5/8" (15.9mm).

3. Place a piece of 5/8" (15.9mm) diameter pipe that has a
minimum length of 3" (76mm) long into the reducer to serve
as a nipple.

4. Connect a piece of fl exible drain tubing such as EPDM
rubber or PVC to the nipple.

5. Loop the drain tubing to provide a trap.

6. Connect the discharge end of the drain tube to the
condensate disposal system externally to the furnace.

IMPORTANT:
ELBOWS WITH DRAIN PORTS
ARE NOT RECOMMENDED, AS
CONDENSATE CAN BYPASS THE
DRAIN ON THE CURVE.

1/2" (12.7mm) ID MAX.

3" (76mm) MIN.
10" (254mm) MAX.
LOOP DIAMETER

ATTACH THIS END TO
CONDENSATE DRAIN
SYSTEM

3" (76mm) MIN.
10" (254mm) MAX.
LOOP DIAMETER

ATTACH THIS END TO
CONDENSATE DRAIN
SYSTEM

1/2" (12.7mm) ID MAX.

USE SWEEP TEE ON
HORIZONTAL LINE

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8.0 NON-DIRECT VENT FURNACE INSTALLATIONS
USING INDOOR COMBUSTION AIR (ONE PIPE
SYSTEM)

H13.0

The furnace, although designed as a direct vent type appliance, may be installed with the intake vent inside th

e

structure.

Adequate provisions for combustion and ventilation air must be in accordance with CAN/CGA-B149 in Canada,

and ANSI Z223.1 - 1992, section 5.3, “Air for Combustion and Ventilation,” in the United States. Check with

local authorities for any additional building codes bylaws or regulations.

AIR FOR COMBUSTION AND VENTILATION PURPOSES MUST NOT ORIGINATE FROM A

CORROSIVE ATMOSPHERE. ANY FURNACE FAILURE CAUSED BY CORROSIVE ELEMENTS IS

EXCLUDED FROM WARRANTY COVERAGE.

CAUTION

!

!

The following types of installation sites (but not limited to the following) will REQUIRE OUTDOOR AIR for
combustion because of chemical exposures:

• Commercial buildings

• Buildings with indoor swimming pools

• Furnaces installed in laundry rooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemical storage areas

Exposure to the following substances in the combustion air supply (but not limited to the following) will also
require OUTDOOR AIR for combustion:

• Aerosols, particularly CFC based or propelled aerosols

• Air fresheners

• “Airplane Glue” and similar adhesives and cements

• Ammonia, as commonly found in permanent wave solutions used in hair dressing salons

• Anti-static fabric softeners used in clothes dryers

• Carbon tetrachloride

• Chlorinated cleaners and waxes

• Chlorine and bromine based swimming pool chemicals

• De-icing salts or chemicals (rock salt, etc.)

• Dry cleaning fl uids such as perchloroethylene

• Fumes from curing polyurethane and similar substances

• Halogen based refrigerants including R-12 and R-22

• Hydrochloric acid, muriatic acid and other acid based masonry washing and curing materials

• Printer’s inks, paint removers, varnishes, varsol, toluene, etc.

• Water softener salt and chemicals

Combustion air must be free of acid forming chemicals such as sulphur, fl uorine and chlorine. These elements
are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish
removers, refrigerants, and many other commercial and household products. When burned in a gas fl ame,
vapors from these products form acid compounds. Acid compounds increase the dew point temperature of the
fl ue products and are highly corrosive after they condense.

H3.11

THIS FURNACE AND ANY OTHER FUEL BURNING APPLIANCE MUST BE PROVIDED
WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE

FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE BROUGHT TO

THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE PERSONAL INJURY, OR DEATH

FROM CARBON MONOXIDE POISONING.

WARNING

!

!

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8.1 DETERMINING COMBUSTION AIR

8.1.1 CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE

8.1.2 CASE 2: FURNACE LOCATED IN A CONFINED SPACE

H13.1

Unconfi ned space does not necessarily mean that ventilation will not have to be introduced from the outdoors,
particularly in airtight homes. The minimum requirement for unconfi ned space is a volume of 50 cubic feet (1.42
m³) for each 1000 Btu/hr for all fuel burning appliances located within the unconfi ned area.

If the amount of combustion and ventilation air is insuffi cient to properly operate the furnace and other fuel
burning appliances within the unconfi ned area, it will be necessary to supply it from the outdoors based on the
criteria used when calculating the air supply for a confi ned space.

NOTE

If planning to use the inside air in an unconfi ned space, remember to test for proper furnace operation (as well
as other fuel burning appliances located within the unconfi ned space) with respect to adequate combustion and
ventilation air with fi replace dampers open, clothes dryer running, bathroom exhaust fans on, kitchen range hood
on, etc.

A confi ned space, (any space smaller than the minimums discussed in Case 1), must have two air openings;
one within 12” (305mm) of the ceiling and the other within 12” (305mm) of the fl oor. The air openings must
be sized based on whether the combustion and ventilation air is being taken from indoors or outdoors, the
method outdoor air (if used) is introduced, and taking into account any other fuel burning appliances in the
confi ned space.

If suffi cient indoor combustion and ventilation air is available for the furnace and all other fuel burning
appliances, size each opening on the basis of one square inch (645mm²) of free area per 1000 Btu/hr.

(Figure 4)

NOTE

Be sure to consider all clothes dryers, bathroom fans, range hoods, etc., when making this calculation.

The minimum requirement for these openings is 100
square inches (645mm²), even for the furnace models
under 100,000 Btu/hr.

NOTE

If using grills to cover the two openings, factor in the
free area of the grill. Typically, a sidewall grill will
have a free area approximately 50% of its nominal
size. Consequently, if the required opening is 10" x
10" (254mm x 254mm), it will have to be doubled if
using a sidewall grill with 50% free area.

FIGURE 4 - COMBUSTION/DILUTION AIR FROM

HEATED INSIDE SOURCES (CASE 2)

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8.1.3 CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR

FROM ATTIC OR CRAWL SPACE

H13.2

IMPORTANT:

IF AN EXHAUST FAN, FIREPLACE, CLOTHES DRYER OR ANY SIMILAR DEVICE IS PRESENT IN THE
INDOOR AREA FROM WHICH THE COMBUSTION AND VENTILATION AIR WILL BE DRAWN, NEGA­TIVE PRESSURE COULD BE A PROBLEM IF NATURAL INFILTRATION FROM THE OUTDOORS DOES
NOT MATCH THE RATE AT WHICH AIR IS EXHAUSTED.

H13.3

FIGURE 5 - OUTSIDE AIR FOR COMBUSTION, ATTIC OR

CRAWL SPACE (CASE 3)

Alternate Combustion Air
from Attic. (12” / 305 mm
above oor)

In this circumstance, the free area of each of the two combustion and ventilation air openings is based on a
minimum of 1 square inch (645mm²) per 4000 Btu/hr. In this confi guration, one opening can originate from the
fl oor drawing combustion and ventilation air from the ventilated crawl space.

The other opening may communicate freely with the ventilated attic. If using the attic air, ensure that the
opening is ducted from the ceiling high enough to be above the insulation. The attic must be adequately

vented with soffi t vents or gable vents (Figure 5).

As an alternative to creating an opening in the fl oor to draw air from a crawl space, a duct may be dropped from
the attic terminating 12” (305mm) above the fl oor.

The following table shows minimum free areas and round pipe sizes when drawing combustion air vertically
from the attic or crawl space for the furnace
only. If other fuel burning appliances are
present, their combustion air and ventilation
air requirements must be added to those of
the furnace.

IMPORTANT:

IF THE ATTIC HAS AN EXHAUST FAN (POWER VENT), IT MAY CREATE A NEGATIVE
PRESSURE SUFFICIENTLY LARGE ENOUGH TO PREVENT THE ATTIC FROM BEING
AN EFFECTIVE SOURCE OF COMBUSTION AND VENTILATION AIR. POWERED ATTIC
FANS DO NOT CUSTOMARILY RUN DURING THE HEATING SEASON; HOWEVER,
SOME ARE CONTROLLED BY A HUMIDISTAT AS WELL AS A THERMOSTAT, WHICH MAY
ALLOW SOME OPERATION DURING THE HEATING SEASON. THE CHOICES ARE (A)
USE THE DIRECT VENT OPTION; (B) OBTAIN OUTDOOR AIR FROM ELSEWHERE; OR
(C) INTERLOCK THE ATTIC EXHAUST FAN WITH THE FURNACE SUCH THAT THE TWO
CANNOT OPERATE SIMULTANEOUSLY.

TABLE 2 - VERTICAL AIR SUPPLY (CASE 3)

Input Free Area

Round Pipe Size

K/Btu/hr Ea. Opening

40

15 in.² (97cm²) 5 in. (127mm)

60

80 20 in.² (129cm²)

6 in. (152mm)

100 25 in.² (16cm²)

120 30 in.² (194cm²) 7 in. (178mm)

H12.16.5

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8.1.4 CASE 4: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR
DUCTED HORIZONTALLY

8.1.5 CONNECTION TO FURNACE NON-DIRECT VENT

H13.4

Similar to Case 3, outdoor air for combustion and ventilation may be drawn through horizontal ducting. The
free area for each opening is calculated on the basis of a minimum of 1 square inch (645mm²) per 2000 Btu/hr
input.

The following table shows minimum free areas and round pipe sizes when drawing combustion air horizontally
from the outdoors for the furnace only. If other fuel burning appliances are present, their combustion air and
ventilation air requirements must be added to those of the furnace.

IMPORTANT:

IF GRILLS ARE USED ON THE OUTSIDE WALL, THEY MUST BE SIZED PROPERLY.
MOST SIDEWALL GRILLS HAVE ONLY 50% FREE AREA. IN THE CASE OF A UNIT WITH
100,000 BTU/HR INPUT, WHICH REQUIRES A PAIR OF 8” (203mm) ROUND PIPES TO
OBTAIN SUFFICIENT COMBUSTION AND VENTILATION AIR, THE DUCT COULD BE AN
EQUIVALENT RECTANGULAR DUCT; 8” X 7” (203mm X 178mm) FOR EXAMPLE. BASED
ON 50% FREE AREA FOR THE INLET GRILLS, THE ACTUAL GRILL SIZE WOULD HAVE
TO BE 14” X 8” (356mm X 203mm) OR ITS EQUIVALENT. A TRANSITION MAY BE USED TO
REDUCE TO THE SMALLER DUCT SIZE IF NECESSARY.

IMPORTANT:

THE OUTDOOR GRILLS MUST BE INSTALLED IN A LOCATION WHERE THEY WILL NOT BE
OBSTRUCTED IN ANY MANNER.

Combustion Air
Duct Terminates
12” (305mm)
above oor.

FIGURE 6 - OUTDOOR AIR FOR COMBUSTION,

HORIZONTAL (CASE 4)

H13.5

FIGURE 7 - NON-DIRECT

COMBUSTION AIR INLET

IMPORTANT:

WHEN USING INDOOR AIR OR THE NON-DIRECT
VENT CONFIGURATION, THE COMBUSTION AIR
INLET TO THE FURNACE MUST BE PROTECTED
FROM BLOCKAGE. USE A DOUBLE ELBOW
ARRANGEMENT IF SUPPLYING COMBUSTION AIR
THROUGH THE TOP, OR A DOWNWARD POINTING
SINGLE ELBOW IF SUPPLYING COMBUSTION AIR

THROUGH THE SIDE. (FIGURE 7)

TABLE 3 - HORIZONTAL AIR

SUPPLY (CASE 4)

Input

K/Btu/hr

Free Area

Ea. Opening

Round Pipe

Size

40

30 in

2

(194cm2)

7 in

(178mm)

60

80

40 in

2

(258cm2)

8 in

(203mm)

100

50 in

2

(323cm2)

120

60 in

2

(387cm2)

9 in

(229mm)

H12.9.5

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9.0 VENTING GUIDELINES

FAILURE TO FOLLOW ALL VENTING GUIDELINES MAY RESULT IN ERRATIC FURNACE

OPERATION, FREEZE-UP OF THE EXHAUST AIR PIPING, OR SOOTING OF THE FURNACE.

CAUTION

!

!

NOTE

• Combustion air intake and exhaust termination should be inspected periodically to ensure they are clear of
obstructions. i.e. vegetation, debris, snow, etc.

• Accumulation of snow around the combustion air intake and exhaust termination may have negative
effects on appliance operation and/or performance. Snow accumulation should be considered when
locating combustion air intake and exhaust terminations.

• Venting may be vertical or horizontal.

• Minimum vent length - 15 total equivalent feet (4.6m). (See Venting Table)

• Horizontal piping must slope back towards the furnace at a minimum rate of 1/4" to the foot (18mm per
meter), so that condensate drains towards the furnace.

• Horizontal runs must be supported at least every 3 feet (914mm). Horizontal sections must not dip or sag.

• All vent runs through unconditioned space where freezing might occur should be insulated with 1” (25mm) thick,
medium density, foil-faced Fiberglass insulation. An equivalent “arm-a-fl ex” or “rub-a-tex” may also be used as
long as there is no heat tape applied to the vent pipe. For horizontal runs where water may collect, wrap the vent
pipe with self regulating 3 or 5 watt heat tape. The heat tape must be CSA, UL, or ULC listed and installed per
the manufacturer’s instructions. This includes travel through unconditioned attic space.

• DO NOT COMMON VENT WITH ANY OTHER APPLIANCE.

• If venting vertically, do not vent up a chimney serving another appliance or install in a chase with a metal
or high temperature plastic pipe from another gas or fuel burning appliance unless the required clearances
to combustibles can be maintained between the furnace venting system and other pipes.

It is recommended that an offset is created (2 x 45°s) in the vertical exhaust vent piping to reduce the risk of
fl ooding the exhauster with excessive vent condensate run down.

All exhaust piping must be installed in accordance with CAN/CGA-B149.in Canada; the latest edition of National
Fuel Gas Code, NFPA 54 / ANSI Z223.1 in the United States, as well as in accordance with local codes.

IMPORTANT:

• CLEAN AND DE-BURR ALL PIPE CUTS (INCLUDING UNCUT VENT LENGTHS). THE

SHAVINGS MUST NOT BE ALLOWED TO BLOCK THE EXHAUST, COMBUSTION AIR INLET
OR CONDENSATE DRAIN LINES.

• IF THE PIPE AND FITTINGS ARE TO BE OTHER THAN PVC, USE THE PROPER CLEANER,

PRIMER AND CEMENT FOR THE DISSIMILAR MATERIALS.

• THE EXHAUST VENT MUST BE SUPPORTED APPROPRIATELY PRIOR TO IT BEING

FITTED TO THE EXHAUSTER. UNDER NO CIRCUMSTANCES SHALL THE EXHAUSTER

BEAR ANY WEIGHT OF THE VENTING SYSTEM.

H3.12

READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY VENT THIS

FURNACE CAN CAUSE CARBON MONOXIDE POISONING OR AN EXPLOSION OR FIRE RESULTING

IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

WARNING

!

!

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9.1 VENT TERMINATION

H14.0

Size the combustion air and exhaust piping in accordance
with Table 4. When calculating allowable vent lengths, be
sure to count all termination fi ttings in addition to counting the
concentric vent as a straight pipe.

Take the building orientation and the presence of other
buildings or other nearby structures into consideration
when planning the venting system location. Certain
external structures could create air turbulence around the
vent termination leading to downdrafts and similar venting
problems. In windy and hill locations, roof venting may improve
operations. Maximum venting length is based on 30 mph
(48 km) winds, areas where higher gusts are dominant it is
suggested to shorten the horizontal vent length.

The vent and combustion air intake shall be installed so that
both are located in the same wind pressure zone.

*3"

(76mm)

MIN.

12"

(305mm)

MIN.

INTAKE

EXHAUST

GRADE

*18" (457mm) MIN. FOR COLD
CLIMATES (SUSTAINED 0°F (-18°C)
FOR 24 OR MORE CONSECUTIVE
HOURS

FIGURE 8 - STANDARD (STRAIGHT)

HORIZONTAL VENT DETAIL

H3.13

DO NOT CONNECT FURNACE TO A CHIMNEY OR FLUE SERVING OTHER APPLIANCES OR A

SOLID FUEL BURNING APPLIANCE.

WARNING

!

!

TABLE 4 - DIRECT AND NON-DIRECT VENT LENGTHS

Maximum Allowable Length Of Exhaust Or Intake. Minimum Vent Length 15 ft. (4.6 m) or equivalent.

INPUT

K/Btu/hr

PIPE
SIZE

NUMBER OF 90° ELBOWS

NOTES

0123456

40**

1½ 60* 55 50 45 40 35 30

1. Count concentric vent
fi tting as straight pipe.

2. Use medium or long
sweep elbows where
possible.

3. One 90° elbow is
equivalent to two 45°
elbows.

4. For direct vent, the
listed lengths are
allowed for each vent
(intake and exhaust).

5. For non-direct vent,
the listed lengths are
allowed for exhaust.
The intake should have
a 1½” or 2” snorkel
intake fi tting. (Figure 7)

2 75* 70 65 60 55 50 45

60

1½ 60* 55 50 45 40 35 30

2 75* 70 65 60 55 50 45

3 100* 95 90 85 80 75 70

80

2 50* 45 40 35 30 25 20

3 100* 95 90 85 80 75 70

100

2 50* 45 40 35 30 25 20

3 100* 95 90 85 80 75 70

120 3 100* 95 90 85 80 75 70

H12.4.5

NOTE When 1½” or 3” pipe is used, exit the cabinet with 2” pipe. Reduce

or increase immediately after exiting the cabinet on both intake and exhaust.

* Maximum allowable vent (intake and exhaust) length.
** 40 K units must be vented with 1½” venting if total run length is to be less

than 25 ft. (7.6m).

orizontal vents should pass through the exterior wall. Figure 8 shows a standard horizontal vent detail.

erminate the vent approximately 8” (203mm) or more from the wall.

xterior vent pipe greater than 24” (610mm) should be insulated with 1/2” (13mm) insulation to prevent

oisture from freezing within the pipe and accumulating.

ize the exhaust pipe as specifi ed in

Table 4 - Direct and Non-Direct Vent

engths. This table lists the maximum

llowable length of pipe with respect to

he number of 90° elbows used. For the

urposes of this calculation, one 90°
lbow is equivalent to two 45° elbows.

Avoid locating the terminal in locations

here dripping condensate may cause
problems such as sidewalks, patios,
above planters, near windows where
exhaust gases may cause fogging, etc.
Avoid locating the termination too close
to shrubs and other vegetation. The
condensate may stunt or kill them.

EQUIVALENTS

Short Radius Elbow = 7 ft (2.13m)
Standard Radius Elbow = 5 ft (1.52m)
Long Radius Elbow = 3 ft (0.91m)
45 Degree Elbow = 2.5 ft (0.76m)

Vent lengths that require more than
6-90° elbows, add listed equivalents
for every elbow up to the maximum

allowable vent length.

W415-1241 / A / 03.18.15

22

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9.2 IN CANADA

9.3 IN UNITED STATES

H14.1

18" (457mm) MIN.

ROOF TERMINATION
EXHAUST

FIGURE 10 - VERTICAL VENTING

MOISTURE IN THE FLUE GASES CONDENSES AS IT LEAVES THE TERMINAL. THIS MOISTURE

CAN FREEZE ON EXTERIOR WALLS, ON SOFFITS, AND OTHER NEARBY OBJECTS. SOME

DISCOLORATION IS TO BE EXPECTED; HOWEVER, IMPROPER LOCATION OR INSTALLATION CAN

CAUSE STRUCTURAL OR EXTERIOR FINISH DAMAGE TO THE BUILDING.

CAUTION

!

!

Caulk all cracks, seams or joints within a 6 foot (1.8m) radius of the termination.
Do not terminate under a deck unless there is adequate clearance to prevent damage from the fl ue gases.

A termination may be located at the end of a patio deck. Piping running beneath the deck must be suitably
insulated and suspended in a manner to prevent condensate from collecting and freezing.

Do not locate the terminal on the side of the building facing the prevailing winter winds.

FIGURE 9 - PERISCOPED VENT DETAIL

INTAKE

EXHAUST

GRADE

*3"

(76mm)

MIN.

12"

(305mm)

MIN.

12"

(305mm)

MIN.

*18" (457mm) MIN. FOR COLD

CLIMATES (SUSTAINED 0°F (-18°C)

FOR 24 OR MORE CONSECUTIVE

HOURS

H14.2A

In addition to the general guidelines, in Canada, the vent exhaust shall not terminate:

• Directly above a paved sidewalk or paved driveway which is located between two single-family dwellings
and serves both dwellings;

• Less than 7 feet (2.1m) above a paved sidewalk or paved driveway located on public property;

• Within 6 feet (1.8m) of a mechanical air supply inlet to any building;

• Above a meter/regulator assembly within 3 feet (.91m) horizontally of the center line of the regulator;

• Within 3 feet (.91m) of any service regulator vent outlet;

• Less than 12” (305mm) above grade level or anticipated snow level;

• Within 12” (305mm) of any door, window, or non-mechanical air supply inlet to any building;

• Within 12” (305mm) of the combustion air inlet of any other appliance;

• Underneath a veranda, porch or deck, unless (a) the veranda, porch or deck is fully open on a minimum
of two sides beneath the fl oor, and (b) the distance between the top of the vent termination and the
underside of the veranda, porch or deck is greater than 12” (305mm).

In addition to the general guidelines, in the United States, the vent exhaust shall be installed in accordance
with the following:

• The clearance from the bottom of the terminal to grade shall be 12” (305mm).

• The vent shall not terminate over public walkways or over an area where condensate or vapor could
create a nuisance or hazard.

• The vent terminal shall be installed 4 feet (1.2m) below, 4 feet (1.2m) horizontally from, or 1 foot (305mm)
above any door, window, soffi t, under eave vent or gravity air inlet to the building.

• The vent terminal shall have a minimum horizontal clearance of 4 feet (1.2m) from electric meters, gas
meters, regulators and relief equipment.

W415-1241 / A / 03.18.15

23

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9.4 FURNACE VENTING INSTALLATIONS

9.4.1 NON-DIRECT VENT INSTALLATION USING INDOOR COMBUSTION AIR
(ONE PIPE SYSTEM)

9.4.2 DIRECT VENT INSTALLATION USING OUTDOOR COMBUSTION AIR (TWO
PIPE SYSTEM)

9.4.3 COMBUSTION AIR

H14.3

• Locate the vent terminal 3 feet (0.91m) above any forced air inlet located w

ithin 10 feet (3m). A

ny fresh air

or make-up air inlet, such as for a dryer or furnace area is considered a forced air inlet.
The vent terminal should be located no fewer than 3 feet (0.91m) from an inside corner formed by two exterior walls.
Recommended clearance from overhangs is a minimum of 1 foot (0.3m) vertically for each foot horizontally up

to 6 feet (1.8m).

H3.14

READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY

VENT THIS FURNACE CAN CAUSE CARBON MONOXIDE POISONING OR AN EXPLOSION

OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

WARNING

!

!

H14.4

Non-direct vent installations require only a vent pipe. This may be desirable when using outdoor combustion
air is not practical.

• Provisions are not made for routing of combustion air;

• The outdoor environment may contain contaminants undesirable for combustion.

• Install a short piece of intake air pipe with a 90° elbow to prevent objects from entering burner
area, and or objects from blocking combustion air intake.

H14.5

The direct vent confi guration is the preferred installation method. The primary advantages are:

• No special kit or modifi cations are required for direct vent installations

• Dedicated combustion air and vent piping eliminates the need to use already heated air for combustion
purposes;

• The probability of corrosive contaminants being present in the combustion air is greatly reduced;

• The direct vent confi guration is unaffected by any other appliances, exhaust fans, or other devices that
tend to create negative pressure conditions while operating.

• No vents for combustion and ventilation air are required in confi ned spaces.

H14.6

This furnace is certifi ed as a Category IV Type FSP Non-Direct and Direct Vent Furnace. When installed
as a direct vent furnace, all combustion air is supplied from the outdoors via the plastic piping system. All
components are fi eld supplied, except for the 2” PVC connector used to connect the combustion air piping to
the furnace.

The combustion air piping, like the exhaust piping, must be air tight throughout the system. The adapter joining
the combustion air to the furnace is supplied with one gasket.

IMPORTANT:

• IF PLANNING TO USE ABS PIPE, USE AN ALL-PURPOSE CLEANER AND ABS
TO PVC TRANSITION CEMENT. IF PLANNING TO USE CPVC PIPE, USE AN ALL­PURPOSE CLEANER, A CLEAR OR PURPLE PRIMER AND ALL-PURPOSE CEMENT
APPROVED FOR THE PURPOSE.

• ADDITIONAL INFORMATION ABOUT CLEANERS, PRIMERS, SOLVENTS AND
CEMENTS MAY BE OBTAINED FROM THEIR MANUFACTURERS.

• IF THE FURNACE IS TO BE INSTALLED IN THE VICINITY OF OTHER FUEL BURNING
APPLIANCES, ADEQUATE COMBUSTION AIR MUST BE AVAILABLE FOR THE NON-

DIRECT VENT APPLIANCES. SEE SECTION 8.1, “DETERMINING COMBUSTION AIR”.