Napoleon NBM040S2A, NBM060S2A, NBM040S3A, NBM060S3A, NBM080S3A Installation And Operating Instructions Manual

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W415-1117 / A / 03.11.14

UM PG 57

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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 (705)721-1212 • Fax (705)722-6031 • www.napoleonheatingandcooling.com • ask@napoleonheatingandcooling.com

SAFETY INFORMATION

ELECTRICAL SHOCK, FIRE OR

EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury, 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.

H1.11

CERTIFIED TO ANSI Z21.47b / CSA 2.3b-2008

9200 SERIES

SINGLE 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 9

4.0 LOCATION OF UNIT 10

4.1 GENERAL GUIDELINES 10

4.2 OTHER CONSIDERATIONS 10

4.3 INSTALLATION IN UPFLOW OR HORIZONTAL POSITIONS 11

4.4 AIR CONDITIONING 12

5.0 COMBUSTIBLE CLEARANCES 12

6.0 DUCTWORK 13

6.1 DUCTWORK STEPS 14

7.0 VENTING AND COMBUSTION PIPING 15

7.1 ACCEPTABLE MATERIALS IN CANADA 15

7.2 ACCEPTABLE MATERIALS IN UNITED STATES 15

7.3 VENT DRAIN OPTION 16

8.0 NON-DIRECT VENT FURNACE INSTALLATIONS USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM) 17

8.1 DETERMINING COMBUSTION AIR 18

8.1.1 CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE 18

8.1.2 CASE 2: FURNACE LOCATED IN A CONFINED SPACE 18

8.1.3 CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR FROM ATTIC OR CRAWL SPACE 19

8.1.4 CASE 4: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR DUCTED HORIZONTALLY 20

8.1.5 CONNECTION TO FURNACE NON-DIRECT VENT 20

9.0 VENTING GUIDELINES 21

9.1 VENT TERMINATION 22

9.2 IN CANADA 23

9.3 IN UNITED STATES 23

9.4 FURNACE VENTING INSTALLATIONS 24

9.4.1 NON-DIRECT VENT INSTALLATION USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM) 24

9.4.2 DIRECT VENT INSTALLATION USING OUTDOOR COMBUSTION AIR (TWO PIPE SYSTEM) 24

9.4.3 COMBUSTION AIR 24

10.0 TERMINATIONS 25

10.1 COMBUSTION AIR 25

10.2 EXHAUST 25

10.3 CONCENTRIC VENTING KIT 25

10.4 CONCENTRIC VENT TERMINATION INSTALLATION INSTRUCTIONS 25

10.5 LOCATION 25

10.6 MULTIPLE VENTING 26

11.0 ROUTING OPTIONS 29

11.1 EXHAUSTER ROTATION INSTRUCTIONS & PRESSURE SWITCH MOUNTING 29

11.2 CONDENSATE DRAINS 30

11.3 PREPARATIONS FOR VENT AND DRAINING OPTION 30 11 .4 DRAIN HOSE INSTALLATION 33

11.4.1 DRAIN TUBING 33

11.4.2 PRIMING CONDENSATE TRAP 34

11.5 ALTERNATE CONDENSATE DRAIN 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 CONVERSION 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

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1.0 INTRODUCTION

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

15.0 LOW VOLTAGE WIRING 43

15.1 THERMOSTAT LOCATION 43

16.0 OPTIONAL ACCESSORIES (FIELD SUPPLIED/INSTALLED) 43

16.1 ELECTRIC AIR CLEANER 43

16.2 POWER HUMIDIFIER 43

17.0 INITIAL STARTUP PROCEDURES 44

17.1 TO START THE FURNACE 44

17.2 TO SHUT DOWN THE FURNACE 44

17.3 SEQUENCE OF OPERATION 45

18.0 AIR FLOW 46

18.1 TEMPERATURE RISE CHECK 46

18.2 CALCULATING AIR FLOW 47

18.3 CONTINUOUS FAN OPERATION 47

19.0 MAINTENANCE AND TROUBLESHOOTING 48

19.1 AIR FILTER 48

19.2 LUBRICATION 49

19.3 TROUBLESHOOTING FLOWCHART 50

19.4 DIAGNOSTIC CODES FOR STATUS LED 51

19.5 FAULT CODE HISTORY 51

20.0 WIRE DIAGRAM FOR SINGLE STAGE FURNACE WITH PSC 52

21.0 WARRANTY 53

22.0 SINGLE STAGE REPLACEMENT PARTS LIST 54

23.0 SERVICE HISTORY 56

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.

H4.0.1

This high efﬁ cient gas ﬁ red single stage condensing furnace is an upﬂ ow, horizontal left and right warm air furnace suitable for residential and light commercial heating applications with inputs from 30,000 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 MA TERIALS 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 LOCA TION WELL A W AY 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 DEP ARTMENT.

PROPER INST ALLATION, ADJUSTMENT, AL TERATION, 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: (416) 747-4000 Phone: (202) 824-7000 website: www.csa.ca website: www.aga.org

National Fire Protection Association 1 Batterymarch Park Quincy, MA, 02169-7471 Phone: (617) 770-3000 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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H3.6

WARNING

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL 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.

FIGURE 1 - FURNACE DIMENSIONS

SIDE CUTOUT

LOW VOLTAGE IN

HIGH VOLTAGE IN

ALTERNATE VENT OUTLET

LEFT SIDE DRAIN HOLES

UPFLOW DRAIN HOLE

AIR INLET

ALTERNATE AIR IN

STD. GAS SUPPLY

& RIGHT SIDE

CONDENSATE DRAIN TRAP w/ 1/2" CPVC DISCHARGE LEFT

2” PVC VENT OUTLET

ALT. VENT OUTLET

ALT. AIR INLET

FOR SIDE CUTOUTS

ALT. GAS LINE IN

VOLTAGE IN

ALT. UPFLOW DRAIN HOLE

ALT. LOW

VOLTAGE IN

WITNESS MARKS

ALT. HIGH

RIGHT SIDE DRAIN HOLES

SIDE CUTOUT

5.125"

(130mm)

TOP

LEFT SIDE FRONT RIGHT SIDE

TABLE A - FURNACE DIMENSIONS

INPUT OUTPUT Width Depth Height Supply Air Return Air

MODEL

Btu/hr

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

NBM030S2A 30 000 28 200

14 1/2"

(356mm)

29 1/2"

(737mm)

32 7/8"

(835mm)

13 1/4" X 19 5/8"

(337mm x 499mm)

14" x 23"

(356mm x 584mm)

NBM040S2A 40 000 36 800

NBM040S3A 40 000 36 800

17 1/2"

(445mm)

16 1/4" X 19 5/8"

(413mm x 499mm)

NBM060S2A 60 000 55 200

14 1/2"

(356mm)

13 1/4" X 19 5/8"

(337mm x 499mm)

NBM060S3A 60 000 55 200

17 1/2"

(445mm)

29 1/2"

(737mm)

32 7/8"

(835mm)

16 1/4" X 19 5/8"

(413mm x 499mm)

14" x 23"

(356mm x 584mm)

NBM080S3A 80 000 73 600

NBM080S4A 80 000 73 600

21"

(533mm)

19 3/4" X 19 5/8"

(502mm x 499mm)

NBM100S4A 100 000 92 000

NBM100S5A 100 000 92 000

24 1/2"

(622mm)

23 1/4" X 19 5/8"

(590mm x 499mm)

NBM120S5A 120 000 110 400

H12.6.1

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TABLE B - MINIMUM CLEARANCES TO COMBUSTIBLE

MATERIALS (INCHES)

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

UPFLOW

HORIZONTAL

TOP

PLENUM TOP

1/2" (13mm)

FRONT

H12.11.1

BACK

SIDES

BOTTOM

FLUE PIPE

ENCLOSURE

CLOSET

1/2" (13mm)

0* 0*

0 0**

0***

*24" (610mm) REQUIRED FOR SERVICE **SUPPLY AIR OUTLET / 1/2" (13mm) RETURN AIR INLET ***CERTIFIED FOR CLOSET INSTALLATION ON COMBUSTIBLE FLOORING.

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3.0 FURNACE SIZING

TABLE 1 - RANGE OF TEMPERATURE RISE

Furnace Models Temperature Rise

NBM030S2A 35 - 65°F (20 - 36°C)

NBM040S2A 35 - 65°F (20 - 36°C)

NBM40S3A 30 - 60°F (17 - 33°C)

NBM060S2A 35 - 65°F (20 - 36°C)

NBM060S3A 35 - 65°F (20 - 36°C)

NBM080S3A 35 - 65°F (20 - 36°C)

NBM080S4A 35 - 65°F (20 - 36°C)

NBM100S4A 30 - 60°F (17 - 33°C)

NBM100S5A 30 - 60°F (17 - 33°C)

NBM120S5A 35 - 65°F (20 - 36°C)

H12.15.1

H7.0.1

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.

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). These furnaces are designed to be operated with a system temperature rise (∆T) of 35 - 65°F (20 - 36°C) or 30 - 60°F (14 - 31°C) depending on what model is installed. 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.

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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” (51mm) ANGLE IRON

• JAM NUTS

• LOCK WASHER

• FLAT WASHER

SUPPLY AIR PLENUM

4.2 OTHER CONSIDERATIONS

H8.1.1

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). Be sure to install a Horizontal Kit. Kit # W370-0027.

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

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4.3 INSTALLATION IN UPFLOW OR HORIZONTAL POSITIONS

H8.2

• “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

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.

H8.3.1

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

accordance with instructions in the appropriate sections of this manual. HORIZONT AL 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 INST ALLATION: 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 INST ALLATION: 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.

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

H8.4.1

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.

Optional Bridge Installation Kit (W370-0028), available to run heat and cool speeds on shared tap.

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.

INST ALLATION 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

H11.1

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.

This furnace must be vented with ULC S636 certiﬁ ed:

• PVC (Polyvinyl Chloride), OR

• PPE (Polypropolene) material

with a rating of 149°F (65ºC) or more.

The combustion air piping does not have ﬂ ue gases travelling through it and may be installed with common ABS, PVC or CPVC piping or ﬁ ttings. This piping, ﬁ ttings, primer and cement will need to be installed as per the manufacturers instructions including cementing, cutting, curing and supporting the piping.

H11.2

For United States installations, the combustion air and vent piping and ﬁ ttings 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

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

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.

H13.2

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.

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.

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

H13.3

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

K/Btu/hr

Free Area

Ea. Opening

Round Pipe

Size

15 in

(97 cm2)

5 in

(127 mm)

20 in

(129 cm2)

6 in

(152 mm)

100

25 in

(161 cm2)

120

30 in

(194 cm2)

7 in

(178 mm)

H12.16.1

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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

TABLE 3 - HORIZONTAL AIR

SUPPLY (CASE 4)

Input

K/Btu/hr

Free Area

Ea. Opening

Round Pipe

Size

30 in

(194 cm2)

7 in

(178 mm)

40 in

(258 cm2)

8 in

(203 mm)

100

50 in

(323 cm2)

120

60 in

(387 cm2)

9 in

(229 mm)

H12.9.1

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)

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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 T O PROPERLY VENT THIS

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

IN PROPERTY DAMAGE, PERSONAL INJUR Y OR LOSS OF LIFE.

WARNING

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9.1 VENT TERMINATION

TABLE 4 - DIRECT AND NON-DIRECT VENT LENGTHS

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

INPUT

K/Btu/hr

PIPE SIZE

NUMBER OF 90° ELBOWS

NOTES

0123 456

1 1/2 75* 70 65 60 55 50 45

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)

2 100* 95 90 85 80 75 70

1 1/2 75* 70 65 60 55 50 45

2 100* 95 90 85 80 75 70

1 1/2 75* 70 65 60 55 50 45

2 100* 95 90 85 80 75 70

3 125* 120 115 110 105 100 95

2 75* 70 65 60 55 50 45

3 125* 120 115 110 105 100 95

100

2 75* 70 65 60 55 50 45

3 125* 120 115 110 105 100 95

120 3 125* 120 115 110 105 100 95

NOTE * Maximum allowable vent (intake and exhaust) length.

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.

H12.4.1

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

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.

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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.

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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 within 10 feet (3m). Any 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”.

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10.0 TERMINATIONS

10.1 COMBUSTION AIR

10.2 EXHAUST

10.3 CONCENTRIC VENTING KIT

10.4 CONCENTRIC VENT TERMINATION INSTALLATION INSTRUCTIONS

10.5 LOCATION

H15.1

HORIZONTAL - The combustion air termination is

made up of a medium or long sweep 90° elbow pointing downward to prevent rain from readily entering the combustion air intake piping.

If the required clearance to grade cannot be obtained with the “straight through” conﬁ guration, the combustion air intake pipe may be “periscoped” up to 24” (610mm) to

gain extra height (Figure 9) VERTICAL - The combustion air termination is made up

of a pair of medium or long sweep 90° elbow pointing downward to prevent rain from entering the combustion air intake piping.

The combustion air inlet must be located a minimum of 12” (305mm) above grade, and 12” (305mm) below the

exhaust outlet. (Figure 11)

12"

(305mm)

MIN.

(76mm)

MIN.

18"

(457mm)

MIN.

12"

(305mm)

MIN.

ROOF TERMINATION EXHAUST

FIGURE 11 - STANDARD VERTICAL VENTING

DETAIL

H15.2

HORIZONTAL - The exhaust termination is normally a 45° elbow or a medium or long sweep 90° elbow

pointing within 45° of the downward position, away from the combustion air intake terminal. If the required clearance to grade cannot be obtained with the “straight through” conﬁ guration, the exhaust pipe

may be “periscoped” up to 24” (610mm) to gain extra height. (Figure 9) In this case, the ﬂ ue gases may be

expelled horizontally. Use the same size pipe as the interior run and count the ﬁ ttings and length as part of the total vent length.

If winter prevailing wind conditions are variable and likely to occasionally blow ﬂ ue gases back in on the combustion air intake, the exhaust termination may be raised 18-24” (457mm x 610mm) above the combustion air intake terminal to take advantage of the natural buoyancy of the ﬂ ue gases to help prevent re-circulation of

the exhaust. (Figure 9) VERTICAL - No termination ﬁ tting is required if venting vertically through a roof.

The end of the exhaust pipe must be 12” (305mm) higher than the entrance of

the combustion air intake terminal. (Figure 11)

The exhaust pipe extending through the roof must extend a minimum of 18” (457mm) above any obstruction within an 18” (457mm) horizontal distance.

Insulate all venting that extends 24” (610mm) or more to the outside.

NOTE: Always clean out exhauster collar after installation. Vent pipe shavings from initial installation can cause blockage in the exhauster collar drain.

H15.3.1

Concentric venting terminal kits may be used for this series furnace. They provide a means of obtaining combustion air and exhausting products of combustion utilizing a single penetration through the exterior wall. This can be useful when there is limited wall space available. Kits are available in 2” and 3” sizes. If venting the 30K or 60K Btu/hr model with 1½” vent material, and a concentric vent kit is necessary, a increase coupling may be used to connect to the 2” concentric venting kit. Read the instructions supplied with the kit for additional installation instructions and details.

H15.4

Follow the concentric vent termination manufacturer instructions for installation of the concentric vent termination kit. These instructions can be found by contacting the furnace manufacture. Furnace manufacturer contact information is found on the front cover of this installation manual and operating instructions.

void locating the terminals where the ﬂ ue gas could become stagnant and allow recirculation into the

combustion air intake.

void locating the terminal in locations where dripping condensate may cause problems such as sidewalks,

patios, above planters, near windows where exhaust gases may cause fogging, icing, etc.

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10.6 MULTIPLE VENTING

H15.5

void locating the termination too close to shrubs and other vegetation. The condensate may stunt or kill them. 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.

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.

hen locating vent terminations, consideration must be given to prevailing winds, location, and other

conditions which may cause recirculation of the combustion products of adjacent vents.

IMPROPER LOCATION OR INSTALLATION CAN RESULT IN STRUCTURAL DAMAGE TO

THE BUILDING, DAMAGE TO THE EXTERIOR FINISH OF THE BUILDING, OR MAY ALLOW

RECIRCULATION OR FREEZING OF THE FLUE GASES ONTO OR INTO THE COMBUSTION

AIR INTAKE.

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

MOISTURE CAN FREEZE ON EXTERIOR WALLS, SOFFITS, AND OTHER NEARBY

OBJECTS. SOME DISCOLORATION IS TO BE EXPECTED.

CAUTION

he vent terminal should be located no fewer than 3 feet (.9m) from an inside corner formed by two exterior walls.

Recommended clearance for overhangs is a minimum of 1 foot (.3m) vertically for each foot horizontally up to 6 feet (1.8m).

ny adjacent painted surfaces should be in good condition; no cracks, peeling paint, etc. If wooden surfaces that

may be periodically exposed to ﬂ ue gases are present, consider treating with a sealer.

H15.6

COMMON VENTING IS PROHIBITED!!

If two of these furnaces are to be installed in close proximity, the combustion air intake and exhaust terminations may be installed as shown in Figures 12 and 13.

IMPORTANT:

WHEN INSTALLING MULTIPLE FURNACES IN CLOSE PROXIMITY, EACH REQUIRES DEDICATED COMBUSTION AIR AND EXHAUST VENTING.

If more than two furnaces are being installed in close proximity, each additional combustion air intake and exhaust termination set shall not terminate less than 12 in (305mm) apart. Note: Canadian installations of 120000 Btu/hr require 3 ft (915mm).

FIGURE 13 - MULTIPLE VENTING (STANDARD

VERTICAL)

12" (305mm) MIN. ABOVE SNOW LEVEL

30" (762mm) MAX.

12" (305mm) MIN.

(76mm)

MIN.

TO BE REDUCED FROM 3" PVC TO 2" PVC BELOW THE

COMBUSTION AIR INTAKE 2" PVC

TWO FURNACES VENTING THROUGH ROOF

(75mm)

MIN.

INTAKE

(203mm)

MIN.

(51mm)

MIN.

12" (305mm) MIN.

12"

(305mm)

MIN.

GRADE

EXHAUST

FIGURE 12 - MULTIPLE VENTING (STANDARD HORIZONTAL)

H3.15

RECIRCULATION OF FLUE GASES MAY OCCUR CAUSING THE INTAKE PIPE TO

FREEZE SHUT DURING COLD WEATHER OPERATION IF THE VENTING SYSTEM IS NOT

INSTALLED PER THESE GUIDELINES.

WARNING

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FIGURE 14A - DIRECT VENT TERMINAL CLEARANCES

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FIGURE 14B - NON-DIRECT VENT TERMINAL CLEARANCES

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11.0 ROUTING OPTIONS

11.1 EXHAUSTER ROTATION INSTRUCTIONS & PRESSURE SWITCH MOUNTING

TABLE 5 - EXHAUSTER ORIENTATION

FURNACE

FLUE

OUTLET

EXHAUSTER

KIT

REQUIRED

SEE FIGURES

16-18 FOR

RECOMMENDED

MOUNTING

Up Left Yes No

Up Right Yes No

Up Vertical No No

Horizontal Left Left No Yes

Horizontal Left Vertical Yes Yes

Horizontal Right Right No Yes

Horizontal Right Vertical Yes Yes

H12.5.1

H16.0.2

This furnace can be installed in any of three positions. Figures 16-18 on the following pages show the three positions. The installer must consider the following services: gas pipe, electrical power, drain trap, intake and exhaust vents. Also consider the air conditioning connections and drain, access to ﬁ lter(s) and access to furnace and a/c for repair. Drains and traps of furnaces installed in spaces subjected to freezing temperature must also be protected against freezing.

The combustion air inlet ﬁ tting is a 2” PVC Socket to Pipe Thread adapter. Choose the intake location and remove the appropriate plastic cap, if applicable. Install the adapter to the exterior panel using the locknut on the inside of the panel, and the gasket on the outside of the panel to create an air tight seal. Failure to apply the gasket on the cabinet exterior voids the warranty.

H16.1.1

IMPORTANT:

KEEP PRESSURE SWITCH HOSES ABOVE HEAT EXCHANGER DRAIN, AND CUT TO APPROPRIATE LENGTH TO PREVENT ANY SAGS OR TRAPS FORMING IN THE HOSES.

1. Disconnect exhauster wire connection (L1 and Neutral).

2. Remove the 3 exhauster screws.

3. Remove pressure switch assembly.

4. Remove exhauster.

5. Reverse the bands on the rubber drain coupling so the screws are accessible if necessary. (Do not reverse the drain coupling.) Conﬁ rm that directional arrow on drain coupling points away from exhauster.

6. Remove the appropriate plastic cap on the side panel. Install cap on vent opening not in use.

7. Reinstall the exhauster and the pressure switch assembly in the correct orientation with the (3) exhauster screws removed in step 2. Reinstall the pressure switch so that it is above the heat exchanger drain, to eliminate the chance of condensate draining into the pressure switch sensing hose causing erratic furnace operation. See Figures 16-18 for reference.

8. Rotate the drain coupling so the drain holes are angled downward 15° and tighten coupling band to exhauster.

9. Complete the venting as installation requires.

Always secure or support the vent and intake to the ﬂ oor joists or rafters to avoid sagging and possible fatigue of venting materials. This ensures proper drainage and prevents spilling the products of combustion into the building.

The blower compartment should be completely isolated from the burner compartment, and in tight rooms with other combustion devices, be completely isolated from the room. Ensure that the combustion door gasket is in good condition.

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11.2 CONDENSATE DRAINS

11.3 PREPARATIONS FOR VENT AND DRAINING OPTION

H16.2.1A

NOTE: It is recommended that pliers be used to ﬁ rmly clamp the plastic hose clamps.

The furnace may condense as much as a 4½ pounds of water per hour (approximately 2 imperial quarts, 2½ U.S. quarts or 2¼ liters). It is necessary to make provisions for draining the condensate away. The furnace is supplied with a drain trap assembly. See Figures 16-18 for possible locations of the drain trap.

Afﬁ x the condensate trap assembly to the interior of the side panel in the blower compartment for upﬂ ow positions. For horizontal positions afﬁ x the condensate trap assembly to the exterior side panels.

Three plastic drain hose clamps are provided in the parts bag. The large ones are used for securing the drain hose to the front manifold cover drain outlet, and securing the drain hose to the 5/8” barbed ﬁ tting on the condensate trap assembly. The small one is used to secure the drain hose to the 1/2” barbed ﬁ tting on the condensate trap assembly.

The drain coupling on the exhauster will work better if the drain holes are pointed down about 15 degrees. The drain hose supplied with the furnace is long enough to reach either side panel; however, it must be cut to ﬁ t each application. This is to prevent kinking in the drain lines.

H16.3.1A

BARB FLANGE

1. Determine the most suitable vent and drain options for installation. See Figures 16-18 for reference, and refer to Exhauster Rotation Instructions section if necessary.

2. Remove the 3½” plastic exhaust vent cap (if required), and cover vent hole not in use. Install rubber grommet (in parts bag) for 2” vent pipe. Connect vent pipe (field supplied). If using 1½” or 3” vent, make transition as close as possible to the unit and on a vertical section.

3. Connect 2” air intake pipe (field supplied). 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.

4. Remove the plastic air inlet cap and connect the 2” PVC air intake connector with the rubber gasket on the outside of the unit using the 2” lock nut (in parts bag).

5. Remove the two plastic caps attached to the blower division, and the one attached to the side panel if applicable.

6. Affix the condensate trap assembly to the interior of the side panel in the blower compartment for upflow positions using the two screws provided in parts bag (Fig.16). For horizontal positions affix the condensate trap assembly to the exterior side panels (Fig. 17 & 18).

7. Make sure combustion compartment is fully sealed.

NOTE

• Condensate drain tubing must be cut to appropriate length and slopping towards condensate trap, ensuring that drain hoses do not create traps prior to the condensate trap assembly.

• Condensate trap must be primed with water prior to initial furnace start up.

• Any increase of venting diameter must be done on the vertical sections NOT on the horizontal sections.

NOTE

Barbed ﬁ ttings must be fully inserted into condensate trap, seated to barb ﬂ ange.

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FIGURE 16 - UPFLOW VENT AND DRAINING OPTION

LEFT VENT INSTALLATION TOP VENT INSTALLATION

NOTE

Trap can be installed on the left or right side of the unit.

Only left side install pictured.

IMPORTANT:

• PRIME CONDENSATE TRAP WITH WATER AND CUT DRAIN HOSES TO PROPER LENGTH.

• CUT PRESSURE SWITCH TUBING TO PROPER LENGTH, IF REQUIRED.

FIGURE 15

IMPORTANT:

CONNECT ½” TEE FITTING (FIELD SUPPLIED) TO THE OUTLET OF THE CONDENSA TE TRAP.

H3.16

THERE MUST NOT BE ANY OPENINGS BETWEEN THE BLOWER DIVISION PANEL AND

THE COMBUSTION COMPARTMENT. THE BLOWER COMPARTMENT IS UNDER GREATER

SUCTION THEN THE COMBUSTION COMPARTMENT AND CAN PULL COMBUSTION

AIR FROM THE BURNERS AND CAUSE INCOMPLETE COMBUSTION AND ERRATIC

FURNACE OPERATION.

WARNING

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RIGHT VENT INSTALLATION

NOTE Upﬂ ow Vent Right - condensate trap may have to be installed on left side in small cabinets.

IMPORTANT:

• PRIME CONDENSATE TRAP WITH WATER AND CUT DRAIN HOSES TO PROPER LENGTH.

• CUT PRESSURE SWITCH TUBING TO PROPER LENGTH, IF REQUIRED.

FIGURE 17 - HORIZONTAL LEFT VENT AND DRAINING OPTION

LEFT VENT INSTALLATION TOP VENT INSTALLATION

FIGURE 16 - UPFLOW VENT AND DRAINING OPTION CONTINUED

IMPORTANT:

• FOR HORIZONTAL INSTALLATIONS, KIT# W370-0027 MUST BE INSTALLED.

• PRIME CONDENSATE TRAP WITH WATER AND CUT DRAIN HOSES TO PROPER LENGTH.

• CUT PRESSURE SWITCH TUBING TO PROPER LENGTH, IF REQUIRED.

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FIGURE 18 - HORIZONTAL RIGHT VENT AND DRAINING OPTION

RIGHT VENT INSTALLATION

TOP VENT INSTALLATION

IMPORTANT:

• FOR HORIZONTAL INSTALLATIONS, KIT# W370-0027 MUST BE INSTALLED.

• PRIME CONDENSATE TRAP WITH WATER AND CUT DRAIN HOSES TO PROPER LENGTH.

• CUT PRESSURE SWITCH TUBING TO PROPER LENGTH, IF REQUIRED..

THE TWO INLETS TO THE DRAIN TRAP ARE FOR VENT PIPE AND CONDENSATE

COLLECTION. THE VENT PIPE INLET IS SMALLER THAN THE CONDENSATE

COLLECTION INLET. ENSURE THAT THE DRAIN HOSES ARE PROPERLY CUT TO THE

REQUIRED LENGTH CONNECTED AND SECURED.

CAUTION

11 .4 DRAIN HOSE INSTALLATION

11.4.1 DRAIN TUBING

H16.4

1. Connect one end of the 5/8” tubing (in parts bag) to the most direct drain outlet on the front manifold cover, and the other end to the larger elbow on the condensate trap assembly. Cut excess tubing if necessary and hold in place with the supplied plastic hose clamps (in parts bag).

2. Connect one end of the 1/2” tubing, using the reducing coupling (in parts bag), to the lower drain outlet on the exhauster coupling, and the other end to the smaller elbow on the condensate trap assembly. Cut excess tubing if necessary.

NOTE All condensate drain tubing must slope towards the condensate trap, ensuring that the drain hoses do not create traps or kinks in the hose prior to the condensate trap assembly.

Condensate from the outlet of the drain trap assembly must be conveyed to a ﬂ oor drain, sump pit, or, if these are unavailable, to a condensate pump. If using a condensate pump, be sure that it is approved for furnace condensate.

DO NOT DRAIN THE CONDENSATE OUTDOORS. DO NOT RUN THE CONDENSATE LINE

THROUGH AREAS WHERE FREEZING MIGHT OCCUR. FREEZING OF CONDENSATE CAN

RESULT IN ERRATIC FURNACE OPERATION AND IN PROPERTY DAMAGE.

CAUTION

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H16.4.1

A typical conﬁ guration would be to cement the side branch of a 1/2” CPVC tee to the drain trap assembly outlet, with the end branches oriented vertically. (Figure 15)

A 1” (25mm) piece of 1/2” CPVC pipe cemented to the upper end branch will serve as a vent, which will prevent the creation of a vapor lock, and serve as an overﬂ ow in the event that the drain line becomes blocked. A similarly sized piece of pipe cemented to the lower end branch will permit connection to the condensate outlet with 5/8” ID / 7/8” OD ﬂ exible tubing, or the condensate may be piped entirely in CPVC to the ﬂ oor drain/sump/condensate pump.

IMPORTANT:

IF AN AIR CONDITIONING EVAPORATOR COIL DRAIN IS TO SHARE THE FURNACE DRAIN LINE, IT SHOULD BE CONNECTED WITH A TEE FITTING DOWNSTREAM FROM THE TRAP. DO NOT CONNECT THE EVAPORATOR COIL CONDENSATE DRAIN UPSTREAM OF THE FURNACE DRAIN TRAP ASSEMBLY.

NOTE It is recommended that the condensate drain assembly not be cemented to the condensate trap outlet, if removal of the condensate trap is required in the future. Use a piece of the provided 1/2” drain hose if removal of the condensate trap is anticipated.

11.4.2 PRIMING CONDENSATE TRAP

H16.4.2

IMPORTANT:

THE CONDENSATE DRAIN TRAP ASSEMBLY SHOULD BE FULL OF WATER (PRIMED) BEFORE STARTING THE FURNACE. TO FILL THE CONDENSATE DRAIN TRAP ASSEMBLY, TEMPORARILY REMOVE THE VENT DRAIN HOSE FROM THE EXHAUSTER ASSEMBLY ELBOW/DRAIN FITTING, AND POUR APPROXIMATELY ONE CUP OF WATER DOWN THE HOSE. WATER WILL BEGIN RUNNING OUT THE CONDENSATE DRAIN TRAP OUTLET WHEN IT IS FULL. REFASTEN THE VENT DRAIN HOSE TO THE EXHAUSTER ASSEMBLY ELBOW/DRAIN FITTING.

THE CONDENSATE DRAINAGE CONFIGURATION REQUIRES A VENT. IT TAKES LESS THAN A ONE INCH RISE ANYWHERE ALONG THE HORIZONTAL ROUTE OF THE DRAIN TUBE TO CREATE A VAPOR LOCK, WHICH WILL PREVENT CONDENSATE FROM DRAINING AWAY FREELY, AND RESULT IN ERRATIC FURNACE OPERATION.

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

1. The supplied parts bag includes a length of 1/2” and 5/8” rubber hose and the condensate trap. Install the condensate trap according to instructions included in this manual.

FIGURE 21 FIGURE 22

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11.6 CONDENSATE NEUTRALIZERS

H16.5.1A

FIGURE 23 FIGURE 24

2. If installing with 1/2” PVC, use the 1/2” hose. If installing with 3/4” CPVC, use the 5/8” hose. Slide the appropriate hose over the condensate trap outlet and cut it ﬂ ush with the end of the outlet. The remaining rubber should be ﬂ ush with the end of the outlet on the condensate trap. The remaining hose is sufﬁ cient length to accommodate all furnace orientations.

3. A 1/2” PVC coupling or bushing will ﬁ t snug over the 1/2” rubber hose. A 3/4” CPVC coupling or bushing will

ﬁ t snug over the 5/8” rubber hose. This method ensures a water tight seal and also allows the condensate trap to be easily removed for service.

4. If extra security is desired, it is recommended to secure a strip of strapping around the drain. Utilize the existing condensate trap screws to secure the strapping.

FIGURE 25 FIGURE 26

H16.6

Some local codes may require the use of a condensate neutralizer. If the furnace condensate is to be routed to a septic system, it may be advisable to use a condensate neutralizer.

When condensate neutralizers are used, it is advisable to install it with an overﬂ ow bypass tube.

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12.0 GAS SUPPLY AND PIPING

12.1 GAS SUPPLY

12.2 GAS PIPING

H3.18

THIS FURNACE IS FACTORY EQUIPPED TO BURN NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A NATURAL GAS TO LP CONVERSION KIT (W370-0018). FAILURE T O USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, EXPLOSION, CARBON

MONOXIDE POISONING, PROPERTY DAMAGE, PERSONAL INJUR Y OR LOSS OF LIFE.

WARNING

H17.1

IMPORTANT:

• CONVERSION OF THIS FURNACE REQUIRES SPECIALIZED EQUIPMENT. CONVERSION MUST BE COMPLETED BY A TRAINED AND QUALIFIED INSTALLER, SERVICE AGENCY OR GAS SUPPLIER.

• CONNECT THIS FURNACE ONLY TO GAS SUPPLIED BY A COMMERCIAL UTILITY OR SUPPLIER. PRIVATE GAS WELLS DO NOT GENERALLY PROVIDE GAS WITH CONSISTENT, UNIFORM AND PREDICTABLE HEATING VALUES AND DENSITIES. MANY NON-COMMERCIAL WELLS CONTAIN IMPURITIES SUCH AS SULPHUR, WHICH MAY DAMAGE THE FURNACE. THIS FURNACE CANNOT OPERATE PROPERLY OR SAFELY USING FUELS OUTSIDE NORMAL COMMERCIAL STANDARDS.

In Canada, the gas piping should be installed in accordance with CAN/CSA-B149.1 and 2, and in accordance with any local codes.

In the United States, the gas piping should be installed in accordance with (NFGC) NFPA 54 / ANSI Z223.1 and any local codes.

If local codes allow the use of a ﬂ exible gas appliance connector, always use a new listed connector. Do not use a connector, which has previously serviced another gas appliance.

IMPORTANT:

To maintain a good seal in the burner area, the gas piping through the side panel into the furnace must be 1/2” Schedule 40 black iron pipe. The pipe passes through a special rubber grommet that is custom manufactured to seal tightly around the gas pipe. (Figure 27)

The gas piping may enter the furnace from either side. Once the routing of the gas pipe is determined, select and remove the plastic cap if necessary and install on other panel, and install the grommet within the hole.

NOTE

We recommend a union between the gas valve and the side panel to allow easy removal of the burner for service purposes.

FIGURE 27 - FURNACE GAS PIPE CONNECTIONS

(NOTE RUBBER GROMMET)

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12.3 GAS INLET PRESSURE

12.4 LEAK TESTING

12.5 PURGING GAS LINES

H17.2A

IMPORTANT:

ALWAYS USE A BACKUP WRENCH TO PREVENT TWISTING OF THE GAS VALVE. ANY STRAINS ON THE GAS V ALVE CAN AFFECT POSITIONING OF THE ORIFICES RELA TIVE TO THE BURNERS. THIS COULD RESULT IN FAULTY BURNER OPERATION.

Install a manual gas shut-off valve and dirt pocket as close to the furnace as possible. Some local codes call for the manual gas shut-off valve to be located between 4 feet (1.2m) to 5 feet (1.5m) above ﬂ oor level to prevent tampering by small children. Ensure that the valve is readily accessible.

IMPORTANT:

ENSURE THAT THE GAS VALVE IS NOT SUBJECTED TO HIGH PRESSURES.

H3.19

DISCONNECT THE MANUAL SHUT-OFF VALVE AND GAS VALVE DURING ANY

PRESSURE TESTING THAT EXCEEDS 1/2 P.S.I.G. (3.45 KPA).

WARNING

H17.3.1

The natural gas inlet supply pressure should be 5” to 7” w.c. (7” w.c. recommended). The LP gas inlet supply pressure should be 11” to 13” w.c. (12” w.c. recommended). These pressures must be maintained while all other gas ﬁ red appliances are operating at maximum conditions.

IMPORTANT:

DO NOT EXCEED 13” W.C. INLET PRESSURE WITH EITHER FUEL.

The gas valve has an adjustable internal regulator for controlling burner manifold pressure. Burner manifold pressure is listed on the furnace rating plate.

H17.4

All new gas piping installations should be pressure tested as speciﬁ ed by CAN/CSA-B149.1 & 2, or NFPA 54

ANSI Z223.1 or ANSI/NFPA 58, “Standard for the Storage and Handling of Liqueﬁ ed Petroleum Gases.”

Gas piping that has not been pressure tested, from the manual shut-off valve to the furnace gas valve for example, should be leak tested using an electronic combustible gas detector, a commercially prepared leak detector, or other locally approved method.

H3.20

NEVER USE A MATCH, TAPER, CIGARETTE LIGHTER, FLAME OR ANY OTHER IGNITION

SOURCE TO CHECK FOR LEAKS IN A GAS LINE.

FAILURE TO ADHERE TO THIS WARNING CAN CAUSE A FIRE OR EXPLOSION

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

WARNING

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13.0 CONVERSIONS

13.3 CONVERSION STEPS

13.4 CHECKING THE INLET GAS PRESSURE

13.1 HIGH ALTITUDE CONVERSION

13.2 NATURAL TO LP GAS CONVERSION

H18.1

In Canada, the modiﬁ cations for high altitude are based on a 10% reduction of input capacity for elevations from 2000 - 4500 feet (610m - 1372m).

In the United States, the modiﬁ cations for high altitude are based on a 4% reduction of input capacity for every 1000 feet (305m) above 2000 feet (610m) above sea level. Table 6 illustrates the impact of altitude for selected elevations. Consult with local fuel suppliers or authorities to determine local regulations or customs.

H18.2A

This series furnace is manufactured as a natural gas appliance that may be converted to LP gas through use of the Conversion Kit part number W370-0018. This kit contains the conversion kit instructions, oriﬁ ces needed for all models, the regulator spring for the gas valve, and a label to afﬁ x adjacent to the appliance rating plate to alert subsequent service technicians of the conversion. The parts removed for this conversion must remain

with the furnace for any future conversion back to natural gas.

Input

K/Btu/hr

ALTITUDE

ORIFICE SIZE (DMS) NATURAL LP GAS

40/60/80

100/120

0-2000 (0-610 m)

45 55

2000-3000 (610-914 m) 48 56

3000-4000 (914-1219 m) 49 57

4000-5000 (1219-1524 m) 50 58

5000-6000 (1524-1829 m)

51 60

6000-7000 (1829-2134 m) 52 61

7000-8000 (2134-2438 m) 53 62

8000-9000 (2438-2743 m) 54 63

9000-10000 (2743-3048 m) 55 65

Input

K/Btu/hr

ALTITUDE

ORIFICE SIZE (DMS)

NATURAL LP GAS

0-2000 (0-610 m)

50 57

2000-3000 (610-914 m) 53 58

3000-4000 (914-1219 m) 54 59

4000-5000 (1219-1524 m)

55 60

5000-6000 (1524-1829 m)

56 62

6000-7000 (1829-2134 m)

57 63

7000-8000 (2134-2438 m)

58 64

8000-9000 (2438-2743 m)

59 65

9000-10000 (2743-3048 m)

60 67

TABLE 6 - HIGH ALTITUDE SPECIFICATIONS (U.S.A.)

Gas input ratings are certiﬁ ed for elevations to 2000 ft. (610 m). For elevations above 2000 ft (610 m), reduce ratings 2% for each 1000 ft (309 m) above sea level.

H12.8.1

H18.3

Refer to Conversion NG to LP Kit (W370-0018) for complete instruction.

WHITE-RODGERS 36J24-214 SINGLE STAGE GAS VALVE

1. Turn off the gas and electrical supply to the furnace.

2. Back inlet pressure test screw (inlet pressure boss, see FIGURE 28 & 29) counterclockwise out one turn maximum, with a 3/32” Allen wrench. Attach a hose and calibrated U-tube or digital manometer to the inlet pressure boss. Hose should overlap boss 3/8”. The manometer must have a scale range of at least 0” to 15” of water column.

3. Turn ON the gas and electrical supply and operate the furnace and all other gas consuming appliances on the same gas supply line. Using a leak detection solution, check for leaks around the gas valve/manifold connection and the burner oriﬁ ces. Repair any leaks before continuing.

4. Measure furnace gas inlet pressure with burners ﬁ ring. Inlet pressure must be within the range speciﬁ ed on the furnace rating plate. 5-7” w.c. (Natural Gas) or 11-13” w.c. (LP).

If the inlet pressure differs from the rating plate, make the necessary adjustments to pressure regulator, gas piping size, etc. and/or consult with local gas utility.

5. Turn off gas and electrical supply to furnace, remove the manometer hose from the inlet pressure tap boss, and tighten the inlet pressure tap screw using the 3/32” Allen wrench. (Clockwise, 7 in-lb minimum).

6. Turn on the gas supply and electrical power to the furnace.

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FIGURE 28 - WHITE RODGERS 36J24-214 GAS VALVE

Outlet Pressure Boss Regulator Vent

On/Off SwitchTerminals

Inlet Pressure

Boss (opt.)

Regulator

Adjust

FIGURE 29 - VALVE PRESSURE CHECK KIT

13.5 SETTING THE MANIFOLD GAS PRESSURE

H18.4.1

7. Using a leak detection solution, check for leaks at pressure boss screw. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY!

8. Turn gas back on and test inlet pressure boss with leak detector.

9. If working on a natural gas system, contact the gas utility. They may insist on any service regulator adjustments being made by their own staff.

If problems were encountered with obtaining enough pressure, ﬁ rst examine the gas piping system to ensure that it is correctly sized. Pipe sizing is speciﬁ ed in CAN/CSA-B-149.1 & 2, and in NFPA 54 / ANSI Z223.1. Be sure to check for restrictions, partially closed valves, etc.

In some circumstances, high inlet pressure can be remedied with the use of an in line appliance regulator. If an in line appliance regulator is used, ensure that it has the capacity to adequately handle the gas volume required by the furnace and any other appliances receiving gas from the header serving the furnace.

When the installation is completed to the “Start-up & Setup” stage, test the gas manifold pressure by following

these steps:

WHITE-RODGERS 36J24-214 SINGLE STAGE GAS VALVE

1. Turn off the gas and electrical supply before proceeding.

2. Back outlet pressure test screw (outlet pressure boss, see ﬁ g. 28 & 29) counterclockwise out one more turn maximum, with a 3/32” Allen wrench. Attach a hose and calibrated U-tube or digital manometer to the outlet pressure boss. Hose should overlap boss 3/8”. The manometer must have a scale range of at least 0” to 15” of water column.

3. Turn on the gas supply and electrical power to the furnace and energize main solenoid by connecting R to W on the integrated control board.

4. Remove regulator adjust cover screw from the outlet pressure regulator adjust tower (ﬁ g.28) and turn the plastic regulator adjustment screw clockwise to increase manifold pressure or counterclockwise to reduce manifold pressure. Manifold pressure should be set to 3.5” w.c for natural gas, 10.5” w.c. for LP gas. Always adjust regulator according to original equipment manufacturer’s speciﬁ cations listed on the appliance rating plate.

When the correct pressure has been established, securely replace the regulator cover screw.

5. Turn off the gas and electrical supply to the furnace.

6. Remove the manometer hose from the outlet pressure tap boss, and tighten the outlet pressure tap screw using the 3/32” Allen wrench. (Clockwise, 7 in-lb minimum).

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H18.6.1

The natural gas supply pressure should be a maximum of 7” w.c. and minimum of 5” w.c. The burner manifold pressure is factory set to 3.5” w.c. The input rating of the furnace is based on 1000 Btu/ft.³ gas with a speciﬁ c gravity of 0.6.

Since heating values for the gas vary geographically, the actual furnace input and output will vary accordingly. For example, natural gas with a 900 Btu/ft.³ heating value will reduce the input to 90% of the rated input. Natural gas with a 1100 Btu/ft.³ heating value will increase the input to approximately 110% of the rated input. This is not usually a problem; however, adjustments to compensate for this can be made by minor adjustment

to the burner manifold pressure or by changing the burner oriﬁ ce size. Contact the fuel supplier for speciﬁ c heating content values.

Any adjustments to the burner manifold pressure should be carried out with the use of a manometer or calibrated Magnehelic® gauge. Do not adjust the gas valve pressure regulator more than ±0.3” w.c. Refer to Setting The Manifold Gas Pressure and Figure 30.

IMPORTANT:

NEVER ADJUST THE INPUT OF THE FURNACE TO EXCEED THE INPUT SHOWN ON THE RA TING PLATE.

Input =

Heating Value of Gas x 3600

Time in Sec. for 1 cu. ft.

where:

• input is expressed in Btu/hr

• heating value of the gas is expressed in Btu/ft

• and time is the number of seconds required for

the test dial to indicate 1 cubic foot.

If using a gas meter with SI (metric) units:

• 1 cubic foot = 0.0283 cubic meters

• 1 cubic meter = 35.315 cubic feet

• 0.01 cubic meter = 0.3531 cubic feet

• 0.5 cubic meter = 1.766 cubic feet

13.6 CHECKING FURNACE INPUT

FIGURE 30 - MANOMETER MEASURING GAS MANIFOLD PRESSURE

H18.5.1

7. Turn on the gas supply and electrical power to the furnace.

8. Turn on system power and energize valve.

9. Using a leak detection solution, check for leaks at pressure boss screw. Bubbles forming indicate a leak. SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY!

H3.21

ALL REGULATOR ADJUSTMENTS MUST BE DONE BY A TRAINED, QUALIFIED

TECHNICIAN. IMPROPER MODIFICATIONS OR ADJUSTMENTS CAN RESULT IN FIRE OR

EXPLOSION CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR LOSS OF

LIFE.

WARNING

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14.0 ELECTRICAL SPECIFICATIONS

14.1 ELECTRICAL WIRING AND CONNECTIONS

FIGURE 31 - ELECTRICAL CONNECTIONS

/ MOLEX CONNECTOR

Before proceeding with the electrical connections, ensure that the available electrical supply is compatible with the voltage, frequency and phase listed on the appliance rating plate.

All furnaces are rated 120 VAC, 60 Hz, 1 Ø. The amperage rating is 15 amps or less. Each furnace requires a dedicated 15 amp over-current device, either a 15 amp circuit breaker or a 15 amp

Type D time delay fuse. It is permissible to connect furnace accessories such as humidiﬁ er transformers, condensate pumps and electronic air cleaners. If adding accessory equipment to the furnace circuit, ensure that the combined amperages listed on the appliance rating plates does not exceed the rating of the overcurrent device.

H3.22

SHUT OFF ELECTRICAL POWER AT THE FUSE BOX OR SERVICE PANEL BEFORE

MAKING ANY ELECTRICAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE

ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE.

• THE FURNACE CABINET MUST HAVE AN UNINTERRUPTED GROUND.

• A GROUND WIRE IS PROVIDED IN THE ELECTRICAL JUNCTION BOX.

• DO NOT USE GAS PIPING AS A GROUND.

FAILING TO GROUND THE FURNACE PROPERLY CAN RESULT IN ELECTRIC SHOCK

RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

H19.1

In Canada, all electrical work must be in accordance with the latest edition of CSA-C22.1, Canadian Electrical Code Part 1, and any applicable local code.

In the United States, all electrical work must be in accordance with the latest edition of the National Electrical Code, ANSI / NFPA 70.

Although a suitably located circuit may serve as a service switch, a separate service switch is recommended. A separate service switch is necessary if the circuit breaker is in a location where accessing it would require getting close to the furnace, or if the furnace is located between the main electrical panel and the entry to the furnace room. The furnace switch (service switch) should be clearly labeled, and installed in a location

where it is not likely to be mistaken as being a light switch or similar control.

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3A FUSE

24 VAC MOLEX

THERMOSTAT

TERMINALS

STATUS LED

120 VAC MOTOR TERMINALS

120 VAC NEUTRAL CONNECTIONS

120 VAC MOLEX

POWER HUMIDIFIER TERMINAL

ELECTRONIC AIR CLEANER TERMINAL

FAULT CODE

BUTTON

FIGURE 32 - INTEGRATED FURNACE IGNITION CONTROL

14.2 FURNACE CONNECTION

H3.23

THIS FURNACE IS EQUIPPED WITH A BLOWER DOOR SAFETY SWITCH. DO NOT

DISABLE THIS SWITCH. FAILURE TO FOLLOW THIS WARNING CAN RESULT IN

ELECTRICAL SHOCK, PERSONAL INJURY, OR LOSS OF LIFE.

WARNING

H19.2

The furnace is shipped fully wired except for the connections to the house wiring. The furnace power connections are made in a junction box inside the blower compartment. The junction box contains a BLACK wire to be connected with L1 (hot), a WHITE wire to be connected with L2 (Neutral), and a GREEN wire to be connected to the ground.

If the junction box must be moved from it’s original location to the other side of the unit.

1. Remove the appropriate plastic cap from the desired left or right side panel, and place it on the panel not being serviced.

2. Fasten the junction box to the selected panel.

3. Secure power line connection into junction box, following above reference.

4. Use only ground screws for junction enclosure.

NOTE

Use good quality wire nuts such as Marrette® connectors, Ideal® wire nuts, etc.

IMPORTANT:

USE COPPER CONDUCTORS ONLY.

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15.0 LOW VOLTAGE WIRING

15.1 THERMOSTAT LOCATION

H53.1

The thermostat and control wiring should be a minimum of 18 AWG copper. Excessive lengths of wire may result in enough voltage drop to impair the proper functioning of the furnace. For thermostat wires in excess of 25 feet (7.6m), use 16 AWG; 50 feet (15.2m), use 14 AWG.

H53.2

The thermostat should be located approximately 5 feet (1524mm) above the ﬂ oor, on an inside wall where there is good natural air circulation, and where the thermostat will be exposed to average room temperatures. Avoid locations where the thermostat will be exposed to cold drafts, heat from nearby lamps or appliances, exposure to sunlight, heat from inside wall stacks, etc.

16.2 POWER HUMIDIFIER

16.0 OPTIONAL ACCESSORIES (FIELD SUPPLIED/ INSTALLED)

16.1 ELECTRIC AIR CLEANER

H20.1.1

The integrated furnace control has provisions to supply power and control an electronic air cleaner rated at 120VAC, 1.0 amp max. 120 volt power will be available at these terminals whenever the circulating fan is operating in the heating or cooling fan modes.

H20.2

NOTE All HUM and EAC terminals are 120V. Do not directly connect 24V equipment to these terminals.

The integrated furnace control has provisions to supply power and control a line voltage humidiﬁ er or the primary of a 120 / 24 volt humidiﬁ er step down transformer, rated at 120VAC, 1.0 amp max.

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17.2 TO SHUT DOWN THE FURNACE

17.0 INITIAL STARTUP PROCEDURES

17.1 TO START THE FURNACE

H21.0

This furnace is equipped with a HSI (Hot Surface Ignition) device. Each time that the room thermostat calls for heat, the HSI lights the main burners directly. See the lighting instructions on the furnace.

When the gas supply is initially connected to the furnace, the gas piping may be full of air. In order to purge this air, it is recommended that the ground union be loosened until the odor of gas is detected. When gas is detected, immediately retighten the union and check for leaks. Allow ﬁ ve minutes for any gas to dissipate before continu- ing with the start-up procedure. Be sure proper ventilation is available to dilute and carry away any vented gas.

During initial start-up, it is not unusual for odor to come out of any room register. To ensure proper ventilation, it is recommended to open windows and doors, before initial ﬁ ring.

The furnace has a negative pressure switch that is a safety during a call for heat. The induced draft blower must pull a negative pressure on the heat exchanger to close the negative pressure switch. The induce draft blower must maintain at least the negative pressure switch set point for the furnace to operate. If the induced draft blower fails to close or maintain the closing of the negative pressure switch, a “no heat call” would result.

NOTE

It is recommended that the drain trap assembly be primed before the initial startup. Refer to the instructions on how to prime the condensate trap on the drain piping section in this manual. A dry trap will allow ﬂ ue gases to ﬂ ow through the recovery coil drain, which will prevent the condensate from draining from the recovery coil. If enough condensate accumulates in the recovery coil, the recovery coil pressure switch will sense this condition and break its electrical contacts, and extinguish combustion. If this takes place, the induced blower will stop after a brief post-purge cycle, the condensate will drain out and ﬁ ll the trap. If the thermostat is still calling for heat, the ignition sequence will start again after a 5 minute wait.

H21.1

1. Shut off the electrical power to the furnace and set the room thermostat to its lowest setting.

2. Remove the burner compartment access door.

IMPORTANT: ENSURE THAT THE MANUAL GAS VALVE SWITCH HAS BEEN IN THE “OFF” POSITION FOR AT LEAST 5 MINUTES. DO NOT ATTEMPT TO MANUALLY LIGHT THE MAIN BURNERS.

3. Turn the gas valve switch to the “ON” position.

4. Replace the burner compartment access door.

5. Turn on furnace appliance shut off valve.

6. Restore electrical power to the furnace.

7. Set the room thermostat to a point above room temperature to light the furnace.

8. After the burners are lit, set the room thermostat to the desired temperature.

H21.2

1. Set the room thermostat to below set point.

2. Remove the burner compartment access door.

3. Turn the gas valve switch to the “OFF” position.

4. The furnace appliance shut-off valve may be closed if desired.

5. Power to the furnace must remain on for the air conditioner to work.

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17.3 SEQUENCE OF OPERATION

H3.24

SHOULD OVERHEA TING OCCUR OR THE GAS BURNERS FAIL TO SHUT OFF, CLOSE THE MANUAL GAS VALVE FOR THE FURNACE BEFORE SHUTTING OFF THE ELECTRICAL POWER TO THE FURNACE. FAILURE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE

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

BEFORE RESTARTING THE FURNACE, CHECK ALL PLASTIC VENTS AND WIRES FOR

DAMAGE.

WARNING

H21.3.1A

1. Room temperature drops causing the room thermostat call for heat by connecting “W” to “R”. The control veriﬁ es the limit switch is closed and the pressure switch(s) are open. The control energizes the exhauster motor and waits for the pressure switch(s) to close. The exhauster remains energized for a 15 second prepurge period. If the pressure switch(s) do not close within 60 seconds, the control will ﬂ ash “2” on the Red Status LED, and de-energize the exhauster for 60 minutes.

2. When the 15 second pre-purge time has elapsed, the control energizes the HSI output for a 5 second warm-up period (10 seconds on retries). The control energizes the gas valve. 4 seconds after the gas is energized, the control de-energizes the HSI output and leaves the gas energized another 1 second for ﬂ ame proving. If ﬂ ame is present at the end of trial for ignition time, the control leaves the gas valve energized, exhauster on, and begins heat blower on delay.

3. Blower on delay time begins when the gas valve is energized.

4. Blower off delay is handled by the control board. When the thermostat “W” call ends, the control deenergizes the gas valve, and starts the blower off delay period.

IN THE EVENT OF FLAME FAILURE:

If ﬂ ame is lost, the control de-energizes the gas valve within 2 seconds, continues running the exhauster motor, and begins timing the inter-purge delay. The indoor blower motor will be energized and/or remain energized on heat speed for the delay off time. When the inter-purge delay is over, the control will re-cycle up to 5 ﬂ ame losses (4 re-cycles) within a single call for heat before going into lockout. The control ﬂ ashes “8” on the Red LED if lockout is due to too many ﬂ ame dropouts (1 hour lockout).

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18.0 AIR FLOW

18.1 TEMPERATURE RISE CHECK

H22.0

For proper furnace operation, air ﬂ ow over the heat exchanger is of utmost importance. Insufﬁ cient airﬂ ow accelerates metal fatigue and possible failure in the heat exchanger, as well as decrease efﬁ ciency. Excessive airﬂ ow promotes accelerated corrosion of the heat exchanger.

IMPORTANT:

DO NOT BYPASS THIS STEP OF THE START UP PROCEDURES.

H22.1.1

When the duct system is complete and the air ﬁ lter or ﬁ lters are in place, determine if the airﬂ ow is correct.

1. Insert a duct thermometer in the supply air duct. The thermometer should be placed as close as practical to the furnace, but out of the “line of sight” of the heat exchanger (this prevents false readings owing to radiant heat). Ensure that the thermometer location is within the duct air stream. Avoid locations such as the inside radius of an elbow, etc.

2. Insert a duct thermometer in the return air duct as close to the furnace as practical. Ensure that the thermometer location will be unaffected by humidiﬁ er bypass ducts, etc. Choose a location well within the main air stream.

3. Operate the furnace long enough to obtain steady state conditions at the input listed on the furnace rating plate.

4. When the two thermometers have stabilized, usually within 5-8 minutes, compare the two readings. Subtract the return air temperature from the supply air temperature. The difference is the temperature rise, also called ∆T.

5. Compare the measured ∆T to the temperature rise range shown on the rating plate.

Unless stated differently on the rating plate, the temperature rise should normally range between 35° to 65°F (20° to 36°C). When adjusting the temperature rise, the ideal temperature rise is approximately 50°F (28°C).

If the measured ∆T is above the approved temperature range, there is too little air ﬂ ow. It must be increased by removing restrictions in the ductwork, adding supply or return ductwork, or by selecting a higher motor speed.

If the measured ∆T is too low, there is too much air ﬂ ow.

PSC ESP 0.1” to 1.0” w.c.

Input

Max A/C TAP

CFM

Tonnage NUMBER

NBM080S3A

N/A

BLACK

1700

N/A

BLUE

1400

3 TON

YELLOW

1200

2 TON

RED

800

NBM080S4A

5 TON

BLACK

1900

4 TON

BLUE

1600

N/A

YELLOW

1400

3 TON

RED

1200

NBM100S4A

5 TON

BLACK

2000

5 TON

BLUE

1900

4 TON

YELLOW

1600

3 TON

RED

1300

NBM100S5A

5 TON

BLACK

2000

5 TON

BLUE

1900

4 TON

YELLOW

1600

3 TON

RED

1300

NBM120S5A

5 TON

BLACK

2000

5 TON

BLUE

1900

4 TON

YELLOW

1600

3 TON RED 1300

PSC ESP 0.1” to 1.0” w.c.

Input

MAX A/C TAP

CFM

Tonnage COLOUR

NBM030S2A

2 TON BLACK 800

2 TON BLUE 700

1 1/2 TON YELLOW 600

1 1/2 TON RED 500

NBM040S2A

2 TON BLACK 800

2 TON BLUE 700

1 1/2 TON YELLOW 600

1 1/2 TON RED 500

NBM040S3A

N/A BLACK 1500

N/A BLUE 1400

3 TON YELLOW 1200

2 TON RED 800

NBM060S2A

N/A BLACK 1500

N/A BLUE 1400

3 TON YELLOW 1200

2 TON RED 800

NBM060S3A

N/A BLACK 1700

N/A BLUE 1400

3 TON YELLOW 1200

2 TON RED 800

NOTE

Airﬂ ow based on approximately 350 - 400 CFM/Ton.

TABLE 7 - AIR FLOW (PSC)

H12.1.1

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18.2 CALCULATING AIR FLOW

18.3 CONTINUOUS FAN OPERATION

TABLE 8 - CONTINUOUS

FAN CFM

Input

K/Btu/hr

PSC

Motor

Continuous

Fan (CFM)

030-2 1/6 650

040-2 1/6 850

040-3 1/2 900

060-2 1/2 900

060-3 1/2 950

080-3 1/2 1200

080-4 1/2 1250

100-4 3/4 1500

100-5 3/4 1700

120-5 3/4 2000

H12.3.1

H22.2.1

There are circumstances where it may be desirable to know the air ﬂ ow delivery through the duct system, such as when estimating the amount of air ﬂ ow available for air conditioning. This can be done by direct measurement with electronic or sloped manometers and velometers, or use the formula in the next column.

CFM =

Output

1.085 x

∆T

where:

• CFM is airﬂ ow in cubic feet per minute;

• ∆T is the temperature rise; and

• Output is the furnace output capacity

from the rating plate

H22.3.1

When the thermostat continuous fan (G) switch is on without a call for heat or cooling, the indoor fan is immediately energized. The fan remains energized as long as the call for fan remains without a call for heat or cooling. This feature allows continuous circulation of air between calls for heating or cooling.

If a callf or heat (W) occurs during continuous fan, the blower will remain energized, the call for heat overrides the fan.

If a call for cool (Y) occurs simultaneously with the call for fan (G), the call for cool overrides the call for fan.

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19.0 MAINTENANCE AND TROUBLESHOOTING

19.1 AIR FILTER

H3.25

DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING

ANY MAINTENANCE. F AILURE T O DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN

PERSONAL INJURY OR LOSS OF LIFE.

WARNING

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING

ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.

ALWAYS VERIFY PROPER OPERATION AFTER SERVICING.

CAUTION

H23.1

The air ﬁ lter should be inspected frequently and cleaned or replaced as necessary. We recommend a monthly inspection at ﬁ rst, perhaps coinciding with the arrival of the monthly fuel bill as a reminder. The frequency may be increased or decreased depending on experience and conditions.

Dirty ﬁ lters result in higher than normal operating temperatures, and lower efﬁ ciency.

Some paper media high efﬁ ciency ﬁ lters, sometimes identiﬁ ed as HEPA ﬁ lters can do an effective and excellent ﬁ ltration of the air; however, some models may also cause a large pressure drop across the ﬁ lter. The contractor should assess the capabilities of the duct system to deliver sufﬁ cient air ﬂ ow if this type of ﬁ lter is considered.

RECOMMENDED: Electronic air cleaners using electrostatic precipitation to remove dust are an excellent ﬁ ltration device when used in conjunction with a pre-ﬁ lter. A 16” x 25” (406mm x 635mm) model is an ideal ﬁ t with this furnace in the case of a side mounted return air inlet. The integrated furnace control is supplied with an electrical terminal for use with electronic air cleaners.

NOTE

If two return air inlets are used, both must be equipped with ﬁ lters.

DO NOT OPERATE THE FURNACE FOR PROLONGED PERIODS OF TIME WITHOUT AN

AIR FILTER.

A PORTION OF THE DUST ENTRAINED IN THE AIR MAY LODGE IN THE SUPPLY AIR

DUCTWORK AND REGISTERS. ANY RECIRCULATED DUST PARTICLES WILL BE HEATED

AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER. THIS RESIDUE

WILL SOIL CEILINGS, WALLS, DRAPERY, CARPETS, AND OTHER HOUSEHOLD ARTICLES.

CAUTION

Page 49

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19.2 LUBRICATION

H23.2.2

Both the exhauster motor and circulating fan motor are sealed bearing type motors. Neither requires routine lubrication.

IMPORTANT: THE MOTOR BEARINGS WERE PRE-LUBRICATED BY THE MOTOR MANUFACTURER. DO NOT ATTEMPT TO LUBRICATE THEM. EXCESS LUBRICATION WILL VOID THE WARRANTY, SHORTEN THE SERVICE LIFE OF THE MOTORS, AND WILL ATTRACT THE BUILDUP OF DUST AND DIRT.

Page 50

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H23.3.1

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19.3 TROUBLESHOOTING FLOWCHART

Page 51

W415-1117 / A / 03.11.14

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19.4 DIAGNOSTIC CODES FOR STATUS LED

19.5 FAULT CODE HISTORY

H23.4.1

STATUS

FAULT CONDITION

LED

Red LED indicates following codes:

LED OFF No power to control or control hardware fault detected

LED ON Normal operation

1 Flash High limit switch open

2 Flashes Pressure switch open with inducer on

3 Flashes Pressure switch closed with inducer off

4 Flashes Lockout due to too many failed ignition attempts (1 hour lockout)

5 Flashes L1/Neutral Polarity problem

6 Flashes Too many limit trips within one call for heat

7 Flashes Pressure switch cycle lockout

8 Flashes Lockout due to too many ﬂ ame dropouts

9 Flashes Not used

10 Flashes Flame present with gas valve off

A 3 colour LED is provided to indicate system faults. LED codes are as follows:

• LED Off - No power to control, push button switch pressed, or control fault

• LED Steady On (any colour) - Control hardware fault detected

• Slow Green Flash - No call for heat, no active errors

• Slow Orange Flash - Call for heat present, no active errors

• Rapid ﬂ ash - Incorrect 24VAC phasing/twinning errors

H23.5

The control stores the last 5 fault codes in memory. When the push button switch is pressed, the control will ﬂ ash the stored fault codes when the switch is released. The most recent fault code is ﬂ ashed ﬁ rst, the oldest last.

Fault history may be cleared by holding the push button switch for more than 5 seconds.

Page 52

W415-1117 / A / 03.11.14

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20.0 WIRE DIAGRAM FOR SINGLE STAGE FURNACE WITH PSC

BLACK

WHITE

GREEN

JUNCTION

BOX

120 VAC

24 VAC

+ 120 VAC -

NEUTRALS

HUM

XFMR

EAC

PARK

HEAT

HI COOL

201

PSC MOTOR

30-2

40-2

40-3

60-2

60-3

80-3

80-4

100-4

100-5

120-5

NEUTRAL

HEAT

COOL

PARK

INDUCER (B)

IGNITOR (B)

INDUCER (W)

IGNITOR (W)

ROLLOUT (R)

HEAT LIMIT (R)

FLAME SENSOR (P)

ROLLOUT (R)

PRESSURE SWITCH (Y)

GAS VALVE (BK)

LEGEND

W = WHITE

R = RED

Y = YELLOW

BU = BLUE

BK = BLACK

G = GREEN

P = PURPLE

BLOWER

DIVISION

PRESSURE SWITCH (Y)

ROLLOUT (R)

GAS VALVE (W)

BLACK

WHITE

(Y)

(G)

(W)

(BK)

H24.1.2A

Page 53

W415-1117 / A / 03.11.14

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21.0 WARRANTY

NAPOLEON® 9200 GAS FURNACE PRESIDENT’S LIMITED LIFETIME WARRANTY

Napoleon® products are designed with superior components and materials, assembled by trained craftsmen who take great pride in their work. The complete appliance is again

thoroughly inspected by a qualiﬁ ed technician before packaging to ensure that you, the customer, receives the quality product that you expect from Napoleon®.

This heating unit is warranted by Wolf Steel Ltd. (“Napoleon®”) to be free from defects in materials and workmanship under normal use and maintenance.

PRESIDENT’S LIMITED WARRANTY (Registered)

To the original registered owner and his or her spouse (“owner”), the HEAT EXCHANGER* is warranted for 20 YEARS in the home which the unit was originally installed, and all remaining parts as warranted for a period of 10 YEARS, except as provided below. These warranties apply only if:

• The unit is installed in an owner-occupied, primary single family residence, and

• The unit is properly registered with Napoleon® online within 60 days after the original installation. To register, go to www.napoleonheatingandcooling.com. Some states and provinces do not allow limitations on how long an implied limited warranty lasts or do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This limited warranty gives you speciﬁ c legal rights, and you may also have other rights which vary by jurisdiction.

LIMITED WARRANTY (Not Registered)

If not registered within 60 days, the HEAT EXCHANGER is warranted for a period of 20 YEARS (pro rated), and all internal functional parts are warranted for a period of 5 YEARS, all other limitations apply.

Proof of purchase will be required. Replacements are subject to review and veriﬁ cation by a Napoleon® representative.

Warranty ceases to exist if the unit is removed from the location where it was originally installed.

This limited warranty will not apply unless the gas furnace is: (1) installed by a licensed or qualiﬁ ed HVAC technician, (2) installed in accordance with the manufacturer’s recommendations in its Installation and Operation Manual, and (3) in compliance with all industry standards, national, provincial/state, and local codes.

Regardless of time of registration, the warranty period begins on the date of the original installation. Where a product is installed in a newly constructed home; the date of installation is the date the homeowner takes possession of the home from the builder. If that date cannot be veriﬁ ed, the warranty period begins three months after the month of manufacture (indicated by the ﬁ rst four digits of the serial number.

As its only responsibility, and your only remedy, Napoleon® will furnish a replacement part, without charge for the part only, to replace any part that is found to be defective due to workmanship or materials under normal use and maintenance.

To make a warranty claim, the defective part must be returned to a Napoleon® heating and air conditioning products dealer/distributor by a certiﬁ ed or licensed contractor. Any part replaced pursuant to this warranty is warranted only for the unexpired portion of the warranty term applying to the original part.

These warranties do not apply to labour, freight, or any other cost associated with the service, repair or operation of the unit, and diagnostic costs.

Napoleon® is not responsible for:

1. Cost or expenses incurred as a consequence of a faulty installation or application.

2. Damage or repairs required as a consequence of faulty installation or application.

3. Damages, defects or failures caused by installation that is not performed in compliance with all applicable federal, provincial, state laws or regulations, and Installation Operating Manual.

4. Damage as a result of vandalism, freight damage, ﬂ oods, ﬁ res, winds, lightning, and accidents, or any acts of nature. Atmospheres contaminated by compounds of chlorine, halogenated hydrocarbons, or other damaging chemicals causing deterioration of components, or other conditions beyond the control of Napoleon®.

5. Use of components or accessories not compatible with this unit.

6. Products installed outside Canada, or the United States and its territories.

7. Routine maintenance, but not limited to, cleaning of the coils, ﬁ lter cleaning and/or replacement and lubrication.

8. Parts not supplied by Napoleon®.

9. If unit is equipped with an ultraviolet bulb, the bulb is warranted for 90 days from date of install.

10. Damage or repairs required as a result of

any improper use,

maintenance, operation,servicing, cleaning or replacing air ﬁ lters.

11. Failure to operate due to interruption and/or inadequate electrical service.

12. Damages, defects or failures caused by accidents or negligent or unreasonable use or operation of the unit and its’ components, including without limitation, operation beyond rated capacity and operation of electrical components at voltage other than that speciﬁ ed on the rating plate.

13. Napoleon® shall not in any event extend warranty coverage to any incidental, consequential or indirect damages.

14. Changes in the appearance of the unit that do not affect its performance.

15. Damages, defects or failures caused by operation of the unit in abnormal environmental conditions (i.e. salt air).

16. Damages, defects or failures caused by conditioned air (return air) supplied to the furnace being greater than 20% from out-ofdoors (13°C/55°F min. return air temperature).

17. Damages, defects or failures caused by the furnace being installed downstream from a cooling coil.

* “Heat Exchanger” means the primary combustion heat exchanger for the gas furnace and the secondary or tertiary heat exchanger. The plastic front manifold

condensate collector attached to the secondary or tertiary heat exchanger is not considered part of the heat exchanger.

For further information about this warranty, contact

Napoleon®

Technical Service Department at (866) 539-2039,

tech@napoleonheatingandcooling.com. or by mail to , 24 Napoleon Road, Barrie, Ontario L4M 0G8 Canada

www.napoleonheatingandcooling.com

Dealer Name

Dealer’s City/Province-State/Postal-Zip Code

Telephone/Fax E-mail Address

Model and Serial Number

(Serial number located on inside bottom door)

Installation Date

10.16.12

RESIDENT’S LIMITED WARRANTY

Registered

)

To the original registered owner and his or her spouse (“owner”), the

HEAT EXCHANGER* is warranted for 20 YEARS in the homewhich th

unit was ori

gin

all

y i

nstalled, and

ll remainin

g p

arts as warranted for

eriod of 10 YEARS, except as provided below. These warranties apply

onl

y i

• The unit is installed in an owner-occupied, primary single famil

esidence, an

• The unit is

istered with

oleon® online within 60

day

after the original installation. To register, go to

www.napoleonheatingandcooling.com

pgg

Some states and provinces do

ot allow limitations on how long an implied limited warranty lasts or do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This limited warranty gives you speciﬁ c legal rights, and you may also

ave other r

ts which var

y b

y j

urisdiction.

IMITED WARRANTY

Not Registered

)

If not registered within 60 days, the HEAT EXCHANGER is warranted

a period of 20 YEA

(

pro rated), and

ll internal functional parts

warranted for a period of 5 YEARS all other limitations apply.

FOR HOMEOWNERS FUTURE REFERENCE

H2.3.1

Page 54

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22.0 SINGLE STAGE REPLACEMENT PARTS LIST

Contact your dealer or the factory for questions concerning prices and policies on replacement parts. Normally all parts can be ordered through your Authorized dealer / distributor.

FOR WARRANTY REPLACEMENT PARTS, A PHOTOCOPY OF THE ORIGINAL INVOICE WILL BE REQUIRED TO HONOUR THE CLAIM.

When ordering replacement parts always give the following information:

• Model & Serial Number of appliance

• Installation date of appliance

• Part number

• Description of part

• Finish

FOR FURTHER INFORMA TION, CONTACT YOUR AUTHORIZED DEALER.

H41.1

FAILURE TO POSITION THE PARTS

IN ACCORDANCE WITH THIS

MANUAL OR FAILURE TO USE ONLY

PARTS SPECIFICALLY APPROVED

WITH THIS APPLIANCE MAY

RESULT IN PROPERTY DAMAGE OR

PERSONAL INJURY.

WARNING

PART NUMBER

PART DESCRIPTION

W010-2987 KIT, SMALL FMC WITH GASKETS 30/40

W010-2988 KIT, MEDIUM FMC WITH GASKETS 60/80

W010-2989 KIT, LARGE FMC WITH GASKETS 100/120

W010-2990 ASSY, MOTOR KIT 1/6 HP PSC 30-2/40-2

W010-2602 ASSY, MOTOR KIT 1/2 HP PSC 40-3/60-2/60-3/80-3/80-4

W010-2603 ASSY, MOTOR KIT 3/4 HP PSC 100-4/100-5/120-5

W010-2609 EXHAUSTER, SINGLE SPEED C-FRAME

W010-2610 BLOWER, 10-6T HOUSING 30-2/40-2/40-3/60-2

W010-2559 BLOWER, 12-7T HOUSING 60-3/80-3/80-4

W010-2560 BLOWER, 12-10T HOUSING 100-4/100-5/120-5

W010-2611 CONTROL, INTEGRATED PSC SS

W010-2562 SENSOR, FLAME - REPLACEMENT

W010-2613 FUSE, 3 AMP SS

W010-2991 SWITCH, PRESSURE UNIT SINGLE

W010-2768 ASSY, CONDENSATE TRAP

W010-2564 IGNITER, 601 TYPE TB 120V

W010-2568 SWITCH, BURNER ROLLOUTS REPL 350°F

W010-2570 SWITCH, HEAT LIMIT 150°F

W010-2992 SWITCH, HEAT LIMIT 160°F

W010-2993 SWITCH, HEAT LIMIT 170°F

W010-2994 SWITCH, HEAT LIMIT 180°F

W010-2572 TRANSFORMER, 120V / 24V 40VA

W010-2614 VALVE, SINGLE STAGE SS

W020-0647 BAGGIE, REPLACEMENT PARTS

Page 55

W415-1117 / A / 03.11.14

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FIGURE 2 - FURNACE COMPONENTS

LEGEND

1. Combustion Air Intake Fitting 11. Burner Assembly

2. Flame Roll-Out Switch(s) 12. Hot Surface Igniter (HSI) - located underneath

3. Flame Sensor - opposite of ignitor 13. Single Speed Exhauster

4. Single Stage Gas Valve 14. Pressure Switch Assembly

5. High Temperature Limit - Supply Air 15. Front Manifold Cover Pressure Tap (2)

6. Vent Drain Assembly Coupling 16. Door Switch

7. Drain for Recovery Coil (2) 17. Junction Box

8. Condensate Trap 18. Blower Motor

9. Single Stage Integrated Furnace Control (IFC) 19. Circulating Air Blower

10. Transformer for 24 VAC / 40 VA

Page 56

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23.0 SERVICE HISTORY

43.1

Page 57

LEAVE THIS MANUAL WITH THE APPLIANCE FOR FUTURE REFERENCE.

CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.

USER’S INFORMATION

MANUAL

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

103 Miller Drive, Crittenden, Kentucky, USA, 41030

Phone (705)721-1212 • Fax (705)722-6031 • www.napoleonheatingandcooling.com • ask@napoleonheatingandcooling.com

SAFETY INFORMATION

ELECTRICAL SHOCK, FIRE OR

EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury, 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.

H1.12

9200 SERIES

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

W415-1117 / A / 03.11.14

Page 58

TABLE OF CONTENTS

1.0 SAFETY SYMBOLS AND WARNINGS 59

2.0 SAFETY ISSUES 60

2.1 GENERAL SAFETY RULES 62

3.0 FURNACE OPERATION INFORMATION 64

3.1 STARTING THE FURNACE 64

3.2 SHUTTING DOWN THE FURNACE 64

3.3 OPERATING TIPS 65

4.0 ROUTINE MAINTENANCE BY HOMEOWNER 66

4.1 AIR FILTER 66

4.2 LUBRICATION 66

4.3 ROUTINE EXAMINATION 66

4.4 ANNUAL INSPECTION/SERVICE 67

4.5 FURNACE APPEARANCE 68

4.6 CLEANING 68

4.7 SEQUENCE OF OPERATION 70

4.8 VARIATIONS 70

4.9 TERMINATIONS 70

5.0 HOMEOWNER’S REFERENCE 71

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

H1.21

IMPORTANT: Read these instructions thoroughly before attempting to operate this furnace.

DO NOT DESTROY THIS MANUAL

Please read carefully and keep in a safe place for future reference by a service technician.

W415-1117 / A / 03.11.14

Page 59

1.0 SAFETY SYMBOLS AND WARNINGS

H3.3.1

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

H3.24

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

BEFORE RESTARTING THE FURNACE, CHECK ALL PLASTIC VENTS AND WIRES FOR

DAMAGE.

WARNING

W415-1117 / A / 03.11.14

Page 60

2.0 SAFETY ISSUES

FIGURE 1 - FURNACE COMPONENTS

LEGEND

1. Combustion Air Intake Fitting 11. Burner Assembly

2. Flame Roll-Out Switch(s) 12. Hot Surface Igniter (HSI) - located underneath

3. Flame Sensor (opposite side of ignitor) 13. Single Speed Exhauster

4. Single Stage Gas Valve 14. Pressure Switch Assembly

5. High Temperature Limit (behind gas valve) 15. Front Manifold Cover Pressure Tap (2)

6. Vent Drain Assembly Coupling 16. Door Switch

7. Drain for Recovery Coil (2) 17. Junction Box

8. Condensate Trap 18. Blower Motor

9. Single Stage Integrated Furnace Control (IFC) 19. Circulating Air Blower

10. Transformer for 24 VAC / 40 VA

H25.0.1

This furnace has been designed to deliver many years of efﬁ cient, dependable service. With regular maintenance, some of which requires the attention of a qualiﬁ ed installer, service agency or gas supplier, some of which you may do yourself, the furnace will operate satisfactorily over many heating seasons.

Please read this manual to familiarize yourself with safety procedures, operation, and routine maintenance procedures. Figure 1 is provided to help identify the components of your furnace.

Do not use this furnace if any part has been under water. A ﬂ ood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in ﬁ re or explosion. A qualiﬁ ed service agency should be contacted to inspect the furnace and to replace all gas controls, control system parts, electrical parts that have been wet or

the furnace, if deemed necessary.

W415-1117 / A / 03.11.14

Page 61

H3.26

FIRE OR EXPLOSION HAZARD - 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.

WARNING

H3.27

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE V APORS AND LIQUIDS, OR

OTHER COMBUSTIBLE MA TERIALS 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 NEIGHBOUR’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 DEP ARTMENT.

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

IMPROPER INST ALLATION, ADJUSTMENT, AL TERATION, 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.

WARNING

H3.4.1

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR

MAINTENANCE CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

FOR ASSISTANCE OR ADDITIONAL INFORMATION, CONSULT A QUALIFIED

INSTALLER, SERVICE AGENCY, OR YOUR GAS SUPPLIER.

WARNING

H3.28

DEVICES ATTACHED TO EITHER THE VENT OR COMBUSTION AIR INTAKE FOR THE

PURPOSES OF EXCEEDING THE LIMITATIONS DESCRIBED IN THE INSTALLATION

MANUAL, INCLUDING FIELD INSTALLED INDUCED BLOWER FANS HAVE NOT BEEN

TESTED AND ARE NOT INCLUDED IN THE DESIGN CERTIFICATION OF THE FURNACE.

THE MANUFACTURER CANNOT AND WILL NOT SPECULATE ON THE EFFECTS OF

SUCH MODIFICATIONS AND CANNOT AND WILL NOT BE RESPONSIBLE FOR INJURY OR

DAMAGE CAUSED BY THE USE OF SUCH UNTESTED AND/OR UNCERTIFIED DEVICES,

ACCESSORIES OR COMPONENTS.

WARNING

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2.1 GENERAL SAFETY RULES

FIGURE 2 - GAS REGULATOR VENT

Regulator vent

Keep free of ice, snow, and debris

H25.0.2

Most natural gas systems and all LP gas systems have a service regulator located near the point where the gas piping enters the building.

The propane tank will normally have an additional ﬁ rst stage regulator located at the tank outlet valve. All of these regulators (located outdoors) will have a vent. (Figure 2)

It is important for these vents to remain clear. Do not allow moisture, which could freeze, to build up in the vent. If you see moisture building up in the regulator vent, contact your gas supplier.

H3.29

OBSTRUCTION OF THE AIR VENT ON AN LP (PROPANE) CYLINDER OR TANK REGULATOR

CAN CAUSE EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, SEVERE

PERSONAL INJURY OR DEATH.

YOUR GAS SUPPLIER SHOULD PERIODICALLY INSPECT AND CLEAN THE AIR VENT

SCREEN TO PREVENT ANY OBSTRUCTION. KEEP PROTECTIVE REGULATOR COVER IN

PLACE, AS EXPOSURE TO THE ELEMENTS CAN CAUSE ICE BUILDUP AND REGULATOR

FAILURE.

WARNING

1. Combustible materials should not be stored against or around the furnace. Keep the furnace area clear and free from all combustible materials such as newspapers, rags, cardboard, foam, plastic, paper backed ﬁ berglass insulation, clothing, etc. This applies especially to gasoline and other ﬂ ammable vapors and liquids.

2. This furnace is CSA certiﬁ ed as a Category IV indirect or direct vent appliance. It is designed to operate as a single pipe (inside combustion air) or two pipe (outdoor combustion air) system. A furnace needs adequate amounts of combustion air to operate properly. Do not block or obstruct the air-intake terminal on the furnace, or air openings supplying combustion air to the area where the furnace is installed, if operatin

as a single pipe system. There are many areas from which your furnace could be receiving combustion air including from within the heated area (inside air), from outdoors, from an attic or crawl space. If renovations are done, be sure that air supply openings are not inadvertently covered over with insulation, vapor barrier, or similar construction material.

3. All doors and panels must be in place during normal furnace operation. Attempting to operate the furnace with missing doors or panels could lead to the creation of carbon monoxide gas.

4. If the furnace is installed in a conﬁ ned space or if you intend to build a furnace room where insulation is present, be aware that some insulating materials are combustible. Do not allow building insulating materials to come into contact with the furnace.

5. Any additions, alterations or conversions required in order for the furnace to properly match the application requirements must be done by a qualiﬁ ed installation contractor, service agency or gas supplier, using factory speciﬁ ed or approved parts.

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H25.1

6. Familiarize yourself with the location of the furnace gas manual shut-off valve and any electrical switch, fuse or circuit breaker associated with the furnace.

7. Do not allow snow, ice or debris to accumulate around the outdoor furnace exhaust and combustion air intake terminals. Blockage of the exhaust or combustion intake terminals can result in inadequate performance or nuisance shut-downs.

8. Familiarize yourself with the location of your furnace ﬁ lter or ﬁ lters. A blocked air ﬁ lter will reduce efﬁ ciency , increase fuel consumption, raise the furnace operating temperature, and shorten the life of furnace components.

9. Do not cover return air grills and supply air registers with drapes, curtains, throw rugs, etc.

10. Avoid shutting off supply air registers in the interests of saving heat. While there is some validity to this practice with space heating, there is little to be gained in central heating systems. The furnace requires a quantity of air passing over the heat exchanger to operate within design temperatures. Reducing the number of supply air registers available for air delivery may have the unforeseen consequence of raising the furnace operating temperature, reducing furnace efﬁ ciency, and shortening the life of the furnace components.

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3.0 FURNACE OPERATION INFORMATION

Outlet Pressure Boss Regulator Vent

On/Off SwitchTerminals

Inlet Pressure

Boss (opt.)

Regulator

Adjust

FIGURE 3

3.1 STARTING THE FURNACE

3.2 SHUTTING DOWN THE FURNACE

H26.1

During the heating season, the operation of the furnace is fully automatic.

1. First read these instructions and safety notices thoroughly.

2. Set the thermostat to below the current set point.

3. Ensure that all supply air registers and return air grills are open.

4. Turn off the electric power to the furnace.

5. Remove the burner access door.

6. Ensure that the furnace manual shut-off gas valve is in the “ON” position. The valve handle is normally in-line with the gas pipe and valve body when it is in the “ON” position; perpendicular to the gas piping and valve body when it is in the “OFF” position.

7. Turn the manual gas valve switch to the “OFF” position. (Figure 3)

8. Wait 5 minutes to clear out any gas. If, after this time you smell gas, STOP. Turn the appliance manual shut-off valve to the “OFF” position. If burning LP gas, smell for gas near the ﬂ oor since propane and butane are both heavier than air. If after this time you do not smell gas, continue to the next step.

9. Turn the manual gas valve switch to the “ON” position.

10. Replace the burner access door, ensuring that it is properly in place.

11. Restore the electric power to the furnace.

12. Adjust the thermostat to the desired setting. If the thermostat also controls an air conditioning system, ensure that the thermostat system switch is in the “HEAT” or “AUTO” mode.

If this is the ﬁ rst time that the furnace has undergone a trial ignition since installation, or if there has been work done on the gas lines, the furnace might not light because of air trapped in the gas supply line.

Simply turn the thermostat down to below the current set point, wait 5 minutes, then adjust the thermostat to the desired setting. If the problem persists, proceed to “Furnace Shut-Down Procedure” and call your Installer, service agency or gas supplier.

1. Set the thermostat to its lowest setting.

2. Shut off electric power to the furnace.

3. Turn the furnace manual shut-off valve to the “OFF” position.

4. Remove the burner access door, turn the manual gas valve switch to the “OFF” position, then re-install the burner access door.

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3.3 OPERATING TIPS

H26.3

1. Clean air ﬁ lters maximize efﬁ ciency, and reduce heating costs.

2. During the heating season, keep windows and doors closed to reduce the heating load on the system.

3. Avoid excessive use of kitchen exhaust hoods and other exhaust fans to reduce the heating load on the system.

4. Arrange the furniture and drapes so that the supply air registers and return air grills are unobstructed.

5. If you have a perimeter duct system, ideally, the warm air should bathe the interior walls. Avoid the use of plastic deﬂ ectors on the supply air registers which tend to short circuit the warm air straight into the return air grills.

6. Avoid placing heat producing appliances such as televisions, radios, lamps, etc. in a location to inﬂ uence the thermostat.

7. Keep combustible articles at least 3 feet (0.91m) away from the furnace. Do not block access for servicing the furnace Do not use the combustion air or exhaust piping as a hanger for clothes or anything else.

IMPORTANT:

NEVER ATTEMPT TO OPERATE THE FURNACE WITHOUT THE BLOWER DOOR AND COMBUSTION COMPARTMENT DOOR IN PLACE OR WHEN THE BLOWER HAS FAILED.

H26.2

IMPORTANT:

If you intend to be away from home for lengthy periods of time during the non-heating season, it is advisable to follow the furnace shut down procedure.

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4.0 ROUTINE MAINTENANCE BY HOMEOWNER

4.1 AIR FILTER

4.2 LUBRICATION

4.3 ROUTINE EXAMINATION

H27.1

DO NOT OPERATE YOUR FURNACE OR AIR CONDITIONER FOR EXTENDED PERIODS OF

TIME WITHOUT AN AIR FILTER.

CAUTION

A portion of the dust entrained in the air may temporarily lodge in the air duct runs and the supply registers. Any recirculated dust particles will be heated and charred by coming into contact with the heat exchanger. This residue will soil ceilings, walls, drapes, carpets, furniture, and other household articles.

Consult your installation contractor or service technician if you have any questions on instructions for removing the air ﬁ lter.

BE SURE THAT THE FILTER IS RE-INSTALLED WITH THE AIRFLOW DIRECTION

IDENTICAL TO ITS PREVIOUS USE. REVERSING THE FILTER WILL CAUSE DUST

TRAPPED WITHIN THE FILTER TO BREAK FREE AND RECIRCULATE WITHIN THE DUCT

SYSTEM.

CAUTION

H3.25.1

DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING

ANY MAINTENANCE. F AILURE T O DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN

PERSONAL INJURY OR LOSS OF LIFE.

WARNING

H27.2

The circulating air blower, and exhauster motors have sealed bearings. The bearings contain permanent special purpose lubricants. Attempting to force common oil into the circulating and exhauster assembly motor bearings will deteriorate the original lubricant and shorten bearing life.

It is good practice to give a quick inspection of your furnace each time you inspect or clean the air ﬁ lter. Things to check:

• Check the furnace for obvious signs of deterioration.

• Check the venting and combustion air piping to ensure that it is still fastened to the furnace. It should not sag, and should have a 1/4” (6mm) per foot (305mm) slope upwards, to the outside wall or termination.

• There should be no water marks on the ﬂ oor under the venting. Water marks may indicate a leaking pipe joint.

• All ductwork should be secured to the furnace, and all ductwork should be solidly supported throughout the heating system.

IMPORTANT:

We recommend that your furnace and exhaust/combustion air vents be checked by a qualiﬁ ed service technician once a year.

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4.4 ANNUAL INSPECTION/SERVICE

H27.3A

• Water should ﬂ ow easily through the condensate drain line. You may be able to observe this while the furnace is operating if your condensate drain line from the drain trap assembly terminates at a ﬂ oor drain or sump pit. If clear plastic was used, it may yellow with age; however, the contents should be reasonably clear. Excess debris in the drain line may indicate a problem which should be referred to your service contractor. If the drain lines are opaque, your service technician will check them during the annual servicing.

• The gas burner should be observed from time to time during the heating season to ensure that the ﬂ ames are clean and blue. A bit of orange color in the ﬂ ame is not likely to be a problem and is probably dust particles burning. If you observe lazy yellow ﬂ ames, call your heating or service contractor immediately. The yellow ﬂ ames inevitably lead to soot-ups.

• The combustion air and exhaust terminals should be inspected occasionally to ensure that they are free of obstructions and debris.

H27.4.1

It is recommended that the furnace be inspected annually by a qualiﬁ ed installation contractor, service agency or fuel supplier. Your annual inspection will normally cover the following:

HEA T EXCHANGER - The heat exchanger should be inspected for corrosion. The ﬂ ue passages (heat exchanger tubes) should be free of scale or excessive corrosion.

BURNERS - The burners should be inspected to ensure that they are free of deterioration.

BE CAREFUL WHEN WORKING ON THE BURNER ASSEMBLY. THE HOT SURFACE

IGNITER IS FRAGILE AND CAN BREAK EASILY.

CAUTION

The ﬂ ame sensor should be inspected and cleaned with ﬁ ne steel wool or Scotch-Brite™ scrubbing pad. The wiring connection should be checked to ensure that it is tight and corrosion free.

DRAINAGE - The condensate drainage system should be inspected and cleaned if necessary. If the drain trap assembly, or any other component becomes blocked, condensate may backup into the secondary or primary heat exchanger causing nuisance trip-outs of the pressure switch(s) or roll out switch(s). The condensate should be observed for signs of dirt, carbon, debris, etc.

CIRCULATING FAN - The condition of the circulating fan should be checked to ensure that it is free of excessive dust buildup, debris, etc. The mechanical fasteners should be inspected and checked for proper tightness and parts alignment. The motor ventilation ports should be cleaned if necessary to prevent restriction to cooling by air over the motor.

ELECTRICAL - All electrical connections should be examined to ensure that they are tight and corrosion free. Repair any connections that have become loose or corroded.

FURNACE OPERA TION - The furnace should be cycled during the annual inspection and servicing to:

1. Test all safety related controls.

2. Determine that the temperature rise falls within the range shown on the appliance rating plate.

3. Ensure that the burner ignition is smooth and that the ﬂ ames are smooth soft blue, and not impinging on the heat exchanger.

4. Ensure gas meter is timed, and/or furnace manifold pressure checked to conﬁ rm the furnace is operating at the input listed on the rating plate.

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4.6 CLEANING

4.5 FURNACE APPEARANCE

FIGURE 5

H27.5

The furnace exterior ﬁ nish is a durable automotive like coating. It may be washed with mild soap if necessary. Galvanized metal surfaces require no maintenance.

It is advisable to keep dust build-up on warm surfaces to a minimum, since dust, in some cases, can be a combustible.

Dust build-up in the circulating fan can impair blower performance; therefore, reduce efﬁ ciency. The recovery coil is located immediately above the blower assembly. Over time, it may become coated with

dust. To clean the recovery coil:

1. Turn off electrical power to the furnace.

2. Remove the blower access door

3. Remove the screws fastening the blower assembly to the blower division panel.

4. Unplug wire harness from the control board, junction box and remove thermostat wires (label wires to correct position).

5. Pull the blower assembly out.

6. Once the blower assembly has been removed, the coils may be vacuumed with the soft brush attachment.

(Figure 5)

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.

ALWAYS VERIFY OPERATION AFTER SERVICING.

CAUTION

IMPORTANT:

Be careful not to bend the ﬁ ns when cleaning. Y ou may wish to leave this maintenance procedure to your service technician.

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H27.6.1B

7. Match up the blower rails with the hangers on the underside of the blower division panel, then slide the blower assembly back into position.

8. Replace the screws fastening the blower assembly to the blower division panel.

9. Secure wire harness to the control board and junction box. Connect thermostat wiring to the control board.

10. Replace the blower access door.

11. Restore electrical power to the furnace.

12. Routine cleaning of the interior of the recovery coil should not be necessary . If evidence develops indicating that a cleaning is necessary , it should be done by a trained and qualiﬁ ed service technician. Evidence may include large amounts of dirt or debris building up in the condensate drain line.

H3.30

ALWAYS DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE REMOVING

THE BURNER COMPARTMENT ACCESS DOOR.

WARNING

H27.6.2

THE FURNACE GAS TRAIN IS DESIGNED TO OPERATE AS A SEALED UNIT. BE SURE

THAT THE BURNER COMPARTMENT ACCESS DOOR IS PROPERLY IN PLACE BEFORE

A TTEMPTING T O RESTART THE FURNACE.

CAUTION

The furnace achieves its high efﬁ ciency in three general areas. First, there is no wasteful standing pilot. The furnace consumes no gas in between cycles. Secondly , the furnace is designed to allow very small amounts of excess air in the combustion process. Older furnaces had heat exchangers which were commonly 40% larger than necessary for complete combustion. While this prevented the creation of carbon monoxide, the heated excess air was expelled up the chimney where it could not beneﬁ t the interior of the home. Special safety controls now prevent the formation of carbon monoxide.

The third general area is the recovery of the latent heat contained in the ﬂ ue gas, which is comprised of water vapor and carbon dioxide. By condensing the ﬂ ue gas in the furnace recovery coil, heat that would otherwise be wasted to the outdoors, is captured and redirected into the duct system where it contributes to home comfort. Each pound of condensation formed releases approximately 970 Btu’s. Your furnace may condense up to 1/2 gallon (1.89L) (5 pounds) (2.27kg) of water per hour if running continuously .

This condensation must be properly disposed into a sump or drainage system. The condensate lines must remain clear and free ﬂ owing. Do not allow plastic drain lines to become pinched or kinked. A blocked drain line can cause the furnace to operate erratically, or not at all.

IMPORTANT: Your furnace should be cleaned and inspected annually by a trained and qualiﬁ ed service technician. Your service technician has the knowledge and test equipment to determine the condition of your furnace.

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4.7 SEQUENCE OF OPERATION

4.8 VARIATIONS

H21.3.1A

3. Blower on delay time begins when the gas valve is energized.

4. Blower off delay is handled by the control board. When the thermostat “W” call ends, the control deenergizes the gas valve, and starts the blower off delay period.

IN THE EVENT OF FLAME FAILURE:

H27.7

If your system includes air conditioning, your thermostat will likely have two switches. The ﬁ rst switch is the system switch. The switch settings usually include HEAT, COOL, and OFF. Some thermostats have system switches which include HEAT, COOL, AUTO, and OFF. The system switch must be in the HEAT or AUTO position for the furnace to run.

The second switch is the fan switch. It usually has settings of ON and AUTO. The fan switch may be in either position when using the furnace. If the fan switch is set to ON, the main blower will run continuously.

4.9 TERMINATIONS

H27.8

The combustion air and exhaust terminals should be inspected occasionally to ensure that they are free of obstructions and debris. If screens were used in either terminal, ensure that they are free of debris, corrosion, or anything preventing the free ﬂ ow of air.

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5.0 HOMEOWNER’S REFERENCE

H28.0

HOMEOWNER’S REFERENCE TABLE

Model No.

Serial No.

(serial number located on bottom of inside door)

Date Installed

Contractor

Contact

Address

Postal Code/Zip Code

Telephone No.

After Hours No.

If different from Installation Contractor:

Service Tech.

Telephone No.

After Hours No.

Fuel Supplier:

Gas Supplier

Contact

Telephone No.

After Hours No.

W415-1117 / A / 03.11.14

Page 72

Other Napoleon

Products

Fireplace Inserts • Charcoal Grills • Gas Fireplaces • Waterfalls • Wood Stoves Heating & Cooling • Electric Fireplaces • Outdoor Fireplaces • Gourmet Grills

Fireplaces / Heating & Cooling call: 705-721-1212 • Grills call: 705-726-4278 napoleonproducts.com

24 Napoleon Road, Barrie, Ontario, Canada L4M 0G8 214 Bayview Drive, Barrie, Ontario, Canada L4N 4Y8 103 Miller Drive, Crittenden, Kentucky, USA 41030 7200 Trans Canada Highway, Montreal, Quebec, Canada H4T 1A3

W415-1117 / A / 02.05.14

Napoleon NBM040S2A, NBM060S2A, NBM040S3A, NBM060S3A, NBM080S3A Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual