NAPOLEON NBX100S5A Installation And Operating Instructions Manual

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.
IOM
INSTALLATION AND
OPERATING INSTRUCTIONS
CERTIFIED TO ANSI Z21.47b / CSA 2.3b-2008
9200 SERIES
SINGLE STAGE MULTI POSITION HIGH EFFICIENCY
(CONDENSING) FORCED AIR GAS FURNACE
SAFETY INFORMATION
!
WARNING
!
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
qualified 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 flammable
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 fire
department.
MANUFACTURER RESERVES THE RIGHT TO DISCONTINUE, OR CHANGE
AT ANY TIME, SPECIFICATIONS OR DESIGNS WITHOUT NOTICE AND
WITHOUT INCURRING OBLIGATIONS.
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 • [email protected]
H1.11
$10.00
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UM
PG
57
2
TABLE OF CONTENTS
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1.0
2.0
3.0
4.0
INTRODUCTION
SAFETY SYMBOLS AND WARNINGS
3
4
2.1
2.2
5
6
SAFETY RULES
CODES
FURNACE SIZING
LOCATION OF UNIT
9
10
4.1
4.2
4.3
4.4
10
10
11
12
GENERAL GUIDELINES
OTHER CONSIDERATIONS
INSTALLATION IN UPFLOW OR HORIZONTAL POSITIONS
AIR CONDITIONING
5.0
6.0
COMBUSTIBLE CLEARANCES
DUCTWORK
7.0
VENTING AND COMBUSTION PIPING
15
7.1
7.2
7.3
15
15
16
6.1
8.0
9.0
10.0
11.0
12.0
13.0
14.0
DUCTWORK STEPS
ACCEPTABLE MATERIALS IN CANADA
ACCEPTABLE MATERIALS IN UNITED STATES
VENT DRAIN OPTION
12
13
14
NON-DIRECT VENT FURNACE INSTALLATIONS USING INDOOR COMBUSTION AIR (ONE PIPE
SYSTEM)
17
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
18
18
18
19
20
20
DETERMINING COMBUSTION AIR
CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE
CASE 2: FURNACE LOCATED IN A CONFINED SPACE
CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR FROM ATTIC OR CRAWL SPACE
CASE 4: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR DUCTED HORIZONTALLY
CONNECTION TO FURNACE NON-DIRECT VENT
VENTING GUIDELINES
21
9.1
9.2
9.3
9.4
9.4.1
9.4.2
9.4.3
22
23
23
24
24
24
24
VENT TERMINATION
IN CANADA
IN UNITED STATES
FURNACE VENTING INSTALLATIONS
NON-DIRECT VENT INSTALLATION USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM)
DIRECT VENT INSTALLATION USING OUTDOOR COMBUSTION AIR (TWO PIPE SYSTEM)
COMBUSTION AIR
TERMINATIONS
25
10.1
10.2
10.3
10.4
10.5
10.6
25
25
25
25
25
26
COMBUSTION AIR
EXHAUST
CONCENTRIC VENTING KIT
CONCENTRIC VENT TERMINATION INSTALLATION INSTRUCTIONS
LOCATION
MULTIPLE VENTING
ROUTING OPTIONS
29
11.1
11.2
11.3
11 .4
11.4.1
11.4.2
11.5
11.6
29
30
30
33
33
34
34
35
EXHAUSTER ROTATION INSTRUCTIONS & PRESSURE SWITCH MOUNTING
CONDENSATE DRAINS
PREPARATIONS FOR VENT AND DRAINING OPTION
DRAIN HOSE INSTALLATION
DRAIN TUBING
PRIMING CONDENSATE TRAP
ALTERNATE CONDENSATE DRAIN INSTALLATION USING 1/2” PVC OR 3/4” CPVC
CONDENSATE NEUTRALIZERS
GAS SUPPLY AND PIPING
36
12.1
12.2
12.3
12.4
12.5
36
36
37
37
37
GAS SUPPLY
GAS PIPING
GAS INLET PRESSURE
LEAK TESTING
PURGING GAS LINES
CONVERSIONS
38
13.1
13.2
13.3
13.4
13.5
13.6
38
38
38
38
39
40
HIGH ALTITUDE CONVERSION
NATURAL TO LP GAS CONVERSION
CONVERSION STEPS
CHECKING THE INLET GAS PRESSURE
SETTING THE MANIFOLD GAS PRESSURE
CHECKING FURNACE INPUT
ELECTRICAL SPECIFICATIONS
41
14.1
14.2
41
42
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ELECTRICAL WIRING AND CONNECTIONS
FURNACE CONNECTION
3
15.0
LOW VOLTAGE WIRING
15.1
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
43
THERMOSTAT LOCATION
43
OPTIONAL ACCESSORIES (FIELD SUPPLIED/INSTALLED)
43
16.1
16.2
43
43
ELECTRIC AIR CLEANER
POWER HUMIDIFIER
INITIAL STARTUP PROCEDURES
44
17.1
17.2
17.3
44
44
45
TO START THE FURNACE
TO SHUT DOWN THE FURNACE
SEQUENCE OF OPERATION
AIR FLOW
46
18.1
18.2
18.3
TEMPERATURE RISE CHECK
CALCULATING AIR FLOW
CONTINUOUS FAN OPERATION
46
47
47
MAINTENANCE AND TROUBLESHOOTING
48
19.1
19.2
19.3
19.4
19.5
48
49
50
51
51
AIR FILTER
LUBRICATION
TROUBLESHOOTING FLOWCHART
DIAGNOSTIC CODES FOR STATUS LED
FAULT CODE HISTORY
WIRE DIAGRAM FOR SINGLE STAGE FURNACE WITH PSC
WARRANTY
SINGLE STAGE REPLACEMENT PARTS LIST
SERVICE HISTORY
52
53
54
56
NOTE: Changes, other than editorial, are denoted by a vertical line in the margin.
ATTENTION:
UPFLOW VENTING RIGHT, MUST DRAIN ON
LEFT SIDE.
IMPORTANT:
PLEASE READ THIS MANUAL CAREFULLY
AND KEEP IN A SAFE PLACE FOR FUTURE
REFERENCE BY A SERVICE TECHNICIAN.
H1.22
1.0 INTRODUCTION
This high efficient gas fired single stage condensing furnace is an upflow, 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 efficient furnace series is CSA certified 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 fired by natural or LP gas (propane), and may be field 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.
H4.0.1
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4
2.0 SAFETY SYMBOLS AND WARNINGS
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Understand and pay particular attention to the words DANGER, WARNING, and CAUTION and the following
defined 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.
!
WARNING
!
INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED,
COULD RESULT IN DEATH OR SERIOUS INJURY.
!
CAUTION
!
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.
H3.3.1
IMPORTANT:
READ THE FOLLOWING INSTRUCTIONS COMPLETELY BEFORE INSTALLING!
H6.0
!
WARNING
!
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE
OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR
LOSS OF LIFE.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS, OR
OTHER COMBUSTIBLE MATERIALS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WHAT TO DO IF YOU SMELL GAS
• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR
BUILDING.
• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE, OR A CELLULAR PHONE FROM A LOCATION WELL AWAY FROM THE BUILDING. FOLLOW THE
GAS SUPPLIER’S INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.
• DO NOT RE-ENTER THE BUILDING UNTIL AUTHORIZED TO DO SO BY THE GAS
SUPPLIER OR THE FIRE DEPARTMENT.
PROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN
CAUSE INJURY, PROPERTY DAMAGE OR LOSS OF LIFE. REFER TO THIS MANUAL.
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
H3.3
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5
!
WARNING
!
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.
H3.4
2.1
SAFETY RULES
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 specified 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 specified in Section 7 of this manual, “Venting and Combustion Piping.”
5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically
for the detection of leaks to check all connections as specified in 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
specified in Sections 3, 6, and 18 of this manual, “Furnace Sizing,” “Ductwork,” and “Airflow.”
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-fired 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 floor. 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 fixed 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 filters must be installed in the system and must be maintained during construction.
•
Air filters 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 final construction clean-up.
•
All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be
verified according to these installation instructions.
H6.1
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6
2.2
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CODES
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
5060 Spectrum Way
Mississauga, Ontario, L4W 5N6
Phone: (416) 747-4000
website: www.csa.ca
American Gas Association
400 North Capitol Street, NW, Suite 450
Washington DC, 20001
Phone: (202) 824-7000
website: www.aga.org
National Fire Protection Association
1 Batterymarch Park
Quincy, MA, 02169-7471
Phone: (617) 770-3000
website: www.nfpa.org
H6.2
!
WARNING
!
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.
H3.5
W415-1117 / A / 03.11.14
7
!
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.
H3.6
FIGURE 1 - FURNACE DIMENSIONS
B
G
A
F
(130mm)
5.125"
TOP
AIR INLET
2” PVC VENT OUTLET
LEFT SIDE DRAIN HOLES
ALTERNATE VENT OUTLET
RIGHT SIDE DRAIN HOLES
ALT. GAS LINE IN
STD. GAS SUPPLY
HIGH VOLTAGE IN
ALT. HIGH
VOLTAGE IN
ALTERNATE AIR IN
CONDENSATE
DRAIN TRAP w/
1/2" CPVC
DISCHARGE LEFT
& RIGHT SIDE
ALT. VENT OUTLET
C
UPFLOW DRAIN HOLE
D
ALT. AIR INLET
ALT. UPFLOW DRAIN HOLE
SIDE CUTOUT
ALT. LOW
VOLTAGE IN
LOW VOLTAGE IN
SIDE CUTOUT
WITNESS MARKS
FOR SIDE CUTOUTS
E
LEFT SIDE
FRONT
RIGHT SIDE
TABLE A - FURNACE DIMENSIONS
INPUT
MODEL
OUTPUT
Width
Depth
Height
Supply Air
Return Air
B
C
(F x G)
(D x E)
Btu/hr
Btu/hr
A
NBM030S2A 30 000
28 200
NBM040S2A 40 000
36 800
14 1/2"
(356mm)
NBM040S3A 40 000
36 800
29 1/2"
32 7/8"
17 1/2"
16 1/4" X 19 5/8"
(737mm) (835mm)
(445mm)
(413mm x 499mm)
NBM060S2A 60 000
55 200
14 1/2"
(356mm)
13 1/4" X 19 5/8"
(337mm x 499mm)
17 1/2"
(445mm)
16 1/4" X 19 5/8"
(413mm x 499mm)
NBM060S3A 60 000
55 200
NBM080S3A 80 000
73 600
NBM080S4A 80 000
73 600
NBM100S4A 100 000
92 000
NBM100S5A 100 000
92 000
NBM120S5A 120 000
110 400
13 1/4" X 19 5/8"
(337mm x 499mm)
29 1/2"
32 7/8"
21"
19 3/4" X 19 5/8"
(533mm) (737mm) (835mm) (502mm x 499mm)
24 1/2"
(622mm)
14" x 23"
(356mm x 584mm)
14" x 23"
(356mm x 584mm)
23 1/4" X 19 5/8"
(590mm x 499mm)
H12.6.1
W415-1117 / A / 03.11.14
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8
TABLE B - MINIMUM CLEARANCES TO COMBUSTIBLE
MATERIALS (INCHES)
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UPFLOW
0
0
1/2" (13mm)
1/2" (13mm)
FRONT
0*
0*
BACK
0
0
SIDES
0
0**
BOTTOM
0***
0
FLUE PIPE
0
0
TOP
PLENUM TOP
0"
0"
Plenum
1/2" (13mm)
on all sides
0"
Top
ENCLOSURE
0"
0"
NOTES:
S - Service clearance 24 inches (610mm) or more.
C - Combustible floor (but not carpet or non-ceramic tile).
All models approved for closet installation.
W415-1117 / A / 03.11.14
HORIZONTAL
CLOSET
CLOSET
*24" (610mm) REQUIRED FOR SERVICE
**SUPPLY AIR OUTLET / 1/2" (13mm) RETURN AIR INLET
***CERTIFIED FOR CLOSET INSTALLATION ON COMBUSTIBLE FLOORING.
H12.11.1
9
3.0 FURNACE SIZING
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 retrofit 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 airflow 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
TABLE 1 - RANGE OF TEMPERATURE RISE
(20 - 36°C) or 30 - 60°F (14 - 31°C) depending on what
Furnace Models
Temperature Rise
model is installed. If the furnace selected has an identical
output capacity as the original furnace, a substantial
NBM030S2A
35 - 65°F (20 - 36°C)
increase in system air flow will be necessary. See Table 1
and the airflow characteristics in Section 18 of this manual,
NBM040S2A
35 - 65°F (20 - 36°C)
“Airflow”.
Existing ductwork should be assessed for its air handling
capabilities.
The “Equal Friction Chart,” as published by ASHRAE
and HRAI, is the basis for the various air duct calculators
available through heating supply companies. Following
the air velocity guide lines, according to the “Equal Friction
Chart,” or a slide rule air duct calculator, a typical 6”
(152mm) round duct has a capacity of approximately 100
cfm.
NOTE:
The return air system is equally as important as the
supply air system. An under-sized return air system
will prevent sufficient quantities of air from reaching
the supply air system and will consequently reduce the
service life of the furnace and its components.
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
W415-1117 / A / 03.11.14
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10
4.0 LOCATION OF UNIT
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4.1
GENERAL GUIDELINES
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 fittings. 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 upflow right venting configuration, furnace must drain on the left side.
H8.1.1
FIGURE 3 - SUGGESTED METHOD FOR SUSPENDING HORIZONTAL FURNACE
ALLOW ENOUGH ANGLE
IRON OVERHANG TO
PERMIT OPENING THE
BLOWER DOOR.
RETURN AIR PLENUM
4.2
• 3/8” THREADED ROD
• 2” (51mm) ANGLE IRON
• JAM NUTS
• LOCK WASHER
• FLAT WASHER
SUPPLY AIR PLENUM
OTHER CONSIDERATIONS
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 fluorine, as may be found in swimming pool chemicals, laundry detergents, etc.,
use outdoor air for combustion. These compounds when exposed to flame, 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
W415-1117 / A / 03.11.14
11
•
•
•
•
•
•
•
•
•
•
•
•
•
“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 fluids 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 finished ceiling or living area, install a field 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.
H8.2
4.3
INSTALLATION IN UPFLOW OR HORIZONTAL POSITIONS
UPFLOW INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed in
accordance with instructions in the appropriate sections of this manual.
HORIZONTAL INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed in
accordance with instructions in the appropriate sections of this manual.
NON-SUSPENDED INSTALLATION: Maintain clearances to combustibles as outlined in Table B. The furnace
must be supported in such a way as to not allow twisting or sagging of the cabinet.
SUSPENDED INSTALLATION: Maintain clearances to combustibles as outlined in Table B. The furnace may
be suspended by field 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.
H8.3.1
W415-1117 / A / 03.11.14
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12
4.4
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AIR CONDITIONING
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.
H8.4.1
5.0 COMBUSTIBLE CLEARANCES
Table B provides the certified clearances to combustibles information. Also see the appliance rating plate
affixed to the furnace for specific 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.
H9.0
!
WARNING
!
THIS FURNACE IS CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORS. THIS
SHALL BE INTERPRETED AS A WOOD FLOOR ONLY.
THE FURNACE MUST NOT BE INSTALLED DIRECTLY ON CARPETING, OR OTHER
COMBUSTIBLE MATERIAL EXCEPT WOOD.
INSTALLATION ON COMBUSTIBLE MATERIAL CAN RESULT IN FIRE, CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL
COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS
AND LIQUIDS.
THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE
USED AS A CLOSET OR FOR ANY OTHER STORAGE PURPOSE.
H3.7
W415-1117 / A / 03.11.14
13
6.0 DUCTWORK
Proper airflow is required for the correct operation of this furnace. Insufficient airflow may cause erratic
operation, could cause the furnace to cycle on the high temperature limit, and may damage the heat
exchanger. Excessive airflow 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 airflow 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 filters) should not exceed 1.0” w.c.
H10.0
!
WARNING
!
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.
H3.8
W415-1117 / A / 03.11.14
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14
6.1
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DUCTWORK STEPS
1. Position the furnace to minimize ductwork length and fittings.
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.
!
WARNING
!
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.
H3.9
3. Connect the return air duct or filter fitting 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 filter 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 flexible connectors, ensure that the adjoining
duct is independently supported.
NOTE: If the airflow requirements exceed 1800 cfm, models will require air openings and filters on:
• both sides, OR
• one side and the bottom, OR
• just the bottom
H10.1
W415-1117 / A / 03.11.14
15
7.0 VENTING AND COMBUSTION PIPING
IOM
!
WARNING
!
READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO
PROPERLY VENT OR SUPPLY COMBUSTION AIR TO THIS FURNACE CAN CAUSE CARBON MONOXIDE POISONING, OR AN EXPLOSION OR FIRE, RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
H3.10
7.1
ACCEPTABLE MATERIALS IN CANADA
Effective August 1, 2007, all vent piping materials and fittings for flue gas venting must be ULC S636 listed
and identified as such on the material. The first 3ft. (900mm) of venting must be readily available for visual
inspection. Specified primers and glues of the certified vent system must be from a single system manufacture,
and not intermixed with other system manufacture’s vent system parts. The components of the certified vent
system must not be interchanged with other vent systems, or unlisted pipe, and or fittings. 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 certified:
• PVC (Polyvinyl Chloride), OR
• PPE (Polypropolene) material
with a rating of 149°F (65ºC) or more.
The combustion air piping does not have flue gases travelling through it and may be installed with common
ABS, PVC or CPVC piping or fittings. This piping, fittings, primer and cement will need to be installed as per
the manufacturers instructions including cementing, cutting, curing and supporting the piping.
H11.1
7.2
ACCEPTABLE MATERIALS IN UNITED STATES
For United States installations, the combustion air and vent piping and fittings 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 fittings including cutting, deburring,
priming, cementing, curing and supporting.
H11.2
W415-1117 / A / 03.11.14
16
7.3
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VENT DRAIN OPTION
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.
USE SWEEP TEE ON
HORIZONTAL LINE
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 specified 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 flexible 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.
3" (76mm) MIN.
10" (254mm) MAX.
LOOP DIAMETER
1/2" (12.7mm) ID MAX.
ATTACH THIS END TO
CONDENSATE DRAIN
SYSTEM
1/2" (12.7mm) ID MAX.
3" (76mm) MIN.
10" (254mm) MAX.
LOOP DIAMETER
ATTACH THIS END TO
CONDENSATE DRAIN
SYSTEM
IMPORTANT:
ELBOWS WITH DRAIN PORTS
ARE NOT RECOMMENDED, AS
CONDENSATE CAN BYPASS THE
DRAIN ON THE CURVE.
H11.3
W415-1117 / A / 03.11.14
17
8.0 NON-DIRECT VENT FURNACE INSTALLATIONS
USING INDOOR COMBUSTION AIR (ONE PIPE
SYSTEM)
The furnace, although designed as a direct vent type appliance, may be installed with the intake vent inside the
structure.
!
WARNING
!
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.
H3.11
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.
!
CAUTION
!
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.
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 fluids 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, fluorine 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 flame,
vapors from these products form acid compounds. Acid compounds increase the dew point temperature of the
flue products and are highly corrosive after they condense.
H13.0
W415-1117 / A / 03.11.14
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18
8.1
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DETERMINING COMBUSTION AIR
8.1.1
CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE
Unconfined space does not necessarily mean that ventilation will not have to be introduced from the outdoors,
particularly in airtight homes. The minimum requirement for unconfined space is a volume of 50 cubic feet (1.42
m³) for each 1000 Btu/hr for all fuel burning appliances located within the unconfined area.
If the amount of combustion and ventilation air is insufficient to properly operate the furnace and other fuel
burning appliances within the unconfined area, it will be necessary to supply it from the outdoors based on the
criteria used when calculating the air supply for a confined space.
NOTE
If planning to use the inside air in an unconfined space, remember to test for proper furnace operation (as well
as other fuel burning appliances located within the unconfined space) with respect to adequate combustion and
ventilation air with fireplace dampers open, clothes dryer running, bathroom exhaust fans on, kitchen range hood
on, etc.
H13.1
8.1.2
CASE 2: FURNACE LOCATED IN A CONFINED SPACE
A confined 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 floor. 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
confined space.
If sufficient 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.
FIGURE 4 - COMBUSTION/DILUTION AIR FROM
HEATED INSIDE SOURCES (CASE 2)
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.
H13.2
W415-1117 / A / 03.11.14
19
8.1.3
CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR
FROM ATTIC OR CRAWL SPACE
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 configuration, one opening can originate from the
floor 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 soffit vents or gable vents (Figure 5).
As an alternative to creating an opening in the floor to draw air from a crawl space, a duct may be dropped from
the attic terminating 12” (305mm) above the floor.
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
FIGURE 5 - OUTSIDE AIR FOR COMBUSTION, ATTIC OR
CRAWL SPACE (CASE 3)
present, their combustion air and ventilation
air requirements must be added to those of
the furnace.
TABLE 2 - VERTICAL AIR
SUPPLY (CASE 3)
Input
Free Area Round Pipe
K/Btu/hr Ea. Opening
Size
30
40
15 in2
(97 cm2)
5 in
(127 mm)
Alternate Combustion Air
from Attic. (12” / 305 mm
above floor)
60
80
20 in2
(129 cm2)
100
25 in2
(161 cm2)
120
30 in2
(194 cm2)
6 in
(152 mm)
7 in
(178 mm)
H12.16.1
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.
H13.3
W415-1117 / A / 03.11.14
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20
8.1.4
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CASE 4: FURNACE LOCATED IN A CONFINED SPACE,
OUTDOOR AIR DUCTED HORIZONTALLY
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.
FIGURE 6 - OUTDOOR AIR FOR COMBUSTION,
HORIZONTAL (CASE 4)
TABLE 3 - HORIZONTAL AIR
SUPPLY (CASE 4)
Input
Free Area Round Pipe
K/Btu/hr Ea. Opening
Size
30
40
30 in2
(194 cm2)
7 in
(178 mm)
60
Combustion Air
Duct Terminates
12” (305mm)
above floor.
80
40 in2
(258 cm2)
100
50 in2
(323 cm2)
120
60 in2
(387 cm2)
8 in
(203 mm)
9 in
(229 mm)
H12.9.1
IMPORTANT:
THE OUTDOOR GRILLS MUST BE INSTALLED IN A LOCATION WHERE THEY WILL NOT BE
OBSTRUCTED IN ANY MANNER.
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.
H13.4
8.1.5
CONNECTION TO FURNACE NON-DIRECT VENT
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)
FIGURE 7 - NON-DIRECT
COMBUSTION AIR INLET
H13.5
W415-1117 / A / 03.11.14
21
9.0 VENTING GUIDELINES
!
CAUTION
IOM
!
FAILURE TO FOLLOW ALL VENTING GUIDELINES MAY RESULT IN ERRATIC FURNACE
OPERATION, FREEZE-UP OF THE EXHAUST AIR PIPING, OR SOOTING OF THE FURNACE.
!
WARNING
!
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.
H3.12
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.
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.
• 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-flex” 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
flooding 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.
W415-1117 / A / 03.11.14
22
Size the combustion air and exhaust piping in accordance
with Table 4. When calculating allowable vent lengths, be
sure to count all termination fittings in addition to counting the
concentric vent as a straight pipe.
IOM
IOM
FIGURE 8 - STANDARD (STRAIGHT)
HORIZONTAL VENT DETAIL
*3"
(76mm)
MIN.
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.
EXHAUST
12"
(305mm)
MIN.
INTAKE
GRADE
*18" (457mm) MIN. FOR COLD
CLIMATES (SUSTAINED 0°F (-18°C)
FOR 24 OR MORE CONSECUTIVE
HOURS
The vent and combustion air intake shall be installed so that
both are located in the same wind pressure zone.
!
WARNING
!
DO NOT CONNECT FURNACE TO A CHIMNEY OR FLUE SERVING OTHER APPLIANCES OR A
SOLID FUEL BURNING APPLIANCE.
9.1
H3.13
H14.0
VENT TERMINATION
Horizontal vents should pass through the exterior wall. Figure 8 shows a standard horizontal vent detail.
Terminate the vent approximately 8” (203mm) or more from the wall.
Exterior vent pipe greater than 24” (610mm) should be insulated with 1/2” (13mm) insulation to prevent
moisture from freezing within the pipe and accumulating.
Size the exhaust pipe as specified in
Table 4 - Direct and Non-Direct Vent
Lengths. This table lists the maximum
allowable length of pipe with respect to
the number of 90° elbows used. For the
purposes of this calculation, one 90°
elbow is equivalent to two 45° elbows.
Avoid 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, 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.
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
NUMBER OF 90° ELBOWS
PIPE
SIZE
0
1
2
3
4
5
6
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
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
2
75*
70
65
60
55
50
45
3
125*
120
115
110
105
100
95
3
125*
120
115
110
105
100
95
30
40
60
80
100
120
1. Count concentric
vent fitting 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
fitting. (Figure 7)
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
W415-1117 / A / 03.11.14
NOTES
23
FIGURE 10 - VERTICAL VENTING
FIGURE 9 - PERISCOPED VENT DETAIL
*3"
(76mm)
MIN.
IOM
ROOF TERMINATION
EXHAUST
12"
(305mm)
MIN.
18" (457mm) MIN.
EXHAUST
12"
(305mm)
MIN.
INTAKE
GRADE
*18" (457mm) MIN. FOR COLD
CLIMATES (SUSTAINED 0°F (-18°C)
FOR 24 OR MORE CONSECUTIVE
HOURS
!
CAUTION
!
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.
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 flue 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.
H14.1
9.2
IN CANADA
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 floor, 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).
H14.2A
9.3
IN UNITED STATES
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, soffit, 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.
L
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) A / fA / 03.11.14
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W415-1117
24
•
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).
IOM
IOM
H14.3
9.4
FURNACE VENTING INSTALLATIONS
!
WARNING
!
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.
9.4.1
H3.14
NON-DIRECT VENT INSTALLATION USING INDOOR COMBUSTION
AIR (ONE PIPE SYSTEM)
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.
H14.4
9.4.2
DIRECT VENT INSTALLATION USING OUTDOOR COMBUSTION AIR
(TWO PIPE SYSTEM)
The direct vent configuration is the preferred installation method. The primary advantages are:
• No special kit or modifications 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 configuration 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 confined spaces.
H14.5
9.4.3
COMBUSTION AIR
This furnace is certified 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 field 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 NONDIRECT VENT APPLIANCES. SEE SECTION 8.1, “DETERMINING COMBUSTION AIR”.
H14.6
W415-1117 / A / 03.11.14
25
10.0
TERMINATIONS
10.1 COMBUSTION AIR
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” configuration, 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)
10.2 EXHAUST
IOM
FIGURE 11 - STANDARD VERTICAL VENTING
DETAIL
3"
(76mm)
MIN.
12"
(305mm)
MIN.
12"
(305mm)
MIN.
18"
(457mm)
MIN.
ROOF TERMINATION
EXHAUST
H15.1
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” configuration, the exhaust pipe
may be “periscoped” up to 24” (610mm) to gain extra height. (Figure 9) In this case, the flue gases may be
expelled horizontally. Use the same size pipe as the interior run and count the fittings and length as part of the
total vent length.
If winter prevailing wind conditions are variable and likely to occasionally blow flue 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 flue gases to help prevent re-circulation of
the exhaust. (Figure 9)
NOTE: Always clean out
VERTICAL - No termination fitting is required if venting vertically through a roof. exhauster collar after instalThe end of the exhaust pipe must be 12” (305mm) higher than the entrance of
lation. Vent pipe shavings
the combustion air intake terminal. (Figure 11)
from initial installation can
The exhaust pipe extending through the roof must extend a minimum of 18”
cause blockage in the ex(457mm) above any obstruction within an 18” (457mm) horizontal distance.
hauster collar drain.
Insulate all venting that extends 24” (610mm) or more to the outside.
10.3 CONCENTRIC VENTING KIT
H15.2
H15
2
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.
H15.3.1
10.4 CONCENTRIC VENT TERMINATION INSTALLATION INSTRUCTIONS
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.
10.5 LOCATION
H15.4
Avoid locating the terminals where the flue gas could become stagnant and allow recirculation into the
combustion air intake.
Avoid 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.
W415-1117 / A / 03.11.14
26
IOM
IOM
Avoid 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 flue 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.
When 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.
!
CAUTION
!
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.
The 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).
Any adjacent painted surfaces should be in good condition; no cracks, peeling paint, etc. If wooden surfaces that
may be periodically exposed to flue gases are present, consider treating with a sealer.
H15.5
10.6 MULTIPLE VENTING
IMPORTANT:
WHEN INSTALLING MULTIPLE FURNACES IN CLOSE PROXIMITY, EACH REQUIRES
DEDICATED COMBUSTION AIR AND EXHAUST VENTING.
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.
FIGURE 12 - MULTIPLE VENTING (STANDARD
HORIZONTAL)
12" (305mm) MIN.
3"
(75mm)
MIN.
12" (305mm) MIN.
2"
(51mm)
MIN.
8"
(203mm)
MIN.
TWO FURNACES VENTING
THROUGH ROOF
3"
(76mm)
MIN.
12" (305mm)
MIN.
COMBUSTION AIR
INTAKE 2" PVC
INTAKE
EXHAUST
12"
(305mm)
MIN.
FIGURE 13 - MULTIPLE VENTING (STANDARD
VERTICAL)
12" (305mm)
MIN. ABOVE
SNOW LEVEL
GRADE
30" (762mm) MAX.
3"
(76mm)
TO BE REDUCED
FROM 3" PVC TO
2" PVC BELOW THE
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).
H15.6
!
WARNING
!
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.
H3.15
W415-1117 / A / 03.11.14
27
FIGURE 14A - DIRECT VENT TERMINAL CLEARANCES
IOM
W415-1117 / A / 03.11.14
28
FIGURE 14B - NON-DIRECT VENT TERMINAL CLEARANCES
IOM
IOM
W415-1117 / A / 03.11.14
29
11.0
ROUTING OPTIONS
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 filter(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 fitting 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.
H16.0.2
11.1 EXHAUSTER ROTATION INSTRUCTIONS & PRESSURE SWITCH
MOUNTING
1.
2.
3.
4.
5.
Disconnect exhauster wire connection (L1 and Neutral).
Remove the 3 exhauster screws.
Remove pressure switch assembly.
Remove exhauster.
Reverse the bands on the rubber drain coupling so the screws are accessible if necessary. (Do not
reverse the drain coupling.) Confirm 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 floor 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.
IMPORTANT:
KEEP PRESSURE SWITCH HOSES ABOVE HEAT EXCHANGER DRAIN, AND CUT TO
APPROPRIATE LENGTH TO PREVENT ANY SAGS OR TRAPS FORMING IN THE HOSES.
H16.1.1
:
+25,=217$/.,7
35(6685(6:,7&+
TABLE 5 - EXHAUSTER ORIENTATION
FURNACE
FLUE
KIT
EXHAUSTER
OUTLET
REQUIRED
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
SEE FIGURES
16-18 FOR
RECOMMENDED
MOUNTING
:
6,1*/(67$*(
35(6685(6:,7&+
:
+25,=217$/.,7
35(6685(6:,7&+
W415-1117 / A / 03.11.14
IOM
30
11.2 CONDENSATE DRAINS
IOM
IOM
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.
Affix the condensate trap assembly to the interior of the side panel in the blower compartment for upflow
positions. For horizontal positions affix 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 fitting on the
condensate trap assembly. The small one is used to secure the drain hose to the 1/2” barbed fitting 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 fit each
application. This is to prevent kinking in the drain lines.
NOTE: It is recommended that pliers be used to firmly clamp the plastic hose clamps.
H16.2.1A
11.3 PREPARATIONS FOR VENT AND DRAINING OPTION
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).
NOTE
7. Make sure combustion compartment is fully sealed.
Barbed fittings must be fully inserted into
condensate trap, seated to barb flange.
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
BARB FLANGE
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.
H16.3.1A
W415-1117 / A / 03.11.14
31
FIGURE 15
IOM
IMPORTANT:
CONNECT ½” TEE FITTING (FIELD SUPPLIED)
TO THE OUTLET OF THE CONDENSATE TRAP.
!
WARNING
!
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.
H3.16
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.
W415-1117 / A / 03.11.14
32
FIGURE 16 - UPFLOW VENT AND DRAINING OPTION CONTINUED
IOM
IOM
RIGHT VENT INSTALLATION
IMPORTANT:
• PRIME CONDENSATE TRAP WITH
WATER AND CUT DRAIN HOSES TO
PROPER LENGTH.
• CUT PRESSURE SWITCH TUBING
TO PROPER LENGTH, IF REQUIRED.
NOTE
Upflow Vent Right - condensate trap may
have to be installed on left side in small
cabinets.
FIGURE 17 - HORIZONTAL LEFT VENT AND DRAINING OPTION
LEFT 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.
W415-1117 / A / 03.11.14
33
FIGURE 18 - HORIZONTAL RIGHT VENT AND DRAINING OPTION
RIGHT VENT INSTALLATION
TOP VENT INSTALLATION
IOM
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..
!
CAUTION
!
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.
11 .4 DRAIN HOSE INSTALLATION
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.
H16.4
H16
4
11.4.1
DRAIN TUBING
Condensate from the outlet of the drain trap assembly must be conveyed to a floor 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.
!
CAUTION
!
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.
W415-1117 / A / 03.11.14
34
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A typical configuration 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 overflow 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 flexible tubing, or the condensate may be piped entirely in CPVC to
the floor drain/sump/condensate pump.
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.
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.
H16.4.1
11.4.2
PRIMING CONDENSATE TRAP
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.
H16.4.2
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
W415-1117 / A / 03.11.14
FIGURE 22
35
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 flush with the end of the outlet. The remaining
rubber should be flush with the end of the outlet on the condensate trap. The remaining hose is sufficient
length to accommodate all furnace orientations.
FIGURE 23
FIGURE 24
3. A 1/2” PVC coupling or bushing will fit snug over the 1/2” rubber hose. A 3/4” CPVC coupling or bushing will
fit 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.
FIGURE 25
FIGURE 26
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.
H16.5.1A
11.6 CONDENSATE NEUTRALIZERS
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 overflow bypass tube.
H16.6
W415-1117 / A / 03.11.14
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36
12.0
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GAS SUPPLY AND PIPING
12.1 GAS SUPPLY
!
WARNING
!
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 TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, EXPLOSION, CARBON
MONOXIDE POISONING, PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
H3.18
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.
H17.1
12.2 GAS PIPING
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 flexible gas appliance connector, always use a new listed connector. Do not
use a connector, which has previously serviced another gas appliance.
IMPORTANT:
FIGURE 27 - FURNACE GAS PIPE CONNECTIONS
(NOTE RUBBER GROMMET)
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.
W415-1117 / A / 03.11.14
37
IMPORTANT:
ALWAYS USE A BACKUP WRENCH TO PREVENT TWISTING OF THE GAS VALVE. ANY
STRAINS ON THE GAS VALVE CAN AFFECT POSITIONING OF THE ORIFICES RELATIVE
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 floor 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.
H17.2A
!
WARNING
!
DISCONNECT THE MANUAL SHUT-OFF VALVE AND GAS VALVE DURING ANY
PRESSURE TESTING THAT EXCEEDS 1/2 P.S.I.G. (3.45 KPA).
H3.19
12.3 GAS INLET PRESSURE
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 fired 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.
H17.3.1
12.4 LEAK TESTING
All new gas piping installations should be pressure tested as specified by CAN/CSA-B149.1 & 2, or NFPA 54
ANSI Z223.1 or ANSI/NFPA 58, “Standard for the Storage and Handling of Liquefied 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.
H17.4
12.5 PURGING GAS LINES
!
WARNING
!
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.
H3.20
W415-1117 / A / 03.11.14
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38
13.0
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CONVERSIONS
13.1 HIGH ALTITUDE CONVERSION
In Canada, the modifications 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 modifications 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.
H18.1
13.2 NATURAL TO LP GAS CONVERSION
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, orifices needed
for all models, the regulator spring for the gas valve, and a label to affix 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.
H18.2A
TABLE 6 - HIGH ALTITUDE SPECIFICATIONS (U.S.A.)
Input
K/Btu/hr
40/60/80
100/120
ORIFICE SIZE (DMS)
ALTITUDE
Input
ORIFICE SIZE (DMS)
ALTITUDE
K/Btu/hr
NATURAL
LP GAS
0-2000 (0-610 m)
50
57
56
2000-3000 (610-914 m)
53
58
49
57
3000-4000 (914-1219 m)
54
59
4000-5000 (1219-1524 m)
50
58
4000-5000 (1219-1524 m)
55
60
5000-6000 (1524-1829 m)
51
60
5000-6000 (1524-1829 m)
56
62
61
6000-7000 (1829-2134 m)
57
63
62
7000-8000 (2134-2438 m)
58
64
65
67
NATURAL
LP GAS
0-2000 (0-610 m)
45
55
2000-3000 (610-914 m)
48
3000-4000 (914-1219 m)
6000-7000 (1829-2134 m)
7000-8000 (2134-2438 m)
52
53
30
8000-9000 (2438-2743 m)
54
63
8000-9000 (2438-2743 m)
59
9000-10000 (2743-3048 m)
55
65
9000-10000 (2743-3048 m)
60
Gas input ratings are certified 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
13.3 CONVERSION STEPS
Refer to Conversion NG to LP Kit (W370-0018) for complete instruction.
H18.3
13.4 CHECKING THE INLET GAS PRESSURE
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 orifices. Repair any leaks before continuing.
4. Measure furnace gas inlet pressure with burners firing. Inlet pressure must be within the range specified 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.
W415-1117 / A / 03.11.14
39
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, first examine the gas piping system to ensure
that it is correctly sized. Pipe sizing is specified 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.
H18.4.1
FIGURE 28 - WHITE RODGERS 36J24-214 GAS VALVE
Outlet Pressure Boss
FIGURE 29 - VALVE PRESSURE CHECK KIT
Regulator Vent
Regulator
Adjust
Inlet Pressure
Boss (opt.)
Terminals On/Off Switch
13.5 SETTING THE MANIFOLD GAS PRESSURE
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 fig. 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 (fig.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 specifications 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).
W415-1117 / A / 03.11.14
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40
!
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WARNING
!
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.
H3.21
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!
H18.5.1
13.6 CHECKING FURNACE INPUT
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 specific
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 adjustments
to the burner manifold pressure or by changing the burner orifice size. Contact the fuel supplier for specific
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:
FIGURE 30 - MANOMETER MEASURING GAS MANIFOLD PRESSURE
NEVER ADJUST THE INPUT
OF THE FURNACE TO
EXCEED THE INPUT SHOWN
ON THE RATING PLATE.
Heating Value of Gas x 3600
Input =
Time in Sec. for 1 cu. ft.
where:
• input is expressed in Btu/hr
• heating value of the gas is expressed in Btu/ft3
• 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
H18.6.1
W415-1117 / A / 03.11.14
41
14.0
ELECTRICAL SPECIFICATIONS
14.1 ELECTRICAL WIRING AND CONNECTIONS
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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 humidifier 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.
!
WARNING
!
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.
H3.22
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.
H19.1
FIGURE 31 - ELECTRICAL CONNECTIONS
/ MOLEX CONNECTOR
W415-1117 / A / 03.11.14
42
FIGURE 32 - INTEGRATED FURNACE IGNITION CONTROL
STATUS LED
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120 VAC MOTOR
TERMINALS
FAULT CODE
BUTTON
ELECTRONIC
AIR CLEANER
TERMINAL
POWER
HUMIDIFIER
TERMINAL
THERMOSTAT
TERMINALS
120 VAC NEUTRAL
CONNECTIONS
3A FUSE
24 VAC MOLEX
120 VAC MOLEX
14.2 FURNACE CONNECTION
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.
NOTE
Use good quality wire nuts such as Marrette®
connectors, Ideal® wire nuts, etc.
IMPORTANT:
USE COPPER CONDUCTORS ONLY.
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.
H19.2
!
WARNING
!
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.
H3.23
W415-1117 / A / 03.11.14
43
15.0
LOW VOLTAGE WIRING
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.
H53.1
15.1 THERMOSTAT LOCATION
The thermostat should be located approximately 5 feet (1524mm) above the floor, 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.
H53.2
16.0
OPTIONAL ACCESSORIES (FIELD SUPPLIED/
INSTALLED)
16.1 ELECTRIC AIR CLEANER
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.
H20.1.1
16.2 POWER HUMIDIFIER
The integrated furnace control has provisions to supply power and control a line voltage humidifier or the
primary of a 120 / 24 volt humidifier step down transformer, rated at 120VAC, 1.0 amp max.
NOTE
All HUM and EAC terminals are 120V. Do not directly connect 24V equipment to these terminals.
H20.2
W415-1117 / A / 03.11.14
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44
17.0
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INITIAL STARTUP PROCEDURES
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 five minutes for any gas to dissipate before continuing 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 firing.
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 flue
gases to flow 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 fill the trap. If the
thermostat is still calling for heat, the ignition sequence will start again after a 5 minute wait.
H21.0
17.1 TO START THE FURNACE
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.
4.
5.
6.
7.
8.
Turn the gas valve switch to the “ON” position.
Replace the burner compartment access door.
Turn on furnace appliance shut off valve.
Restore electrical power to the furnace.
Set the room thermostat to a point above room temperature to light the furnace.
After the burners are lit, set the room thermostat to the desired temperature.
H21.1
17.2 TO SHUT DOWN THE FURNACE
1.
2.
3.
4.
5.
Set the room thermostat to below set point.
Remove the burner compartment access door.
Turn the gas valve switch to the “OFF” position.
The furnace appliance shut-off valve may be closed if desired.
Power to the furnace must remain on for the air conditioner to work.
H21.2
W415-1117 / A / 03.11.14
45
!
WARNING
!
SHOULD OVERHEATING 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.
H3.24
17.3 SEQUENCE OF OPERATION
1. Room temperature drops causing the room thermostat call for heat by connecting “W” to “R”. The control
verifies 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 flash “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 flame proving. If flame 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 flame 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 flame losses (4 re-cycles) within a single call for heat before going into lockout. The control flashes “8” on
the Red LED if lockout is due to too many flame dropouts (1 hour lockout).
H21.3.1A
W415-1117 / A / 03.11.14
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46
18.0
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AIR FLOW
For proper furnace operation, air flow over the heat exchanger is of utmost importance. Insufficient airflow
accelerates metal fatigue and possible failure in the heat exchanger, as well as decrease efficiency. Excessive
airflow promotes accelerated corrosion of the heat exchanger.
IMPORTANT:
DO NOT BYPASS THIS STEP OF THE
START UP PROCEDURES.
H22.0
18.1 TEMPERATURE RISE CHECK
When the duct system is complete and the air filter or filters are in place, determine if the airflow 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 humidifier 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 flow. It must be
increased by removing restrictions
in the ductwork, adding supply or
return ductwork, or by selecting a
higher motor speed.
TABLE 7 - AIR FLOW (PSC)
PSC
Input
NBM030S2A
NBM040S2A
NBM040S3A
If the measured ∆T is too low, there
is too much air flow.
H22.1.1
NBM060S2A
NBM060S3A
ESP 0.1” to 1.0” w.c.
MAX A/C
TAP
Tonnage
COLOUR
2 TON
BLACK
2 TON
BLUE
1 1/2 TON
YELLOW
600
1 1/2 TON
RED
2 TON
PSC
ESP 0.1” to 1.0” w.c.
Max A/C
TAP
Tonnage
NUMBER
800
N/A
BLACK
1700
700
N/A
BLUE
1400
3 TON
YELLOW
1200
500
2 TON
RED
800
BLACK
800
5 TON
BLACK
1900
4 TON
BLUE
1600
N/A
YELLOW
1400
CFM
Input
NBM080S3A
2 TON
BLUE
700
1 1/2 TON
YELLOW
600
1 1/2 TON
RED
500
3 TON
RED
1200
N/A
BLACK
1500
5 TON
BLACK
2000
N/A
BLUE
1400
5 TON
BLUE
1900
3 TON
YELLOW
1200
4 TON
YELLOW
1600
2 TON
RED
800
3 TON
RED
1300
N/A
BLACK
1500
5 TON
BLACK
2000
N/A
BLUE
1400
5 TON
BLUE
1900
3 TON
YELLOW
1200
4 TON
YELLOW
1600
2 TON
RED
800
3 TON
RED
1300
N/A
BLACK
1700
5 TON
BLACK
2000
N/A
BLUE
1400
5 TON
BLUE
1900
3 TON
YELLOW
1200
4 TON
YELLOW
1600
2 TON
RED
800
3 TON
RED
1300
NBM080S4A
NBM100S4A
NBM100S5A
NBM120S5A
NOTE
Airflow based on approximately 350 - 400 CFM/Ton.
H12.1.1
W415-1117 / A / 03.11.14
CFM
47
18.2 CALCULATING AIR FLOW
There are circumstances where it may be desirable to know the air flow delivery through the duct system,
such as when estimating the amount of air flow available for
Output
CFM =
air conditioning. This can be done by direct measurement with
1.085 x ∆T
electronic or sloped manometers and velometers, or use the
where:
formula in the next column.
• CFM is airflow in cubic feet per minute;
•
•
∆T is the temperature rise; and
Output is the furnace output capacity
from the rating plate.
H22.2.1
H22
21
18.3 CONTINUOUS FAN OPERATION
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.
H22.3.1
TABLE 8 - CONTINUOUS
FAN CFM
Input
K/Btu/hr
PSC
Motor
HP
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
W415-1117 / A / 03.11.14
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48
19.0
MAINTENANCE AND TROUBLESHOOTING
IOM
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!
WARNING
!
DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING
ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN
PERSONAL INJURY OR LOSS OF LIFE.
!
CAUTION
!
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING
ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.
ALWAYS VERIFY PROPER OPERATION AFTER SERVICING.
H3.25
19.1 AIR FILTER
The air filter should be inspected frequently and cleaned or replaced as necessary. We recommend a monthly
inspection at first, 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 filters result in higher than normal operating temperatures, and lower efficiency.
Some paper media high efficiency filters, sometimes identified as HEPA filters can do an effective and
excellent filtration of the air; however, some models may also cause a large pressure drop across the filter. The
contractor should assess the capabilities of the duct system to deliver sufficient air flow if this type of filter is
considered.
RECOMMENDED: Electronic air cleaners using electrostatic precipitation to remove dust are an excellent filtration
device when used in conjunction with a pre-filter. A 16”
NOTE
x 25” (406mm x 635mm) model is an ideal fit with this
If two return air inlets are used, both must be equipped
furnace in the case of a side mounted return air inlet. The
with filters.
integrated furnace control is supplied with an electrical
terminal for use with electronic air cleaners.
!
CAUTION
!
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.
H23.1
W415-1117 / A / 03.11.14
49
19.2 LUBRICATION
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.
H23.2.2
W415-1117 / A / 03.11.14
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50
19.3 TROUBLESHOOTING FLOWCHART
SEQUENCE OF OPERATION
IOM
IOM
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H23.3.1
W415-1117 / A / 03.11.14
51
19.4 DIAGNOSTIC CODES FOR STATUS LED
A 3 colour LED is provided to indicate system faults. LED codes are as follows:
IOM
• 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 flash - Incorrect 24VAC phasing/twinning errors
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 flame dropouts
9 Flashes
Not used
10 Flashes
Flame present with gas valve off
H23.4.1
19.5 FAULT CODE HISTORY
The control stores the last 5 fault codes in memory. When the push button switch is pressed, the
control will flash the stored fault codes when the switch is released. The most recent fault code is
flashed first, the oldest last.
Fault history may be cleared by holding the push button switch for more than 5 seconds.
H23.5
W415-1117 / A / 03.11.14
40-3
W
R
Y
BK
BU
60-2
W
BU
R
BK
Y
60-3
W
Y
Y
BK
BU
R
W415-1117 / A / 03.11.14
PARK
(BK)
(W)
(G)
(Y)
(Y)
HI COOL
+ 120 VAC -
NEUTRAL
HEAT
COOL
PARK
PARK
PARK
24 VAC
PSC MOTOR
80-3 80-4 100-4 100-5 120-5
W
W
W
W W
Y
BK
BU BU BU
BU BU
Y BK R
BK BK
Y
BK Y
R
Y
R
R
R
201
NEUTRALS
BLACK JUNCTION
WHITE BOX
GREEN 120 VAC
WHITE
WHITE
BLACK
BLACK
P2
BLOWER
DIVISION
8
GAS VALVE (BK)
GAS VALVE (W)
H24.1.2A
20.0
LEGEND
W = WHITE
R = RED
Y = YELLOW
BU = BLUE
BK = BLACK
G = GREEN
P = PURPLE
40-2
W
BK
BK
BU
Y
R
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30-2
W
BU
BK
Y
R
52
WIRE DIAGRAM FOR SINGLE STAGE
FURNACE WITH PSC
FLAME SENSOR (P)
HEAT LIMIT (R)
HEAT LIMIT (R)
PRESSURE SWITCH (Y)
PRESSURE SWITCH (Y)
ROLLOUT (R)
ROLLOUT (R)
ROLLOUT (R)
ROLLOUT (R)
IGNITOR (W)
IGNITOR (B)
INDUCER (W)
INDUCER (B)
P1
HUM
XFMR
L1
EAC
HEAT
53
21.0
WARRANTY
IOM
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 qualified technician before packaging to ensure that you, the customer, receives the quality product that you expect from Napoleon®.
NAPOLEON® 9200 GAS FURNACE PRESIDENT’S LIMITED LIFETIME WARRANTY
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.
www.napoleonheatingandcooling.com
p
g
g
. 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 specific legal rights, and you may also
have other rights which vary by jurisdiction.
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, floods,
fires, 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®.
OR
5. Use of components or accessories not compatible with this unit.
LIMITED WARRANTY (Not Registered)
6. Products installed outside Canada, or the United States and its
If not registered within 60 days, the HEAT EXCHANGER is warranted for
territories.
a period of 20 YEARS (pro rated), and all internal functional parts are
7. Routine maintenance, but not limited to, cleaning of the coils, filter
warranted for a period of 5 YEARS, all other limitations apply.
cleaning and/or replacement and lubrication.
Proof of purchase will be required. Replacements are subject to review and
8. Parts not supplied by Napoleon®.
verification by a Napoleon® representative.
9. If unit is equipped with an ultraviolet bulb, the bulb is warranted
Warranty ceases to exist if the unit is removed from the location where it was
for 90 days from date of install.
originally installed.
10. Damage or repairs required as a result of any improper use,
This limited warranty will not apply unless the gas furnace is: (1) installed by
maintenance, operation,servicing, cleaning or replacing air filters.
a licensed or qualified HVAC technician, (2) installed in accordance with the
11. Failure to operate due to interruption and/or inadequate electrical
manufacturer’s recommendations in its Installation and Operation Manual,
service.
and (3) in compliance with all industry standards, national, provincial/state,
12. Damages, defects or failures caused by accidents or negligent or
and local codes.
unreasonable use or operation of the unit and its’ components,
Regardless of time of registration, the warranty period begins on the date of
including without limitation, operation beyond rated capacity and
the original installation. Where a product is installed in a newly constructed
operation of electrical components at voltage other than that
home; the date of installation is the date the homeowner takes possession of
specified on the rating plate.
the home from the builder. If that date cannot be verified, the warranty period
begins three months after the month of manufacture (indicated by the first four 13. Napoleon® shall not in any event extend warranty coverage to
any incidental, consequential or indirect damages.
digits of the serial number.
14. Changes in the appearance of the unit that do not affect its
As its only responsibility, and your only remedy, Napoleon® will furnish a
performance.
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 15. Damages, defects or failures caused by operation of the unit in
abnormal environmental conditions (i.e. salt air).
maintenance.
16.
Damages, defects or failures caused by conditioned air (return
To make a warranty claim, the defective part must be returned to a
air) supplied to the furnace being greater than 20% from out-ofNapoleon® heating and air conditioning products dealer/distributor by a
doors (13°C/55°F min. return air temperature).
certified or licensed contractor. Any part replaced pursuant to this warranty is
17.
Damages, defects or failures caused by the furnace being
warranted only for the unexpired portion of the warranty term applying to the
installed downstream from a cooling coil.
original part.
* “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 HOMEOWNERS FUTURE REFERENCE
Dealer Name
Dealer’s City/Province-State/Postal-Zip Code
Model and Serial Number
(Serial number located on inside bottom door)
Telephone/Fax
Installation Date
E-mail Address
For further information about this warranty, contact Napoleon® Technical Service Department at (866) 539-2039,
email [email protected]. or by mail to
, 24 Napoleon Road, Barrie, Ontario L4M 0G8 Canada
www.napoleonheatingandcooling.com
10.16.12
H2.3.1
W415-1117 / A / 03.11.14
54
22.0
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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
FAILURE
TO POSITION THE PARTS
ORIGINAL INVOICE WILL BE REQUIRED TO HONOUR THE CLAIM.
IN ACCORDANCE WITH THIS
When ordering replacement parts always give the following information:
MANUAL OR FAILURE TO USE ONLY
• Model & Serial Number of appliance
PARTS SPECIFICALLY APPROVED
• Installation date of appliance
WITH THIS APPLIANCE MAY
• Part number
RESULT IN PROPERTY DAMAGE OR
• Description of part
PERSONAL INJURY.
• Finish
FOR FURTHER INFORMATION, CONTACT YOUR AUTHORIZED DEALER.
WARNING
H41.1
PART DESCRIPTION
PART NUMBER
W415-1117 / A / 03.11.14
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
55
FIGURE 2 - FURNACE COMPONENTS
1
IOM
5
7
11
17
2
12
15
6
3
4
13
8
16
14
9
10
19
18
LEGEND
1. Combustion Air Intake Fitting
2. Flame Roll-Out Switch(s)
3. Flame Sensor - opposite of ignitor
4. Single Stage Gas Valve
5. High Temperature Limit - Supply Air
6. Vent Drain Assembly Coupling
7. Drain for Recovery Coil (2)
8. Condensate Trap
9. Single Stage Integrated Furnace Control (IFC)
10. Transformer for 24 VAC / 40 VA
11.
12.
13.
14.
15.
16.
17.
18.
19.
Burner Assembly
Hot Surface Igniter (HSI) - located underneath
Single Speed Exhauster
Pressure Switch Assembly
Front Manifold Cover Pressure Tap (2)
Door Switch
Junction Box
Blower Motor
Circulating Air Blower
W415-1117 / A / 03.11.14
56
23.0
SERVICE HISTORY
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43.1
W415-1117 / A / 03.11.14
57
LEAVE THIS MANUAL WITH THE APPLIANCE FOR FUTURE REFERENCE.
CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.
USER’S INFORMATION
MANUAL
9200 SERIES
SINGLE STAGE MULTI POSITION HIGH EFFICIENCY
(CONDENSING) FORCED AIR GAS FURNACE
SAFETY INFORMATION
!
WARNING
!
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
qualified 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 flammable
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 fire
department.
MANUFACTURER RESERVES THE RIGHT TO DISCONTINUE, OR CHANGE
AT ANY TIME, SPECIFICATIONS OR DESIGNS WITHOUT NOTICE AND
WITHOUT INCURRING OBLIGATIONS.
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 • [email protected]
H1.12
W415-1117 / A / 03.11.14
UM
58
TABLE OF CONTENTS
UM
1.0
SAFETY SYMBOLS AND WARNINGS
59
2.0
SAFETY ISSUES
60
2.1
GENERAL SAFETY RULES
62
FURNACE OPERATION INFORMATION
64
3.1
STARTING THE FURNACE
64
3.2
SHUTTING DOWN THE FURNACE
64
3.3
OPERATING TIPS
65
3.0
4.0
5.0
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
HOMEOWNER’S REFERENCE
71
NOTE: Changes, other than editorial, are denoted by a vertical line in the margin.
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.
H1.21
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59
1.0 SAFETY SYMBOLS AND WARNINGS
Understand and pay particular attention to the words DANGER, WARNING, and CAUTION and the following
defined 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.
!
WARNING
!
INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED,
COULD RESULT IN DEATH OR SERIOUS INJURY.
!
CAUTION
!
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.
H3.3.1
!
WARNING
!
SHOULD OVERHEATING 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.
H3.24
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60
2.0 SAFETY ISSUES
This furnace has been designed to deliver many years of efficient, dependable service.1 With regular
maintenance, some of which requires the attention of a qualified 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.
UM
Do not use this furnace if any part has been under water. A flood-damaged furnace is extremely dangerous.
Attempts to use the furnace can result in fire or explosion. A qualified 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.
H25.0.1
FIGURE 1 - FURNACE COMPONENTS
1
2
11
12
3
5
4
6
13
14
17
15
7
7
8
9
16
10
18
19
LEGEND
1. Combustion Air Intake Fitting
2. Flame Roll-Out Switch(s)
3. Flame Sensor (opposite side of ignitor)
4. Single Stage Gas Valve
5. High Temperature Limit (behind gas valve)
6. Vent Drain Assembly Coupling
7. Drain for Recovery Coil (2)
8. Condensate Trap
9. Single Stage Integrated Furnace Control (IFC)
10. Transformer for 24 VAC / 40 VA
W415-1117 / A / 03.11.14
11.
12.
13.
14.
15.
16.
17.
18.
19.
Burner Assembly
Hot Surface Igniter (HSI) - located underneath
Single Speed Exhauster
Pressure Switch Assembly
Front Manifold Cover Pressure Tap (2)
Door Switch
Junction Box
Blower Motor
Circulating Air Blower
61
!
WARNING
!
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.
H3.26
!
WARNING
UM
!
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS, OR
OTHER COMBUSTIBLE MATERIALS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WHAT TO DO IF YOU SMELL GAS
•
DO NOT TRY TO LIGHT ANY APPLIANCE.
•
DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE
IN YOUR BUILDING.
•
IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A 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
DEPARTMENT.
•
DO NOT RE-ENTER THE BUILDING UNTIL AUTHORIZED TO DO SO BY THE
GAS SUPPLIER OR THE FIRE DEPARTMENT.
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN
CAUSE INJURY, PROPERTY DAMAGE OR LOSS OF LIFE. REFER TO THIS MANUAL.
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
H3.27
!
WARNING
!
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.
H3.4.1
!
WARNING
!
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.
H3.28
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62
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 first 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.
H25.0.2
FIGURE 2 - GAS REGULATOR VENT
UM
Regulator vent
Keep free of ice, snow,
and debris
!
WARNING
!
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.
H3.29
2.1
GENERAL SAFETY RULES
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
fiberglass insulation, clothing, etc. This applies especially to gasoline and other flammable vapors and
liquids.
2. This furnace is CSA certified 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 operating
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 confined 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 qualified installation contractor, service agency or gas supplier, using
factory specified or approved parts.
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63
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 filter or filters. A blocked air filter will reduce efficiency,
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 efficiency, and shortening the life of the furnace
components.
H25.1
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64
3.0 FURNACE OPERATION INFORMATION
3.1
STARTING THE FURNACE
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.
UM
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 floor 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 first 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.
H26.1
FIGURE 3
Outlet Pressure Boss
Regulator Vent
Regulator
Adjust
Inlet Pressure
Boss (opt.)
Terminals On/Off Switch
3.2
SHUTTING DOWN THE FURNACE
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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65
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.
H26.2
3.3
OPERATING TIPS
1. Clean air filters maximize efficiency, and reduce heating costs.
UM
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 deflectors 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 influence
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.
H26.3
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66
4.0 ROUTINE MAINTENANCE BY HOMEOWNER
4.1
AIR FILTER
!
CAUTION
!
DO NOT OPERATE YOUR FURNACE OR AIR CONDITIONER FOR EXTENDED PERIODS OF
TIME WITHOUT AN AIR FILTER.
UM
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.
!
WARNING
!
DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING
ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN
PERSONAL INJURY OR LOSS OF LIFE.
H3.25.1
Consult your installation contractor or service technician if you have any questions on instructions for removing
the air filter.
!
CAUTION
!
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.
H27.1
4.2
LUBRICATION
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.
H27.2
4.3
ROUTINE EXAMINATION
IMPORTANT:
We recommend that your furnace and exhaust/combustion air vents be checked by a qualified
service technician once a year.
It is good practice to give a quick inspection of your furnace each time you inspect or clean the air filter. 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 floor 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.
W415-1117 / A / 03.11.14
67
•
•
•
Water should flow 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 floor 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 flames
are clean and blue. A bit of orange color in the flame is not likely to be a problem and is probably dust
particles burning. If you observe lazy yellow flames, call your heating or service contractor immediately.
The yellow flames 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.
H27.3A
4.4
ANNUAL INSPECTION/SERVICE
It is recommended that the furnace be inspected annually by a qualified installation contractor, service agency
or fuel supplier. Your annual inspection will normally cover the following:
HEAT EXCHANGER - The heat exchanger should be inspected for corrosion. The flue 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.
!
CAUTION
!
BE CAREFUL WHEN WORKING ON THE BURNER ASSEMBLY. THE HOT SURFACE
IGNITER IS FRAGILE AND CAN BREAK EASILY.
The flame sensor should be inspected and cleaned with fine 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 OPERATION - 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 flames are smooth soft blue, and not impinging on
the heat exchanger.
4. Ensure gas meter is timed, and/or furnace manifold pressure checked to confirm the furnace is operating
at the input listed on the rating plate.
H27.4.1
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68
4.5
FURNACE APPEARANCE
The furnace exterior finish is a durable automotive like coating. It may be washed with mild soap if necessary.
Galvanized metal surfaces require no maintenance.
H27.5
4.6
UM
CLEANING
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 efficiency.
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.
!
CAUTION
!
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION.
ALWAYS VERIFY OPERATION AFTER SERVICING.
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)
FIGURE 5
IMPORTANT:
Be careful not to bend the fins when cleaning. You may wish to leave this maintenance procedure
to your service technician.
W415-1117 / A / 03.11.14
69
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 qualified service technician. Evidence may include
large amounts of dirt or debris building up in the condensate drain line.
H27.6.1B
!
WARNING
!
ALWAYS DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE REMOVING
THE BURNER COMPARTMENT ACCESS DOOR.
H3.30
!
CAUTION
!
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
ATTEMPTING TO RESTART THE FURNACE.
The furnace achieves its high efficiency 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 benefit 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 flue gas, which is comprised of water
vapor and carbon dioxide. By condensing the flue 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 flowing. 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 qualified
service technician. Your service technician has the knowledge and test equipment to
determine the condition of your furnace.
H27.6.2
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70
4.7
SEQUENCE OF OPERATION
1. Room temperature drops causing the room thermostat call for heat by connecting “W” to “R”. The control
verifies 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 flash “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 flame proving. If flame 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.
UM
IN THE EVENT OF FLAME FAILURE:
If flame 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 flame losses (4 re-cycles) within a single call for heat before going into lockout. The control flashes “8” on
the Red LED if lockout is due to too many flame dropouts (1 hour lockout).
H21.3.1A
4.8
VARIATIONS
If your system includes air conditioning, your thermostat will likely have two switches. The first 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.
H27.7
4.9
TERMINATIONS
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 flow of air.
H27.8
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71
5.0 HOMEOWNER’S REFERENCE
HOMEOWNER’S REFERENCE TABLE
Model No.
Serial No.
(serial number located on bottom of inside door)
UM
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.
H28.0
W415-1117 / A / 03.11.14
®
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Fireplaces / Heating & Cooling call: 705-721-1212 • Grills call: 705-726-4278
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