Napoleon 9600 SERIES Installation And Operating Instructions Manual
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Napoleon 9600 SERIES Installation And Operating Instructions Manual

Two stage natural and propane gas high efficiency (condensing) forced air furnace
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CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.
TWO STAGE NATURAL AND
PROPANE GAS HIGH EFFICIENCY
(CONDENSING) FORCED AIR
FURNACE

SAFETY INFORMATION

WARNING
!
ELECTRICAL SHOCK, FIRE OR
EXPLOSION HAZARD
Failure to follow safety warnings exactly
could result in serious inquiry, death or
property damage.
Improper servicing could result in
dangerous operation, serious injury, death
or property damage.
- Installation and service must be performed by a
qualifi ed installer, service agency or the gas supplier.
- Before servicing, disconnect all electrical power to
furnace.
- When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.
- Verify proper operation after servicing.
- Do not store or use gasoline or other fl ammable
vapors and liquids in the vacinity of this or any other
appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbour's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the fi re
department.
Phone (705)721-1212 • Fax (705)722-6031 • www.napoleonheatingandair.com • ask@napoleonproducts.com
$10.00
INSTALLER: LEAVE THIS MANUAL WITH THE APPLIANCE.
OPERATING INSTRUCTIONS
CERTIFIED TO ANSI Z21.47b / CSA 2.3b-2008
!
Wolf Steel Ltd., 24 Napoleon Rd., Barrie, ON, L4M 4Y8 Canada /
103 Miller Drive, Crittenden, Kentucky, USA, 41030
INSTALLATION AND
1
W415-0919 / 10.12.10

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Summary of Contents for Napoleon 9600 SERIES

  • Page 1: Safety Information

    • If you cannot reach your gas supplier, call the fi re department. Wolf Steel Ltd., 24 Napoleon Rd., Barrie, ON, L4M 4Y8 Canada / 103 Miller Drive, Crittenden, Kentucky, USA, 41030 Phone (705)721-1212 • Fax (705)722-6031 • www.napoleonheatingandair.com • ask@napoleonproducts.com W415-0919 / 10.12.10...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION SAFETY SYMBOLS AND WARNINGS SAFETY RULES CODES INSTALLATION REQUIREMENTS SPECIFIC TO THE STATE OF MASSACHUSETTS FOR DIRECT VENT, MECHANICAL VENT, AND DOMESTIC HOT WATER APPLIANCES. FURNACE SIZING LOCATION OF UNIT GENERAL GUIDELINES OTHER CONSIDERATIONS INSTALLATION IN UPFLOW, DOWNFLOW OR HORIZONTAL POSITIONS AIR CONDITIONING COMBUSTIBLE CLEARANCES DUCTWORK...

  • Page 3: Introduction

    17.3 SEQUENCE OF OPERATION 18.0 AIR FLOW 18.1 TEMPERATURE RISE CHECK 18.2 CALCULATING AIR FLOW 18.3 ADJUSTING BLOWER SPEEDS ON MODELS EQUIPPED WITH ECM 2.3 BLOWER MOTORS 18.4 DEHUMIDIFICATION - ECM 2.3 18.5 SETTING BLOWER “ON” AND “OFF” TIMINGS - ECM 2.3 MODELS ONLY 18.6 CONTINUOUS FAN OPERATION 19.0...

  • Page 4: Safety Symbols And Warnings

    2.0 SAFETY SYMBOLS AND WARNINGS Understand and pay particular attention to the words DANGER, WARNING, and CAUTION and the following defi ned symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels. DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

  • Page 5: Safety Rules

    WARNING 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. THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS FURNACE.

  • Page 6: Furnace Operation Information

    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, Canadian Electrical Code (Part 1). c. United States: current edition of ANSI/NFPA 70, National Electrical Code. Codes and additional information may be obtained from: Canadian Standards Association American Gas Association...
  • Page 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” 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.

  • Page 8: Installation Requirements Specific To The State Of Massachusetts For Direct Vent, Mechanical Vent, And Domestic Hot Water Appliances

    INSTALLATION REQUIREMENTS SPECIFIC TO THE STATE OF MASSACHUSETTS FOR DIRECT VENT, MECHANICAL VENT, AND DOMESTIC HOT WATER APPLIANCES. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven feet above fi...
  • Page 9 7. INSTALLATION INSTRUCTIONS: A copy of all installation instructions, and any instructions relating to venting shall remain with the furnace at the completion of the installation. FIGURE 2 - FURNACE COMPONENTS LEGEND 1. Combustion Air Intake Fitting 11. Burner Assembly 2.

  • Page 10: Furnace Sizing

    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.

  • Page 11: Location Of Unit

    4.0 LOCATION OF UNIT 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 fi ttings. Be sure to check that the proposed termination location will meet code requirements with respect to location and minimum clearances.

  • Page 12: Other Considerations

    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 fl uorine, as may be found in swimming pool chemicals, laundry detergents, etc., use outdoor air for combustion.

  • Page 13: Air Conditioning

    IMPORTANT NOTE • THE FURNACE MUST BE INSTALLED ON A These furnaces are approved for installation LEVEL SURFACE. IT IS RECOMMENDED in attics, alcoves, utility rooms, closets THAT THE REAR OF THE FURNACE BE and crawl spaces. If this furnace is to be ELEVATED 1/4”...

  • Page 14: Ductwork

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

  • Page 15: Ductwork Steps

    DUCTWORK STEPS 1. Position the furnace to minimize ductwork length and fi ttings. 2. Cut open a return air inlet. The choices are furnace bottom, either side, or any combination thereof (i.e., two sides or a side and the bottom).In all cases, cut the return air opening the full width of the return air markers on the side panel.

  • Page 16: Acceptable Materials In United States

    ACCEPTABLE MATERIALS IN UNITED STATES For United States installations, the combustion air and vent piping and fi ttings may be comprised of: • Schedule 40 PVC, ASTM D1785 or CSA B137.3 • PVC-DWV, ASTM D2665 or CSA B181.2 • Schedule 40 CPVC, ASTM F441 or CSA B137.6 •...

  • Page 17: Determining Combustion Air

    • Carbon tetrachloride • Chlorinated cleaners and waxes • Chlorine and bromine based swimming pool chemicals • De-icing salts or chemicals (rock salt, etc.) • Dry cleaning fl uids such as perchloroethylene • Fumes from curing polyurethane and similar substances •...

  • Page 18: Case 3: Furnace Located In A Confined Space, Outdoor Air From Attic Or Crawl Space

    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.

  • Page 19: Case 4: Furnace Located In A Confined Space, Outdoor Air Ducted Horizontally

    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.

  • Page 20: Connection To Furnace Non-Direct Vent

    8.1.5 CONNECTION TO FURNACE NON-DIRECT VENT When using indoor air or the non-direct vent confi guration, FIGURE 7 - NON-DIRECT the combustion air inlet to the furnace must be protected from COMBUSTION AIR INLET 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.

  • Page 21: Vent Termination

    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 FIGURE 8 - STANDARD (STRAIGHT) HORIZONTAL the United States, as well as in accordance with local VENT DETAIL codes.

  • Page 22: In Canada

    FIGURE 9 - PERISCOPED VENT DETAIL FIGURE 10 - VERTICAL VENTING 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.

  • Page 23: Furnace Venting Installations

    • The vent terminal shall have a minimum horizontal clearance of 4 feet from electric meters, gas meters, regulators and relief equipment. • Locate the vent terminal 3 feet above any forced air inlet located within 10 feet. Any fresh air or make-up air inlet, such as for a dryer or furnace area is considered a forced air inlet.

  • Page 24: Terminations

    10.0 TERMINATIONS 10.1 COMBUSTION AIR HORIZONTAL - The combustion air termination is made up of a FIGURE 11 - STANDARD VERTICAL medium or long sweep 90° elbow pointing downward to prevent VENTING DETAIL rain from readily entering the combustion air intake piping. An intake screening is optional;...

  • Page 25: Location

    10.5 LOCATION Avoid locating the terminals where the fl ue 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, etc. Avoid locating the termination too close to shrubs and other vegetation.

  • Page 26: In Canada

    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 (300 mm) apart. Note: Canadian installations of 120000 Btu/hr require 3 ft (900 mm). WARNING RECIRCULATION OF FLUE GASES MAY OCCUR CAUSING THE INTAKE PIPE TO FREEZE SHUT DURING COLD WEATHER OPERATION IF THE VENTING SYSTEM IS NOT...
  • Page 27 FIGURE 21A - DIRECT VENT TERMINAL CLEARANCES W415-0919 / 10.12.10...
  • Page 28 FIGURE 21B - NON-DIRECT VENT TERMINAL CLEARANCES W415-0919 / 10.12.10...

  • Page 29: Routing Options

    10.9.1 ROUTING OPTIONS This furnace can be installed in any of four positions. Figures 22-25 on the following pages show the four positions. The installer must consider the following services: gas pipe, electrical power, drain trap, intake and exhaust vents. Also consider the air conditioning connections and drain, access to fi lter(s) and access to furnace and a/c for repair.

  • Page 30: Preparations For Vent And Draining Option

    Condensate trap comes pre-assembled with the barbed hose fi ttings installed. For upfl ow installations only, removal of the larger 5/8” barbed fi tting is required prior to placement of condensate trap. Reinstall fi tting after fi nal placement of condensate trap. Affi...
  • Page 31 FIGURE 22 - UPFLOW VENT AND DRAINING OPTION LEFT VENT TOP VENT RIGHT VENT NOTE Condensate trap must be installed on left side. W415-0919 / 10.12.10...
  • Page 32 FIGURE 23 - HORIZONTAL LEFT VENT AND DRAINING OPTION LEFT VENT TOP VENT FIGURE 24 - HORIZONTAL RIGHT VENT AND DRAINING OPTION RIGHT VENT W415-0919 / 10.12.10...
  • Page 33 FIGURE 24 - HORIZONTAL RIGHT VENT AND DRAINING OPTION CONTINUED TOP VENT FIGURE 25 - DOWNFLOW VENT AND DRAINING OPTION LEFT VENT RIGHT VENT W415-0919 / 10.12.10...

  • Page 34: Condensate Drains

    11.0 CONDENSATE DRAINS 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.

  • Page 35: Condensate Neutralizers

    IMPORTANT: THE CONDENSATE DRAIN TRAP ASSEMBLY SHOULD BE FULL OF WATER 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.

  • Page 36: Gas Supply And Piping

    12.0 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. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, EXPLOSION, CARBON MONOXIDE POISONING, PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

  • Page 37: Gas Inlet Pressure

    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 to 5 feet above fl...

  • Page 38: Conversions

    13.0 CONVERSIONS HIGH ALTITUDE: In Canada, this furnace does not need to FIGURE 29 - INSHOT BURNER ASSEMBLY be converted for high altitude (2000 - 4500 feet). It has been certifi ed to operate at high altitude as manufactured. In the United States, the modifi cations for high altitude are based on a 4% reduction of input capacity for every 1000 feet above 2000 feet above sea level.

  • Page 39: Checking The Inlet Gas Pressure

    10. Remove the plastic high fi re regulator adjustment screw (beneath the cover screw). 11. Remove the high fi re natural gas regulator spring only, (colour-coded silver/plain) from regulator sleeves. 12. Insert the LP regulator spring (provided in the conversion kit and colour-coded white) into the regulator sleeve.

  • Page 40: Setting The Manifold Gas Pressure

    13.3 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 36G54 TWO STAGE GAS VALVE 1. Turn off the gas and electrical supply before proceeding. 2.

  • Page 41: Checking Furnace Input

    13.4 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. High Fire, 1.4” w.c. Low Fire. The input rating of the furnace is based on 1000 Btu/ft.³...

  • Page 42: 120 Furnace Connection

    In Canada, all electrical work must be in accordance with the latest FIGURE 35 - ELECTRICAL CONNECTIONS / edition of CSA-C22.1, Canadian Electrical Code Part 1, and any MOLEX CONNECTOR 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.

  • Page 43: Low Voltage Wiring

    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, use 16 AWG;...

  • Page 44: Power Humidifier

    16.2 POWER HUMIDIFIER The integrated furnace control has provisions to supply power and control a line voltage humidifi er or the primary of a 120 / 24 volt humidifi er step down transformer, rated at 120vac, 1.0 amp max. NOTE All HUM and EAC terminals are 120V.

  • Page 45: To Shut Down The Furnace

    17.2 TO SHUT DOWN THE FURNACE 1. Set the room thermostat to its lowest setting. 2. Remove the burner compartment access door. 3. Turn the gas valve switch to the “OFF” position. 4. The furnace appliance shut-off valve may be closed if desired. 5.

  • Page 46: Air Flow

    18.0 AIR FLOW For proper furnace operation, air fl ow over the heat exchanger is of utmost importance. Insuffi cient airfl ow accelerates metal fatigue and possible failure in the heat exchanger, as well as decrease effi ciency. Excessive airfl ow promotes accelerated corrosion of the heat exchanger. TABLE 1 - RANGE OF TEMPERATURE RISE IMPORTANT: Furnace Models...

  • Page 47: Calculating Air Flow

    18.2 CALCULATING AIR FLOW There are circumstances where it may be desirable to know the air fl ow delivery through the duct system, such as when estimating the amount of air fl ow available for Output air conditioning. This can be done by direct measurement with CFM = ∆T 1.085 x...

  • Page 48: Dehumidification - Ecm

    18.4 DEHUMIDIFICATION - ECM 2.3 For situations where humidity control is a problem, a dehumidifi cation feature has been built into the variable speed motor. At the start of each cooling cycle, the variable speed motor will run at 82% of the rated airfl ow for 7.5 minutes.

  • Page 49: Maintenance And Troubleshooting

    19.0 MAINTENANCE AND TROUBLESHOOTING 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.

  • Page 50: Lubrication

    19.2 LUBRICATION Both the exhauster motor and circulating fan motor are ball-bearing type motors. Neither requires routine lubrication. IMPORTANT: THE MOTOR BEARINGS WERE PRE-LUBRICATED BY THE MOTOR MANUFACTURER. DO NOT ATTEMPT TO LUBRICATE THEM. EXCESS LUBRICATION WILL VOID THE WARRANTY, SHORTEN THE SERVICE LIFE OF THE MOTORS, AND WILL ATTRACT THE BUILDUP OF DUST AND DIRT.

  • Page 51: Annual Inspection/Service

    19.6 ANNUAL INSPECTION/SERVICE The furnace must be inspected annually by a qualifi ed 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 fl ue passages (heat exchanger tubes) should be free of scale or excessive corrosion.

  • Page 52: Troubleshooting Flowchart

    19.7 TROUBLESHOOTING FLOWCHART SEQUENCE OF OPERATION W415-0919 / 10.12.10...

  • Page 53: Diagnostic Codes For Status Led

    19.8 DIAGNOSTIC CODES FOR STATUS LED STATUS FAULT CONDITION LEDs 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 exhauster on 3 Flashes Pressure switch closed with exhauster off 4 Flashes Lockout due to too many failed ignition attempts (1 hour lockout)

  • Page 54: Wire Diagram For Two Stage Furnace With Ecm

    20.0 WIRE DIAGRAM FOR TWO STAGE FURNACE WITH ECM 2.3 24 VAC 120 VAC P13-5 P15-9 120 VAC NEUTRAL NEUT3 FUSE P21-5 P22-4 COOL1 NEUT4 FAN1 NEUT5 NEUT1 2ND STAGE HEAT1 ELECTRONIC CLEANER 1ST STAGE HEAT1 EAC1 P13-11 CONT1 HIGH LIMIT1 HUMIDIFIER1 HUM1 ROLLOUT1...

  • Page 55: Installation Checklist

    21.0 INSTALLATION CHECKLIST  INSTALLATION CHECKLIST Ensure condensate drain lines are correctly connected, and sloping towards condensate trap with no sags. Vent tee installed on outlet of condensate trap. The vertical exhaust vent pipe MUST be supported so that the exhauster does not bear the weight of the venting.

  • Page 56: Replacement Parts List

    22.0 REPLACEMENT PARTS LIST Contact your dealer or the factory for questions concerning prices and policies on replacement parts. Normally all parts can be ordered through your Authorized dealer / distributor. FOR WARRANTY REPLACEMENT PARTS, A PHOTOCOPY OF THE ORIGINAL INVOICE WILL BE REQUIRED TO HONOUR THE CLAIM.

  • Page 57: Service History

    23.0 SERVICE HISTORY 43.1 W415-0919 / 10.12.10...

  • Page 58: Notes

    24.0 NOTES W415-0919 / 10.12.10...
  • Page 59 W415-0919 / 10.12.10...
  • Page 60 • If you cannot reach your gas supplier, call the fi re department. Wolf Steel Ltd., 24 Napoleon Rd., Barrie, ON, L4M 4Y8 Canada / 103 Miller Drive, Crittenden, Kentucky, USA, 41030 Phone (705)721-1212 • Fax (705)722-6031 • www.napoleonheatingandair.com • ask@napoleonproducts.com...
  • Page 61 TABLE OF CONTENTS SAFETY SYMBOLS AND WARNINGS SAFETY ISSUES GENERAL SAFETY RULES FURNACE OPERATION INFORMATION ROUTINE MAINTENANCE BY HOMEOWNER AIR FILTER LUBRICATION ROUTINE EXAMINATION FURNACE APPEARANCE CLEANING SEQUENCE OF OPERATION - ECM 2.3 AND X-13 VARIATIONS HOMEOWNER’S REFERENCE NOTES IMPORTANT: DO NOT DESTROY THIS MANUAL Please read carefully and keep in a safe place Read these instructions thoroughly before...

  • Page 62: Safety Issues

    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.
  • Page 63 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. WARNING 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.

  • Page 64: General Safety Rules

    Most natural gas systems and all LP gas systems have a service FIGURE 2 - GAS REGULATOR VENT regulator located near the point where the gas piping enters the building. Regulator vent The propane tank will normally have an additional fi rst stage Keep free of ice, snow, regulator located at the tank outlet valve.
  • Page 65 8. Familiarize yourself with the location of your furnace fi lter or fi lters. A blocked air fi lter will reduce effi ciency, increase fuel consumption, raise the furnace operating temperature, and shorten the life of furnace components. 9. Do not cover return air grills and supply air registers with drapes, curtains, throw rugs, etc. 10.

  • Page 66: Routine Maintenance By Homeowner

    FURNACE SHUT-DOWN PROCEDURE: 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.

  • Page 67: Routine Examination

    ROUTINE EXAMINATION IMPORTANT: We recommend that your furnace and vents be checked by a qualifi ed 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 fi lter. Things to check: •...
  • Page 68 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 fi ns when cleaning. You may wish to leave this maintenance procedure to your service technician.

  • Page 69: Sequence Of Operation - Ecm 2.3 And

    SEQUENCE OF OPERATION - ECM 2.3 AND X-13 1. Room temperature drops causing the room thermostat call for fi rst NOTE: stage heat by connecting “W1” to “R”. The control verifi es the limit Soft start and soft stop features switch is closed and both the low and high pressure switches are available on ECM 2.3 models.

  • Page 70: Homeowner's Reference

    5.0 HOMEOWNER’S REFERENCE HOMEOWNER’S REFERENCE TABLE Model No. Serial No. 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.

  • Page 71: Notes

    6.0 NOTES W415-0919 / 10.12.10...
  • Page 72 W415-0919 / 10.12.10...

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