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INSTALLATION INSTRUCTIONS
Modulating Gas Valve, Variable Speed Motor
35" Tall High Efficiency Condensing Gas Furnace
These instructions must be read and understood completely before attempting installation.
DANGER, WARNING, CAUTION, and NOTE
The
signal
words
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and
throughout this manual and other manual that may
apply to the product.
DANGER − Immediate hazards which will result in
severe personal injury or death.
WARNING − Hazards or unsafe practices which
could result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
NOTE − Used to highlight suggestions which will
result in enhanced installation, reliability, or
operation.
TABLE OF CONTENTS
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Portions of the text and tables are reprinted from NFPA 54 /ANSI Z223.1−2012, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington, DC
20001. This reprinted material is not the complete and official position of the NFPA or ANSI, on the referenced subject, which is represented only by the standard in its entirety.
Printed in U.S.A.
Safety Labeling and Signal Words
DANGER,
WARNING,
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(F/G)9MAE
Signal Words in Manuals
The signal word WARNING is used throughout
this manual in the following manner:
WARNING
!
The signal word CAUTION is used throughout
this manual in the following manner:
CAUTION
!
Signal Words on Product Labeling
Signal words are used in combination with
colors and/or pictures or product labels.
Safety−alert symbol
When you see this symbol on the unit and in
instructions or manuals, be alert to the
potential for personal injury.
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INSTALLER: Affix these instructions on or adjacent to the
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furnace.
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CONSUMER:
reference.
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Use of the AHRI Certified TM Mark indicates a
manufacturer's participation in the program.
For verification of certification for individual
products, go to www.ahridirectory.org .
Retain
these
instructions
440 01 4300 02
for
future
12/5/2013
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS Modulating Gas Valve, Variable Speed Motor 35” Tall High Efficiency Condensing Gas Furnace (F/G)9MAE These instructions must be read and understood completely before attempting installation. Safety Labeling and Signal Words DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals signal words DANGER,... - Page 2 Required Notice for Massachusetts Installations Important The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA−54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: (a) 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 (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: INSTALLATION OF CARBON MONOXIDE DETECTORS.
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Page 3: Safety Considerations
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Safety Considerations changing residential construction practices. We require these instructions as a minimum for a safe installation. Follow all safety codes. Wear safety glasses, protective WARNING clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. -
Page 4: Introduction
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE accessory gas conversion kit is required to convert because of furnace model size capacity increments. Heating furnace for use with propane gas. load estimates can be made using approved methods available See Table 1 for required clearances to combustible from Air Conditioning Contractors of America (Manual J);... -
Page 5: Electrostatic Discharge Precautions Procedure
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Combustion and Ventilation Air Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE US: Section 9.3 of the NFPA54/ANSI Z223.1−2012, CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S Air for Combustion and Ventilation ELECTROSTATIC CHARGE TO GROUND. -
Page 6: Dimensions
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 2 Dimensions SD5060−4 Rev F (F/G)9MAE SHIP WT. CABINET BOTTOM LB (KG) FURNACE SIZE OUTLET WIDTH AIR INTAKE WIDTH INLET WIDTH 0601714 17−1/2 (445) 15−7/8 (403) 16 (406) 8 3/4 (222) 154 (69) 0602120 21 (533) 19−3/8 (492) 19−1/2 (495) -
Page 7: Location
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Location WARNING CAUTION CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD unit component damage. Improper use or installation of this furnace may result in premature Corrosive or contaminated air may cause failure of parts containing flue furnace component failure. -
Page 8: Location Relative To Cooling Equipment
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 3 Multipoise Orientations THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT... -
Page 9: Air For Combustion And Ventilation
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Air for Combustion and Air for Combustion, Ventilation, Figure 6 and Dilution for Outdoors Ventilation Introduction Direct Vent (2−Pipe) Applications When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required. However, other gas appliances installed in the space with the furnace may require outside air for combustion. -
Page 10: Condensate Trap
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Table 3 Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO OPENINGS OR TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING VERTICAL DUCTS (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) (1 SQ. - Page 11 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Condensate Trap − Downflow To Relocate the Condensate Trap: Orient the furnace in the downflow position. Orientation Figure 8 shows the condensate trap and tubing before and When the furnace is installed in the downflow position, the after relocation.
- Page 12 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Downflow Trap Configuration Trim excess tube. Connect pressure switch tube to port on collector Install plugs on box. open ports on collector box. Attach condensate trap with screw to collector Connect relief tube to box. port on collector box.
- Page 13 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 9 Unconverted Factory Configuration as viewed in the Horizontal Left Orientation Remove trap from collector box. If alternate vent position is required, loosen clamp Remove relief tube on vent elbow inlet. from relief port on condensate trap.
- Page 14 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 10 Unconverted Factory Configuration as viewed in the Horizontal Right Orientation Remove plug from collector box. DO NOT DISCARD. If alternate vent position is required, loosen clamp on inlet of vent elbow. Remove trap from collector box.
- Page 15 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE must terminate at an inside drain to prevent freezing of the Figure 11 Example of Field Drain Attachment condensate and possible property damage. Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper operation or damage to the equipment.
- Page 16 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE 10. Align the ”Z” pipe with the long end of the grommet inside Avoid misalignment of the drain pipe which may cause the furnace and insert slightly. The angled end of the kinks in the elbow or grommet. tube at the other side of the casing should be facing the 7.
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Page 17: Installation
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 14 Drain Trap Connection and Routing Figure 16 Horizontal Drain Trap Grommet Attach elbow to condensate trap Cut formed end off condensate drain Formed end of elbow grommet Connect short end of “Z” pipe to modified drain elbow Remove knockout. -
Page 18: Downflow Installation
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE supply−side accessories MUST be connected to duct external Figure 19 Leveling Legs to furnace main casing. Return Air Connections WARNING FIRE HAZARD A failure to follow this warning could cause personal injury, death and/or property damage. Never connect return−air ducts to the back of the furnace. -
Page 19: Return Air Connections
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Connect supply−air duct to supply−air outlet on furnace. Bend Floor and Plenum Opening Figure 20 flange inward past 90_ with wide duct pliers (See Table 1 Dimensions Figure 21) The supply−air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing (when used). -
Page 20: Horizontal Installation
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Table 5 Opening Dimensions − in. (mm) FURNACE PLENUM OPENING FLOOR OPENING CASING WIDTH APPLICATION IN. (mm) Upflow Applications on Combustible or Noncombustible Flooring 21−5/8 16−5/8 22−1/4 (subbase not required) (406) (549) (422) (565) Downflow Applications on Noncombustible Flooring 15−7/8 16−1/2 19−5/8... -
Page 21: Suspended Furnace Support
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE WARNING Furnace, Plenum, and Coil Figure 23 Assembly on a Combustible Floor FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD EAM4X, END4X, ENW4X Failure to follow this warning could result in personal injury, death, or property damage. Do not install the furnace on its back or hang furnace with control compartment facing downward. -
Page 22: Supply Air Connections
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 25 Working Platform for Attic Installation COMBUSTION − AIR PIPE (SEE VENTING SECTION) 2−in. (51 mm) ROLLOUT PROTECTION RE- QUIRED Install 1.2” x 22” (305 x 559 mm) sheet metal in front of burner compartment area. -
Page 23: Filter Arrangement
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Filter Arrangement * Recommended to maintain air filter face velocity. See Product Data for part number. WARNING Refer to the instructions supplied with the Filter Rack or accessory air filter for additional assembly and installation options. - Page 24 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Table 7 Filter Media Pressure Drop (Clean) Versus Airflow - in. w.c. (Pa) Representative After-Market Filter Media* Factory-Accy Fiberglass* Pleated* 14 x 25 Filter Washable (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in.
- Page 25 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE External Filter Cabinet Configurations Downflow Return Air Figure 26 Configurations and Restrictions Figure 29 Accessory Side Filter Rack FURNACE FILTER FRAME L10F033 Upflow Return Air Configurations Figure 27 and Restrictions DOOR TABS FILTER L10F027 ⅜” 2 ⅜”...
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Page 26: Air Ducts
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Air Ducts Figure 30 Accessory Bottom Filter Rack NOTICE Many states, provinces and localities are considering or have implemented standards and/or restrictions on duct sizing practices, ductwork leakage, and/or ductwork thermal, airflow and electrical efficiencies. CONSULT LOCAL CODE OFFI- CIALS for ductwork design and performance requirements in your area. -
Page 27: Gas Piping
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE GAS PIPING WARNING WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could result in personal injury, death, and/ or property damage. FIRE OR EXPLOSION HAZARD If local codes allow the use of a flexible gas appliance connector, always Failure to follow this warning could result in personal injury, death, use a new listed connector. -
Page 28: Electrical Connections
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Piping should be pressure and leak tested in accordance with Figure 33 Gas Entry the current addition of the NFGC in the United States, local, and national plumbing and gas codes before the furnace has Left Side Gas Entry. -
Page 29: J−Box Installation
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE CAUTION FURNACE MAY NOT OPERATE HAZARD Failure to follow this caution may result in intermittent furnace SWITCH operation. COPPER WIRE ONLY Furnace control must be grounded for proper operation or else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw. - Page 30 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Route external field power wires through holes in Figure 35 Optional J−Box Locations electrical box and casing. Connect field ground wire and factory ground wire to green ground screw on J−Box mounting bracket as shown in Figure 36. Connect field power and neutral leads to furnace power leads.
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Page 31: Alternate Power Supplies
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE 3. Secure BX cable to J−Box bracket with connectors male 1/4−in quick−connect terminals on the control approved for the type of cable used. board marked EAC−1 and EAC−2. The terminals are rated for 115VAC, 1.0 amps maximum and are 4. - Page 32 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 38 Isolation Relay for Humidifiers with Internal Power Supply To HUM 24 VAC Terminal To Humidifier Leads On Furnace Control Board 24 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip A11157 Figure 39 Variable Speed Furnace Control −...
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Page 33: Venting
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 39 − continued Example of Variable Speed Furnace Control for ECM Blower Motor (Modulating) COMMUNICATION CONTINUOUS FAN OUTDOOR SW4 SETUP CONNECTOR (CF) AIRFLOW IR TEMP SWITCHES SETUP SWITCHES CONNECTOR MODEL PLUG MODULATING CONNECTOR GAS VALVE CONNECTOR SW1 SETUP SWITCHES AND... - Page 34 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE General L’apprêt GVS-65 (Purple) et le ciment-solvant GVS-65 doivent être utilisé avec les Royal Pipe. Système IPEX 636, apprêt If this furnace replaces a furnace that was connected to a vent PVC/CPVC, Purple pour évacuation des gaz de combustion et system or chimney, the vent or vent connectors of other système IPEX 636(1)t, ciment PVC pour évacuation des gaz remaining appliances may need to be re−sized.
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Page 35: Direct Vent / 2−Pipe System
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Venting Systems NOTICE WARNING Optional Configuration for Combustion Air Inlet Pipe CARBON MONOXIDE POISONING HAZARD In applications where there is a risk of excessive moisture Failure to follow the instructions outlined in Locating the Vent Termination for each appliance being placed into operation could result in carbon entering the combustion air inlet pipe, a moisture trap may be monoxide poisoning or death. -
Page 36: Locating The Vent Termination
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Table 13 Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A. Installation) ASTM SPECIFICATION SOLVENT CEMENT AND MATERIAL PIPE FITTINGS DESCRIPTION (MARKED ON PRIMERS MATERIAL) Pipe − − Schedule−40 D1527 Pipe − − Schedule−40 D1785 For ABS −... -
Page 37: Termination Requirements For The Provinces Of Alberta And Saskatchewan
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Ventilated Combustion Air resistance material due to the corrosive properties of combustion products from vent system as well as protection of The vent pipe for a Ventilated Combustion Air System must adjacent structures. terminate outdoors. See Figure 58 for references to vent clearances required by National code authorities. - Page 38 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 43 Tee at Termination Outlet Figure 45 Vent Terminations OPTIONAL TERMINATION OPTIONAL BRACKET FOR 2-PIPE BRACKET TERMINATIONS COUPLING 12 IN. (305 MM) MIN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND 12 IN. (305 MM) MIN. BOTTOM OF VENT.
- Page 39 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 46 Combustion Air and Vent Pipe Termination for Direct Vent (2−Pipe) System Roof Termination (Preferred) Note: 36−in. separation between pairs of inlets only required for direct−vent systems Note: Vertical separation between At least 36 in. “A”...
- Page 40 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Size the Vent and Combustion Air Pipes NOTICE General Optional Configuration for Combustion Air Inlet Approved 2−pipe Pipe termination fittings Vent or Combustion Air In applications where there is a risk of excessive moisture 2−in. 3−in.
- Page 41 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 49 Optional Combustion Air Inlet Moisture Trap TO CODE−APPROVED DRAIN OR CONDENSATE PUMP Representative drawing only, some models may vary in appearance. L12F028 The External Vent Trap Kit accessory may be used as a trap for The measured length of pipe used in a 2−pipe termination is the combustion air inlet pipe if a large amount of moisture must included in the total vent length.
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Page 42: Configure The Furnace
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Configure the Furnace 7. Select a diameter of vent pipe from Table 14 and Table 16 and note the Maximum Equivalent Vent Length WARNING (MEVL) shown for that application for that specific furnace input size. Compare the Total Equivalent Vent Length (TEVL) to the MEVL: CARBON MONOXIDE POISONING HAZARD a. - Page 43 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 52 Downflow Configurations Figure 51 Upflow Configurations UPFLOW LEFT − VENT CONFIGURATION Representative drawing only, some models may vary in appearance. A11309 DOWNFLOW LEFT − VENT CONFIGURATION Representative drawing only, some models may vary in appearance. A11311 UPFLOW RIGHT −...
- Page 44 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 53 Horizontal Left Configurations Figure 54 Horizontal Right Configurations HORIZONTAL LEFT − VERTICAL VENT CONFIGURATION Representative drawing only, some models may vary in appearance. HORIZONTAL RIGHT − VERTICAL VENT CONFIGURATION Representative drawing only, some models may vary in appearance. HORIZONTAL LEFT −...
- Page 45 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE NOTES: 6. Tighten the clamp around the outlet of the vent elbow. Torque the clamp to 15 lb−in. 1. Attach vent pipe adapter with gasket to furnace casing. 2. Align notches in rubber coupling over standoffs on NOTICE adapter.
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Page 46: Installing The Vent Termination
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE 19. Use appropriate methods to seal openings where Figure 55 Combustion Air Pipe combustion air pipe and vent pipe pass through roof or sidewall. WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death. - Page 47 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Direct Vent (2-Pipe) Termination NOTICE NOTE: Follow the instructions of the vent terminal manufacturer. These instructions are provided as a reference, Recommended Support for Vent Terminations only. It is recommended that rooftop vent terminations in excess of 36 inches (1.0 M) in vertical length be supported by EITHER the NOTICE Direct Vent Termination Kit shown in Table 12 or by...
- Page 48 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 56 Crawl Space Vent Termination Ventilated Combustion Air intake pipe Pipe hangar 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE Figure 57 Attic Vent Termination Ventilated Combustion Air intake pipe Vent through roof flashing...
- Page 49 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 58 Direct Vent Termination Clearance 25−24−65−2 NOTE: The following is based upon National codes for gas appliances, and is provided as a reference. Refer to Local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations...
- Page 50 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Figure 59 Other than Direct Vent Clearance − Ventilated Combustion Air Option 25−24−65−2 NOTE: The following is based upon National codes for gas appliances, and is provided as a reference. Refer to Local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations...
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Page 51: Maximum Equivalent Vent Length
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Table 14 MAXIMUM EQUIVALENT VENT LENGTH - Feet (Meters) Note: Maximum Equivalent Vent Length (MEVL) does NOT include elbows or terminations Use Table 15 − DEDUCTIONS FROM MEVL to determine allowable vent length for each application. DIRECT VENT (2-PIPE) AND VENTILATED COMBUSTION AIR Altitude Unit Size... - Page 52 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Example 1 A direct-vent 60,000 BTUH furnace installed at 2100 ft. (640M). Venting system includes FOR EACH PIPE 100 feet (30 M) of vent pipe, 95 feet (28 M) of combustion air inlet pipe, (3) 90º long-radius elbows, (2) 45º long-radius elbows, and a factory accessory concentric vent kit.
- Page 53 INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Table 16 MAXIMUM EQUIVALENT VENT LENGTH - Feet (Meters) Note: Maximum Equivalent Vent Length (MEVL) does NOT include elbows or terminations. Use DEDUCTIONS FROM MEVL − Table 15 to determine allowable vent length for each application. Note: Vent sizing for Canadian installations over 4500 ft.
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Page 54: Maximum Allowable Exposed Vent Lengths
INSTALLATION INSTRUCTIONS Gas Furnace: (F/G)9MAE Maximum Allowable Exposed Vent Lengths in Unconditioned Space Table 17 Maximum Length of Uninsulated and Insulated Vent Pipe-Ft (M) No Insulation 3/8-in. (9.5 mm) 1/2-in. (12.7 mm) (F/G)9MAE Winter Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Length Max.