Portions of the text and tables are reprinted from NFPA 54 /ANSI Z223.1−2009©, 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)9MAC

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this manual in the following manner:

WARNING

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CAUTION

Signal Words on Product Labeling

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Safety−alert symbol

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instructions or manuals, be alert to the

potential for personal injury.

INSTALLER: Affix these instructions on or adjacent to the

furnace.

CONSUMER:

reference.

Use of the AHRI Certified TM Mark indicates a

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July 2012

Table of Contents

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Summary of Contents for ICP G9MAC Series

Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS Modulating Gas Valve, Variable Speed Motor 35” Tall High Efficiency Condensing Gas Furnace (F/G)9MAC 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.
Page 3: Safety Considerations
Safety Considerations Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. CAUTION WARNING CUT HAZARD FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this caution may result in personal injury. Failure to follow this warning could result in dangerous Sheet metal parts may have sharp edges or burrs.
Page 4: Introduction
(914 mm) horizontally from the furnace. See NFPA 90B Freeze Protection and Return Air Figure 1 or local code for further requirements. Temperature Minimum Clearances to Table 1 Combustible Materials for All Units SUPPLY AIR MAX 80°F/27°C CLEARANCE POSITION In(mm) REAR FRONT (Combustion air openings in fur- 1 (25)
Page 5: Electrostatic Discharge (Esd)
Duct Systems Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE US and CANADA: Air Conditioning Contractors CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S Association (ACCA) Manual D, Sheet Metal and Air ELECTROSTATIC CHARGE TO GROUND.
Page 6: Dimensions
Figure 2 Dimensions SD5060−4 (F/G9MAC) 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) 10 1/2 (267) 159 (72) 0801714 17−1/2 (445)
Page 7: Location
Location • be located close to the chimney or vent and attached to an air distribution system. Refer to Air Ducts section. • be provided ample space for servicing and cleaning. CAUTION Always comply with minimum fire protection clearances shown in Table 1 or on the furnace clearance to combustible construction label.
Page 8: Location Relative To Cooling Equipment
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 ABOVE THE LOCATED TO THE LEFT...
Page 9 Ventilated Combustion Air Applications Air for Combustion, Ventilation, Figure 6 and Dilution for Outdoors When the furnace is installed using the ventilated combustion air option, the attic or crawlspace must freely communicate with the outdoor to provide sufficient air for combustion. The combustion air pipe cannot be terminated in attics or crawlspaces that use ventilation fans designed to operate during the heating season.
Page 10 Outdoor Combustion Air Method d. TWO OPENINGS OR VERTICAL DUCTS require 1 square inch (25.4 square mm)of free area per 4,000 Provide the space with sufficient air for proper Btuh (550 mm /kW) for combined input of all gas combustion, ventilation, and dilution of flue gases using appliances in the space per Figure 6 and Table 3.
Page 11: Condensate Trap
CONDENSATE TRAP 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. If the furnace CAUTION environment has the potential of freezing, the drain trap and drain line must be protected.
Page 12 Figure 9 Unconverted Factory Configuration as viewed in the Downflow Orientation Remove pressure switch tube from pressure switch port. Remove relief tube from relief port on condensate trap. Remove tube from Remove trap from relief port. collector box. Loosen clamp on inlet Remove middle and bottom plugs.
Page 13 Condensate Trap − Horizontal NOTE: The condensate trap extends below the side of the casing in the horizontal position. A minimum of 2 in. (51 mm) of Orientation clearance is required between the casing side and the furnace platform for the trap to extend out of the casing in the horizontal When the furnace is installed in the horizontal right position, the position.
Page 14 Figure 10 − continued Horizontal Left Trap Configuration Install plugs in open ports on collector box. Rotate elbow to desired position and Connect relief tube to torque clamp on inlet port on collector box. 15 lb.−in. Slide relief tube in stand−offs to adjust length.
Page 15 Figure 11 − continued Horizontal Right Trap Configuration Slide relief tube in stand-offs to adjust length. Attach condensate trap Vent elbow shown in alternate to collector box with orientation. Tighten clamp on screw. inlet to vent elbow 15 lb.-in. Install plug in open Align trap over middle and port on collector box.
Page 16 8. Open the spring clamp and insert the long end of the housing has been removed to ease installation in upflow adapter of the 1/2−in. CPVC pipe into the outlet stub on applications, this step is not needed.) the drain tube. 7.
Page 17 3. Remove the knock−out for the condensate trap in the Figure 14 Modify Rubber Drain Elbow side of the casing. Cut line for left side condensate drain. 4. Install the drain trap grommet in the casing, if required for Do not discard parts after cutting. direct−vent applications.
Page 18: Installation
Figure 16 Formed Rubber Drain Grommet Figure 18 Furnace Pitch Requirements INSTALL CLAMPS ON DRAIN ELBOW LEVEL 0-IN. (0 MM) TO ATTACH DRAIN ELBOW TO CONDENSATE 1/2-IN. (13 MM) MAX DRAIN TRAP PULL DRAIN STUB MIN 1/4-IN. (6 MM) TO THROUGH CASING 1/2-IN.
Page 19: Downflow Installation
Install another nut on other side of furnace base. (Install Figure 19 Removing Bottom Closure Panel flat washer if desired.) Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement. Reinstall bottom closure panel if removed. DOWNFLOW INSTALLATION NOTE: The furnace must be pitched as shown in Figure 18 for proper condensate drainage.
Page 20 humidifier, or other accessories. All supply−side accessories sides (left or right). Bypass humidifier connections should be MUST be connected to duct external to furnace casing. made at ductwork or coil casing sides exterior to furnace. (See Figure 27) Return Air Connections Bottom Return Air Inlet WARNING These furnaces are shipped with bottom closure panel installed...
Page 21: Horizontal Installation
Furnace, Plenum, and Subbase Furnace, Plenum, and Coil Figure 23 Figure 24 Installed on a Combustible Floor Assembly on a Combustible Floor END4X, ENW4X L11F104 A96285 WARNING HORIZONTAL INSTALLATION NOTE: The furnace must be pitched forward as shown in FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD Figure 18 for proper condensate drainage.
Page 22 Figure 25 Suspended Furnace Installation COMBUSTION − AIR PIPE (SEE VENTING SECTION) 2−in. (51 mm) A11155 NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling Figure 26 Working Platform for Attic Installation COMBUSTION −...
Page 23: Filter Arrangement
Roll−Out Protection For upflow applications, the filter can be installed on either side of the furnace, the bottom of the furnace or any combination of Provide a minimum 12−in. x 22−in. (305 x 559 mm) piece of side and bottom of the furnace. (See Figure 28, Figure 30, and sheet metal for flame roll−out protection in front of burner area Figure 31) for furnaces closer than 12−in.
Page 24 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. / 2.5 cm) (2-in.
Page 25 External Filter Cabinet Configurations Downflow Return Air Figure 27 Configurations and Restrictions Figure 30 Accessory Side Filter Rack FURNACE FILTER FRAME L10F033 Upflow Return Air Configurations Figure 28 and Restrictions DOOR TABS FILTER L10F027 ⅜” 2 ⅜” ½” 1 ¼” (1 cm) (1.3 cm) (6 cm)
Page 26: Air Ducts
Air Ducts Figure 31 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
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 connect- Failure to follow this warning could result in personal injury, or, always use a new listed connector.
Page 28: Electrical Connections
Piping should be pressure and leak tested in accordance with Figure 34 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. Gas Pipe Gas Pipe Grommet Required been connected.
Page 29: J−Box Installation
not operate if polarity is incorrect or if the furnace is not Use a separate, fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 11 for grounded. wire size and fuse specifications. A readily accessible means of Verify that the voltage, frequency, and phase correspond to that electrical disconnect must be located within sight of the specified on unit rating plate.
Page 30 Route external field power wires through holes in Figure 36 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 37. Connect field power and neutral leads to furnace power leads.
Page 31 2. Route BX connector through 7/8−in. (22 mm) diameter male 1/4−in quick−connect terminals on the control hole in casing and J−Box bracket. board marked EAC−1 and EAC−2. The terminals are rated for 115VAC, 1.0 amps maximum and are 3. Secure BX cable to J−Box bracket with connectors energized during blower motor operation.
Page 32 Figure 39 Isolation Relay for Humidifiers with Internal Power Supply To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip A11157 Figure 40 Variable Speed Furnace Control − Switch Locations SW* 1 L11F080 440 01 4201 03...
Page 33: Venting
Figure 40 − 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 BLOWER OFF DELAY AIR CONDITIONING...
Page 34 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.
Page 35: Direct Vent / 2−Pipe System
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 entering the combustion air inlet pipe, a moisture trap may be Termination for each appliance being placed into operation added to the inlet pipe to help prevent moisture from entering could result in carbon monoxide poisoning or death.
Page 36 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 − − Solvent Cement For ABS D2235...
Page 37: Termination Requirements For The Provinces Of Alberta And Saskatchewan
Locating the Vent Termination WARNING General CARBON MONOXIDE POISONING HAZARD NOTE: Termination Requirements for the Provinces of Failure to follow the instructions outlined below for each Alberta and Saskatchewan are located at the end of this appliance being placed into operation could result in carbon section.
Page 38 Figure 44 Tee at Termination Outlet Sample Inlet Air Pipe Connection Figure 45 for Polypropylene Venting Systems EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. OPTIONAL TERMINATION BRACKET FOR 2 PIPE TERMINATIONS L12F030 A12220 Figure 46 Vent Terminations OVERHANG OR ROOF VENT Angle...
Page 39 Figure 47 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” denotes 0 To 2 in. (51mm) combustion air and vent (914mm) Between the first 2 vents Third...
Page 40 Optional Combustion Air Inlet NOTICE Moisture Trap As an option to prevent moisture from trickling into the furnace OPTIONAL CONFIGURATION FOR COMBUSTION AIR vestibule, a trap can be installed in the intake air pipe near the INLET PIPE furnace. Connecting a drain line to the trap is optional as trace In applications where there is a risk of excessive moisture amounts of moisture will evaporate into the intake air stream.
Page 41 The measured length of pipe used in a 2−pipe termination is For vent systems longer than 10 ft. (3.0 M), any larger diameter included in the total vent length. Include deductions from the shown in Table 14 and Table 16 for that size model may be Maximum Equivalent Vent Length (MEVL) contained in the used.
Page 42 Upflow Configurations − continued Figure 50 Inducer Vent Elbow − Variable MODUL ATING INDUCER ASSEMBLY VENT ELBOW CL AMP TORQUE 15 LB−IN. INDUCER OUTLET VENT PIPE CL AMP TORQUE 15 LB−IN. UPFLOW VERTICAL − VENT CONFIGURATION Representative drawing only, some models may vary in appearance. A11310 * See NOTES following figures.
Page 43 Downflow Configurations − continued Horizontal Left Configurations − continued HORIZONTAL LEFT − RIGHT VENT CONFIGURATION* * Requires accessory Internal Vent Kit Representative drawing only, some models may vary in appearance. DOWNFLOW VERTICAL − VENT CONFIGURATION Requires Accessory Internal Vent Kit * See NOTES following figures.
Page 44 1. Apply the gaskets to the vent pipe and combustion air Horizontal Right Configurations − continued pipe adapters. If supplied, remove and discard round center “slug” from interior of gasket. See Figure 41. NOTE: The vent pipe adapter can be distinguished from the inlet pipe adapter by the absence of an internal pipe-stopping ring.
Page 45 piping and vent piping a minimum of every 5 ft. (1.5M) [3 NOTICE ft. (.91M) for SDR−21 or −26 PVC] using perforated metal hanging strap or commercially available hangars designed to support plastic pipe. FOR POLYPROPYLENE VENTING SYSTEMS 17. Prevent condensate from accumulating in the pipes by When using polypropylene venting systems, all venting ma- sloping the combustion air piping and vent piping terials used, including the vent terminations, must be from the...
Page 46 Sidewall Terminations Determine an appropriate location for termination kit using the guidelines provided in section “Locating The Vent Termination” Concentric Vent in this instruction. NOTE: Follow the instructions of the vent terminal 1. Cut two holes, one for each pipe, of appropriate size for manufacturer.
Page 47 Figure 55 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 56 Attic Vent Termination Ventilated Combustion Air intake pipe Vent through roof flashing 12”...
Page 48 Figure 57 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 U.S.
Page 49 Figure 58 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...
Page 50: Maximum Equivalent Vent Lenth
Table 14 MAXIMUM EQUIVALENT VENT LENTH - 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 Vent Pipe Diameter (in.)
Page 51 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 52 Table 16 MAXIMUM EQUIVALENT VENT LENTH - 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. (1370 M) above sea level are subject to acceptance by the local authorities having jurisdiction.
Page 53: Maximum Allowable Exposed Vent Lengths
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)9MAC Winter Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Length Max.

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ICP G9MAC Series Installation Instructions Manual

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