ICP NTGM/GNK Series Installation Instructions Manual

Upflow/horizontal and downflow/horizontal

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NTGM/GNK

Series

Upflow/Horizontal

NCGM/GCK

Series

Downflow/Horizontal

SAFETY

REQUIREMENTS

Recognize safety information.

This is the safety-alert

symbol _.

When you see this symbol on the furnace and in instructions

manuals be alert to the potential for personal injury.

Understand the signal words DANGER,

WARNING, or CAUTION.

These words are used with the safety-alert

symbol.

DANGER

identifies the most serious hazards, those that will result in severe personal injury or death. WARNING signifies a hazard that could

result in personal injury or death. CAUTION is used to identify unsafe practices that could result in minor personal injury or product and

property damage.

Installing and servicing heating equipment can be hazardous due to gas and electrical components.

Only trained and qualified person-

nel should install, repair, or service heating equipment.

Untrained service personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations

must be performed by trained service personnel.

When working on heating equipment,

observe precautions in the literature, on tags,

and on labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes. In the United States, follow all safety codes including the current edition National Fuel Gas Code (NFGC) NFPA

No. 54/ANStZ223.1.

In Canada, refer tothe current edition of the National Standard Canada CAN/CGA-B149.1

- and .2-M91 Natural

Gas and Propane Installation Codes (NSCNGPIC).

Wear safety glasses and work gloves. Have fire extinguisher available during start-

up and adjustment

procedures and service calls.

These instructions cover minimum requirements

and conform to existing national standards and safety codes.

In some instances,

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing residential

construction practices.

We requre these instructions

as a minimum for a safe installation.

Design Certified

byAGA

Manufactured

by:

International

Comfort

Products

Corporation

(USA)

Lewisburg, TN USA 37091

Table of Contents

1. SafeInstallationRequirements ................

2. Installation...............................

3. Combustion & Ventilation Air ................

4.Vent& Combustion Air Piping ................

5. GasSupplyand Piping ......................

6. ElectricalWiring ........................

7. Ductworkand Filter(Upflow/Horizontal)......

8. Ductworkand Filter(Downflow/Horizontal) . ...

9. ChecksandAdjustments .................

10. FurnaceMaintenance ...................

11.Concentric VentTermination..............

Fire or Explosion hazard.

This furnace is not designed for use in mobile

homes, trailers or recreational vehicles.

Such use could result in death, bodily injury

and/or property damage.

LP1

6/9/2000

440 01 1002 01

Table of Contents

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Summary of Contents for ICP NTGM/GNK Series

Page 1: Table Of Contents
NTGM/GNK Series Upflow/Horizontal NCGM/GCK Series Downflow/Horizontal SAFETY REQUIREMENTS Recognize safety information. This is the safety-alert symbol _. When you see this symbol on the furnace and in instructions manuals be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, or CAUTION.
Page 2: Safeinstallationrequirements
1. Safe InstallationRequirements The U.S. Consumer Product Safety Commission recom- mends that users of gas-burning appliances install carbon monoxide detectors. There can be various sources of car- Installation repairs made unqualified bon monoxide in a building or dwelling. The sources could persons can result in hazards to you and others.
Page 3 START-UP CHECK SHEET (Keep this page for future reference) Dealer Name: Address: Business Card Here City, State(Province), Zip or Postal Code: Phone: Owner Name: YES _1 NO _1 Drip-Leg Upstream of Gas Valve? Address: NO_1 Condensate Drain Connected? YES _1 City, State(Province), Zip or Postal Code: Noel...
Page 4: Installation
2. Installation Typical Upflow Installation Poison carbon monoxide gas Hazard. Aluminum or non-rusting shield recommended. (SeeVentTerminationShieldin for dimensions). This furnace can NOT be common vented or connected to any type B, BW or L vent or vent connector, nor to any portion of a factory-built or masonry chimney.
Page 5 iiiiiii!!i!liiiii/l;i!iiiii/!iiiiiiii!liil;iii/iiiiiiiiii'ii!iii!!///!i !! !!!! Oimensionsand C,earances,or Up.ow Furnace Combustible Clearances Cabinet to Back i I'C IF= TI 'O Drain TOP I BOT" 0" Connection """'-_ 25-20-65 718 (22) ElectricalConnections ReturnAir Unit Cabinet SupplyAir Bottom Side LeftSide Low Volt Capacity 50,000 191t8 281_ 11/2 11/2...
Page 6 Dimensions and Clearances for Downflow iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii Cabinet to Combustible Clearances BOT. BACK FRNT FLUE ¥ 0" 0"* 0" 0" 0" 3" O" * Can not be installed directly on combustible flooring. Supp _' plenum must have 1" clearance for first 6' from furnace.
Page 7 For horizontal installations, line contact is permissible only Typical Horizontal Installation between lines formed by intersection of back and two sides (NCGM/GCK) of furnace jacket, and building joists, studs or framing. Residential garage installations require: Inlet Pipe (Optional) • Burners ignition sources installed...
Page 8 Condensate DrainTrap Blocked Drain Pressure Switch (Upflow/Horizontal Installation) For horizontal furnace installations, the condensate drain trap MUST be installed below the furnace. See Figure 9 for dimen- sions of the drain trap and the proper material to be used. The Air Pressure Horn.offal Condensate Pressure Switch...
Page 9: Combustion& Ventilationair
3. Combustion& VentilationAir After it has been determined that each appliance vents properly, return doors, windows, appliances etc. to their normal condition. Poison carbon monoxide gas Hazard. If improper venting is observed, the cause MUST be cor- rected using the appropriate tables in code books of coun- Use methods described here to provide combustion try having jurisdiction.
Page 10 Outside Air (This is ONLY a guide. Subject to codes of country having jurisdiction.) This installation NOT approved in Canada Gas V - GableVe_ Soffit Vent Air (1) GableVent Gas Vent Inlet Air (1) Soft, Vent MinimumOne Inlet and OneOutlet Air Supplyis Required May be in andCombinationShown Inlet Inlet...
Page 11: Vent& Combustion Air Piping
An attic or crawlspace may be considered an unconfined be provided using the methods described in section titled Con- space provided there are adequate ventilation openings di- fined Space Installation: rectly to outdoors. Openings MUST remain open and NOT Unusually tight construction is defined as: Construction with have any means of being closed off.
Page 12 10. All horizontal pipe runs MUST be supported at least every If situations require pipe to be run on the exterior wall to five feet with galvanized strap or other rust resistant materi- reach a suitable termination point, it MUST be properly in- sulated.
Page 13 Pipe Diameter Table Pipe Diameter Table Single Piping ONLY Dual Piping ONLY 50,000 Btuh Furnaces 50,000 & 75,000 Btuh Furnaces Max No. Of Feet of Pipe* Max No. 0f Feet of Pipe* Elbowsin Elbows in onosi°e 00110141151012024125201303413540 0neSide_ 110-14115-19120-24125-29130-34135-40 UP TO 5 All combinations use "A"...
Page 14 Determine termination locations based on clearances spe- Consideration MUST be given to type of filter being cified in following steps and as shown in Figure 12, installed. 125,000 Btuh furnace require Figure 16, Figure 17, Figure 18. 2-16"x25"x1" filters(one on each side of furnace). This configuration does NOT allow the condensate drain line to For "Concentric...
Page 15 Vent Pipe Connection Proper Sealing Procedure for Combustion Blower Install the vent pipe to the combustion blower using the flexible coupling and clamps (provided). On the downflow models remove the three screws holding the vent collar to Vent Pipe the top panel. Remove the vent collar. Remove the two screws in the chase tube.
Page 16 Vent Trap and Furnace Connections (Downflow) Vent Pipe Air Intake Pipe Vent pipe MUST be installed 2" to 2 1/2" or 3" Adaptor with flexible coupling required (Field Supplied) clamps (supplied) at the com- bustion blower. Chase Tube Horizontal Drain Stub 2"...
Page 17 Horizontal Termination Wipe all excess cement from the joint with a rag. Allow 15 minutes before handling. Cure time varies according to fit, Cut two holes. 21/2" (67mm) for 2" (50mm) pipe, 3"(75mm) temperature and humidity. for 21/2 ,,(67mm) pipe, or 31/2,,(90mm) for 3" (75mm) pipe. Do NOT make the holes oversized, or it will be necessary to ConnectingVent Pipesand Termination add a sheet metal or plywood plate on the outside with the...
Page 18 sizes (check parts l ist). U se ofthese screens isrecommended Figure 20, Figure 21, Figure 22and Figure 23, but the next vent cept i ncold climate a reas w here i ceislikely toform onthem. Use termination must be at least 36" away from first 2 terminations. RTV sealant ONLY o nthescreen i nside t he termination elbow us- is important that vent terminations be made as shown to avoid re-...
Page 19: Gassupplyand Piping
5. Gas Supplyand Piping Supply Pressure Poison carbon monoxide gas, fire and explosion hazard. Fire hazard. Models designated for Natural Gas are to be used Do NOT set input rating above that shown on with Natural Gas Only, unless properly converted rating plate.
Page 20 Connect manometer to the tapped opening on the outlet Changing Orifices for High Altitude side of gas valve or on the manifold pipe. Use manometer with a 0-min.12" water column range. Turn gas ON, fire the furnace and remove adjustment screw cover on gas valve.
Page 21 Natural Gas Input RatingCheck Example NaturalGas No.ofSeconds Time PerCubic | BTUPer NOTE: The gas meter can be used to measure input to furnace. Rating is based on a natural gas BTU content of 1,000 BTU's per BTUContent t 1,000 PerHour 3,600 Footin Secondst 75,000...
Page 22: Electricalwiring
6. ElectricalWiring However, the electronic air cleaner is NOT energized during con- tinuous fan operation controlled by the electronic fan control. Electrical shock hazard. Fan Control The fan control is preset at the factory with an adjustable blower Turn OFF electric power at fuse box or service pan- ON delay of 30 seconds in the heating mode.
Page 23: Ductworkand Filter(Upflow/Horizontal)
Control Center Fuse iii// iiiiiii i i ii i E,ectrica, Connections Downflow The 24V circuit contains a 5-amp, automotive-type fuse located on control center. (See Figure 29) Any electrical shorts of 24V Air Intake Pipe wiring during installation, service, or maintenance may cause (Direct-Vent Installation only)
Page 24 When thefurnace i slocated i nanarea near o radjacent totheliv- Filters ingarea, t hesystem should becarefully designed withreturns to minimize noise t ransmission through thereturn g rille. Anyblower A Filter must be used: moving a high volume o f airwillproduce a udible noise which Filters are not supplied with these furnaces, but can be purchased could b eobjectionable towhen t heunit i slocated very close t oliv-...
Page 25: Ductworkand Filter(Downflow/Horizontal)
Addition Of Air Conditioning Filters Installed on Two Sides When a refrigeration coil is used in conjunction with this unit, it iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii must be installed on the discharge side of the unit to avoid con- densation on the heat exchanger. The coil installation instructions must be consulted for proper coil location and installation proce- dures.
Page 26 ing areas. It is advisable to route the return air ducts between size areas. Washable, high velocity filters can be replaced ONLY floors or through the attic. with same type and size. Installation of locking-type dampers are recommended Filter Installation all branches, or in individual ducts to balance system's air flow.
Page 27 Slide remaining filter into unit and up into place on right means to prevent operation of either unit unless the damper is in hand side of unit. See Figure 37. full heat or full cool position. If there is insufficient plenum height for this type of installation, fil- Downflow Furnace Installation ters may be installed in any accessible location in the return air Non-Combustible Floor Installation...
Page 28: Checksandadjustments
Setting the Subbase Furnace Subbase iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii Furna Plenum Insulation of Combustible Floor Bas __Wood Floor 1" Combustible Floor Base Wood Scre_L _/_" Plenum 25-20-46a 25-20-46 A = 4 1/4" Minimum clearance from beck of hole to wall or other obstruction. This subbase for combustible floors has been designed so that the height of the subbase raises the downflow coil off the floor to allow easy installation of the condensate drain.
Page 29 Main Burner Fire or explosion hazard. Turn OFF gas at shut off before connecting manometer. Burner Face Failure to turn OFF gas at shut off before connecting manometer can result in death, personal injury and/or property damage. With gas OFF, connect manometer to tapped opening on gas valve or on manifold tap.
Page 30: Furnacemaintenance
Continuous Fan Operation Blower Speed Chart A terminal is provided on the electronic fan control located in the Wire Color Motor Speed circulating blower compartment for operation of the continuous Black High fan option. This connection is intended for the low speed motor tap, and has a lower contact rating (8 amps) than the heat and Orange* Med-High...
Page 31 Field supplied pipe and fittings are required to complete the instal- Concentric Vent Dimensional lation. Drawing Kit Components 3" Dia. PVC _41/2" Dia. Kit Contents: 3" Rain Cap 4" Diameter SDR-26 Pipe, 371/8" Long 21/2" Diameter SDR-26 Pipe, 24" Long 3"...
Page 32 Install the Y concentric fitting and the pipe assembly through the structure's hole. Forvertical termination, install the parts through the field supplied roof boot/flashing. NOTE: De not allow insulation or other materials to accu- mulate inside the pipe assembly when installing through the structure's hole.

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ICP NTGM/GNK Series Installation Instructions Manual

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