ICP F9MXE0801716A1 Installation Instructions Manual
ICP F9MXE0801716A1 Installation Instructions Manual

ICP F9MXE0801716A1 Installation Instructions Manual

Variable speed motor, two-stage ecm motor and single-stage 35" tall, high efficiency condensing gas furnace

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HJJ(J|)i(i)))_J))1))
These instructions must be read and understood completely before attempting installation.
Safety Labeling and Signal Words
DANGER,
WARNING,
CAUTION,
and NOTE
The
signal
words
DANGER,
WARNING,
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.
Signal
Words
in Manuals
The signal word WARNING
is used throughout
this manual
in the following
manner:
The signal word CAUTION
is used throughout
this manual
in the following
manner:
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
Signal
Words
on Product
Labeling
Signal words are used in combination
with
colors and/or
pictures
or product
labels.
Z_
Safety-alert
symbol
When you see this symbol
on the unit and in
instructions
or
manuals,
be alert
to
the
potential for personal
injury.
SAFETY
CONSiDERATiONS
.......................................
3
iNTRODUCTiON
...............................................
4
CODES
AND STANDARDS
........................................
4
ELECTROSTATIC
DISCHARGE
(ESD) PRECAUTIONS
PROCEDURE
...........
5
DIMENSIONS
.................................................
6
LOCATION
...................................................
7
LOCATION
RELATIVE
TO COOLING
EQUIPMENT
........................
9
AiR FOR COMBUSTION
AND VENTiLATiON
............................
9
CONDENSATE
TRAP
............................................
12
iNSTALLATION
................................................
18
UPFLOW
INSTALLATION
.........................................
18
DOWNFLOW
INSTALLATION
.......................................
19
HORIZONTAL
INSTALLATION
......................................
22
FILTER ARRANGEMENT
.........................................
24
AiR DUCTS
...................................................
26
GAS PiPiNG
..................................................
26
ELECTRICAL
CONNECTIONS
......................................
28
J-BOX
iNSTALLATION
...........................................
29
VENTING
....................................................
35
SPECIAL
VENTING
REQUIREMENTS
FOR INSTALLATIONS
iN CANADA
........
35
DIRECT
VENT
/ 2-PIPE
SYSTEM
...................................
41
VENTILATED
COMBUSTION
AiR
....................................
41
TERMINATION
REQUIREMENTS
FOR THE
PROVINCES
OF ALBERTA
AND
SASKATCHEWAN
.......................
41
iNSTALLING
THE VENT TERMINATION
...............................
46
MAXIMUM
EQUIVALENT
VENT
LENTH
...............................
50
MAXIMUM
ALLOWABLE
EXPOSED
VENT
LENGTHS
iN
UNCONDITIONED
SPACE
- SINGLE
STAGE
..........................
51
MAXIMUM
ALLOWABLE
EXPOSED
VENT
LENGTHS
iN
UNCONDITIONED
SPACE
- TWO-STAGE
............................
52
IS0 9001)
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
.
INSTALLER:
Affix these instructions on or adjacent to the
furnace,
CONSUMER:
Retain
these
instructions
for
future
reference.
Portions
of the text and tables are reprinted from NFPA 54/ANSI
Z223.1-2009_;P, 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 inU.S.A.
440 01 4001 02 Sept.2011

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  • Page 1 HJJ(J|)i(i)))_J))1)) 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, WARNING, The signal word WARNING is used throughout CAUTION, and NOTE are used to identify levels of this manual in the following manner:...
  • Page 2: Installations

    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: 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...
  • Page 3: Safety Considerations

    Safety Considerations CUT HAZARD Failure to follow this caution may result in personal FIRE, EXPLOSION, ELECTRICAL SHOCK, injury. CARBON MONOXIDE POISONING HAZARD Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety Failure to follow this warning could result in dangerous operation, personal injury, death, or property damage.
  • Page 4: Codes And Standards

    Maintain a 1-in. (25 mm) clearance from combustible I Freeze Protection and Return Air Figure 1 materials to supply air ductwork for a distance of 36-in. Temperature (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements. SUPPLY MAX 80°F/27°C Minimum Clearances to...
  • Page 5: Duct Systems

    Disconnect power furnace. Multiple Duct Systems disconnects may be required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE • US and CANADA: Air Conditioning Contractors CONTROL PRIOR TO DISCHARGING YOUR BODY'S Association (ACCA) Manual D, Sheet Metal and Air ELECTROSTATIC CHARGE TO GROUND.
  • Page 6 Figure 2 JDimensions 615/1( [17&1] 23/10 NOlle; ALL DIMENSIONS IN INCH [MM] 6 11116 [17o41 OUTLET WIDTH AIR FLOW LOCATION [22.2] POWERCONN (F/G)9MVT SHIP WT, BOTTOM FURNACE SIZE CABINET WIDTH OUTLET WIDTH AIR INTAKE LB (KG) INLET WIDTH 40,000 14-3/16 (361) 12-1/2 (319) 12-9/16...
  • Page 7 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. Always comply with minimum fire protection clearances shown in Table 1 or on the furnace clearance combustible construction label.
  • Page 8: Fire Hazard

    Figure 3 1Multipoise Orientations AIRFLOW THE BLOWER iS LOCATED BELOW THE BURNER SECTION, AND CONDiTiONED AIR iS DISCHARGED UPWARD. THE BLOWER iS LOCATED TOTHE RIGHT OFTHE BURNER SECTION, AND AIR CONDiTiONED AiR iS DISCHARGED TO THE LEFT. HORIZONTAL RIGHT/AIFF_LQW THE BLOWER iS THE BLOWER iS LOCATED ABOVE THE LOCATED TO THE LEFT...
  • Page 9: Location Relative To Cooling Equipment

    Location Relative to Cooling Equipment FURNACE CORROSION HAZARD The cooling coil must be installed parallel with, or on the Failure to follow this caution may result in furnace downstream side of the unit to avoid condensation in the heat damage. exchangers.
  • Page 10 b. Not less than the sum of the areas of all vent The Standard Method: connectors in the space. The space has no less volume than 50 cubic feet per The opening shall commence within 12-in. (300 mm) of the 1,000 Btuh (4.8 cubic meters per kW) of the maximum ceiling.
  • Page 11: Air For Combustion, V Entilation

    In spaces that use the Indoor Combustion Air Method, Air for Combustion, V entilation, infiltration should be adequate to provide air for Figure 7 and Dilution from Indoors combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction,...
  • Page 12 Table 4 Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL (1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE) Space Volume Ft 3 (M3) 1,050 1,400 1,750 1,400 1,500 2,000 2,500 3,000...
  • Page 13 12. Install the trap over the ports on the lower right side of 17. Connect the new pressure switch tube to the port on the the collector box. front pressure switch. Route tube through stand-offs on the inducer assembly and connect to the 13.
  • Page 14 8. Remove the relief tube from the condensate trap. Condensate Trap - Horizontal 9. Remove the screw that secures the condensate trap to Orientation the collector box. When the furnace is installed in the horizontal right position, the 10. Remove the trap. factory-installed trap will be located at the bottom of the...
  • Page 15 Figure 11 _Unconverted Factory Configuration as viewed in the Horizontal Right Orientation collector box. emove plug from DO NOT DISCARD. If alternate vent position is required, loosen clamp on inlet of vent elbow. Remove trap from collector box. (1 AND 2 STAGE UNITS) Horizontal Right Trap Configuration Slide relief tube in stand-offs to adjust length.
  • Page 16: Drain Connection

    Figure 1Unconverted Factory Configuration as viewed in the Horizontal Left Orientation Remove trap from collector is required, loosen clamp Remove relief tube from on vent elbow inlet. relief port on condensate trap. f alternate vent position box. Remove front pressure switch tube and discard.
  • Page 17: Cut Hazard

    4. Install the grommet for the 1/2-in. CPVC drain line in the Figure13 Example of Field Drain Attachment 7/8-in. knockout in the casing. 5. Remove the pre-formed drain tube, the offset 1/2-in. CPVC pipe and two spring clamps from the loose parts OPEN STAND bag.
  • Page 18: Upflow Installation

    7. Slide the other spring clamp down the plain end of the Figure 15 Modify Drain Tube drain tube. Cutand remove formed end of 8. Connect additional 1/2-in. CPVC piping to a condensate drain tube for left side and horizontal pump approved for use with acidic furnace condensate drain connection or to a code-approved...
  • Page 19: Return Air Connections

    Connect supply-air duct to flanges on furnace supply-air openings in DOWNFLOW configuration. (See Figure27, outlet. Bend flange upward to 90 ° with wide duct pliers. (See Figure 28 and Figure 29) Figure 22) The supply-air duct must be connected to ONLY Leveling Legs (If Desired) the furnace supply-outlet-air...
  • Page 20 4. Install asshown inFigure 23.IfCoil A ssembly Part i s used, i nstall asshown i nFigure 24. Floor and Plenum Opening Figure 21 CUT HAZARD Dimensions Failure to follow this caution result in personal injury. Sheet metal parts may have sharp edges or burrs. care and wear appropriate...
  • Page 21 Table 5 Opening Dimensions - in. (mm) FURNACE PLENUM OPENING FLOOR OPENING CASING WIDTH APPLICATION IN, (mm) 12-11/1 Upflow Applications on Combustible or Noncombustible Flooring 21-5/8 13-5/16 22-1/4 (subbase not required) (322) (549) (338) (565) Downflow Applications on Noncombustible Flooring 12-9/16 13-3/16 19-5/8...
  • Page 22: Horizontal Installation

    Bottom Return Air Inlet furnace can be installed horizontally in an attic crawlspace on either the left-hand (LH) or right-hand (RH) These furnaces are shipped with bottom closure panel installed side. The furnace can be hung from floor joists, rafters or in bottom return-air opening.
  • Page 23: Roll-Out Protection

    Figure 26 Working Platform for Attic Installation COMBUSTION - AIR PIPE VENT (SEE VENTING SECTION) A 12-1N, (305 ram) MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH A SHORT (5 TO 8 FT / 1,5 TO 2,4 M) VENT SYSTEM TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM...
  • Page 24: Filter Arrangement

    Filter Arrangement Figure 27 Configurations and Restrictions J Downflow Return Air FIRE, CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury, or death. Never operate a furnace without a filter or filtration device installed. Never operate a furnace with filter or filtration ®...
  • Page 25 External Filter Cabinet Configurations Figure 31 Accessory Bottom Filter Rack Figure 30 _Accessory Side Filter Rack ® ® Lt0F031 L10F027 ._,,1_,,i_ 3/8, ' 1/2"--_ _D,,_ _,_--1 1/4 '' /I TABS (TYP.) I ......2 3/8" "=--1 1/4" ..._ 251/8" 22-5/t 6 (566.4) 28-7/16 23 1/8"...
  • Page 26: Air Ducts

    Air Ducts General Requirements FIRE OR EXPLOSION HAZARD The duct system should be designed and sized according to Failure to follow this warning could result in personal accepted national standards such as those published by: Air injury, death, and/or property damage. Conditioning Contractors Association (ACCA), Sheet Metal and...
  • Page 27: Maximum Capacity Of Pipe

    Table 8 Maximum Capacity of Pipe Figure I Gas Valves NOMINAL LENGTH OF PIPE - FT (M) Redundant Automatic Gas Valve (Two-Stage) INTERNAL IRON PIPE DIA. SIZE IN.(aM) (3.0) (6.0) (9.1) (12.1) (15.2) IN.(aM) Regulator Seal 1/2 (13) 0.622(158) RegulatorAdjustment 1,2"...
  • Page 28: Electrical Shock Hazard

    See Figure 35 for field wiring diagram showing typical field Gas Pipe Grommet 115-v wiring. Check all factory and field electrical connections For direct vent (2-pipe) applications, the knockout for the gas for tightness. pipe must be sealed to prevent air leakage. Remove the Field-supplied wiring shall conform with the limitations of 63°F knockout, install the grommet in the knockout, then insert the...
  • Page 29: Fused Disconnect

    Figure 35 (CONT.) [Typical Two-Stage Field Wiring Diagram ..FIELD 24-VOLT WIRING ..FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING NOTE 2 1-STAGE FIVE THERMOSTAT FIELD-SUPPLIED TERMINALS FUSED DISCONNECT WIRE _ BLOWER THREE WIRE "1 208/230- OR DOOR _ HEATING- SWITCH...
  • Page 30: Power Cord Installation

    box is attached to the outside of the furnace casing and the box screws from inside electrical box into casing. (See is grounded to the green ground wire of the main wiring Figure 38) harness and the earth ground of the field electrical supply. Route field power wiring into external electrical box.
  • Page 31: Alternate Power Supplies

    7. Attach furnace J-Box cover to mounting bracket with Humidifier (HUM) screws supplied in loose parts bag. Do not pinch wires (F/G)gMVT The HUM terminal is a 24 VAC output, between cover and bracket. energized when the blower is operating during a call BX Cable Installation in Furnace J-Box...
  • Page 32 Table 9 Electrical Data (F/G)9MVT TWO-STAGE, VARIABLE SPEED FURNACES MAXIMUM MAXIMUM OPERATING VOLTAGE VOLTS- MAXIMUM MINIMUM WIRE FUSE OR CKT RANGE* HERTZ- UNIT UNIT WIRE SIZE LENGTH PHASE Maximum* Minimum* AMPS AMPACITY# UNIT SIZE FT (i)$ AMPSt 115-60-1 11.0 40,000 33 (10.0) 115-60-1 13.0...
  • Page 33 Figure 40 Variable Speed Furnace Control for ECM Blower Motor COMMUNICATION CONTINUOUS OUTDOOR SETUP SWITCHES CONNECTOR (CF) AIRFLOW TEMP SETUP SWITCHES CONNECTOR MODEL PLUG CONNECTOR SETUP SWITCHES BLOWER DELAY OFF- CONDITIONING -.._ (A/C) AIRFLOW HUMIDIFIER SETUP SWITCHES TERMINAL (24-VAC 0.5 AMP MAX. ,..
  • Page 34 Figure 42 I Single Stage Furnace Control for ECM Blower Motor HEAT OFF-DELAY 24-V THERMOSTAT TERMINALS TWINNING AND/OR COMPONENT TEST TEST/TWIN TERMINAL HUMIDIFIER TERMINAL (24-VAC 0,5 AMP MA)_ CONNECTIONS TRANSFORMER2'ViC 3-AMP FUSE COM BLUE 24VAC RED P1 - LOW VOLTAGE MAIN _O_€...
  • Page 35 VENTING standard Canadien recommande I' inspection par un personel qualifie et ce, une fois par annee. Furnace is set in place in the required orientation. autoritees ayant juridiction (inspecteurs gas, Special Venting Requirements for Installations inspecteurs en b&timents, departement des incendies, etc) devraient _tre consultees avant I'instatlation afin de determiner in Canada...
  • Page 36: Venting Systems

    Other gas appliances with their own venting system may also discharged to outdoor atmosphere. Combustion-air and vent use the abandoned chimney as a raceway providing it is pipes must terminate together in the same atmospheric permitted by local code, the current edition of the National Fuel pressure zone, either through...
  • Page 37 Table11 Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A. Installation) ASTM SPECIFICATION SOLVENT CEMENT AND MATERIAL PIPE FITTINGS DESCRIPTION (MARKED PRIMERS MATERIA_ D1527 Schedule-40 Pipe D1785 Schedule-40 Pipe D2235 For ABS Solvent Cement For ABS D2241 SDR-21 & SDR-26 Pipe D2466 Schedule-40...
  • Page 38: Upflow Left Vent

    Figure 44 l Upflow Right Vent Any other unused knockout may be used for combustion connection. Rotate vent elbow to required position. UPFLOW RIGHT CONFIGURATION Attach vent pipe adapter with gasket to furnace casing. C) Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.
  • Page 39 Figure 46 _ Downflow Left Vent Rotate vent elbow to required position. ® DOWNFLOW LEFT CONFIGURATION © (_) Attach vent pipe adapter with gasket to furnace casing. (_) Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. Slide vent pipe through adapter and coupling into vent elbow.
  • Page 40: Locating The Vent Termination

    Figure48 1Downflow Vertical Vent Figure _Vent Pipe Flush with Adaptor VENT PIPE ADAPTER WITH GASKET INSTALLED ON FURNACE VENT PIPEIS CUTFLUSH WITH TOP OF ADAPTER. Figure 51 Vent Pipe Flush Showing Coupling ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND-OFF ON ADAPTER.
  • Page 41 1. Comply with clearance requirements stated The concentric vent kit currently cannot be modified to attach Figure 62 or Figure 63 per application. an elbow to the vent portion of the rain cap. A tee attached to the rain cap could potentially direct the flue gas plume toward 2.
  • Page 42 Figure54 1Combustion Air and Vent Pipe Termination for Direct Vent (2-Pipe) System Roof Te rmination (Preferred) ..At _east36 _n (914mm) Con_ntric Vent Corn bustion Roof Termination {pteturted) ... Ver tica_ separation between combustion ak and vent 8 3/4 in (222ram)for 3 in (76ram)kit 63/4in (172mm)for2in...
  • Page 43: Carbon Monoxide Poisoning

    1. Measure the individual distance from the furnace to the Configure the Furnace termination for each pipe. 2. Select a Maximum Equivalent Vent Length (MEVL) longer than the measured distance of the individual vent and combustion air connections to the vent termination. CARBON MONOXIDE POISONING HAZARD 3.
  • Page 44 Figure 57 JHorizontal Left Vent Configuration Figure 58 _Horizontal Right Vent Configuration _""_ ALTERNATE HORIZONTAL LEFT VERTICAL VENT M1327 COMBUSTION CONNECTmONS Representative drawing only, some mode_s vary in appearance Al1337 HORIZONTAL RIGHT, VERTICAL VENT Representative drawing Ol]]y, some models vary in appearance Al1328 HORIZONTAL...
  • Page 45: Carbon Monoxide

    socket to prevent buildup of excess cement. Apply Installing the Vent Pipe Adapter second coat. Combustion Air Pipe Adapter 13. While cement is still wet, twist pipe into socket with 1/4-in. turn. Be sure pipe is fully inserted into fitting socket.
  • Page 46: Installing The Vent Termination

    Holes in the roof for two pipe terminations should be spaced no Figure 59 Combustion Air Pipe more than 18-in. (457 mm) apart. Pointelbow down towards Termination elbows will be installed after the vent and (if used) back of furnace combustion air pipe is installed.
  • Page 47 Figure 60 Crawl Space Vent Termination Ventilated Combustion Air intake pipe Pipe hangar 3" (76 mm) 12"(305 ram) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE Figure 61 _Attic Vent Termination Ventilated Combustion Air intake pipe t throuhgb.__._ roof flashmng ATTIC L11F016...
  • Page 48 Figure 62 1Direct Vent Termination Clearance AREAWHERE TERMINAL IS NOT PERMITED \\\\\ VEHTTERMINAL AIR SUPPLY INLET Item ClearanceDescription Canadian Installation (1) U.S.Installation (2) Clearance above grade,veranda, porch, deck, balcony,or 12 in. (305 ram).18 in. (457mm)above roof surface 12in. (305 mr'n) anticipatedsnow level 12 in.
  • Page 49 Figure 63 _Other than Direct Vent Clearance - Ventilated Combustion Air Option _Xi AIR SUPPLY INLET VENT TERMINAL AREAWHERETERMINAL IS NOT PERMITED Y_":x Item ClearanceDescriptions Canadian Installation(1) U.S. Installation (2) Clearance above grade, verand& porch, decL balcony, or anticipatedsnow level 12in.
  • Page 50 Table 12 (F/G)9MVT, (F/G)9MXT, (F/G)9MXE - MAXIMUM EQUIVALENT VENT LENTH - Feet (Meters) Note: Maximum Equivalent Vent Length (MEVL) does NOT include elbows or terminations Use Table 14 - DEDUCTIONS FROM MEVL to determine allowable vent len.qth for each application. DIRECT VENT (2-PIPE) AND NON-DIRECT VENT (1-PIPE) Altitude Unit Size...
  • Page 51 Table 14 DEDUCTIONS FROM MAXIMUM EQUIVALENT VENT LENGTH - Feet (Meters) 1-1/2 2-1/2 Pipe Diameter (in): Mitered 90 ° Elbow (2.4) (2.4) (2.4) Medium Radius 90 ° Elbow (1.5) (1.5) (1.5) Long Radius 90 ° Elbow (0.9) (0.9) (0.9) (0.9) (0.9) Mitered 45 -0Elbow...
  • Page 52 Maximum AllowableExposedVentLengthsin Unconditioned Space - Two-Stage Table16 Maximum Lengthof Uninsulated andInsulated VentPipe-Ft ( M) (F/G)9MVT No Insulation 3/8-in. (9.5 mm) 1/2-in. (12.7 & Winter Pipe Diameter - in. (mm) Pipe Diameter - in. (mm) Pipe Diameter - in. (mm) Pipe Length (F/G)eMXT Design in Ft.

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