Table of Contents
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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.
Signal Words in Manuals
The signal word WARNING is used throughout this manual in
the following manner:
DANGER - Immediate hazards which will result in severe person-
al 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 wilt result in en-
hanced installation, reliability, or operation.
The signal word CAUTION is used throughout this manual in
the following manner:
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 manu-
als, be alert to the potential for personal injury.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS
...............................
3
INTRODUCTION
.........................................
4
CODES AND STANDARDS
................................
4
SAFETY .................................................
4
GENERAL INSTALLATION
.................................
5
COMBUSTION
AND VENTILATION
AIR .....................
5
DUCT SYSTEMS
.........................................
5
ACOUSTICAL
LINING AND FIBROUS GLASS DUCT ..........
5
GAS PIPING AND GAS PIPE PRESSURE TESTING
..........
5
ELECTRICAL
CONNECTIONS
.............................
5
VENTING
...............................................
5
ELECTROSTATIC
DISCHARGE
(ESD)
PRECAUTIONS
PROCEDURE
.............................
5
LOCATION
..............................................
6
AIR FOR COMBUSTION
AND VENTILATION
.................
8
INSTALLATION ..........................................
10
U PFLOW INSTALLATION
.................................
10
DOWNFLOW
INSTALLATION
.............................
11
HORIZONTAL
INSTALLATION .............................
12
FILTER ARRANGEMENT
.................................
13
AIR DUCTS .............................................
13
GAS PIPING ............................................
16
ELECTRICAL
CONNECTIONS
............................
19
SERVICE AND MAINTENANCE
PROCEDURES
.............
40
SEQUENCE
OF OPERATION
.............................
44
WIRING DIAGRAM
......................................
46
TROUBLESHOOTING
GUIDE .............................
47
IS0 9001
Use of the AHRI Certified
TM Mark indic-
ates a manufacturer's
participation
in the
program. For verification
of certification
for
individual
products,
go to www.ahridirect-
ory.org
.
PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
Failure to carefully read and follow this warning could
result in equipment
malfunction,
property damage,
3ersonal injury and/or death.
Installation
or repairs made by unqualified
persons
could
result
in equipment
malfunction,
property
damage, personal injury and/or death.
The information contained in this manual is intended for
use by a qualified service technician familiar with safety
3rocedures and equipped with proper tools and test
instruments.
Installation must conform with local building codes and
with the
Natural
Fuel Gas Code
(NFCG)
NFPA
54/ANSI Z223.1
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.t -2009@), with permission
of National
Fire Protection
Association,
Quincy, MA 02269 and American Gas Association,
Washing-
ton, DC 20001.
This reprinted
material is not the complete
and official position of the NFPA or ANSI, on the referenced
subiect,
which is represented
only
by the standard
in its entirety.
Printed in U.S.A.
441 01 1411 03 May 2012
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Table of Contents
Related Manuals for ICP F8MXN
Summary of Contents for ICP F8MXN
- Page 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 The signal words DANGER, WARNING, CAUTION, and NOTE The signal word WARNING is used throughout this manual in the following manner: are used to identify levels of hazard seriousness.
- Page 2 Figure 1 - Dimensional Drawing I-- 5 16/16 [150.7] / r- s 1/2 i 1,;o.tt '1:' s] L 1/1e [51.O] L,., ___. [,k_s] 1"_-71 ='"1 _7/8 [=21=] ACC_ ..21.6 BOT._M [s'la.5] [1_7] INLET _86/8 28,39 [els] -_1 61_V16-- ['nl.2] p7e.Sl ['n_ [148.S] S_--...
-
Page 3: Safety Considerations
SAFETY CONSIDERATIONS CUT HAZARD Failure to follow this caution may result in personal FIRE, EXPLOSION, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING HAZARD injury. Sheet metal parts may have sharp edges or burrs. Failure to follow this warning could result in dangerous Use care and wear appropriate protective clothing,... -
Page 4: Codes And Standards
INTRODUCTION (16°C)db or intermittent operation down to 55"F (13°C) db such as when used with night setback thermostat. F8MXN, G8MXN, F8MXL, G8MXL, 4-way multipoise Return-air temperature must not exceed 85°F (29°C) Category I fan-assisted furnace is CSA design-certified. Failure to follow these return-air temperature limits may affect... - Page 5 Figure 3 - Return Air Temperature ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE °F FURNACE RELIABILITY HAZARD AX 80 °F/27 °C Improper installation or service of furnace may cause premature furnace component failure. FRONT Electrostatic discharge affect electronic components. Follow Electrostatic Discharge Precautions Procedure listed below...
- Page 6 Figure 4 - Multipoise Orientations AIRFLOW THE BLOWER IS LOCATED BELOWTHE BURNER SECTION, AND CONDITIONED AIR iS DISCHARGED UPWARD. THE BLOWER IS LOCATED TOTHE RIGHT OFTHE BURNER SECTION, AND AIR CONDITIONED AIR IS DISCHARGEDTO THE LEFT. HORIZONTAL RIGH_AIRF L_C THE BLOWER IS LOCATED ABOVE THE LOCATED TO THE LEFT BURNER SECTION, AND...
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Page 7: Fire Hazard
All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between furnace cabinet PERSONAL INJURY AND/OR PROPERTY return-air duct to prevent pulling air from the burner area and DAMAGE HAZARD from draft safeguard opening. - Page 8 Table 3 - Minimum Space volumes for 100% combustion, Ventilation, and Dilution from Indoors 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) 0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300...
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Page 9: Carbon Monoxide
c. TWO HORIZONTAL DUCTS require 1 square inch of free area per 2,000 Btuh (1,100 mm2/kW) of combined input for all gas appliances in the space per Figure 7 and Table 2. CARBON MONOXIDE POISONING HAZARD d. TWO OPENINGS OR VERTICAL DUCTS require 1 Failure to follow this warning could result in death square inch of free area per 4,000 Btuh (550 mm2/kW) -
Page 10: Upflow Installation
Combination of Indoor and Outdoor Air in 12" (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). (See 1. Indoor openings shall comply with the Indoor Combus- Figure 8) tion Air Method below and, c. - Page 11 closure panel to install leveling legs. To remove bottom Figure 11 - Floor and Plenum Opening Dimensions closure panel, see Item 1. in Bottom Return Air Inlet section. To install leveling legs: 1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace.
-
Page 12: Horizontal Installation
Table 4 - Opening Dimensions - In. (mm) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications on Combustible or Noncombustible Flooring 12-11/16 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 14-3/16... -
Page 13: Filter Arrangement
NOTE: Flexible connections should be used between 2. Rotate bottom filler panel downward to release holding tabs. ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should 3. Remove bottom closure panel. insulated and sealed to enhance system performance. When 4. - Page 14 Figure 14 - Duct Flanges UPFLOW DOWNFLOW HORIZONTAL i ..120"_ 120°\_ 120 °_ A02020 Figure 15 - Horizontal Unit Suspension 4 REQ. /4" (6mm) THREADED OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 xS/4'' (19ram) SCREWS TYPICAL FOR 2 SUPPORTS 8"...
- Page 15 Figure 16- Horizontal Suspension withStraps 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS .-'OPENING OUTER DOOR ASSEMBLY llll METHOD USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAR THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.
- Page 16 furnace casing as shown in Figure 20 and Figure 22. Bypass Refer to Table 6 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all humidifier may be attached into unused return air side of the gas piping with appropriate straps, hangers,...
- Page 17 Table 5 - Air Delivery - CFM 0Nith Filter)* UNIT SIZE COLOR SPEED EXTERNAL STATIC PRESSURE (In.W.C.) Gray 1185 1145 1115 1075 1035 Yellow 0451408 Blue Orange Gray 1625 1585 1535 1495 1460 1415 1365 1295 1220 1125 Yellow 1405 1360 1320 1280...
- Page 18 Figure 20 - Upflow Return Air Configurations and Restrictions UPFLOW RETURN CONFiGURATiONS RESTRICTIONS CONNECTION CONNECTION CONNECTION COMBINATIONS FLOW MODELS RETURN RETURN RETURN RETURN ONLY ONLY ONLY 1,2, GREATER 5 TONS OTHER MODELS • 2000 GREATER HI COOLING SPEED RETURN RETURN RETURN RESTRICTIONS RETURN...
- Page 19 Table 7- Electrical Data OPERATING MAX WIRE VOLTS- UNIT MAX FUSE/ VOLTAGE* FURNACE MAX UNIT MIN WIRE HERTZ-- AMPACITY# LENGTHS CKT BKR? (VOLTS) MODEL GAGE (AMPS) PHASE (AMPS) FT. (M) (AMPS) 0451408A 115-60-1 10.9 34 (10) 0701716A 115-60-1 10.8 14.2 26 (8) 0902116A 115-60-1...
-
Page 20: Electrical Connection To J-Box
ELECTRICAL CONNECTION TO J-BOX Figure 24 - Field-Supplied Electrical Box on Furnace Casing Electrical Box on Furnace Casing Side FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death, or property damage. If field-supplied manual disconnect switch is to be... - Page 21 ACCESSORIES the control board thermostat strip. The HUM 24VAC terminal is energized when there is a call for heat (W) 1. Electronic Air Cleaner (EAC) and the gas valve relay is energized. (See Connect an accessory Electronic Air Cleaner (if used) Figure 25 and Figure 55).
- Page 22 Figure 27 - ECM Single-Stage Furnace with Single Figure 28 - ECM Single-Stage Furnace with Two-Stage Air Conditioner Stage Air Conditioner ICPTHERMOSTAT ICP THERMOSTAT ECM SINGLE- ]3NO-,STAGE ECM SINGLE- SINGLE--STAGE STAGE FURNACE AIR CONDITIONER STAGE...
- Page 23 Figure 29- ECM Single-Stage Furnace w ithSingle- Figure 31 - ECM Single-Stage Furnace and Humidifier Stage Heat P ump (Dual F uel) Only HUMIDITY SENSING ICP THERMOSTAT SINGLE- SINGLE--STAGE SINGLE-STAGE STAGE FURNACE HEAT PUMP THERMOSTAT FURNACE HUMIDIFIER Fz_-q See note 6...
- Page 24 5 all dual fuel application. minutes of main burner operation. Use the flame of 3. Refer to ICP thermostat Installation Instructions for ad- a match or candle. ditional information and setup procedure.
-
Page 25: Masonry Chimney Requirements
following information and warning must be considered a. Shows signs of vent gas condensation, the chimney should be relined in accordance with local codes and addition to the requirements defined in the NFGC. the authority having jurisdiction. The chimney should 1. - Page 26 APPLIANCE APPLICATION REQUIREMENTS system. Do not use vent dampers on appliances common vented with this furnace. Appliance operation significant impact ADDITIONAL VENTING REQUIREMENTS performance of the venting system. If the appliances sized, installed, adjusted, and operated properly, the venting A 4" (101 mm) round vent elbow is supplied with the furnace. system and/or appliances...
- Page 27 Figure 34- Chimney I nspection C hart CHIMNEY INSPECTION CHART For additionalrequirementsrefer to the National Fuel Gas Code NFPA54/ANSI Z223.1 and ANSI/NFPA 211 Chimneys, Fireplaces,Vents, and Solid Fuel BurningAppliances Crown condition: Rebuild Missing mortar crown. or brick? Is chimney property lined with clay tile liner? Repair Reline...
-
Page 28: Burn Hazard
The horizontal portion of the venting system shall slope upwards not less than 1/4-in. per linear ft. (21 mm/M) from the furnace to the vent and shall be rigidly supported every 5 ft. (2 M) or less with metal hangers or straps to ensure there BURN HAZARD is no movement after installation. - Page 29 Figure 37- Downflow A pplication-Vent Elbow Upthen Figure 39 - Downflow Application-Vent Elbow Left then Left SEE NOTES:1,2,3,4,5,7,8,9 on the page following SEE NOTES: 1,2,4,5,6,7,8,9 these figures on the page following these figures A03210 A03207 Figure 40 - Downflow Application-Vent Elbow Up then Figure 38 - Downflow Application-Vent...
- Page 30 Figure 41 - Horizontal Left Application-Vent Elbow Left Figure 45 - Horizontal Right Application-Vent Elbow Left then Up © SEE NOTES: 1,2,4,7,8,9 on the page following these figures A03213 Figure 42 - Horizontal Left Application-Vent Elbow Right then Up A03219 Figure 46 - Horizontal Left Application-Vent...
- Page 31 5. Four-inch single-wall (26 ga. min.) vent must be used Step 2--Start-Up Procedures inside furnace casing and when the Downflow Vent Guard Kit is used external to the furnace. 6. Accessory Downflow Vent Guard Kit, required downflow installations with lower vent configuration. FIRE AND EXPLOSION HAZARD 7.
-
Page 32: Fire Hazard
Step 3 --Adjustments Table 10 -Altitude Derate Multiplier for U.S.A. ALTITUDE PERCENT DERATE (FT,/ M) MULTIPLIER DERATE FACTOR* FIRE HAZARD 0-2000 (0-610) 1.00 Failure to follow this warning could result in injury, 2001_3000 (610-914) 8-12 0.90 death and/or property damage. 3001-4000 (914-1219) 12-16... -
Page 33: Electrical Shock Hazard
If clocked rate does not match required input from Step 1, Figure 48 - Gas Control Valve increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct input is achieved. Reinstall regulator seat cap on gas valve. - Page 34 h. Re-install vent connector. 6. Set thermostat heat anticipator. a. Mechanical thermostat - Set thermostat heat anticip- NOTE: Should switch remain open longer than 8 minutes, furnace control board will lockout the furnace for 3 hours. To ator to match the amp. draw of the electrical compon- ents in the R-W circuit.
- Page 35 Table 11-GasRate (CuFt./Hr.) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 REVOLUTION FOR 1 REVOLUTION 2 Cu Ft. Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. Cu Ft. 1800 1636 1500 1385 1286 1200 1125 1059...
-
Page 36: Specific Gravity
Table 13 - Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (TABULATED DATA BASED ON 22,000 BTUH PER BURNER, DERATED 4%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL RANGE HEAT VALUE 0.58 0.60 0.62 0.64... - Page 37 Table 13 - Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (CENT) (TABULATED DATA BASED ON 22,000 BTUH PER BURNER, DERATED 4%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0.58 0.60 0.62...
- Page 38 Table 14 - Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate (TABULATED DATA BASED ON 21,000 BTUH PER BURNER, DERATED 4%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL RANGE HEAT VALUE 0.58 0.60 0.62 0.64...
- Page 39 Table 14- Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate (CONT) (TABULATED DATA BASED 21,000 BTUH BURNER, DERATED 4%/1000 (305M) ABOVE LEVEL) ALTITUDE AVG. SPECIFIC GRAVITY OF NATURAL RANGE HEAT VALUE 0.58 0.60 0.62 0.64 ALTITUDE Orifice Manifold Orifice Manifold...
- Page 40 SERVICE AND MAINTENANCE PROCEDURES The electrical ground and polarity for 115-v wiring must be properly maintained. Refer to Figure 26 for field wiring information and to Figure 55 for furnace wiring information. FIRE, INJURY, OR DEATH HAZARD NOTE: If the polarity is not correct, the STATUS LED on the Failure to follow this warning could result in personal control will flash a status code 10 and prevent the furnace injury, death and/or property damage.
- Page 41 BLOWER MOTOR AND WHEEL ELECTRICAL SHOCK A NDFIRE HAZARD ELECTRICAL SHOCK HAZARD Failure to follow this warning could result personal injury, death or property damage. Failure to follow this warning could result in personal Turn off the gas and electrical supplies to the unit injury or death.
- Page 42 10. Reassemble motor and blower by reversing steps 11f 20. Cycle furnace through one complete heating and cool- through 11a, finishing with 11a. Be sure to reattach ing cycle. Verify the furnace temperature rise as shown ground wire to the blower housing. in "Adjustments"...
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Page 43: Fire Or Explosion Hazard
Figure 52- Igniter P osition-Side View NOTE: A releasing agent such as a vegetable oil cooking spray that does not contain corn oil, canola oil, halogenated hydrocarbons or aromatic content, which may prevent an inadequate seat from occuring, and RTV sealant such as 7.1 mm G.E. - Page 44 Sequence of Operation NOTE: Furnace control must be grounded for proper EAC 1 AMP is energized and remains energized as long as the blower motor BLWM is energized. operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and manifold bracket f.
- Page 45 fy mode. If the DHUM input is low for more than 48 Heat pump hours, the furnace control reverts back to non-humidity (See Figure 26 - Figure 33 for thermostat connec- sensing thermostat mode. tions.) When installed with a heat pump, the furnace The cooling operation described in item 2.
- Page 46 CONNECTION DIAGRAM TO 115 VAC FIELD DISCONNECT SWITCH SCHEMATIC DIAGRAM HEAT OFF-DELAY NOTE #2 JUMPER SELECTOR (NATURAL & PROPANE GASES) FRS2 NEUTRAL L2 EQUIPMENT maROUND DHUM '<1" NOTE #B Y/Y2 FRS1 '<1" TEST/TWIN OR_G _UUM 24VAC FUI_ 0/VHEN USED) NOTE :fl_ FUSE 3AMP °...
- Page 47 Troubleshooting Guide -Single Stage START Is LED status light ON solid, alternately .--L }--_ Is door switch closed? Close the door switch. tlashing bright--dim-bright-dim like a heartbeat, or flashing ON and OFF? IS there 115V at L1 and NEUTRAL? Is there 24V at 24VAC and COM? is there115V going to switch ?
- Page 48 NOTE: NUMBER IN UPPER LEFT HAND CORNER REPRESENTS FLASH CODE PRESSURE SWITCH DID NOT OPEN LIMIT CIRCUIT LOCKOUT -Lockout Check for: occurs if the limit, draft safeguard, flame rollout, or blocked vent switch (if used) Obstructed pressure tube. Pressure switch stuck closed.
-
Page 49: Parts Replacement
PARTS REPLACEMENT INFORMATION GUIDE CASING GROUP BLOWER GROUP Gas valve Manual reset limit switches Outer door Blower housing Blower door Blower cutoff HEAT EXCHANGER GROUP Blower motor Top filler plate Blower wheel Bottom filler plate Heat exchanger cell Bottom enclosure Capacitor (where used) Celt panel ELECTRICAL GROUP...