ICP NTGM/GNK Series, Installation Instructions Manual

Page 1: ... 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...

Page 2: ...dwelling The sources could be gas fired clothes dryers gas cooking stoves water heaters furnaces gas fired fireplaces wood fireplaces and several other items Carbon monoxide can cause seri ous bodily injury and or death Therefore to help alert people of potentially dangerous carbon monoxide levels you should have carbon monoxide detectors listed by a na tionally recognized agency e g Underwriters ...

Page 3: ...and Size Fan Time ON Setting Fan Time OFF Setting Manual Gas Shut Off Upstream of Furnace Drip Leg YES _1 NO _1 Dealer Comments Drip Leg Upstream of Gas Valve Condensate Drain Connected YES _1 Condensate Drain Trapped YES _1 YES _1 NO _1 NO_1 Noel Horizontal Condensate Switch Installed YES _1 NO _1 Blower Speed Checked YES _1 NO _1 All Electrical Connections Tight YES _1 NO _1 Gas Valve OK YES _1 ...

Page 4: ...urnace is a replacement it is usually best to install the furnace where the old one was Choose the location or evaluate the existing location based upon the minimum clearance and furnace dimensions Figure 3 or Figure 4 CAUTION Special precautions MUST be made if installing furnace in an area which may drop below freezing This can cause improper operation or damage to equipment If furnace environme...

Page 5: ...8 231 2 221 2 t41t2 Unit Capacity 50 000 75 000 100 000 125 000 GasConnections RightSide LeftSide N P N P R 321 2 237t8 321 2 261 16 107 8 321 2 237 8 321 2 261 16 107 8 321 2 237t8 321 2 261 16 107 8 321 2 237t8 321 2 261 16 107 8 Drain Connections Right Side Left Side S S 23 4 61t2 23 4 61 2 23 4 61 2 23 4 61 2 SupplyAir T V 211116 413 16 211 16 413 16 211 16 413 16 211 16 413 16 ReturnAir Botto...

Page 6: ... 1213 16 17 20 Y 3 13 16 3 13 16 3 13 16 3 13 16 ram Equivalents 48 1219 191 8 486 223 4 578 263 8 670 281 2 724 11 2 38 15 8 41 21 2 64 41 2 114 t75 16 440 181 2 470 175 8 448 211 4 540 247 8 632 247t8 632 23118 587 t43 4 375 t83 4 476 231 2 597 221 2 572 141 2 368 321 2 825 237 8 606 261 16 662 107 8 276 23 4 70 61 2 165 211 16 68 413 16 122 127 8 327 1411116 373 18 457 211t16 68 21 8 54 17 8 48...

Page 7: ...tallation NCGM GCK Inlet Pipe Optional Vent Pipe Condensate Trap field supplied 25 21 81 NOTE 5 bottom clearance required for condensate trap If the furnace is to be suspended from the floor joists in a crawl space or the rafters in an attic it is necessary to use steel pipe straps or an angle iron frame to ridgely attach the furnace to pre vent movement These straps should be attached to the furn...

Page 8: ...be used The drain connection to the condensate trap must also be properly sloped to an open drain See Section 5 under Condensate Drain Trap and Neutralizer The condensate drain trap connects to the drain stub on the left side of the plastic transition See Figure 7 and Figure 9 Remove the plastic cap and clamp from the drain stub Use the 90 com pression fitting elbow provided to connect the drain t...

Page 9: ...l condition 8 If improper venting is observed the cause MUST be cor rected using the appropriate tables in code books of coun try having jurisdiction NOTE If flame pulls towards draft hood this indicates sufficient infiltration air NOTE Non direct vent appliances occupying same enclosed space as furnace MUST have enough air for proper combustion and ventilation All duct or openings for supplying c...

Page 10: ... shall communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors and shall have a mini mum free area of 1 sq in per 3000 Btu per hr 7cm 2 per kW ofthe total input rating of all equipment located in the enclosure and Not less than the sum of the areas of all vent connectors in the confined space Inlet Air 2 UnconfinedSpaceIn...

Page 11: ...ygen burned See Confined Space Installation in the Combustion and Ventilation Air chapter If combustion air is drawn from outside the structure it MUST be taken from the same atmospheric pressure zone as the vent pipe ContaminatedCombustionAir Installations in certain areas or types of structures will increase the exposure to chemicals or halogens that may harm the fur nace The following areas or ...

Page 12: ...ate pipe when the exhaust vent passes through an un conditioned space or raceway 2 If situations require pipe to be run on the exterior wall to reach a suitable termination point it MUST be properly in sulated 3 If it is necessary to insulate piping when an inactive chim ney is used as a chase the top of the chimney MUST be sealed flush or crowned up to seal against rain or melting snow so ONLY th...

Page 13: ...B E B C F C F 4 A D B E B E B C F C F C F 5 D B E B E B C F C F C F C F 100 000 Btuh Furnace Feet of Pi e 0 9 10 14 15 19 20 24 25 29 30 34 35 40 1 A A A D B E B E B C F 2 A A D B E B E F C F C F 3 A D B E B E F C F C F C F 4 D B E B E F C F C F C F C F 5 D B E F C F C F C F C F C F 125 000 Btuh Furnace Feet of Pipe 0 9110 14 115 10 120 24 125 20130 34 135 40 UP TO 5 All combinations use F a 3 Exh...

Page 14: ...uire 2 16 x25 x1 filters one on each side of furnace This configuration does NOT allow the condensate drain line to be run out the side of furnace If line MUST be run out the side an optional standoff filter rack with one 20 x25 x1 fil ter is needed Install optional filter rack on side of furnace opposite the side where condensate drain line will exit 4 A condensate or sump pump MUST be used if re...

Page 15: ...emble in re verse order Proper Sealing Procedure for Combustion Blower Clamps_ Blower_ 25 21 86 Vent Pipe Rubber Coupling Vent Trap and Furnace Connections Upflow pe Vent pipe MUST be installed with the flexible coupling and clamps supplied at the com bustion blower RTV sealant used to join Air Inlet Pipe to Combustion Air Inlet See Figure 6 Condensate compression fitting can be turned to exit out...

Page 16: ...rty damage This furnace is approved for venting with Schedule 40 PVC CPVC ABS Cellular Core pipe fittings and SDR 26 PVC NOTE SDR pipe is not approved for use in Canada NOTE All PVC CPVC ABS and Cellular Core pipe fittings sol vent cement primers and procedures MUST conform to Ameri can National Standard Institute and American Society for Testing and Materials ANSI ASTM standards Pipe and Fittings...

Page 17: ...stem is installed in an existing chimney make sure clearances shown in Figure 18 are maintained Hori zontal section before the termination elbow can be ex tended on the inlet air to provide necessary clearance 440 01 100201 HorizontalTermination 1 Cut two holes 21 2 67mm for 2 50mm pipe 3 75mm for 21 2 67mm pipe or 31 2 90mm for 3 75mm pipe Do NOT make the holes oversized or itwill be necessary to...

Page 18: ...vented near each other each furnace must be individually vented Concentric Vent and Combustion Air Roof Termination 12 Min Grade or Snow Level Combustior Air Dimension A is touching or 2 maximum separation Concentric Vent and Combustion Air Sidewall Termination Exhaust Vent 25 22 02d Dimension A is touching or 2 maximum separation When two 2 or more furnaces are vented near each other two 2 vent t...

Page 19: ... Rating Rating Orifice Orifice 50 000 40 000 44 55 75 000 60 000 44 55 100 000 80 000 44 55 125 000 100 000 44 55 Gas Type Gas Pressures Above 2000 Manifold Min Pressure Natural 4 5 3 5 1 1 kPa 0 9 kPa LP 11 10 2 7 kPa 2 5 kPa Important Notes Supply Pressure Recommended Max 7 14 1 7 kPa 3 5 kPa 11 14 2 7 kPa 3 5 kPa With Propane gas the rated input is obtained when the BTU content is 2 500 BTU per...

Page 20: ...rough your distributor HighAltitudeAir PressureSwitch Altitudes over 4 000 require a different air pressure switch than the one installed at the factory Check parts list for pressure switch and consult your distributor for part number and availability In Canada provincial codes may govern installation of switch Check with governing authorities Drip Leg and Electrical shock fire or explosion hazard...

Page 21: ... 26 for the general layout at the furnace The rules listed apply to natural and LP gas pipe installations NOTE Refer to Figure 25 for the general layout at the furnace The rules listed apply to natural and LP gas pipe installations 4 Use black iron or steel pipe and fittings or other pipe ap proved by local code 5 Use ground joint unions and install a drip leg no less than 3 long to trap dirt and ...

Page 22: ...le na tional codes Install wiring in accordance with manufacturer s instructions Humidifier ElectronicAir Cleaner The furnace is wired for humidifier and or electronic air cleaner connection CAUTION Do NOT exceed 115V 0 8 amp maximum current load for both the EAU terminal and the HUM terminal com bined NOTE The humidifier will be powered when the furnace is fired and the circulating air blower com...

Page 23: ...ctions The access panel MUST be sealed to prevent leaks 4 If separate evaporator and blower units are used install good sealing dampers for air flow control Chilled air going through the furnace could cause condensation and shorten the furnace life NOTE Dampers field supplied can be either automatic or manual Manually operated dampers MUST be equipped with a means to prevent furnace or air conditi...

Page 24: ...rille to reduce noise NOTE To further reduce noise install acoustical air turning vanes and or line the inside of duct with acoustical material Sizing Existing or new ductwork MUST be sized to handle the correct amount of airflow for either heating only or heating and air condi tioning Insulation 1 Insulate ductwork installed in attics or other areas exposed to outside temperatures with a minimum ...

Page 25: ...ssible when the fur nace is installed so that the heat exchanger can be viewed for inspections The access panel MUST be sealed to pre vent leaks NOTE Dampers field supplied can be either automatic or manual Manually operated dampers MUST be equipped with a means to prevent furnace or air conditioning operation unless damper is in the full heat or cool position Installation NOTE Design and install ...

Page 26: ...e size and type s of filter supplied with the furnace will handle the airflow required if central air conditioning is used with the furnace Use either filter type Washable high velocity filter based on a maximum air flow rating of 600 FPM Disposable low velocity filter based on a maximum air flow of 300 FPM when used with filter grille NOTE Disposable low velocity filters may be replaced with wash...

Page 27: ...bbase for Combustible Floors MUST be used when a downflow furnace is set on a combustible floor even when the fur nace is installed on a coil box 1 Cut the opening in the floor according to Table 8 The hole in the floor must be cut to the dimensions listed in Table S since the base is equipped with locating tabs that center the base over the opening The opening in the base is 11 4 32mm shorter and...

Page 28: ...stments The furnaces with greater than 1600 CFM requires that both left and right side returns are used in side return applications Two 16 x 25 high velocity filters and racks are provided with furnace Fil ter racks must be mounted externally If return air must be on one side only an optional 20 x 25 filter standoff rack kits can be used See Figure 33 For bottom return an optional 20 x 25 filter r...

Page 29: ...er Face 10 10 78 TemperatureRise Check The blower speed MUST be set to give the correct air temperature rise through the furnace as marked on the rating plate Tempera ture rise is the difference between supply and return air tempera tures To check temperature rise use the following procedure 1 Place thermometers in supply and return air registers as close to furnace as possible avoiding direct rad...

Page 30: ...leads should already be connected to the Heat and Cool terminals Heating and Continuous Blower Speed the Same If it is necessary to operate the heating speed and continuous blower speed using the same blower speed connect a jumper be tween the Heat and Cont terminals on the electronic fan con trol Note There should be only ONE motor lead going to the Heat and Cont terminals t Poison carbon monoxid...

Page 31: ...ucture Dimension D may be lengthened to 60 max or shortened by cutting the pipes to 12 min Dimension A will change ac cording to D dimension Concentric Vent Dimensional Drawing 3 Dia PVC 11 2 _ 3 Dia _41 2 Dia D 317_ PVC Intake Combustion Air A 463 4 25 22 03 3 Concentric Termination Kit _O NAHA001CV Venting Table Dual Piping ONLY 50 000 Btuh Furnaces No ofEIbows 0 9 10 14 15 t9 20 24 25 29 30 34 ...

Page 32: ...he 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 Secure the assembly to the structure as shown in Figure 45 or Figure 49 using field supplied metal strap ping or equivalent material NOTE Ensure the termination height is above the roof sur face or anticipated sn...