International comfort products N8MXL, Installation Instructions Manual

Page 1: ...AFETY CHECK 30 General 30 Start up Procedures 30 Adjustments 30 Check Safety Controls 32 Checklist 33 SERVICE AND MAINTENANCE PROCEDURES 39 Introduction 39 Electrical Controls and Wiring 39 Care and Maintenance 40 Cleaning and or Replacing Filter 41 Blower Motor and Wheel 41 Cleaning Heat Exchanger 42 Sequence of Operation 43 Wiring Diagrams 44 Troubleshooting 44 PARTS REPLACEMENT INFORMATION GUID...

Page 2: ... a location and position as spe cified in the Location section of these instructions 3 Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and Ventilation section 4 Combustion products must be discharged outdoors Con nect this furnace to an approved vent system only as spe cified in the Venting section of these instructions 5 Never test for gas l...

Page 3: ...1 2 140 3 140 3 8 7 16 8 7 16 213 5 213 5 FRONT OF CASING FRONT OF CASING TOP OF CASING TOP OF CASING 6 1 6 1 155 7 155 7 2 1 16 2 1 16 51 6 51 6 5 1 5 1 130 5 130 5 1 7 1 7 43 5 43 5 Ø7 8 Ø7 8 22 2 22 2 ACCESSORY 2 ACCESSORY 2 AIR FLOW AIR FLOW AIR FLOW AIR FLOW BOTTOM RETURN BOTTOM RETURN WIDTH WIDTH AIR FLOW AIR FLOW KNOCK OUTS FOR KNOCK OUTS FOR VENTING 5 VENTING 5 PLACES PLACES A10290 NOTES 1...

Page 4: ...Specifications are subject to change without notice 4 441 01 1421 02 A10269 Fig 2 Clearances to Combustibles ...

Page 5: ... DISCHARGE ESD PRECAUTIONS PROCEDURE FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrosta...

Page 6: ...OXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death and unit component damage Corrosive or contaminated air may cause failure of parts containing flue gas which could leak into the living space Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and ...

Page 7: ... also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained between 55_F 13_C and 80_F 27_C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittentoperation per our installation instructions The ai...

Page 8: ...ipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with S U S installations Section 9 3 of the current edition of NFGC NFPA54 ANSI Z223 1 Air for Combustion and Ventilation and applicable provisions of the lo...

Page 9: ...IDE POISONING HAZARD Failure to follow this warning could result in death and or personal injury Many homes require air to be supplied from outdoors for furnace combustion ventilation and dilution of flue gases The furnace combustion air supply must be provided in accordance with this instruction manual WARNING CIRCULATING AIR DUCTS 6 MIN FRONT Ü CIRCULATING AIR DUCTS VENT THROUGH ROOF 1 SQ IN PER...

Page 10: ...electrical and gas lines etc Combination of Indoor and Outdoor Air 1 Indoor openings shall comply with the Indoor Combus tion Air Method below and 2 Outdoor openings shall be located as required in the Out door Combustion Air Method mentioned previously and 3 Outdoor openings shall be sized as follows a Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion...

Page 11: ...l as shown in Fig 13 NOTE It is required that the perforated supply air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange back and forth until it breaks off Be careful of sharp edges See Fig 14 Bottom Return Air Inlet These f...

Page 12: ...ired 15 7 8 403 19 483 16 1 2 419 19 5 8 498 Downflow Applications on Combustible Flooring subbase required 15 1 8 384 19 483 16 3 4 425 20 5 8 600 Downflow Applications on Combustible Flooring Coil with Coil END4X ENW4X or Coil Casing NAEA subbase not required 15 1 2 394 19 483 16 1 2 419 20 508 21 533 Upflow Applications on Combustible or Noncombustible Floor ing subbase not required 19 1 2 495 ...

Page 13: ...ir Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when side return air inlet s is used without a bottom return air inlet Not all horizontal furnaces are approved for side return air connections See Fig 21 FILTER ARRANGEMENT CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in personal inju...

Page 14: ...upply air outlet on furnace Bend flange inward past 90_ with wide duct pliers See Fig 14 The supply air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the factory approved accessory subbase or a factory approved air conditioning coil casing DO NOT cut main furnace ca...

Page 15: ...S IN BOTTOM A10131 Fig 16 Horizontal Suspension with Straps 30 IN 762mm MIN WORK AREA 6 MIN TYPE B VENT 17 3 4 22 SHEET METAL SEDIMENT TRAP EQUIPMENT MANUAL SHUT OFF GAS VALVE LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING GAS ENTRY 17 3 4 451mm OVERALL 4 3 4 121mm UNDER DOOR 1 25mm UNDER FURNA...

Page 16: ...e shall be installed at the furnace gas control valve and extend a minimum of 2 in 51 mm outside the furnace WARNING Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC Installations must be made in accordance with all authorities having jurisdiction If possible the gas supply line should be a separateline running directly from meter to furnace...

Page 17: ...0 Yellow 3 1425 1380 1335 1290 1235 1185 1125 1075 1020 940 Orange 2 1260 1210 1160 1105 1050 990 935 880 820 755 Red 1 3 1095 1040 980 905 845 780 720 650 585 520 0902120 Gray 5 2180 2130 2080 2030 1980 1925 1870 1805 1745 1680 Yellow 4 1900 1845 1795 1740 1685 1635 1570 1500 1435 1375 Blue 3 1685 1620 1565 1505 1455 1385 1320 1260 1200 1140 Orange 2 1390 1315 1240 1175 1095 1030 970 900 825 760 ...

Page 18: ...onal plumbing and gas codes before the furnace has been connected After all connections have been made purge lines and check for leakage at furnace prior to operating furnace If pressure exceeds 0 5 psig 14 In W C gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test If test pressure is equal to or less than 0 5 psig 14 In W C turn off electric sh...

Page 19: ...o change without notice 19 441 01 1421 02 A02163 Fig 20 Downflow Return Air Configurations and Restrictions A02162 Fig 21 Horizontal Return Air Configurations and Restrictions 2 51mm Street Elbow A08551 Fig 22 Burner and Manifold ...

Page 20: ...D Failure to follow this warning could result in personal injury death or property damage The cabinet MUST have an uninterrupted or unbroken ground according to current edition of NEC NFPA 70 or local codes to minimize personal injury if an electrical fault should occur This may consist of electrical wire conduit approved for electrical ground or a listed grounded power cord where permitted by loc...

Page 21: ...3 Secure power cord to J Box bracket with a strain relief bushing or a connector approved for the type of cord used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 25 6 Reinstall cover to J Box Do not pinch wires between cover and bracket BX CABLE INSTALLATION IN FURNACE J BOX 1 Remove cover from J Box 2 Route BX cable into 7 8 inch di...

Page 22: ...N Fig 24 Furnace Control 115 V FIELD SUPPLIED DISCONNECT AUXILIARY J BOX 24 V TERMINAL BLOCK THREE WIRE HEATING ONLY FIVE WIRE NOTE 1 NOTE 2 FIELD SUPPLIED DISCONNECT CONDENSING UNIT TWO WIRE FURNACE C O N T R O L R G COM W C R G Y GND GND FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING 208 230 OR 460 V THREE PHASE 208 230 V SINGLE PHASE BLOWER DOOR SWITCH...

Page 23: ... proper vent sizing and installation requirements including local building codes the current edition of National Fuel Gas Code ANSI Z223 1 NFPA 54 NFGC Parts 12 and 13 the local building codes and furnace and vent manufacturers instructions These furnaces are design certified as Category I furnaces in accordance with current edition of ANSI Z21 47 CSA 2 3 and operate with a non positive vent stati...

Page 24: ...ce between the chimney and the metal liner Exterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors NFPA AGA Table 8 Combined Appliance Maximum Input Rating in Thousands of BTUH per Hour VENT HEIGHT FT M INTERNAL AREA OF CHIMNEY IN2 MM2 12 7741 19 12258 28 18064 38 24516 6 1 8 74 119 178 257 8 2 4 80 130 193 279 10 3 0 84 138 207 299 15 4 5 NR 152 233 334 20 6 0 NR NR...

Page 25: ...ebris in cleanout Mortar tile metal vent fuel oil residue Is liner and top seal in good condition Is chimney property lined with clay tile liner Crown condition Missing mortar or brick Rebuild crown Yes Yes No No No Reline Yes Repair Yes Yes Yes No No Remove mortar and tile debris Remove metal vent or liner No No No No Yes Yes Suitable Suitable Not Suitable Line chimney with property sized listed ...

Page 26: ...rews The factory supplied vent elbow does NOT count as part of the number of vent connector elbows The vent connector can exit the furnace through one of 5 locations on the casing 1 Attach the single wall vent connector to the furnace vent elbow and fasten the vent connector to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180_ apart NOTE An accesso...

Page 27: ... 2 Horizontal Left Vent elbow right Fig 35 132 000 5 127 7 2 NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 4 in 102 mm inside casing or vent guard Including 4 in 102 mm vent section s SEE NOTES 1 2 4 7 8 9 on the page following these figures A03208 Fig 27 Upflow Application Vent Elbow Up SEE NOTES 1 2 3 4 7 8 9 on the pages following these figures A03...

Page 28: ... Left then Up SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures A03212 Fig 32 Downflow Application Vent Elbow Up then Right SEE NOTES 1 2 4 7 8 9 on the page following these figures A03213 Fig 33 Horizontal Left Application Vent Elbow Left SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03214 Fig 34 Horizontal Left Application Vent Elbow Right then Up ...

Page 29: ... and downflow installations must use Type B vent immediately after exiting the furnace except when factory authorized Downflow Vent Guard Kit is used in the downflow position See Specification Sheet for accessory listing 4 Type B vent where required refer to Note 1 above 5 Four inch single wall 26 ga min vent must be used inside furnace casing and when the Downflow Vent Guard Kit is used external ...

Page 30: ... valve and humidifier will not be turned on See Fig 24 ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes WARNING NOTE The furnace control allows all components excep...

Page 31: ... d Turn gas valve ON OFF switch to ON e Manually close blower door switch f Set thermostat to call for heat g Remove regulator seal cap and turn regulator adjusting screw counterclockwise out to decrease input rate of clockwise in to increase input rate h Install regulator seal cap i Leave manometer or similar device connected and pro ceed to Step 4 NOTE DO NOT set manifold pressure less than 3 2 ...

Page 32: ...t the wires normally connected to thermostat sub base terminals R and W The thermostat anticipator should NOT be in the circuit while measuring current 1 Remove thermostat from subbase or from wall 2 Connect an amp meter as shown in Fig 42 across the R and W subbase terminals or R and W wires at wall 3 Record amp draw across terminals when furnace is in heating and after blower starts 4 Set heat a...

Page 33: ... off 115 v power to furnace b Disconnect inducer motor lead wires from wire harness c Turn on 115 v power to furnace d Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface ignit er should NOT glow and control flashes a status code 3 If hot surface igniter glows when inducer motor is discon nected shut down furnace immediately e Determine reason...

Page 34: ... 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 8...

Page 35: ...Specifications are subject to change without notice 35 441 01 1421 02 Table 12 Orifice Size and Manifold Pressure In W C for Gas Input Rate A10180 ...

Page 36: ...Specifications are subject to change without notice 36 441 01 1421 02 Table 12 Orifice Size and Manifold Pressure In W C for Gas Input Rate CONT A10180A ...

Page 37: ...Specifications are subject to change without notice 37 441 01 1421 02 Table 13 Orifice Size And Manifold Pressure In W C For Gas Input Rate A10181 ...

Page 38: ...Specifications are subject to change without notice 38 441 01 1421 02 Table 13 Orifice Size And Manifold Pressure In W C For Gas Input Rate CONT A10181A ...

Page 39: ...r is discharged upward Since this furnace can be installed in any of the 4 positions shown in Fig 4 you must revise your orientation to component location accordingly ELECTRICAL CONTROLS AND WIRING ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death There may be more than one electrical supply to the furnace Check accessories and cooling unit for add...

Page 40: ...WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Never operate unit without a filter or with filter access door removed WARNING CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety gl...

Page 41: ...ent Blower wheel blades may be cleaned with a small paint or flux brush Do not remove or disturb balance weights clips on blower wheel blades 8 Vacuum any loose dust from blower housing wheel and motor 9 If a greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appro priate degreaser To remove wheel NOTE Before disassembly mark blower motor and blower ...

Page 42: ...ternal vent pipe remove internal vent pipe within the casing 5 Disconnect wires to the following components Mark wires to aid in reconnection of be careful when discon necting wires from switches because damage may occur a Draft safeguard switch b Inducer motor c Pressure switch es d Limit over temperature switch e Gas valve f Hot surface igniter g Flame sensing electrode h Flame rollout switches ...

Page 43: ...ematic diagram follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If a power interruption occurs during a call for heat W the control will start a 90 sec blower only ON period two seconds after power is restored if the thermostat is still calling for gas heating The GREEN LED light will flash code 1 2 during the 90 sec period after w...

Page 44: ...al EAC 1 AMP is energized as long as the blower motor BLWM is ener gized During a call for heat the blower BLWM will stop during igniter warm up 17 sec ignition and blower ON delay 25 sec allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at HEAT speed When the thermostat calls for cooling the blower motor BLWM will operate at COOL s...

Page 45: ...Specifications are subject to change without notice 45 441 01 1421 02 Fig 47 Wiring Diagram ...

Page 46: ...Specifications are subject to change without notice 46 441 01 1421 02 ...

Page 47: ...Specifications are subject to change without notice 47 441 01 1421 02 NOTE NUMBER IN UPPER LEFT HAND CORNER REPRESENTS FLASH CODE Fig 48 Troubleshooting Guide ...

Page 48: ... stage T Two stage TYPE N Standard L Low Nox FEATURE 045 45 000 BTU hr 070 70 000 BTU hr 090 90 000 BTU hr 110 110 000 BTU hr 135 135 000 BTU hr HEAT INPUT 14 143 16 17 171 2 21 21 24 241 2 CABINET WIDTH 08 800 CFM 12 1200 CFM 14 1400 CFM 16 1600 CFM 20 2000 CFM 22 2200 CFM COOLING AIRFLOW SALES MAJOR REVISION DIGIT ENGINEERING MINOR REVISION DIGIT TO OBTAIN INFORMATION ON PARTS Consult your insta...