Napoleon 9600E E-STAR Series, Installation And Operating Instructions Manual

Page 1: ...operation serious injury death or property damage Installation and service must be performed by a qualified installer service agency or the gas supplier Before servicing disconnect all electrical powe...

Page 2: ...N DIRECT VENT INSTALLATION USING INDOOR COMBUSTION AIR ONE PIPE SYSTEM 24 9 4 2 DIRECT VENT INSTALLATION USING OUTDOOR COMBUSTION AIR TWO PIPE SYSTEM 24 9 4 3 COMBUSTION AIR 24 10 0 TERMINATIONS 25 10...

Page 3: ...C CODES FOR STATUS LED 52 19 5 FAULT CODE HISTORY 52 20 0 WIRE DIAGRAM FOR TWO STAGE FURNACE 53 20 1 TWO STAGE FURNACE WITH ECM EON 53 21 0 WARRANTY 54 22 0 REPLACEMENT PARTS LIST 55 23 0 SERVICE HIST...

Page 4: ...SE INSTRUCTIONS IS NOT FOLLOWED EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AN...

Page 5: ...the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range listed on the furnace rating plate and as specified in Sections 3 6 an...

Page 6: ...TALL THIS FURNACE IN A MOBILE HOME THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME DOING SO COULD CAUSE FIRE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE THE FURNACE CONTAINS FOIL CO...

Page 7: ...EED THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE TABLE A FURNACE DIMENSIONS MODEL INPUT HIGH OUTPUT HIGH INPUT LOW OUTPUT LOW Width Depth H...

Page 8: ...the older furnaces were equipped with large belt drive blower systems operating at low RPM s If replacing an existing furnace be sure that the existing ductwork can handle the amount of airflow necess...

Page 9: ...on air is laden with chemical compounds such as bromine chlorine or fluorine as may be found in swimming pool chemicals laundry detergents etc use outdoor air for combustion These compounds when expos...

Page 10: ...oom hot water heater for example It is not permissible to use a rear return on this appliance Use only side and bottom returns H8 4 3 This furnace may be used as part of an air conditioning system The...

Page 11: ...VER CLEARANCE TO COMBUSTIBLES H3 7 THIS FURNACE IS CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORS THIS SHALL BE INTERPRETED AS A WOOD FLOOR ONLY THE FURNACE MUST NOT BE INSTALLED DIRECTLY ON CARPETI...

Page 12: ...able The total static pressure drop of the air distribution system including filters should not exceed 1 0 w c H3 8 DO NOT ALLOW GAS PIPING TO BE ROUTED THROUGH JOIST SPACES THAT ARE USED FOR RETURN A...

Page 13: ...rning appliances 4 Ensure that there is adequate space and accessibility for air filter removal 5 If an air conditioning evaporator coil is required position it on the supply air side of the furnace E...

Page 14: ...rtified vent system must not be interchanged with other vent systems or unlisted pipe and or fittings Follow the venting manufacturers instructions on installation cutting de burring cementing curing...

Page 15: ...mm or 3 76mm in the horizontal run or vertical riser closest to the furnace 2 Place a reducer bushing of proper diameter in the stem portion of the tee The recommended size for the reducer is 5 8 15 9...

Page 16: ...rplane Glue and similar adhesives and cements Ammonia as commonly found in permanent wave solutions used in hair dressing salons Anti static fabric softeners used in clothes dryers Carbon tetrachlorid...

Page 17: ...st fans on kitchen range hood on etc A confined space any space smaller than the minimums discussed in Case 1 must have two air openings one within 12 305mm of the ceiling and the other within 12 305m...

Page 18: ...soffit vents or gable vents Figure 5 As an alternative to creating an opening in the floor to draw air from a crawl space a duct may be dropped from the attic terminating 12 305mm above the floor The...

Page 19: ...FFICIENT COMBUSTION AND VENTILATION AIR THE DUCT COULD BE AN EQUIVALENT RECTANGULAR DUCT 8 X 7 203mm X 178mm FOR EXAMPLE BASED ON 50 FREE AREA FOR THE INLET GRILLS THE ACTUAL GRILL SIZE WOULD HAVE TO...

Page 20: ...rough unconditioned attic space DO NOT COMMON VENT WITH ANY OTHER APPLIANCE If venting vertically do not vent up a chimney serving another appliance or install in a chase with a metal or high temperat...

Page 21: ...s In windy and hill locations roof venting may improve operations Maximum venting length is based on 30 mph 48 km winds areas where higher gusts are dominant it is suggested to shorten the horizontal...

Page 22: ...r vent pipe greater than 24 610mm should be insulated with 1 2 13mm insulation to prevent moisture from freezing within the pipe and accumulating Size the exhaust pipe as specified in Table 4 Direct a...

Page 23: ...imum of two sides beneath the floor and b the distance between the top of the vent termination and the underside of the veranda porch or deck is greater than 12 305mm H14 3 In addition to the general...

Page 24: ...is unaffected by any other appliances exhaust fans or other devices that tend to create negative pressure conditions while operating No vents for combustion and ventilation air are required in confine...

Page 25: ...o take advantage of the natural buoyancy of the flue gases to help prevent re circulation of the exhaust Figure 9 VERTICAL No termination fitting is required if venting vertically through a roof The e...

Page 26: ...oot 1 8m radius of the termination Do not terminate under a deck unless there is adequate clearance to prevent damage from the flue gases A termination may be located at the end of a patio deck Piping...

Page 27: ...W415 2159 D 11 24 17 27 IOM FIGURE 14A DIRECT VENT TERMINAL CLEARANCES...

Page 28: ...W415 2159 D 11 24 17 28 IOM IOM FIGURE 14B NON DIRECT VENT TERMINAL CLEARANCES...

Page 29: ...ional arrow on drain coupling points away from exhauster 6 Remove the appropriate plastic cap on the side panel Install cap on vent opening not in use 7 Reinstall the exhauster and the pressure switch...

Page 30: ...suitable vent and drain options for installation See Figures 16 20 for reference and refer to Exhauster Rotation Instructions section if necessary 2 Remove the 3 1 2 plastic exhaust vent cap if requir...

Page 31: ...ND CUT DRAIN HOSES TO PROPER LENGTH CUT PRESSURE SWITCH TUBING TO PROPER LENGTH NOTE Trap can be installed on the left or right side of the unit Only left side install pictured H3 16 THERE MUST NOT BE...

Page 32: ...ORTANT PRIME CONDENSATE TRAP WITH WATER AND CUT DRAIN HOSES TO PROPER LENGTH CUT PRESSURE SWITCH TUBING TO PROPER LENGTH FIGURE 16 UPFLOW VENT AND DRAINING OPTION CONTINUED LEFT VENT RIGHT DRAIN INSTA...

Page 33: ...IN PROPERTY DAMAGE CAUTION A typical configuration would be to cement the side branch of a 1 2 CPVC tee to the drain trap assembly outlet with the end branches oriented vertically Figure 15 A 1 25mm...

Page 34: ...REATE A VAPOR LOCK WHICH WILL PREVENT CONDENSATE FROM DRAINING AWAY FREELY AND RESULT IN ERRATIC FURNACE OPERATION 1 The supplied parts bag includes a length of 1 2 and 5 8 rubber hose and the condens...

Page 35: ...lize the existing condensate trap screws to secure the strapping FIGURE 25 FIGURE 26 H16 6 Some local codes may require the use of a condensate neutralizer If the furnace condensate is to be routed to...

Page 36: ...uld be installed in accordance with NFGC NFPA 54 ANSI Z223 1 and any local codes If local codes allow the use of a flexible gas appliance connector always use a new listed connector Do not use a conne...

Page 37: ...7 w c 7 w c recommended These pressures must be maintained while all other gas fired appliances are operating at maximum conditions IMPORTANT DO NOT EXCEED 13 W C INLET PRESSURE The gas valve has two...

Page 38: ...let pressure boss see FIGURE 31 counterclockwise out one turn maximum with a 3 32 Allen wrench Attach a hose and calibrated U tube or digital manometer to the inlet pressure boss Hose should overlap b...

Page 39: ...O STAGE GAS VALVE 1 Turn off the gas and electrical supply before proceeding 2 Back outlet pressure test screw outlet pressure boss see Fig 31 counterclockwise out one turn maximum with a 3 32 Allen w...

Page 40: ...Input Heating Value of Gas x 3600 Time in Sec for 1 cu ft where input is expressed in Btu hr heating value of the gas is expressed in Btu ft3 and time is the number of seconds required for the test d...

Page 41: ...dian Electrical Code Part 1 and any applicable local code In the United States all electrical work must be in accordance with the latest edition of the National Electrical Code ANSI NFPA 70 Although a...

Page 42: ...connected with L2 Neutral and a GREEN wire to be connected to the ground If the junction box must be moved from it s original location to the other side of the unit 1 Remove the appropriate plastic c...

Page 43: ...e control will automatically start high heat after 5 minutes of continuous low heat op eration If the jumper is in the 10 minute position the control will automatically start high heat after 10 minute...

Page 44: ...ect 24V equipment to these terminals The integrated furnace control has provisions to supply power and control a line voltage humidifier or the primary of a 120 24 volt humidifier step down transforme...

Page 45: ...drain trap assembly be primed before the initial startup Refer to the instructions on how to prime the condensate trap on the drain piping section in this manual A dry trap will allow flue gases to f...

Page 46: ...oven and starts a 30 second blower delay before full capacity blower level 4 When there is a demand for 2nd stage heat from thermostat W2 or automatic staging the control changes the exhauster from lo...

Page 47: ...tain steady state conditions at both input rates High Fire and Low Fire 4 When the two thermometers have stabilized usually within 5 8 minutes compare the two readings Subtract the return air temperat...

Page 48: ...If the blower speeds require adjustment follow these steps 1 Remove the blower compartment door 2 Locate the 4 position movable HEAT jumper to adjust heat speed 3 Remove the jumper from position A an...

Page 49: ...ive all the time With the JW40 jumper clipped the thermostat or humidstat controls dehumidification H22 5 Blower on off delays are handled by ECM motor programming The control de energizes the ECM hea...

Page 50: ...e capabilities of the duct system to deliver sufficient air flow if this type of filter is considered RECOMMENDED Electronic air cleaners using electrostatic precipitation to remove dust are an excell...

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Page 52: ...within one call for heat 7 Flashes Pressure switch cycle lockout 8 Flashes Lockout due to too many flame dropouts 9 Flashes Not used 10 Flashes Flame present with gas valve off A green LED AN2 is prov...

Page 53: ...LACK WHITE RED BLACK WHITE EMPTY 1 2 3 4 5 6 1 2 3 4 5 C1 H24 6 3 7 1 6 5 C2 HOUSING VIEW FROM OPPOSITE OF WIRE INSERTION END PLASTIC 9 PIN HOUSING AMP 1 480707 0 METAL CONTACT TERMINAL MALE PIN AMP 3...

Page 54: ...caused by installation that is not performed in compliance with all applicable federal provincial state laws or regulations and Installation Operating Manual 4 Damage as a result of vandalism freight...

Page 55: ...60 80 W010 3495 KIT LARGE FMC W O CHOKES 100 120 W010 3976 ASSY MOTOR KIT 1 3 HP ES EON 40 W010 3977 ASSY MOTOR KIT 1 2 HP ES EON 60 W010 3978 ASSY MOTOR KIT 1 2 HP ES EON 80 3 W010 3979 ASSY MOTOR K...

Page 56: ...Flame Sensor located underneath 13 Two Speed Exhauster 4 Two Stage Gas Valve 14 Pressure Switch Assembly 5 Air High Temperature Limit 15 Front Manifold Cover Pressure Tap 3 6 Vent and Drain Assembly...

Page 57: ...W415 2159 D 11 24 17 57 IOM 23 0 SERVICE HISTORY 43 1...

Page 58: ...W415 2159 D 11 24 17 58 IOM IOM 24 0 NOTES 44 1...

Page 59: ...er appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your...

Page 60: ...4 2 LUBRICATION 68 4 3 ROUTINE EXAMINATION 68 4 4 ANNUAL INSPECTION SERVICE 69 4 5 FURNACE APPEARANCE 70 4 6 CLEANING 70 4 7 SEQUENCE OF OPERATION ECM 2 3 EON 72 4 8 VARIATIONS 72 4 9 TERMINATIONS 72...

Page 61: ...IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY WARNING INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINS...

Page 62: ...e has been designed to deliver many years of efficient dependable service With regular maintenance some of which requires the attention of a qualified installer service agency or gas supplier some of...

Page 63: ...ION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE INJURY PROPERTY DAMAGE OR LOSS OF LIFE REFER TO THIS MANUAL INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENC...

Page 64: ...gure 2 It is important for these vents to remain clear Do not allow moisture which could freeze to build up in the vent If you see moisture building up in the regulator vent contact your gas supplier...

Page 65: ...ulating materials are combustible Do not allow building insulating materials to come into contact with the furnace 5 Any additions alterations or conversions required in order for the furnace to prope...

Page 66: ...t off valve to the OFF position If burning LP gas smell for gas near the floor since propane and butane are both heavier than air If after this time you do not smell gas continue to the next step 9 Tu...

Page 67: ...and other exhaust fans to reduce the heating load on the system 4 Arrange the furniture and drapes so that the supply air registers and return air grills are unobstructed 5 If you have a perimeter du...

Page 68: ...CE FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE WARNING H27 2 The circulating air blower and exhauster motors have sealed bearings The bearings contain perm...

Page 69: ...AREFUL WHEN WORKING ON THE BURNER ASSEMBLY THE HOT SURFACE IGNITER IS FRAGILE AND CAN BREAK EASILY CAUTION The flame sensor should be inspected and cleaned with fine steel wool or Scotch Brite scrubbi...

Page 70: ...y coil 1 Turn off electrical power to the furnace 2 Remove the blower access door 3 Remove the screws fastening the blower assembly to the blower division panel 4 Unplug wire harness from the control...

Page 71: ...allow very small amounts of excess air in the combustion process Older furnaces had heat exchangers which were commonly 40 larger than necessary for complete combustion While this prevented the creati...

Page 72: ...h is open because it is directly in series with the high pressure switch 5 When the thermostat W2 call ends and W1 remains two stage thermostat the control de energizes the high gas output and immedia...

Page 73: ...cated on bottom of inside door Date Installed Contractor Contact Address Postal Code Zip Code Telephone No After Hours No If different from Installation Contractor Service Tech Telephone No After Hour...

Page 74: ...6 0 NOTES 44 1 W415 2159 D 11 24 17 UM 74...

Page 75: ...44 1 W415 2159 D 11 24 17 UM 75...

Page 76: ...S 7200 Route Transcanadienne Montr al Qu bec H4T 1A3 24 Napoleon Road Barrie Ontario Canada L4M 0G8 214 Bayview Drive Barrie Ontario Canada L4N 4Y8 103 Miller Drive Crittenden Kentucky USA 41030 Phone...