Tempstar F9MAC Installation Instructions Manual Download

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INSTALLATION INSTRUCTIONS

Gas Furnace: (F/G)MAC

440 01 4201 01

Specifications subject to change without notice.

Duct Systems

US and CANADA: Air Conditioning Contractors

Association (ACCA) Manual D, Sheet Metal and Air

Conditioning Contractors National Association

(SMACNA), or American Society of Heating,

Refrigeration, and Air Conditioning Engineers (ASHRAE)

2005 Fundamentals Handbook Chapter 35.

Acoustical Lining and Fibrous Glass

Duct

US and CANADA: current edition of SMACNA, NFPA

90B as tested by UL Standard 181 for Class I Rigid Air

Ducts

Gas Piping and Gas Pipe Pressure

Testing

U.S.A.: NFPA 54/ANSI Z223.1

−

2009, NFGC; Chapters

5, 6, 7, and 8 and national plumbing codes.

CANADA: CAN/CSA

−

B149.1

−

2010, Parts 4, 5, 6 and

In the state of Massachusetts:

This product must be installed by a licensed plumber or

gas fitter.

When flexible connectors are used, the maximum

length shall not exceed 36

−

in. (914 mm).

When lever type gas shutoffs are used they shall be

−

handle type.

The use of copper tubing for gas piping is not

approved by the state of Massachusetts.

Electrical Connections

U.S.A.: National Electrical Code (NEC) ANSI/NFPA

−

2011

CANADA: Canadian Electrical Code CSA C22.1

Electrostatic Discharge (ESD)

Precautions Procedure

CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit com-

ponent damage.
Electrostatic discharge can affect electronic compon-

ents. Take precautions during furnace installation and

servicing to protect the furnace electronic control. Pre-

cautions will prevent electrostatic discharges from per-

sonnel and hand tools which are held during the pro-

cedure. These precautions will help to avoid exposing

the control to electrostatic discharge by putting the

furnace, the control, and the person at the same elec-

trostatic potential.

1. Disconnect all power to the furnace. Multiple

disconnects may be required. DO NOT TOUCH THE

CONTROL OR ANY WIRE CONNECTED TO THE

CONTROL PRIOR TO DISCHARGING YOUR BODY’S

ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the

furnace chassis which is close to the control. Tools held

in a person’s hand during grounding will be satisfactorily

discharged.

3. After touching the chassis, you may proceed to service

the control or connecting wires as long as you do nothing

to recharge your body with static electricity (for example;

DO NOT move or shuffle your feet, do not touch

ungrounded objects, etc.).

4. If you touch ungrounded objects (and recharge your

body with static electricity), firmly touch a clean,

unpainted metal surface of the furnace again before

touching control or wires.

5. Use this procedure for installed and uninstalled

(ungrounded) furnaces.

6. Before removing a new control from its container,

discharge your body’s electrostatic charge to ground to

protect the control from damage. If the control is to be

installed in a furnace, follow items 1 through 4 before

bringing the control or yourself in contact with the

furnace. Put all used and new controls into containers

before touching ungrounded objects.

7. An ESD service kit (available from commercial sources)

may also be used to prevent ESD damage.

Accessories

See Specification Sheets for a list of accessories for this

product.

Table 2

Loose Parts Bag Contents

(shipped in blower compartment)

QUANTITY

COMPONENT NAME

Air Intake Pipe Flange

Vent Pipe Flange

Coupling Flange Gaskets

Sharp Tip Screws (Vent and Inlet Flanges)

Vent Pipe Coupling

Vent Pipe Coupling Clamps

Pressure Switch Tube

Outlet Choke Plate (used with 40k BTUH

furnaces, only)

Drain Tube Elbow

Drain Extension Tube

Drain Tube Clamps

Drain Line Grommet

Gas Line Grommet

Gas Line Knockout Plug

Junction Box Cover

Junction Box Base

Green Ground Screw

Blunt Tip Screws (Junction Box)

Thermostat Wire Grommet

Summary of Contents for F9MAC

Page 1: ... in instructions or manuals be alert to the potential for personal injury TABLE OF CONTENTS 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 10 INSTALLATION 17 UPFLOW INSTALLATION 17 DOWNFLOW INSTALLATION 18 HORIZONTAL...

Page 2: ... grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state of local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless u...

Page 3: ... this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces This is the safety alert symbol When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNI...

Page 4: ... the design heating load requirement plus any margin that occurs because of furnace model size capacity increments Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive oversizing of the furnace could cause the ...

Page 5: ...t all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch the clean unpainted metal surface of the furnace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily discharged 3 After touching the chassi...

Page 6: ...4 1 2 622 22 7 8 581 23 584 12 1 4 311 203 91 NOTE Doors may vary by model a For 800 CFM 16 in 406 mm round or 14 x 12 in 368 x 305 mm rectangle b For 1200 CFM 20 in 508mm round of 14 x 19 in 368 x 495 mm rectangle c For 1600 CFM 22 in 559 mm round or 14 x 22 1 16 in 368 x 560 mm rectangle d For airflow requirements above 1800 CFM see Air Delivery table in Installation Instructions for specific us...

Page 7: ...ls are shipped in the main blower compartment See Table 2 for loose parts bag contents This furnace must be installed so the electrical components are protected from water not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS be located close to the chimney or vent and attached to an air distribution system Refer to Air Ducts section be provi...

Page 8: ...mage When the furnace is installed in a residential garage the burners and ignition sources must be located at least 18 in 457 mm above the floor The furnace must be located or protected to avoid damage by vehicles When the furnace is installed in a public garage airplane hangar or other building having a hazardous atmo sphere the furnace must be installed in accordance with the NFPA 54 ANSI Z223 ...

Page 9: ...uate combustion ventilation and dilution air must be provided in accordance with U S Installations Section 9 3 of the NFPA 54 ANSI Z223 1 2009 Air for Combustion and Ventilation and applicable provisions of the local building codes Canadian Installations Part 8 of CAN CSA B149 1 2010 Venting Systems and Air Supply for Appliances and all authorities having jurisdiction CAUTION FURNACE CORROSION HAZ...

Page 10: ...NPUT 100 000 30 000 130 000 divided by 4 000 32 5 Sq In for each two Vertical Ducts or Openings 60 000 40 000 100 000 divided by 3 000 33 3 Sq In for each Single Duct or Opening 80 000 30 000 110 000 divided by 2 000 55 0 Sq In for each two Horizontal Ducts Table 4 Minimum Space Volumes for 100 Combustion Ventilation and Dilution Air from Outdoors OTHER THAN FAN ASSISTED TOTAL 1 000 S BTUH GAS INP...

Page 11: ...ve the pressure switch tube from the stand offs on the inducer assembly 10 Loosen the clamp around the inlet of the vent elbow on the inducer 11 Remove the middle and bottom plugs from the lower right side of the collector box and set aside Do Not Discard Plugs 12 Refer to the appropriate figure to begin the trap conversion 13 Install the two 2 plugs previous removed from the collector box in the ...

Page 12: ...epresentative drawing only some models may vary in appearance Condensate Trap Horizontal Orientation When the furnace is installed in the horizontal right position the factory installed trap will be located at the bottom left corner of the collector box When the furnace is installed in the horizontal left position the factory installed trap will be located at the top of the collector box The trap ...

Page 13: ...tor box 10 Remove the trap Horizontal Left only 1 Remove the relief tube from of the port on the collector box It is not necessary to remove the hose from the inducer assembly 2 Remove the pressure switch tube from the port on the collector box 3 Remove the pressure switch tube from the stand offs on the inducer assembly For Horizontal Right only 1 The pressure switch tube location is not modified...

Page 14: ... tube from port on collector box Representative drawing only some models may vary in appearance Horizontal Left Trap Configuration Rotate elbow to desired position and torque clamp on inlet 15 lb in Slide relief tube in stand offs to adjust length Attach condensate trap to collector box with screw Align trap over middle and right hand port on collector box Install plugs in open ports on collector ...

Page 15: ... is installed in the horizontal position and the attic temperature is below 32 F 0 C If freeze protection for the condensate trap is required use condensate freeze protection accessory See Product Data for current kit offering The remaining condensate drain line can be protected by using a 3 to 6 watt per ft 3M at 120v and 40 F 4 4 C self regulating shielded and waterproof heat tape Wrap field dra...

Page 16: ...ect the drain line as shown below 3 Remove the knock out from the left side of the casing See Figure 15 4 Install the grommet for the 1 2 in CPVC drain line in the 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 bag 6 Remove the formed grommet on the tube by cutting the tube along the vertical line located abou...

Page 17: ...rvice of the condensate trap and drain line 2 Remove the knock out for the condensate trap in the side of the casing 3 Install the drain trap grommet in the casing for direct vent applications If necessary remove the trap install the grommet and re install the trap 4 Remove the pre formed drain tube the offset 1 2 in CPVC pipe and two spring clamps from the loose parts bag 5 Remove the formed grom...

Page 18: ...hese furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when only side return air is used NOTE Side return air openings can be used in UPFLOW and most HORIZONTAL configurations Do not use side return air openings in DOWNFLOW configuration See Figure 26 Figure 27 and Figure 28 Leveling Legs If Desired In upflow position with side return...

Page 19: ...ccessory subbase or a factory approved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace casing Return Air Connections WARNING FIRE HAZARD A failure to follow this warning could cause personal injury death and or property damage Never connect return air ducts to th...

Page 20: ...looring subbase required 18 5 8 473 19 483 20 1 4 514 20 5 8 600 Downflow Applications on Combustible Flooring with Coil Assembly or coil box subbase not required 19 483 19 483 20 508 20 508 24 1 2 622 Upflow Applications on Combustible or Noncombustible Flooring subbase not required 23 584 21 1 8 537 23 5 8 600 22 1 4 565 Downflow Applications on Noncombustible Flooring subbase not required 22 7 ...

Page 21: ...pport The furnace may be supported under the entire length of the furnace with threaded rod and angle iron See Figure 24 Secure angle iron to bottom of furnace as shown Platform Furnace Support Construct working platform at location where all required furnace clearances are met See Table 1 and Figure 25 For furnaces with 1 in 25 mm clearance requirement on side set furnace on non combustible block...

Page 22: ...t to flanges on furnace supply air outlet Bend flange upward to 90 with wide duct pliers See Figure 21 The supply air duct must be connected to ONLY the furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing side to attach supply air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace main casin...

Page 23: ...cleaner can be connected to the bottom opening on the furnace For side return use in the horizontal position refer to Figure 28 If both side and bottom openings are used in Figure 28 each opening used will require a filter A filter rack or any field supplied accessory air cleaner can also be installed in the common return duct prior to entering the return air opening in any orientation See Table 6...

Page 24: ...R DOOR FURNACE L10F027 OPENING TABS TYP 3 4 OPENING 14 1 2 16 1 8 23 8 1 2 3 8 11 4 11 4 25 1 8 17 1 8 23 1 8 Figure 30 Accessory Bottom Filter Rack L10F031 B A 28 7 16 722 2 22 5 16 566 4 2 3 16 55 5 A Table 7 Dimensional Drawing inch mm KIT NO FURNACE WIDTH A B NAHB00601FF 17 1 2 444 5 14 5 8 371 5 17 5 8 447 7 NAHB00701FF 21 533 4 18 1 8 460 4 21 1 8 536 6 NAHB00801FF 24 1 2 622 3 21 5 8 549 3 ...

Page 25: ... damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury dea...

Page 26: ...rnace has been connected Refer to current edition of NSCNGPIC in Canada After all connections have been made purge lines and check for leakage at furnace prior to operating furnace NOTE The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in w c stated on gas control valve See Figure 32 F...

Page 27: ...and grounded NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control status indicator light flashes rapidly and furnace does NOT operate Verify that the voltage frequency and phase correspond to that specified on unit rating plate Also check to be sure that service provided by utility is sufficient to handle load imposed by this equipment Refer to rating plate or ...

Page 28: ...the J Box cover and mounting bracket from the loose parts bag Select a 7 8 in 22 mm knock out on the desired side of the casing Remove the knock out from the casing Drill two 1 8 in 3 mm pilot holes in the casing dimples by the desired 7 8 in 22 mm knock out Align the J Box mounting bracket against the inside of the casing and secure the mounting bracket with the screws See Figure 36 Electrical Bo...

Page 29: ...d copper thermostat wire for lengths up to 100 ft 30 5 M For wire lengths over 100 ft use AWG No 16 wire The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during installation service or maintenance could cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse of identical size Thermostats and Control Settings For best results use...

Page 30: ...Z PHASE OPERATING VOLTAGE RANGE MAXIMUM UNIT AMPS UNIT AMPACITY MINIMUM WIRE SIZE AWG MAXIMUM WIRE LENGTH FT M MAXIMUM FUSE OR CKT BKR AMPS Maximum Minimum 60 000 115 60 1 127 104 9 7 12 7 14 29 8 8 15 80 000 115 60 1 127 104 9 7 12 7 14 29 8 8 15 100 000 115 60 1 127 104 14 8 19 1 12 30 9 1 20 120 000 115 60 1 127 104 14 8 19 1 12 30 9 1 20 Permissible limits of the voltage range at which the uni...

Page 31: ...om one manufacturer with a vent system from a different manufacturer Follow the manufacturer s instructions in the use of primer and cement and never use primer or cement beyond its expiration date The safe operation as defined by ULC S636 of the vent system is based on following these installation instructions the vent system manufacturer s installation instructions and proper use of primer and c...

Page 32: ... remaining appliances may need to be re sized Vent systems or vent connectors of other appliances must be sized to the minimum size as determined using appropriate table found in the current edition of National Fuel Gas Code NFPA 54 ANSI Z 223 1 In Canada refer to CAN CSA B149 1 An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion air when applicabl...

Page 33: ...Schedule 40 D1785 PVC Pipe Schedule 40 D2235 For ABS Solvent Cement For ABS D2241 PVC Pipe SDR 21 SDR 26 D2466 PVC Fittings Schedule 40 D2468 ABS Fittings Schedule 40 D2564 For PVC Solvent Cement For PVC D2661 ABS Pipe Fittings DWV at Schedule 40 IPS sizes D2665 PVC Pipe Fittings DWV F438 CPVC Fittings Schedule 40 F441 CPVC Pipe Schedule 40 F442 CPVC Pipe SDR F493 For CPVC Solvent Cement For CPVC ...

Page 34: ...w to required position Any other unused knockout may be used for combustion air connection A11308 Representative drawing only some models may vary in appearance Figure 42 Upflow Left Vent 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 Insert...

Page 35: ...2 3 4 5 6 7 5 Rotate vent elbow to required position A11311 Representative drawing only some models may vary in appearance Figure 44 Downflow Right Vent 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 Insert vent pipe into vent elbow Torque a...

Page 36: ... pipe and combustion air adapters Figure 47 Vent Pipe Flush with Adaptor VENT PIPE ADAPTER WITH GASKET INSTALLED ON FURNACE VENT PIPE IS CUT FLUSH WITH TOP OF ADAPTER Figure 48 Vent Pipe Flush Showing Coupling ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND OFF ON ADAPTER TORQUE LOWER CLAMP 15 LB IN WHEN REMAINING VENT PIPE IS INSTALLED TORQUE UPPER CLAMP TO 15 LB IN Figure 49 Combustion Air Pipe 1...

Page 37: ...ion clearances shown in Figure 60 Allowable vent terminations are shown in Figure 53 The combustion air pipe terminates in a well ventilated attic or crawl space When the furnace is installed in a well ventilated attic or crawlspace install the combustion air pipe as shown in Figure 49 Follow the clearances as shown in Figure 57 and Figure 58 The combustion air pipe cannot terminate in attics or c...

Page 38: ...preferred 1 in 25mm maximum typ from wall to inlet 12 in 305mm minimum from overhang or roof Maintain 12 in min clearance above highest anticipated snow level or grade whichever is greater A At least 36 in Concentric Vent and Combustion Air Side T e rmination A At least 36 in Side wall termination of less than 12 in 305mm above highest snow level 12 in min from overhang or roof 12 in 305mm separat...

Page 39: ...length of all the elbows for each pipe 5 If a Tee is used on the termination record the equivalent length of the Tee used 6 Record the equivalent length of the termination to be used 7 Subtract the equivalent lengths of the fittings and terminations from the Maximum Equivalent Vent Length 8 If the Maximum Vent Length calculated is longer than the individual measured length of the vent pipe and com...

Page 40: ...ut on opposite sides where the knockout meets the casing Fold the knockout down with duct pliers and work the knockout back and forth until it is removed Trim any excess metal from the knockout with tin snips The vent elbow can be rotated to the required location on the casing if necessary See Figure 54 To rotate the vent elbow 1 Loosen the clamp on the inlet of the vent elbow attached to the indu...

Page 41: ...pipe adapter has a pipe stop at the end 2 Align the screw holes in the plastic vent pipe adapter with the dimples in the casing 3 Pilot drill the screw holes for the adapter in the casing and attach the vent pipe adapter to the furnace with sheet metal screws 4 Slide the end of the rubber vent coupling with notches in it over the standoffs on the vent pipe adapter 5 Insert a length of vent pipe th...

Page 42: ...bustion Air Pipe Installing the Vent Termination Roof Terminations A roof termination of any type will require a 4 in 102 mm flashing for a 2 in 51 mm concentric vent or a 5 in diameter 127 mm flashing for a 3 in 76 mm concentric vent kit For 2 pipe or single pipe vent systems a flashing for each pipe of the required diameter will be necessary It is recommended that the flashing be installed by a ...

Page 43: ...ay be installed as shown in Figure 52 but next vent termination must be at least 36 in 914 mm away from first two terminations It is important that vent terminations be made as shown in Figure 52 to avoid recirculation of flue gases Inducer Outlet Restrictor The loose parts bag may contain an inducer outlet restrictor The outlet restrictor is NOT used on these furnaces Discard restrictor Figure 57...

Page 44: ... 15 kW 12 30 cm for appliances u 50 000 Btuh 14 7 kW K Clearance to a mechanical air supply inlet 6 ft 1 8 m 3 ft 9 m above if within 10 3m horizontally L Clearance under a veranda porch deck or balcony 12 in 305 mm Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor For clearances not specified in ANSI Z223 1 NFPA 54 or CAN CSA B149 1 clearanc...

Page 45: ... Btuh 30 kW 36 in 914 mm for appliances u 100 000 Btuh 30 kW 4 ft 1 2 m below or to the side of opening 1 ft 3 m above opening K Clearance to a mechanical air supply inlet 6 ft 1 83 m 3 ft 9 m above if within 10 ft 3 m horizontally L Clearance under a veranda porch deck or balcony 12 in 305 mm Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor...

Page 46: ...67 4 N A 80 000 23 7 0 85 25 9 146 44 5 195 59 4 216 65 8 100 000 N A 40 12 2 91 27 7 200 61 0 222 67 7 120 000 N A N A N A 80 24 4 211 64 3 5001 to 6000 1524 to 1829 60 000 37 11 3 103 31 4 186 56 7 207 63 1 N A 80 000 22 6 7 76 23 2 137 41 8 183 55 8 200 61 0 100 000 N A 33 10 1 85 25 9 188 57 3 208 63 4 120 000 N A N A N A 74 22 6 199 60 7 6001 to 7000 1829 to 2134 60 000 35 10 7 96 29 3 174 53...

Page 47: ... 55 0 60 0 52 0 42 0 N A M 4 3 2 7 2 1 0 0 N A 16 8 14 9 13 1 10 4 N A 16 8 18 3 15 8 12 8 N A 20 30 Ft 5 0 0 0 0 0 0 0 N A 41 0 32 0 26 0 18 0 N A 50 0 40 0 33 0 24 0 N A M 1 5 0 0 0 0 0 0 N A 12 5 9 8 7 9 5 5 N A 15 2 12 2 10 1 7 3 N A 40 40 Ft 0 0 0 0 0 0 0 0 N A 30 0 21 0 16 0 8 0 N A 37 0 28 0 22 0 13 0 N A M 0 0 0 0 0 0 0 0 N A 9 1 6 4 4 9 2 4 N A 11 3 8 5 6 7 4 0 N A 80000 20 10 Ft 35 0 39 ...

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