ICP G9MAC Series, Installation Instructions Manual

Page 1: ...afety alert symbol When you see this symbol on the unit and 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 5 DIMENSIONS 6 LOCATION 7 LOCATION RELATIVE TO COOLING EQUIPMENT 8 AIR FOR COMBUSTION AND VENTILATION 8 CONDENSATE TRAP 11 INSTALLATION 18 UPFLOW INSTALLATION 1...

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: ... and attached to the unit CAUTION 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 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 potentia...

Page 4: ...equirement 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 furnace and or vent to fai...

Page 5: ... 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...

Page 6: ...8 22 2 POWER CONN AIR FLOW SEE NOTE 3 TOP VIEW NOTES 1 Doors may vary by model 2 Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations for equivalent diameters a For 800 CFM 16 in 406 mm round or 14 1 2 x 12 in 368 x 305 mm rectangle b For 1200 CFM 20 in 508 mm round or 14 1 2 x 19 1 2 in 368 x 495 mm rectangle c For 1600 CFM 2...

Page 7: ...wer 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 provided ample space for servicing ...

Page 8: ...NG FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Do not install the furnace on its back or hang furnace with con trol compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace See Figure 5 Figure 5 Prohibited Installations BACK POSITIONED DOWNWARD AIR RETURN CUT...

Page 9: ...an Installations Part 8 of CAN CSA B149 1 2010 Venting Systems and Air Supply for Appliances and all authorities having jurisdiction CAUTION FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace damage Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and shorten fur...

Page 10: ...r Duct to Outdoors FURNACE INPUT BTUH TWO HORIZONTAL DUCTS 1 SQ IN 2 000 BTUH 1 100 SQ MM KW SINGLE DUCT OR OPENING 1 SQ IN 3 000 BTUH 734 SQ MM KW TWO OPENINGS OR VERTICAL DUCTS 1 SQ IN 4 000 BTUH 550 SQ MM KW Free Area of Opening and Duct Sq In Sq mm Round Duct In mm Dia Free Area of Open ing and Duct Sq In Sq mm Round Duct In mm Dia Free Area of Open ing and Duct Sq In mm Round Duct In mm Dia 6...

Page 11: ...nace environment has the potential of freezing the drain trap and drain line must be protected Use 3 to 6 watt per foot of 115 volt 40 F 4 C self regulating shielded and water proof heat tape Wrap the drain trap and drain line with the heat tape and secure with the ties Follow the heat tape manufacturer s recommendations Prime the trap before furnace operation Condensate Trap Upflow Orientation Wh...

Page 12: ...bottom plugs DO NOT DISCARD Remove tube from relief port A11585A Downflow Trap Configuration A11585B Representative drawing only some models may vary in appearance 7 9 Install plugs on open ports on collector box Connect relief tube to port on collector box Rotate elbow to desired position and tighten clamp to 15 lb in Slide tube in stand offs to adjust length Trim excess tube Connect pressure swi...

Page 13: ... meter of slope down and away from the furnace in horizontal sections of drain line NOTE The condensate trap extends below the side of the casing in the horizontal position A minimum of 2 in 51 mm of clearance is required between the casing side and the furnace platform for the trap to extend out of the casing in the horizontal position Allow at least 1 4 in 6 mm per foot of slope away from the fu...

Page 14: ...d right hand port on collector box Install plugs in open ports on collector box Connect relief tube to port on collector box Trim excess tube Route pressure switch tube underneath relief tube and connect to port on collector box Connect relief tube to relief port on condensate trap Figure 11 Unconverted Factory Configuration as viewed in the Horizontal Right Orientation Remove plug from collector ...

Page 15: ...tected A self regulating shielded and waterproof heat tape rated at 3 to 6 watt per foot 10 to 20 watt per meter at 115 volt 40 F 4 C may be used to help provide freeze protection Wrap the drain trap and drain line with the heat tape and secure with appropriate plastic ties Follow the heat tape manufacturer s recommendations Prime the trap before furnace operation Upflow Downflow Orientation In th...

Page 16: ...from the rubber drain tube through the 7 8 in drain knockout in the casing 9 Pull the grommet through the casing from the outside until it is seated in the knockout 10 Align the Z pipe with the long end of the grommet inside the furnace and insert slightly The angled end of the tube at the other side of the casing should be facing the front of the furnace 11 Slide a spring clamp over the end of th...

Page 17: ...drain tube 10 Connect additional condensate piping to a code approved drain or to a condensate pump approved for use with acidic furnace condensate and compatible with mineral and vegetable oils such as canola oil Allow at least 1 4 in per foot 20 mm per meter of slope down and away from the furnace in horizontal sections of drain line Figure 13 Knockout Removal L12F019 CAUTION CUT HAZARD Failure ...

Page 18: ... using light assistance or a probe can be inserted for sampling the air stream The cover attachment shall prevent leaks Connect supply air duct to flanges on furnace supply air outlet Bend flange upward to 90 with wide duct pliers See Figure 22 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 ...

Page 19: ... proper condensate drainage Supply Air Connections NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the following two accessories are used see Specification sheets for list of approved accessories Special Base NAHA01101SB Cased Coil Assembly EAM4X END4X ENW4X 1 Determine application being installed from Table 5 2 Construct hole in floor per Ta...

Page 20: ... IN mm APPLICATION PLENUM OPENING FLOOR OPENING A B C D 17 1 2 445 Upflow Applications on Combustible or Noncombustible Flooring subbase not required 16 406 21 5 8 549 16 5 8 422 22 1 4 565 Downflow Applications on Noncombustible Flooring subbase not required 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 6...

Page 21: ... RH side The furnace can be hung from floor joists rafters or trusses or installed on a non combustible platform blocks bricks or pad Figure 24 Furnace Plenum and Coil Assembly on a Combustible Floor L11F104 END4X ENW4X WARNING FIRE EXPLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death or property damage Do not install the furnace on it...

Page 22: ...densate trap when a condensing furnace is installed over a finished ceiling Figure 26 Working Platform for Attic Installation 2 in 51 mm A11154 ROLLOUT PROTECTION RE QUIRED Install 1 2 x 22 305 x 559 mm sheet metal in front of burner compartment area COMBUSTION AIR PIPE SEE VENTING SECTION NOTE Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a fi...

Page 23: ... For upflow applications the filter can be installed on either side of the furnace the bottom of the furnace or any combination of side and bottom of the furnace See Figure 28 Figure 30 and Figure 31 For downflow applications the filter rack or field supplied accessory air cleaner must only be connected to the bottom opening on the furnace See Figure 27 and Figure 31 and Table 9 For horizontal app...

Page 24: ...fter Market Filter Media Fiberglass Pleated CFM L s 1 in 2 5 cm 1 in 2 5 cm 2 in 5 cm 1 in 2 5 cm 2 in 5 cm 800 378 0 03 9 0 05 12 0 07 18 0 17 43 0 11 28 1000 472 0 04 11 0 06 16 0 09 24 0 22 55 0 15 37 1200 566 0 05 13 0 08 20 0 12 31 0 27 68 0 18 47 1400 661 0 06 15 0 10 24 0 15 38 0 23 58 1600 755 0 06 16 0 11 29 0 18 45 0 28 69 1800 850 0 07 18 0 13 34 0 21 53 2000 944 0 08 19 0 16 39 0 24 61...

Page 25: ...rizontal Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL SIDE RETURN AIR NOT PERMITTED FOR 2000 CFM AND ABOVE OF AIR FLOW L10F034 External Filter Cabinet Configurations Figure 30 Accessory Side Filter Rack TABS FILTER FRAME FILTER DOOR FURNACE L10F027 OPENING TABS TYP OPENING 11 4 23 59 cm 25 64 cm 1 cm 1 3 cm 2 6 cm 17 43 5 cm 2 cm 16 41 cm 14 37 cm L1...

Page 26: ...andled by duct s sealed to the furnace casing and terminating outside the space containing the furnace Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through uncondition...

Page 27: ...ded gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of one hanger every 6 ft 1 8 M Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to the action of propane gas WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could resu...

Page 28: ... leakage Remove the knockout install the grommet in the knockout then insert the gas pipe The grommet is included in the loose parts bag See Figure 34 Figure 34 Gas Entry Gas Pipe Grommet Required For Direct Vent Applications Left Side Gas Entry Gas Pipe Grommet Required For Direct Vent Applications A11338 ELECTRICAL CONNECTIONS WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could ...

Page 29: ...lt in personal injury death or property damage If field supplied manual disconnect switch is to be mounted on furnace casing side select a location where a drill or fastener cannot damage electrical or gas components The J Box is used when field line voltage electrical connections are made to the furnace wiring harness inside the furnace casing The J Box is not required if a field supplied electri...

Page 30: ...w on J Box mounting bracket as shown in Figure 37 7 Connect field power and neutral leads to furnace power leads as shown in Figure 35 8 Attach furnace J Box cover to mounting bracket with screws supplied in loose parts bag Do not pinch wires between cover and bracket 9 Complete external disconnect wiring and installation Connect line voltage leads as shown in Figure 38 Use best practices NEC ANSI...

Page 31: ...ng blower motor operation 2 Humidifier HUM The HUM terminal is a 24 VAC output energized when the blower is operating during a call for heat Connect an accessory 24 VAC 0 5 amp Maximum if used to the 1 4 in male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip NOTE If the humidifier has its own 24 VAC power supply an isolation relay may be required Connec...

Page 32: ...nal Power Supply 24 V Coil To Humidifier Leads To Com 24V Screw Terminal on Thermostat Strip To HUM Terminal On Furnace Control Board To Humidifier Leads A11157 Figure 40 Variable Speed Furnace Control Switch Locations OAT PL9 PL4 PL7 SW 1 SW2 SW3 SW4 O N W2 Y1 DHUM 8 7 6 5 4 3 2 1 3 2 1 O N O N O N 3 2 1 3 2 1 L11F080 ...

Page 33: ... accessory concentric vent termination kits and accessory external drain trap available from the furnace manufacturer have been certified to ULC S636 for use with those Royal Pipe and IPEX PVC vent components which have been certified to this standard In Canada the primer and cement must be of the same manufacturer as the vent system GVS 65 Primer Purple for Royal Pipe or IPEX System 636 PVC CPVC ...

Page 34: ...quipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Code 9 After it has been determined that each appl...

Page 35: ... either through the roof preferred or a sidewall See Figure 57 for references to clearances required by National code authorities NOTICE OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE In applications where there is a risk of excessive moisture entering the combustion air inlet pipe a moisture trap may be added to the inlet pipe to help prevent moisture from entering the furnace from the comb...

Page 36: ...e Fittings DWV F438 CPVC Fittings Schedule 40 F441 CPVC Pipe Schedule 40 F442 CPVC Pipe SDR F493 For CPVC Solvent Cement For CPVC F628 ABS Pipe Cellular Core DWV at Schedule 40 IPS sizes F656 For PVC Primer For PVC F891 PVC Pipe Cellular Core Schedule 40 DWV Figure 41 Vent Coupling and Adapter with Gaskets Vent Coupling and Adapter Attach gaskets to vent pipe and combustion air adapters A11314 Fig...

Page 37: ... each appliance being placed into operation could result in carbon monoxide poisoning or death For all venting configurations for this appliance and other gas appliances placed into operation for the structure provisions for adequate combustion ventilation and dilution air must be provided in accordance with U S A Installations Section 9 3 NFPA 54 ANSI Z223 1 1 2009 Air for Combustion and Ventilat...

Page 38: ...ropylene Venting Systems EXAMPLE FOR UPFLOW INSTALLATIONS MAY BE APPLIED TO OTHER CONFIGURATIONS A12220 Figure 46 Vent Terminations MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER VENT 12 IN SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT OVERHANG OR ROOF COMBUSTIONïAIR ELBOW PARALLEL TO WALL 22 5 to 45 o off wall Angle o OPTIONAL BRACKET ...

Page 39: ...en the first 2 vents Third vent and fourth vent if used must be 36 in Away 914mm Note 36ïin separation between pairs of inlets only required for directïvent systems Figure 48 Vent Pipe Termination for Ventilated Combustion Air System Abandoned masonry used as raceway per code 12 in 305 mm min from overhang or roof Maintain 12 in 305mm minimum clearance above highest anticipated snow level or grade...

Page 40: ... may vary in appearance TO CODE APPROVED DRAIN OR CONDENSATE PUMP L12F028 The External Vent Trap Kit accessory may be used as a trap for the combustion air inlet pipe if a large amount of moisture must be removed The drain line may be connected to the same drain as the furnace condensate and the evaporator coil condensate line ONLY if the inlet air trap drain and the evaporator coil drain empty in...

Page 41: ...an the longer TEVL of the vent pipe or combustion air pipe then that diameter of pipe selected may be used When installing vent systems with pipe lengths of 10 ft 3 0 M or less use the smallest allowable pipe diameter Using pipe size greater than required for short venting systems may result in loss of efficiency incomplete combustion flame disturbance or flame sense lockout For vent systems longe...

Page 42: ...ONFIGURATION A11308 Representative drawing only some models may vary in appearance UPFLOW RIGHT VENT CONFIGURATION Upflow Configurations continued A11310 Representative drawing only some models may vary in appearance UPFLOW VERTICAL VENT CONFIGURATION See NOTES following figures Figure 52 Downflow Configurations A11311 Representative drawing only some models may vary in appearance DOWNFLOW LEFT VE...

Page 43: ...ly some models may vary in appearance HORIZONTAL LEFT LEFT VENT CONFIGURATION Representative drawing only some models may vary in appearance Horizontal Left Configurations continued HORIZONTAL LEFT RIGHT VENT CONFIGURATION Requires accessory Internal Vent Kit Representative drawing only some models may vary in appearance See NOTES following figures Figure 54 Horizontal Right Configurations HORIZON...

Page 44: ... 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 through the coupling into the outlet of the vent elbow 6 Tighten the clamp around the outl...

Page 45: ...a 1 8 in hole in the combustion air pipe adapter 14 Complete the vent and combustion air pipe as shown in Install the Vent and Combustion Air Pipe NOTICE FOR POLYPROPYLENE VENTING SYSTEMS When using polypropylene venting systems all venting ma terials used including the vent terminations must be from the same manufacturer Installing the Vent Termination Roof Terminations A roof termination of any ...

Page 46: ...excess of 24 inches 0 6 M in vertical length be supported by EITHER the Direct Vent Termination Kit in Table 12 or by field supplied brackets or supports fastened to the structure Determine an appropriate location for termination kit using the guidelines provided in section Locating The Vent Termination in this instruction 1 Cut two holes one for each pipe of appropriate size for pipe size being u...

Page 47: ...tion 3 76 mm 12 305 mm Pipe hangar VentilatedCombustion Air intake termination in crawl space Ventilated Combustion Air intake pipe CRAWL SPACE Figure 56 Attic Vent Termination ATTIC 12 305 mm min above higest level of insulation Vent through roof flashing Ventilated Combustion Air intake pipe L11F016 ...

Page 48: ...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 See Note 4 Manufacturer s Recommendation See Notes 3 8 M Clearance to each side of the centerline extended above or below vent terminal of the furnace to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 in 305 mm 12 in 305 mm N Inlet air c...

Page 49: ...nce 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 See Note 4 Manufacturer s Recommendation See Notes 3 8 M Clearance to each side of the centerline extended above or below vent terminal of the furnace to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 in...

Page 50: ...bles See Table 16 for altitudes over 4500 ft 1370m Table 15 DEDUCTIONS FROM MAXIMUM EQUIVALENT VENT LENGTH Feet Meters Pipe Diameter in 1 1 2 2 2 1 2 3 4 Mitered 90º Elbow 8 2 4 8 2 4 8 2 4 8 2 4 8 2 4 Medium Radius 90º Elbow 5 1 5 5 1 5 5 1 5 5 1 5 5 1 5 Long Radius 90º Elbow 3 0 9 3 0 9 3 0 9 3 0 9 3 0 9 Mitered 45º Elbow 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 Medium Radius 45º Elbow 2 5 0 8 2 5 0 8 2 5 ...

Page 51: ...0 feet 30 M of vent pipe 95 feet 28 M of combustion air inlet pipe 3 90º long radius elbows and a polypropylene concentric vent kit Also includes 20 feet 6 1 M of flexible polypropylene vent pipe included within the 100 feet 30 M of vent pipe Assume that one meter of flexible 60mm or 80mm polypropylene pipe equals 1 8 meters of PVC ABS pipe VERIFY FROM VENT MANUFACTURER S INSTRUCTIONS Can this app...

Page 52: ...80 000 18 5 5 66 20 1 120 36 6 159 48 5 170 51 8 100 000 NA 29 8 8 73 22 3 167 50 9 182 55 5 120 000 NA NA NA 62 18 9 175 53 3 8001 to 9000 2438 to 2743 60 000 30 9 1 82 25 0 152 46 3 168 51 2 NA 80 000 17 5 2 62 18 9 111 33 8 148 45 1 156 47 5 100 000 NA 27 8 2 67 20 4 157 47 9 170 51 8 120 000 NA NA NA 56 17 1 164 50 0 9001 to 10 000 2743 to 3048 60 000 27 8 2 76 23 2 142 43 3 156 47 5 NA 80 000...

Page 53: ... 000 20 10 Ft 35 0 39 0 39 0 33 0 25 0 35 0 118 0 107 0 92 0 76 0 35 0 130 0 125 0 109 0 90 0 M 10 7 11 9 11 9 10 1 7 6 10 7 36 0 32 6 28 0 23 2 10 7 39 6 38 1 33 2 27 4 0 20 Ft 22 0 16 0 14 0 7 0 0 0 35 0 69 0 60 0 49 0 35 0 35 0 83 0 72 0 60 0 45 0 M 6 7 4 9 4 3 2 1 0 0 10 7 21 0 18 3 14 9 10 7 10 7 25 3 21 9 18 3 13 7 20 30 Ft 11 0 5 0 2 0 0 0 0 0 35 0 46 0 39 0 29 0 16 0 35 0 57 0 48 0 37 0 23...