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ICP F9MAE Installation instructions manual

Manual is about: Modulating Gas Valve, Variable Speed Motor 35” Tall High Efficiency Condensing Gas Furnace

Summary of F9MAE

  • Page 1

    Printed in u.S.A. 440 01 4300 00 aug. 2012 installation instructions modulating gas valve, variable speed motor 35” tall high efficiency condensing gas furnace (f/g)9mae these instructions must be read and understood completely before attempting installation. Safety labeling and signal words danger,...

  • Page 2: Important

    440 01 4300 00 specifications are subject to change without notice. 2 required notice for massachusetts installations important the commonwealth of massachusetts requires compliance with regulation 248 cmr as follows: 5.08: modifications to nfpa−54, chapter 10 2) revise 10.8.3 by adding the followin...

  • Page 3: Safety Considerations

    440 01 4300 00 3 specifications subject to change without notice. Safety considerations ! Warning fire, explosion, electrical shock, and carbon monoxide poisoning hazard failure to follow this warning could result in dangerous operation, personal injury, death, or property damage. Improper installat...

  • Page 4: Introduction

    4 440 01 4300 00 specifications subject to change without notice. (914 mm) horizontally from the furnace. See nfpa 90b or local code for further requirements. Table 1 minimum clearances to combustible materials for all units position clearance in(mm) rear 0 front (combustion air openings in fur- nac...

  • Page 5: Precautions Procedure

    440 01 4300 00 5 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 engi...

  • Page 6

    6 440 01 4300 00 specifications subject to change without notice. Figure 2 dimensions sd5060−4 rev f (f/g)9mae furnace size a b c d ship wt. Lb (kg) cabinet width outlet width bottom inlet width air intake 0601714 17−1/2 (445) 15−7/8 (403) 16 (406) 8 3/4 (222) 154 (69) 0602120 21 (533) 19−3/8 (492) ...

  • Page 7: Location

    440 01 4300 00 7 specifications subject to change without notice. Location ! Caution personal injury and/or property damage hazard improper use or installation of this furnace may result in premature furnace component failure. This gas furnace may be used for heating buildings under construction pro...

  • Page 8: Warning

    8 440 01 4300 00 specifications subject to change without notice. Figure 3 multipoise orientations the blower is located to the right of the burner section, and conditioned air is discharged to the left. The blower is located below the burner section, and conditioned air is discharged upward. The bl...

  • Page 9: Caution

    440 01 4300 00 9 specifications subject to change without notice. Ventilated combustion air applications when the furnace is installed using the ventilated combustion air option, the attic or crawlspace must freely communicate with the outdoor to provide sufficient air for combustion. The combustion...

  • Page 10

    10 440 01 4300 00 specifications subject to change without notice. Outdoor combustion air method 1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoo...

  • Page 11: Condensate Trap

    440 01 4300 00 11 specifications subject to change without notice. Condensate trap ! Caution frozen and burst water pipe hazard failure to protect against the risk of freezing may result in property damage. Special precautions must be made if installing furnace in an area which may drop below freezi...

  • Page 12

    12 440 01 4300 00 specifications subject to change without notice. Figure 9 unconverted factory configuration as viewed in the downflow orientation representative drawing only, some models may vary in appearance. Remove relief tube from relief port on condensate trap. Remove pressure switch tube fro...

  • Page 13: Notice

    440 01 4300 00 13 specifications subject to change without notice. Condensate trap − horizontal orientation when the furnace is installed in the horizontal right position, the condensate trap will be initially located at the bottom of the collector box, as received from the factory. See the top imag...

  • Page 14

    14 440 01 4300 00 specifications subject to change without notice. Figure 10 − continued horizontal left trap configuration a11586b representative drawing only, some models may vary in appearance. Rotate elbow to desired position and torque clamp on inlet 15 lb.−in. Slide relief tube in stand−offs t...

  • Page 15: Caution

    440 01 4300 00 15 specifications subject to change without notice. Figure 11 − continued horizontal right trap configuration attach condensate trap to collector box with screw. Install plug in open port on collector box. Slide relief tube in stand-offs to adjust length. Vent elbow shown in alternate...

  • Page 16: Notice

    16 440 01 4300 00 specifications subject to change without notice. 8. Open the spring clamp and insert the long end of the adapter of the 1/2−in. Cpvc pipe into the outlet stub on the drain tube. 9. Connect additional condensate piping to a code−approved drain, or to a condensate pump approved for u...

  • Page 17: Caution

    440 01 4300 00 17 specifications subject to change without notice. 3. Remove the knock−out for the condensate trap in the side of the casing. 4. Install the drain trap grommet in the casing, if required for direct−vent applications. If necessary, remove the trap, install the grommet and re−install t...

  • Page 18: Installation

    18 440 01 4300 00 specifications subject to change without notice. Figure 16 formed rubber drain grommet l12f022 install clamps on drain elbow attach drain elbow to condensate drain trap pull drain stub through casing open spring clamp insert factory−supplied 1/2−in. Cpvc to 3/4−in. Pvc adapter or 1...

  • Page 19: Caution

    440 01 4300 00 19 specifications subject to change without notice. Figure 19 removing bottom closure panel l11f004 bottom plate side return air inlet these 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 ...

  • Page 20: Warning

    20 440 01 4300 00 specifications subject to change without notice. Humidifier, or other accessories. All supply−side 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/...

  • Page 21: Warning

    440 01 4300 00 21 specifications subject to change without notice. Figure 23 furnace, plenum, and subbase installed on a combustible floor a96285 horizontal installation note: the furnace must be pitched forward as shown in figure 18 for proper condensate drainage. ! Warning fire, explosion, and car...

  • Page 22

    22 440 01 4300 00 specifications subject to change without notice. Figure 25 suspended furnace installation 2−in. (51 mm) a11155 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 finished ceiling fi...

  • Page 23: Warning

    440 01 4300 00 23 specifications subject to change without notice. Roll−out protection provide a minimum 12−in. X 22−in. (305 x 559 mm) piece of sheet metal for flame roll−out protection in front of burner area for furnaces closer than 12−in. (305 mm) above the combustible deck or suspended furnaces...

  • Page 24

    24 440 01 4300 00 specifications subject to change without notice. Table 7 filter media pressure drop (clean) versus airflow - in. W.C. (pa) 14 x 25 filter factory-accy washable representative after-market filter media* fiberglass* pleated* cfm l/s (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1...

  • Page 25

    440 01 4300 00 25 specifications subject to change without notice. Figure 27 downflow return air configurations and restrictions l10f033 figure 28 upflow return air configurations and restrictions l10f032 figure 29 horizontal return air configurations and restrictions horizontal top return not permi...

  • Page 26: Air Ducts

    26 440 01 4300 00 specifications subject to change without notice. Figure 31 accessory bottom filter rack l10f031 b a 28−7/16 (722.2) 22−5/16 (566.4) 2−3/16 (55.5) a table 9 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...

  • Page 27: Gas Piping

    440 01 4300 00 27 specifications subject to change without notice. Gas piping ! Warning fire or explosion hazard failure to follow this warning could result in personal injury, death, and/or property damage. Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flam...

  • Page 28: Electrical Connections

    28 440 01 4300 00 specifications subject to change without notice. Piping should be pressure and leak tested in accordance with the current addition of the nfgc in the united states, local, and national plumbing and gas codes before the furnace has been connected. Refer to current edition of nscngpi...

  • Page 29: Warning

    440 01 4300 00 29 specifications subject to change without notice. Not operate if polarity is incorrect or if the furnace is not grounded. 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 suffi...

  • Page 30

    30 440 01 4300 00 specifications subject to change without notice. Figure 36 optional j−box locations representative drawing only, some models may vary in appearance. L12f024 optional j−box locations remove the j−box cover and mounting bracket from the loose parts bag. Select a 7/8−in. (22 mm) knock...

  • Page 31

    440 01 4300 00 31 specifications subject to change without notice. 2. Route bx connector through 7/8−in. (22 mm) diameter hole in casing and j−box bracket. 3. Secure bx cable to j−box bracket with connectors approved for the type of cable used. 4. Connect field ground wire and factory ground wire to...

  • Page 32

    32 440 01 4300 00 specifications subject to change without notice. Figure 39 isolation relay for humidifiers with internal 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 s...

  • Page 33: Venting

    440 01 4300 00 33 specifications subject to change without notice. Figure 40 − continued example of variable speed furnace control for ecm blower motor (modulating) l11f091 24ïv thermostat pl2 ć hot surface igniter & inducer motor connector 115ïvac (l2) neutral connections 115ïvac (l1) line voltage ...

  • Page 34: Warning

    34 440 01 4300 00 specifications subject to change without notice. L’apprêt gvs-65 (purple) et le ciment-solvant gvs-65 doivent être utilisé avec les royal pipe. Système ipex 636, apprêt pvc/cpvc, purple pour évacuation des gaz de combustion et système ipex 636(1)t, ciment pvc pour évacuation des ga...

  • Page 35: Warning

    440 01 4300 00 35 specifications subject to change without notice. Venting systems warning ! Carbon monoxide poisoning hazard failure to follow the instructions outlined in locating the vent termination for each appliance being placed into operation could result in carbon monoxide poisoning or death...

  • Page 36

    36 440 01 4300 00 specifications subject to change without notice. Table 13 approved combustion-air and vent pipe, fitting and cement materials (u.S.A. Installation) astm specification (marked on material) material pipe fittings solvent cement and primers description d1527 abs pipe − − schedule−40 d...

  • Page 37: Notice

    440 01 4300 00 37 specifications subject to change without notice. Locating the vent termination general note: termination requirements for the provinces of alberta and saskatchewan are located at the end of this section. Combustion−air inlet pipe (direct bent/2−pipe system only) and vent pipe must ...

  • Page 38

    38 440 01 4300 00 specifications subject to change without notice. Figure 44 tee at termination outlet l12f030 optional termination bracket for 2ïpipe terminations figure 45 sample inlet air pipe connection for polypropylene venting systems example for upflow installations. May be applied to other c...

  • Page 39

    440 01 4300 00 39 specifications subject to change without notice. Figure 47 combustion air and vent pipe termination for direct vent (2−pipe) system l12f044 a a 0 90 a vertical separation between combustion air and vent 8 ¾ in. (222mm) for 3 in.(76mm) 6 ¾ in. (172mm) for 2in. (51mm) maintain 12 in....

  • Page 40: Notice

    40 440 01 4300 00 specifications subject to change without notice. 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 f...

  • Page 41: Warning

    440 01 4300 00 41 specifications subject to change without notice. The measured length of pipe used in a 2−pipe termination is included in the total vent length. Include deductions from the maximum equivalent vent length (mevl) contained in the venting tables for elbows and flexible vent pipe. Facto...

  • Page 42

    42 440 01 4300 00 specifications subject to change without notice. Figure 50 inducer vent elbow − variable modul ating inducer assembly inducer outlet vent elbow cl amp torque 15 lb−in. Vent elbow vent pipe cl amp torque 15 lb−in. Figure 51 upflow configurations a11309 representative drawing only, s...

  • Page 43

    440 01 4300 00 43 specifications subject to change without notice. Downflow configurations − continued l11f063 representative drawing only, some models may vary in appearance. Requires accessory internal vent kit see specification sheets for current kit number downflow vertical − vent configuration ...

  • Page 44: Warning

    44 440 01 4300 00 specifications subject to change without notice. Horizontal right configurations − continued horizontal right − right vent configuration representative drawing only, some models may vary in appearance. * see notes following figures. Notes: 1. Attach vent pipe adapter with gasket to...

  • Page 45: Warning

    440 01 4300 00 45 specifications subject to change without notice. Piping and vent piping a minimum of every 5 ft. (1.5m) [3 ft. (.91m) for sdr−21 or −26 pvc] using perforated metal hanging strap or commercially available hangars designed to support plastic pipe. 17. Prevent condensate from accumula...

  • Page 46: Notice

    46 440 01 4300 00 specifications subject to change without notice. Sidewall terminations concentric vent note: follow the instructions of the vent terminal manufacturer. These instructions are provided as a reference, only. Determine an appropriate location for termination kit using the guidelines p...

  • Page 47

    440 01 4300 00 47 specifications subject to change without notice. Figure 55 crawl space vent termination 3” (76 mm) 12” (305 mm) pipe hangar ventilated combustion air intake termination in crawl space ventilated combustion air intake pipe crawl space figure 56 attic vent termination attic 12” (305 ...

  • Page 48

    48 440 01 4300 00 specifications subject to change without notice. Figure 57 direct vent termination clearance v v 25−24−65−2 note: the following is based upon national codes for gas appliances, and is provided as a reference. Refer to local codes which may supersede these standards and/or recommend...

  • Page 49

    440 01 4300 00 49 specifications subject to change without notice. Figure 58 other than direct vent clearance − ventilated combustion air option v v 25−24−65−2 note: the following is based upon national codes for gas appliances, and is provided as a reference. Refer to local codes which may supersed...

  • Page 50

    50 440 01 4300 00 specifications subject to change without notice. Table 14 maximum equivalent vent length - feet (meters) note: maximum equivalent vent length (mevl) does not include elbows or terminations use table 15 − deductions from mevl to determine allowable vent length for each application. ...

  • Page 51

    440 01 4300 00 51 specifications subject to change without notice. Example 1 a direct-vent 60,000 btuh furnace installed at 2100 ft. (640m). Venting system includes for each pipe 100 feet (30 m) ofvent pipe, 95 feet (28 m) of combustion air inlet pipe, (3) 90º long-radius elbows, (2) 45º long-radius...

  • Page 52

    52 440 01 4300 00 specifications subject to change without notice. Table 16 maximum equivalent vent length - feet (meters) note: maximum equivalent vent length (mevl) does not include elbows or terminations. Use deductions from mevl − table 15 to determine allowable vent length for each application....

  • Page 53

    440 01 4300 00 53 specifications subject to change without notice. Table 17 maximum allowable exposed vent lengths in unconditioned space maximum length of uninsulated and insulated vent pipe-ft (m) (f/g)9mae max. Heat input winter design temp °f (°c) pipe length in ft. & m no insulation 3/8-in. (9....