Installation guide

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80+ GAS FURNACE

Category I Furnace

*8MPT Two-Stage Heating

*8MPV Variable Speed, Two-Stage Heating & Supports

Two- Stage Cooling Units * Denotes Brands (C, R, T)

See Section 5 for Category ! definition.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or

other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency,

or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits

or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when

installing.

Follow att safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing

operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions

included in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel Gas

Code (NFCG) NFPA 54/ANSI Z223.1, and the National Electrical Code (NEC) NFPA 70.

In Canada refer to the current editions of the National standards of Canada CAN/CSA-B149.1 and .2 Natural Gas and

Propane Installation Codes, and Canadian Electrical Code CSA C22.1.

Recognize safety information. This is the safety-alert symbol z_. When you see this symbol on the unit and in instructions

or manuals, be alert to the potential for personal injury. Understand these signal words; DANGER, WARNING, and

CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will

result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death.

CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage.

NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

International Comfort Products, LLC

Lewisburg, TN.37091

1. SafeInstallationRequirements.................. 4

2.Installation................................. 5

3.SideVenting................................ 8

4.Combustion&VentilationAir ................... 9

5.GasVentInstallation ......................... 12

6.HorizontalVenting ........................... 13

7.ChimneyAdapterVenting...................... 15

8.GasSupplyandPiping........................ 18

9.ElectricalWiring............................. 22

INSTALLER: Affix these instructions on or

adjacent to the furnace.

CONSUMER: Retain these instructions for

future reference.

Table of Contents

10. Ductwork and Filter (Upflow/Horizontal) ......... 25

11. DuctworkandFilter(Downflow) ............... 27

12. ChecksandAdjustments .................... 30

13. FurnaceMaintenance....................... 33

14. Sequenceof Operation& Diagnostic(*8MPT) ..... 34

15. WiringDiagram(*8MPT) ..................... 36

16. Sequenceof Operation& Diagnostic(*8MPV) ..... 37

17. WiringDiagram(*8MPV) ..................... 39

18. ThermostatWiringGuide .................... 40

ELECTRIC SHOCK HAZARD

Failure to follow this warning

could result in personal injury

and/or death.

Turn Off All Power Before

Servicing.

CARBON MONOXIDE POISONING AND FIRE

HAZARD.

Failure to follow this warning could result in

personal injury, death and/or property dam-

age.

This furnace is not designed for use in mobile

homes, trailers or recreational vehicles.

Portions of the text and tables are reprinted from NFPA 54 / ANSi Z223.1-2006@, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association

Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSi on the referenced subject which is represented only by the standard in its

entirety.

Specificationsare subject to changewithout notice 441 01202301 March2009

Summary of content (42 pages)

PAGE 1
80+ GAS FURNACE *8MPT *8MPV Category I Furnace Two-Stage Heating Variable Speed, Two-Stage Two- Stage Cooling Units Heating & Supports * Denotes Brands (C, R, T) See Section 5 for Category ! definition. SAFETY CONSIDERATIONS Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage.
PAGE 2
START-UP CHECK SHEET For PSC Models *8MPT (This sheet is optional. Date of Start-Up:. Keep for future reference.) Calculated Input (BTU) Rate: (See Checks and Adjustments Section).
PAGE 3
START-UP CHECK SHEET For Variable Speed Models *8MPV (This sheet is optional. Date of Start-Up:. Keep for future reference.) Calculated Input (BTU) Rate: (See Checks and Adjustments Section).
PAGE 4
1. Safe Installation Requirements Seal around supply and return air ducts. FIRE, EXPLOSION, AND POISONING HAZARD CARBON Install correct filter type and size. MONOXIDE Improper adjustment, alteration, service, maintenance or installation could result in personal injury, death and/or property damage. Installation or repairs made by unqualified persons could result in hazards to you and others.
PAGE 5
FrozenWater Pipe Hazard If your furnace remains off for an extended time, the pipes in your home could freeze and burst, resulting in serious water damage. If the structure wilt be unattended during cold weather you should take these precautions. WATER DAMAGE TO PROPERTY HAZARD 1, Failure to protect against the risk of freezing could result in property damage.
PAGE 6
The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy. The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is com)leted. Dimensions and Clearances (*8MPT/*8MPV) i TOP ° I REAR eate * ;iiii!!,i i r ....
PAGE 7
iiiiiiiiii!i!i T p,ca, up,,ow,nsta,,a,,on The horizontal furnaces may be installed directly on combustible wood flooring or supports, however, it is recommended for further fire protection cement board or sheet metal is placed between the furnace and the combustible wood floor and extend 12" (305 mm) beyond the front of the furnace louver door. (This is a recommendation only, not a requirement).
PAGE 8
3. New labels for rightside-up application on outside of blower compartment door may be purchased in a kit from your distributor to cover upside-down labels. PressureSwitch Relocation If the furnace is installed in the upflow position, the pressure switch will remain in the same position as installed by the factory unless the inducer is rotated. If the furnace is installed in an orien- T ,ca, oown.ow.nsta.a.
PAGE 9
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PAGE 10
Air Openings and Connecting Ducts 1. Requirements Total maximum input ratings for all gas appliances in the space MUST be considered when determining free area of openings. 1. Provide confined space with sufficient air for proper combustion and ventilation of flue gases using horizontal or vertical ducts or openings. 2. Figure 8 illustrates how to provide combustion and ventilation air when two permanent openings, one inlet and one outlet, are used. 2.
PAGE 11
Free Area iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii BTUH(kW) Input Rating Minimum FreeAreaRequired for EachOpening or DucttoOutdoors TwoVerticalDuctsor SingleOpening Openings BTUH(kW) BTUH(kW) TwoHorizontal Ducts BTUH(kW) sq.in./2,000(1 cm2/.09) 50,000 (14.65) 25sq.in. (161 75,000 (21.98) 37.5sq.in.(242 sq. in./3,000 (1 cm2/.135) 16.7sq.in.
PAGE 12
Required Volume RequiredV°lume fan_ fan_ 15ft3 ACH ( "42m3 ACH ( If an 1000 BTUH ) If an .293 kW / • • For fan-assisted 2. appliances such as this furnace, If: ] other = combined input of all other than fan-assisted appliances in BTUH I fan BTUH = combined input of all fan-assisted appliances in ACH = air changes per hour (ACH shall not exceed 0.60) The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.
PAGE 13
Ventingand CombustionAir Check NOTE: When an existing Category ! furnace placed, the original venting system may no properly vent the attached appliances, and to adequate combustion air for all appliances, LOWING CHECK. VentCheck is removed or relonger be sized to make sure there is MAKE THE FOL- iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii ....
PAGE 14
Other than Direct Vent Termination Clearance .......-r ............... / / i .............. ............. // /' // ,/ i A 25-24-65-2 D VENTTERMINAL Item %X/' A R SUPPLY /_ \ Clearance Descriptions AREA WHERE TERMINAL IS NOT PERMITED NLET Canadian Installation (1) U.S.
PAGE 15
7. Masonry Chimney Venting Chimney Inspection All masonry chimney construction must conform to Standard NFPA 211-2006 and to any state or local codes applicable. The chimney must be in good condition and a complete chimney inspection must be conducted prior to furnace installation. If the inspection reveals damage or abnormal conditions, make necessary repairs or seek expert help. See "The Chimney Inspection Chart" Figure 11.
PAGE 16
Exterior Masonry Chimney, FAN+NAT Installations with Type-B Double-Wall Vent Connectors © NFPA & AGA Table ACombined Appliance MaximumInput Rating in Thousands of Btu per Hr VENT HEIGHT b. INTERNAL AREA OF CHIMNEY SQ IN.(cm) FT(m) 6(1.8) 12(77.4) 74 19(122.6) 119 28(180.6) 178 38(245.2) 257 8(2.4) 80 130 193 279 10(3) 84 138 207 299 15(4.6) NR 152 233 334 20(6.1) NR NR 250 368 30(9.
PAGE 17
CHIMNEY INSPECTION CHART For additiona(requirements refer to the Nationa(Fue(Gas Code NFPA 54/ANSIZ223.1 2006 and NFPA 211 2006 Chimneys,Firep)aces,Vents, and So))d Fue)Burning App(iancesin the U.S.A. or to the Canadian InstallationCode CSA-B149.1 in Canada. Missing mortar or brick? condition: Rebuild crown I 1 with day tile liner? No (iner or top sea( sea()n good condition Yes Reline or reline chimneyas necessary.
PAGE 18
8. Gas Supply and Piping Gas Pressures iiii,i.iii i._i_..iiiiiiii.ii..iiiii.i.i..iii.iii.iii.iii.iii.iii.iii.iii.iii.iii.iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_ FIRE AND EXPLOSION HAZARD Gas Type Failure to follow this warning could result in personal injury, death and/or property damage. Supply Pressure Recommended Natural Models designated for Natural Gas are to be used with Natural Gas ONLY, unless properly converted to use with Propane gas. Max. Min. 14 in wc 4.
PAGE 19
; 1i; ] J)i ]J ; i Gas Valve with Elbows (*8MPT/*SMPV) FIRE HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. Use wrench to hold furnace gas control valve when turning elbows and gas line to prevent damage to the gas control valve and furnace. 6. Use two pipe wrenches when making connections vent gas valve from turning. to pre- NOTE: If local codes allow the use of a flexible gas appliance connector, always use a new listed connector.
PAGE 20
CARBON MONOXIDE POISONING HAZARD Ensure furnace is equipped with the correct main burner orifices. Refer to Table 5 or Table 4 for correct orifice size and manifold pressure for a given heating value and specific gravity for natural and propane gas. Failure to follow this warning could result in personal injury, death and/or property damage. NOx inserts for use with Natural Gas units ONLY. If Propane Gas is required, NOx inserts must be removed. Operation Above 2000ft (609.
PAGE 21
MANIFOLDPRESSUREAND ORIFICE SIZE FOR HIGH ALTITUDEAPPLICATIONS NATURAL GAS MANIFOLD PRESSURE MEAN ELEVATION FEET ABOVE SEA LEVEL if(m) 3001to4000 4001to5000 5001to6000 (914.7to 1219.2) (1219.5to 1524) (1524.3 to 1828.8) iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii .... HEATING VALUEat ALTITUDE BTU/CU. FT, 700 0 to2000 (0to609.6) 2001to3000 (609.9to914.4) Orifice Mnfld Pres- No. sure HI (in wc) Orifice MnfldPressure Orifice No.
PAGE 22
FinalGas Piping Check Manifold FIRE OR EXPLOSION HAZARD Failure to follow this warning personal injury and/or death. could result in 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. RISQUE D'EXPLOSION 5. Carefully remove the manifold assembly. 6. Remove the orifices from the manifold and replace them with proper sized orifices. See Figure 18. 7.
PAGE 23
2. Move large hole plug from right to left J-Box location. *8MPV 3. Clip wire tie holding J-Box wires if needed. 4. Move J-Box to alternate location and attach screws removed from left side location. using two If single-stage cooling is used, the Y and G from the thermostat must be connected to the control board Y/Y2 and G to energize cooling blower speed. 5. Position all wires away from hot surfaces, sharp edges, and moving parts.
PAGE 24
Electrical *8MPV Connections Control Connections NOTE: Junction Boxcan be mounted to eitherthe left or right side. 115M 60 Hz. Ground I LowVoltage I TerminalBoard I I I i I r _ SingleStage Thermostat LowVoltage TerminalBoard .......
PAGE 25
10. Ductwork and Filter (Upflow/Horizontal) Duct InstallationRequirements When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside of the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. CARBON MONOXIDE POISONING HAZARD Failure to properly seal personal injury or death.
PAGE 26
See Table 6 for required high-velocity Cabinet Width in (mm) High Velocity Internal Filter in(mm) Bottom 151/2 (393.7) 191/8 (485.8) 223/4 (577.9) 14X25 (355.6 x 635) 16 X 25 * (406.4 x 635) * 20 X 25 (508 x 635)* Air Filter filter sizes. Sizes (max.600 FPM) External Filter Rack Bottom 14X25 (355.6 x 635) NOTE: Disposable, low-velocity filters may be replaced with washable, high-velocity filters providing they meet the minimum size areas for 300 FPM or less.
PAGE 27
Internal Filter in Bottom Return Installation When installing _bottom-mounted filter inside the furnace, install the filter clips on the edge of the bottom duct opening with the wider end of the clips toward the blower, as shown in Figure 26. Clips may be obtained from your distributor or fabricated from sheet metal (Figure 27). Insert filter into side clips first and push filter back until it is fully engaged into back clip.
PAGE 28
The Sub-base for Combustible Floors MUST be used when a downflow furnace is set on a combustible floor, even when the furnace is installed on a coil box. FIRE HAZARD 1. Failure to install furnace on noncombustible subbase could result in personal injury, death and/or property damage. Place furnace on noncombustible subbase on downflow applications, unless installing on non-combustible flooring. The opening in the base is 11/4" (31.8mm) shorter and 11/8" (28.
PAGE 29
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PAGE 30
• • With a parallel flow arrangement, the dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering the furnace. Chilled air going through the furnace could cause condensation and shorten furnace life. Dampers (purchased locally) can be either automatic or manual. Manually or automatically operated dampers MUST be equipped with a means to prevent furnace and air conditioning operation, unless damper is in the full heat or cool position.
PAGE 31
3. Repeat step 2 with jumper wire on R to Wl for Low Heat. NOTE: If meter uses a 2 cubic foot dial, divide results (seconds) by two. NOTE: SWl DIP switch #3 must be in ON position. (See furnace wiring diagram). Return SWl DIP switch #3 to previous setting after check. Refer to Example. The Example is based on a natural gas BTU content of 1,000 BTU's per cubic foot. Ignitor Location in(mm) 21/16(52.4) Example NaturalGas BTUContent per cu. foot 1,000 No.
PAGE 32
Hard-Wired Continuous Fan BlowerAdjustments (*SMPT) Changing Blower Speed ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Turn OFF power to furnace before changing speed taps. NOTE: The speed taps that the manufacturer sets at the factory for this furnace are based on a nominal 400 CFM per ton for cooling and the basic mid range on the temperature rise for heating.
PAGE 33
and DIP SW2 switch #2. EAC will be energized in this mode. Continuous- Fan using "G" NOTE: In heating, the fan will not turn off during furnace ignition and warm up. Energizing the "G" terminal on the furnace control board provides continuous fan operation. This is done by connecting the G terminal of the thermostat to the G terminal on the furnace control board.
PAGE 34
14. Sequence of Operation & Diagnostics for *8MPT The following is the normal operating sequence at factory default settings (SWl OFF/ON/OFF) Cooling (Y) Request: 24VAC signals applied to Y/Y2 & G terminals of FCB (furnace control board). • Cool motor speed is energized after 5 second Cool Fan On Delay time. Y/Y2 & G signals removed from FCB • Coot motor speed is de-energized after 90 second Coot Fan Off Delay time. NOTE: DEHUM not available on the *8MPT models.
PAGE 35
Heating Request with Gas Shut Off: 24 VAC signal applied to Wl terminal of FCB. The FCB will attempt 4 cycles for ignition then go to soft lockout for 3 hours, and then try for ignition again as long as the heat call remains. Power reset will clear lockout. • • • Inducer motor turns on at high speed. Following a 15 second prepurge delay, the ignitor begins warm up. The ignitor glows red-hot for 22 seconds, then turns off. The FCB flashes error code 6.
PAGE 36
15. WiringDiagram*8MPT(TwoStageHeatingwith PSCMotor) I COOL ON COOL OFF DELAY: HiGH I I EAT HEAT EAC 5 SEC DELAY: SWl HEAT =1, SWl OFF DELAY =2 THERMOSTAT SWI TYPE =3 ] ] I DELAY 45 SEC. HUM 1.0A MAX I NED CONTROL SWl SEC.
PAGE 37
16. Sequence of Operation & Diagnostics for *8MPV The following is the normal operating sequence at factory default settings (SWl OFF/ON/OFF, SW2 all OFF) NOTE: SW1 DIP switches (G, Y/Y2, W1, W2 thermostat terminals) and DEHUM (1/4" male quick connect terminal) are located on the FCB. SW2 DIP switches and Y1 and O thermostat terminals are located on the TSlB.
PAGE 38
Wl • • • • signal removed from FCB. The gas valve de-energizes and the main burners go out. The inducer runs at its present speed for a 15 second postpurge period. The fan runs at its present speed. The blower de-energizes after the selected Heat Fan Off Delay time expires timed from the gas valve de-energizing.
PAGE 39
17.
PAGE 40
18. Thermostat Wiring Guide 1. These diagrams are for reference. See thermostat wiring instructions for specific terminal assignments, connections or operation. 8. 24V HUM terminal on furnace control is used to power a humidifier (on call for heat and pressure switch closed) if no HUM thermostat option is available. 2. Humidifier/humidistat with the furnace. 9. 3.
PAGE 41
No HUM and/or DEHUM Terminal available from thermostat. Dehumidify wiring (*MPV models only) Humidifier Wiring (*MPT/MPV models) TSI B NOTE5 NO CONNECTION _] NO CONNECTION TWO-STAGE or VS FURNACE CONTROL SINGLE-STAGE THERMOSTAT OPTIONAL DEHUMIDISTAT (*MPV Models SINGLE-STAGE _] AIR CONDITIONER _] Fq Only) ............--_ .............4_ql_ q Connect 1 to Y/Y2 1-stage AC/HP applications for i , L._. NOTE 3 n DEHUM -U l_q Fq l_q.. ....... .[] 24V HUM -.
PAGE 42
Two-Stage Thermostat with Two-Stage and Single-Stage Air Conditioner Furnace or Variable Speed Furnace (*MPT/MPV Models) TWO-STAGE THERMOSTAT TSIB NOTES ]ii SINGLE STAGE AIR CONDITIONER VS FURNACE CONTROL OPTIONAL r DEHUMIDISTAT , (*MPV Models Only) _ If no DEHUM from _ \ \ \ thermostat available ', i \ Fq i i i Connect 1 to Y1 for2stage AC-HP applications.