International comfort products F8MXL Installation Instructions Manual Download

Page: 1 / 49

Portions of the text and tables are reprinted from NFPA 54 /ANSI Z223.1

−

2012

, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washing-

ton, 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.

Printed in U.S.A.

441 01 1411 04 July 2013

INSTALLATION INSTRUCTIONS

80% Single Stage, ECM Motor

Category I, Gas Furnace

F8MXN, G8MXN, F8MXL, G8MXL

These instructions must be read and understood completely before attempting installation.

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE

Signal Words in Manuals

The signal words

DANGER, WARNING

CAUTION

and

NOTE

are used to identify levels of hazard seriousness. The signal word

DANGER

is only used on product labels to signify an immediate

hazard. The signal words

WARNING

CAUTION

, and

NOTE

will

be used on product labels and throughout this manual and other
manual that may apply to the product.

The signal word

WARNING

is used throughout this manual in

the following manner:

The signal word

CAUTION

is used throughout this manual in

the following manner:

WARNING

DANGER

−

Immediate hazards which will result in severe person-

al injury or death.

WARNING

−

Hazards or unsafe practices which could result in

severe personal injury or death.

CAUTION

−

Hazards or unsafe practices which may result in

minor personal injury or product or property damage.

NOTE

−

Used to highlight suggestions which will result in en-

hanced installation, reliability, or operation.

CAUTION

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures

or product labels.

Safety

−

alert symbol

When you see this symbol on the unit and in instructions or manu-

als, be alert to the potential for personal injury.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CODES AND STANDARDS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMBUSTION AND VENTILATION AIR

. . . . . . . . . . . . . . . . . . . . .

DUCT SYSTEMS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACOUSTICAL LINING AND FIBROUS GLASS DUCT

. . . . . . . . . .

GAS PIPING AND GAS PIPE PRESSURE TESTING

. . . . . . . . . .

ELECTRICAL CONNECTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VENTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FOR COMBUSTION AND VENTILATION

. . . . . . . . . . . . . . . . .

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UPFLOW INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DOWNFLOW INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HORIZONTAL INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILTER ARRANGEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR DUCTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GAS PIPING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND MAINTENANCE PROCEDURES

. . . . . . . . . . . . .

SEQUENCE OF OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING GUIDE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of the AHRI Certified TM Mark indic-

ates a manufacturer’s participation in the

program. For verification of certification for

individual products, go to www.ahridirect-

ory.org .

WARNING

PERSONAL INJURY, AND/OR PROPERTY

DAMAGE HAZARD

Failure to carefully read and follow this warning could

result in equipment malfunction, property damage,

personal injury and/or death.

Installation or repairs made by unqualified persons

could result in equipment malfunction, property

damage, personal injury and/or death.

The information contained in this manual is intended for

use by a qualified service technician familiar with safety

procedures and equipped with proper tools and test

instruments.

Installation must conform with local building codes and

with the Natural Fuel Gas Code (NFCG) NFPA

54/ANSI Z223.1

INSTALLER:

Affix these instructions on or adjacent to the furnace.

CONSUMER:

Retain these instructions for future reference.

Summary of Contents for F8MXL

Page 1: ...uct Labeling Signal words are used in combination with colors and or pictures or product labels Safety alert symbol When you see this symbol on the unit and in instructions or manu als be alert to the potential for personal injury TABLE OF CONTENTS SAFETY CONSIDERATIONS 3 INTRODUCTION 4 CODES AND STANDARDS 4 SAFETY 4 GENERAL INSTALLATION 5 COMBUSTION AND VENTILATION AIR 5 DUCT SYSTEMS 5 ACOUSTICAL...

Page 2: ...roduct Data literature for specific use of single side inlets The use of both side inlets a combination of 1 side and the bottom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM Table 1 Dimensions FURNACE SIZE A B C D VENT CABINET WIDTH IN MM OUTLET WIDTH IN MM TOP AND BOTTOM FLUE COLLAR IN MM BOTTOM WIDTH IN MM VENT CONNECTION SIZE IN MM SHIP WT ...

Page 3: ...et 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 CAUTION 1 Use only with type of gas approved for this furnace Refer to the furnace rating plate 2 Install this furnace only in a location and position as specified in the Location section of these instructions 3 Provide adequate combust...

Page 4: ...t not exceed 85_F 29_C db Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls See Figure 3 For accessory installation details refer to the applicable instruction literature NOTE Remove all shipping brackets and materials before operating the furnace Figure 2 Clearances to Combustibles CODES AND STANDARDS Follow all national and local ...

Page 5: ...vicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electrostatic potential CAUTION 1 Disconnect all power to the furnace Multiple discon ne...

Page 6: ... combust ible label The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures S Commercial buildings S Buildings with indoor pools S Laundry rooms S Hobby or craft rooms and S Chemical storage areas CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death and unit component damage Corrosive or conta...

Page 7: ...t also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained between 55_F 13_C and 80_F 27_C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions The ...

Page 8: ... they must be equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with S U S installations Section 9 3 of the NFGC NFPA54 ANSI Z223 1 2012 Air for Combustion and Ventilation and applicable provisions of the...

Page 9: ...in death and or personal injury Many homes require air to be supplied from outdoors for furnace combustion ventilation and dilution of flue gases The furnace combustion air supply must be provided in accordance with this instruction manual WARNING The Standard Method 1 The space has no less volume than 50 cubic feet per 1 000 Btuh of the maximum input ratings for all gas ap pliances installed in t...

Page 10: ...ints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines etc Combination of Indoor and Outdoor Air 1 Indoor openings shall comply with the Indoor Combus tion Air Method below and 2 Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previ ously and...

Page 11: ...ownflow subbase is used install as shown in Figure 12 If coil model numbers END4X ENW4X or coil casing model number NAEA are used install as shown in Figure 13 NOTE It is recommended that the perforated supply air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory supplied cased coil or coil casing To remove the supply air duct flange use wide d...

Page 12: ...nace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace WARNING The furnace can be installed horizontally in an attic or crawl space on either the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or trusses or installed on a non combust...

Page 13: ...led to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in 25 mm clearance from combustible materials to supply air ductwork for a distance of 36 in 914 mm horizontally from the furnace See NFPA 90B or local code for further requirements Ductwork Acoustical Treatment NOTE Metal duct systems that do not have a 90 degree elbow and 10 ft 3 M of main...

Page 14: ...MIN YES 120 MIN 90 90 A02020 Figure 15 Horizontal Unit Suspension 1 4 6mm THREADED ROD 4 REQ SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 8 x3 4 19mm SCREWS TYPICAL FOR 2 SUPPORTS 1 25mm SQUARE 1 1 4 x1 1 4 x1 8 32x32x3mm ANGLE IRON OR UNI STRUT MAY BE USED 2 HEX NUTS 2 WASHERS 2 LOCK WASHERS REQ PER ROD 8 203mm MIN FOR DOOR REMOVAL OUTER DOOR ASSEMBLY A10130 ...

Page 15: ...R FRAMING GAS ENTRY 17 3 4 451mm OVERALL 4 3 4 121mm UNDER DOOR 1 25mm UNDER FURNACE EXTEND OUT 12 305mm FROM FACE OF DOOR WHEN USED WITH SINGLE WALL VENT CONNECTIONS UNION 152mm 451mm 559mm A10164 Return Air Connections FIRE HAZARD Failure to follow this warning could cause personal injury death and or property damage Never connect return air ducts to the back of the furnace Refer to the followin...

Page 16: ...from meter to furnace NOTE In the state of Massachusetts 1 Gas supply connections MUST be performed by a li censed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 inches 915 mm 3 When lever handle type manual equipment shutoff valves are used they shall be T handle valves 4 The use of copper tubing for gas piping is NOT ap proved by the state of Mas...

Page 17: ...uired for each return air inlet Airflow performance included 3 4 in 19 mm washable filter media such as contained in factory authorized accessory filter rack To determine airflow performance without this filter assume an additional 0 1 in w c available external static pressure Indicates unstable operating conditions Table 6 Maximum Capacity of Pipe NOMINAL IRON PIPE INTERNAL DIAMETER LENGTH OF PIP...

Page 18: ...ons 5 TONS AND GREATER 2000 CFM AND GREATER AT 6 ESP HI COOLING SPEED Figure 21 Downflow Return Air Configurations and Restrictions 5 TONS AND GREATER 2000 CFM AND GREATER AT 6 ESP HI COOLING SPEED Figure 22 Horizontal Return Air Configurations and Restrictions 5 TONS AND GREATER 2000 CFM AND GREATER AT 6 ESP HI COOLING SPEED ...

Page 19: ...proper wire gauge Do not use gas piping as an electrical ground WARNING FURNACE MAY NOT OPERATE Failure to follow this caution may result in intermittent furnace operation Furnace control must be grounded for proper operation or else control will lock out Control must remain grounded through green yellow wire routed to gas valve and manifold bracket screw CAUTION 115 V WIRING Verify that the volta...

Page 20: ...s as shown in Figure 26 Use best practices NEC in U S for wire bushings strain relief etc 13 Reinstall cover to J Box Do not pinch wires between cover and bracket Figure 23 Relocating J Box FACTORY INSTALLED LOCATION ALTERNATE FIELD LOCATION Figure 24 Field Supplied Electrical Box on Furnace Casing A10141 POWER CORD INSTALLATION IN FURNACE J BOX NOTE Power cords must be able to handle the electric...

Page 21: ...rol relay connected to EAC terminals may be added if humidifier operation is desired during blower operation NOTE DO NOT connect furnace control HUM 24VAC terminal to H humidifier terminal on humidity sensing thermostat or similar device See humidity sensing thermostat thermostat or controller manufacturer s instructions for proper connection Figure 25 Furnace Control ÏÏÏÏ ÏÏÏÏ ÏÏÏÏ ÏÏÏÏ TWINNING ...

Page 22: ... FURNACE COM R W C Y R G GND GND FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING Connect Y Y2 terminal as shown for proper operation Some thermostats require a C terminal connection as shown If any of the original wire as supplied must be replaced use same type or equivalent wire 208 230 OR 460 VOLT THREE PHASE 208 230 VOLT SINGLE PHASE WHT BLK...

Page 23: ...ECM Single Stage Furnace with Single Stage Heat Pump Dual Fuel Figure 30 ECM Single Stage Furnace with Two Stage Heat Pump Dual Fuel Figure 31 ECM Single Stage Furnace and Humidifier Only Figure 32 AC with ECM Single Stage Furnace Humidi fier and Dehumidification See notes 5 and 6 ...

Page 24: ...rizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building ...

Page 25: ... having jurisdiction approves If all of these conditions cannot be met an alternative venting design shall be used such as the listed chimney adapter kit with these furnaces which are listed for use with the kit a listed chimney lining system or a Type B common vent Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair an...

Page 26: ...such products in the combustion air supply Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds causing premature failure of the furnace or venting system due to corrosion Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system Do not use vent dampers on appliances common vented with...

Page 27: ...27 441 01 1411 04 Specifications are subject to change without notice Figure 34 Chimney Inspection Chart ...

Page 28: ... approved by the authority having jurisdiction Select the listed mechanical venter to match the Btuh input of the furnace being vented Follow all manufacturer s installation requirements for venting and termination included with the listed mechanical venter Caution For the following applications use the minimum vertical vent heights as specified below For all other applications follow exclusively ...

Page 29: ...se figures A03210 Figure 38 Downflow Application Vent Elbow Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Figure 39 Downflow Application Vent Elbow Left then Up SEE NOTES 1 2 4 5 6 7 8 9 on the page following these figures A03207 Figure 40 Downflow Application Vent Elbow Up then Right SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures A03212 ...

Page 30: ... Left then Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03219 Figure 46 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03216 Figure 47 Horizontal Right Application Vent Elbow Left SEE NOTES 1 2 4 5 7 8 9 A02068 Venting Notes for Figure 35 Figure 47 1 For common vent vent connector sizing and vent material United States u...

Page 31: ... door Door must be in place to operate furnace 6 Replace outer door Step 2 Start Up Procedures FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause personal injury death and or property damage 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 WARNING 1 Purge gas lines after al...

Page 32: ...able 10 11 13 and 14 Use only factory supplied orifices See EXAMPLE 1 Table 10 Altitude Derate Multiplier for U S A ALTITUDE FT M PERCENT OF DERATE DERATE MULTIPLIER FACTOR 0 2000 0 610 0 1 00 2001 3000 610 914 8 12 0 90 3001 4000 914 1219 12 16 0 86 4001 5000 1219 1524 16 20 0 82 5001 6000 1524 1829 20 24 0 78 6001 7000 1829 2134 24 28 0 74 7001 8000 2134 2438 28 32 0 70 8001 9000 2438 2743 32 36...

Page 33: ...temperature rise is outside this range first check 1 Gas input for heating operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restric tions causing static pressures greater than 0 50 in w c c Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise d Turn thermostat d...

Page 34: ... safe shut down of the furnace during certain blocked vent condi tions a Verify vent pipe is cool to the touch b Disconnect power to furnace and remove vent con nector from furnace vent elbow c Restore power to furnace and set room thermostat above room temperature d After normal start up allow furnace to operate for 2 minutes then block vent elbow in furnace 80 percent of vent area with a piece o...

Page 35: ...248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 ...

Page 36: ...36 441 01 1411 04 Specifications are subject to change without notice Table 13 Orifice Size and Manifold Pressure in w c for Gas Input Rate A10180 ...

Page 37: ...37 441 01 1411 04 Specifications are subject to change without notice Table 13 Orifice Size and Manifold Pressure in w c for Gas Input Rate CONT A10180A ...

Page 38: ...38 441 01 1411 04 Specifications are subject to change without notice Table 14 Orifice Size And Manifold Pressure in w c For Gas Input Rate A10181 ...

Page 39: ...39 441 01 1411 04 Specifications are subject to change without notice Table 14 Orifice Size And Manifold Pressure in w c For Gas Input Rate CONT A10181A Figure 51 Service Label ...

Page 40: ...gure 26 for field wiring information and to Figure 55 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash a status code 10 and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the ...

Page 41: ...warning could result in personal injury or death Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes WARNING NOTE The blower wheel should not be dropped or bent as balance will be affected The following steps should be performed by a qualified service agency To e...

Page 42: ...ng and cool ing cycle Verify the furnace temperature rise as shown in Adjustments Section Adjust temperature rise as shown in Adjustments Section If outdoor temperature is below 70_F 21_C turn off circuit breaker to outdoor unit before running furnace in the cooling cycle Turn outdoor circuit breaker on after completing cooling cycle CLEANING HEAT EXCHANGER The following steps should be performed ...

Page 43: ... or aromatic content which may prevent an inadequate seal from occuring and RTV sealant such as G E RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant are required DO NOT substitute any other type of RTV sealant 12 Apply new sealant to flange of collector box and attach to cell panel using existing screws making sure all screws are secure 13 Reconnect wires to the following components Use connect...

Page 44: ...e and operate the inducer motor IDM until flame is no longer proved e Blower On Delay If the burner flame is proven the blower motor is energized on HEAT speed 25 seconds after the gas valve GV is energized Simultaneously the electronic air cleaner terminal EAC 1 AMP is energized and remains energized as long as the blower motor BLWM is energized f Heat Off Delay When the thermostat is satisfied t...

Page 45: ... continuous blower speed When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM operation 5 Heat pump See Figure 26 Figure 33 for thermostat connec tions When installed with a heat pump the furnace control automatically changes the timing sequence to avoid long blower off times during demand defros...

Page 46: ...46 441 01 1411 04 Specifications are subject to change without notice Figure 55 Wiring Diagram ...

Page 47: ...47 441 01 1411 04 Specifications are subject to change without notice Figure 56 Troubleshooting Guide Single Stage ...

Page 48: ...48 441 01 1411 04 Specifications are subject to change without notice NOTE NUMBER IN UPPER LEFT HAND CORNER REPRESENTS FLASH CODE ...

Page 49: ...70 000 BTU hr 090 90 000 BTU hr 110 110 000 BTU hr 135 135 000 BTU hr HEAT INPUT 14 143 16 17 171 2 21 21 24 241 2 CABINET WIDTH 08 800 CFM 12 1200 CFM 14 1400 CFM 16 1600 CFM 20 2000 CFM 22 2200 CFM COOLING AIRFLOW SALES MAJOR REVISION DIGIT ENGINEERING MINOR REVISION DIGIT TO OBTAIN INFORMATION ON PARTS Consult your installing dealer or the classified section of your local telephone directory un...

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