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Installation, Operation and Maintenance
CATEGORY I NATURAL GAS AND LP GAS
HIGH EFFICIENCY
TWO STAGE VARIABLE SPEED
WARM AIR FURNACE
FV95A054 FV95A072 <
MODEL 77
FV95A090 <
FV95A108
For future reference write down the model, serial
number, and date of purchase. Use these numbers in
any correspondence or service calls concerning your
furnace.
Model
Serial Number
Date of Purchase
Keep these instructions for future reference.
Please read the operating instructions and safety
precautions care
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Table of Contents GAS SUPPLY ............................................................................. 28 INTRODUCTION ....................................................................... 1 SAFETY ..................................................................................... 1 Gas Piping ..................................................................... 28 Leak Testing ................................................................. 28 Safety Rules..............................
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6. Always install furnace to operate within the furnace’s INTRODUCTION intended temperature rise range with a duct system This 95% efficient gas fired furnace series is CGA / AGA which has an external static pressure within the design certified as a Category I (condensing with positive allowable range, as specified in the Furnace Sizing vent pressure) non-direct or direct vent central forced air fur- section on page 4, the Ductwork section on page 7, and nace. It is an upflow, downflow, horizont
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DANGER DANGER WHAT TO DO IF YOU SMELL GAS: WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND • DO NOT TRY TO LIGHT ANY APPLIANCE IGNITION SOURCE ARE LOCATED NO LESS THAN 18 • DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT INCHES ABOVE THE FLOOR TO PREVENT THE RISK OF USE ANY PHONE IN YOUR BUILDING IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN THE GARAGE. • IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE, OR A CELLULAR PHONE FROM A THE FURN
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with an alarm is installed on each additional level of CODES: the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall This furnace must be installed: be the responsibility of the property owner to secure • In accordance with all local codes, bylaws and the services of qualified licensed professionals for the regulations by those authorities having jurisdiction installation of hard wired carbon monoxide detectors. • In the United States, this f
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Existing ductwork should be assessed for its air handling FURNACE SIZING capabilities. For residential applications, the recommended The maximum hourly heat loss for each heated space shall air velocity of a supply air trunk duct is 700 feet per minute be calculated in accordance with the procedures described (fpm), and should not exceed 900 fpm. The recommended in Manual J titled, "Load Calculation" published by the Air air velocity of a supply air branch run is 600 fpm, and should Conditioning
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LOCATION of UNIT Other Considerations: General 1. This furnace is not to be used for temporary heating of buildings or structures under construction. 1. The furnace is not weatherized. Select a dry indoor location. 2. If this furnace is to be used with air conditioning and is to be installed in an area over a finished ceiling or 2. Select a location where the exhaust and combustion air living area, install a field fabricated auxiliary drain pan piping can be routed between the furnace and their
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FIGURE 2: DIMENSIONS CLEARANCES Table 2 provides the certified clearances to combustibles. 1 IMPORTANT K G This furnace requires a minimum of 24-inches of front clearance for service purposes. For this purpose, service L clearance takes precedence over clearance to F J combustibles. L TABLE 2: CLEARANCES TO COMBUSTIBLES B A UPFLOW COUNTERFLOW HORIZONTAL G TOP 1" 0" 2" PLENUM 1" 1" 2.5" TOP/BOTTOM PLENUM SIDES 0.5" 0.5" 0.5" UNIT FRONT 0" * 0" * 0" * UNIT BACK 0" 0" 0" C UNIT SIDES 0" 0" 1" ** UN
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DUCTWORK WARNING Proper airflow is required for the correct operation of this DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT furnace. Insufficient airflow may cause erratic operation, RETURN OR SUPPLY AIR DUCTWORK TO OR FROM ANY could cause the furnace to cycle on the high temperature OTHER HEAT-PRODUCING DEVICE SUCH AS A FIREPLACE limit, and may damage the heat exchanger. Excessive INSERT, STOVE, ETC. DOING SO MAY RESULT IN FIRE, airflow may result in an excessively noisy duct system and CARBON MONOX
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INSTALLATION POSITIONS IMPORTANT The furnace can be installed in any of four positions: Clean and de-burr all pipe cuts. The shavings must not • Upflow be allowed to block the exhaust, combustion air inlet or condensate drain lines. • Downflow • Horizontal left Combustion Air Inlet Connection • Horizontal right The combustion air inlet fitting is a 2” PVC Socket to Pipe Maintain clearances to combustibles as outlined in Table 2. Thread adapter. Chose the intake location and open the Support th
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Instructions for Re-orienting Air Inducer This furnace comes assembled ready for left side or vertical FIGURE A : RIGHT INDUCER POSITION venting. Rotate the inducer 180 degrees to exit the right hand side. 1. Disconnect inducer wire connections. 2. Remove pressure switch hoses. 3. Remove pressure switches. 4. Remove 4 inducer screws 5. Remove inducer. 6. Reverse the bands on the rubber drain coupling so the screws are accessible if necessary. (Do not reverse the drain coupling.) Confirm tha
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Upflow Installation The combustion air and exhaust vent may exit through the top, left or right side of the cabinet when viewed in the upflow position. The inducer is installed so that the exhaust vent may exit the top and left sides without requiring rotation. If exhaust vent exits the top panel, use the two street elbows to route the vent. One elbow secured to the inducer drain connector, will angle toward the front of cabinet with the second nested inside directed towards the top panel. (The
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Downflow Installation The opening in the floor must provide adequate clearances When the furnace is installed in the downflow position to the combustible material. the combustion air and exhaust vent may exit through A half-inch of clearance will be required between the the left or right side of the cabinet (when viewed in the plenum and the combustible material. If installed on a upflow position.). The inducer is installed so that the left non-combustible material, zero clearance is required.
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B A A A Horizontal Left Installation Horizontal Right Installation In the horizontal left installation the combustion air and In the horizontal right installation the combustion air exhaust vent may exit through the top or left side of the and exhaust vent may exit through the top or right side cabinet (when viewed in the upflow position). It is not of the cabinet (when viewed in the upflow position). In permissible to vent downwards. The inducer is installed the horizontal right installation,
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CASE 1: CASE 3: FURNACE LOCATED IN AN UNCONFINED SPACE FURNACE LOCATED IN A CONFINED SPACE, OUT- DOOR Unconfined space does not necessarily mean that combus- tion and ventilation will not have to be introduced from AIR FROM ATTIC OR CRAWL SPACE the outdoors, particularly in airtight homes. Refer to the In this circumstance, refer to the appropriate installa- appropriate installation code requirements regarding the tion code for the free area of the combustion and minimum combustion air requir
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FURNACE VENTING DANGER The following types of installation sites (but not limited Direct Venting Pipe Connections to the following) will require OUTDOOR AIR for (USING OUTDOOR COMBUSTION AIR) combustion because of chemical exposures: commercial buildings, buildings with indoor swimming pools, The direct vent configuration is the preferred instal- furnaces installed in laundry rooms, furnaces in hobby lation method. The primary advantages are: or craft rooms, furnaces installed near chemical st
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Air Filters Exhaust Vent Piping IAQ types of air filters may cause higher static, higher WARNING temperature rise and erratic furnace operation and, with an ECM drive, can cause blower over speed more noise. Also NEVER ALLOW THE PRODUCTS OF COMBUSTION FROM the consumer may at some time want to add UV treatment, THE FLUE TO ENTER THE RETURN AIR OR SUPPLY AIR and electrostatic air cleaners or HEPA filters. Thus the return DUCTWORK. duct should be sized larger than traditionally and also more ALL
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JOINING PIPE AND FITTINGS CAUTION Acceptable Materials for Combustion Air and FAILURE TO FOLLOW ALL VENTING GUIDELINES MAY Exhaust Vent Pipe RESULT IN ERRATIC FURNACE OPERATION, FREEZE-UP OF THE VENTILATION AIR PIPING, OR SOOTING OF THE The furnace products of combustion include both flue FURNACE. gases and condensate. All venting and drain materials are plastic. The combustion air and vent piping and fittings may be Guidelines comprised of: • Venting may be vertical or horizontal. • Schedul
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PROCEDURE: Direct Vent Piping Termination This guide is intended specifically for PVC pipe; however, the general procedure applies to all plastic piping systems. CAUTION MATERIALS: PVC Cleaner / Primer and PVC Solvent Cement. Moisture in the flue gases condenses as it leaves the terminal. This moisture can freeze on exterior walls, on IMPORTANT soffits, and other nearby objects. Some discoloration is to be expected; however, improper location or installa- After cutting pipe, remove all ragge
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Recommended clearance for overhangs is a minimum of 1 foot vertically for each foot horizontally up to 6 feet. As a protection against freezing, do not expose a 3 x 2 reducing coupling to outdoor ambient temperatures. Any adjacent painted surfaces should be in good condition; no cracks, peeling paint, etc. If wooden surfaces that may be periodically exposed to flue gases are present, consider treating with a sealer. Calculating Piping Length When calculating allowable vent lengths, be sure to
