Installation, Operation and Maintenance CATEGORY I NATURAL GAS AND LP GAS HIGH EFFICIENCY TWO STAGE VARIABLE SPEED WARM AIR FURNACE MODEL FV 7 95A054 FV95A072 < 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.
Table of Contents INTRODUCTION ....................................................................... 1 SAFETY ..................................................................................... 1 Safety Rules ................................................................... 1 CODES....................................................................................... 3 FURNACE SIZING ..................................................................... 4 AIR CONDITIONING ..............................
INTRODUCTION This 95% efficient gas fired furnace series is CGA / AGA design certified as a Category I (condensing with positive vent pressure) non-direct or direct vent central forced air furnace. It is an upflow, downflow, horizontal left and right furnace suitable for residential and light commercial heating applications from 54,000 to 108,000 BTU/Hr. When installed as a direct vent furnace, all combustion air is supplied directly to the furnace burners through a special air intake system.
DANGER DANGER WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN THE GARAGE.
with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.
FURNACE SIZING The maximum hourly heat loss for each heated space shall be calculated in accordance with the procedures described in Manual J titled, "Load Calculation" published by the Air Conditioning Contractors of America, or by any other method which is suitable for local conditions, provided the results obtained are in substantial agreement with, and not less than those obtained using the procedure described in their manual.
LOCATION of UNIT General Other Considerations: 1. The furnace is not weatherized. Select a dry indoor location. 2. Select a location where the exhaust and combustion air piping can be routed between the furnace and their terminations with a minimum of lengths and fittings. Be sure to check that the proposed termination location will meet code requirements with respect to location and minimum clearances. (See venting section for minimum and maximum limits.) 3.
CLEARANCES FIGURE 2: DIMENSIONS 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 clearance takes precedence over clearance to combustibles. L J F L TABLE 2: CLEARANCES TO COMBUSTIBLES LOOKING AT UNIT AS INSTALLED TOP PLENUM TOP/BOTTOM UPFLOW 1" 1" COUNTERFLOW 0" HORIZONTAL 1" 2.5" 0.5" PLENUM SIDES 0.5" 0.
DUCTWORK WARNING Proper airflow is required for the correct operation of this furnace. Insufficient airflow may cause erratic operation, could cause the furnace to cycle on the high temperature limit, and may damage the heat exchanger. Excessive airflow may result in an excessively noisy duct system and may result in undesirable consequences such as creating uncomfortable drafts and causing drapes or curtains to blow around.
INSTALLATION POSITIONS IMPORTANT The furnace can be installed in any of four positions: Clean and de-burr all pipe cuts. The shavings must not be allowed to block the exhaust, combustion air inlet or condensate drain lines. • Upflow • Downflow • Horizontal left Combustion Air Inlet Connection • Horizontal right The combustion air inlet fitting is a 2” PVC Socket to Pipe Thread adapter. Chose the intake location and open the appropriate knock out.
Instructions for Re-orienting Air Inducer This furnace comes assembled ready for left side or vertical 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.
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.
Downflow Installation The opening in the floor must provide adequate clearances to the combustible material. When the furnace is installed in the downflow position the combustion air and exhaust vent may exit through the left or right side of the cabinet (when viewed in the upflow position.). The inducer is installed so that the left side exits require no rotation. A half-inch of clearance will be required between the plenum and the combustible material.
Horizontal Left Installation Horizontal Right Installation In the horizontal left installation the combustion air and exhaust vent may exit through the top or left side of the cabinet (when viewed in the upflow position). It is not permissible to vent downwards. The inducer is installed so that the top and left side exits require no rotation. In the horizontal right installation the combustion air and exhaust vent may exit through the top or right side of the cabinet (when viewed in the upflow position).
CASE 1: CASE 3: FURNACE LOCATED IN AN UNCONFINED SPACE FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR Unconfined space does not necessarily mean that combustion and ventilation will not have to be introduced from the outdoors, particularly in airtight homes. Refer to the appropriate installation code requirements regarding the minimum combustion air required for all fuel burning appliances located within the unconfined area.
FURNACE VENTING DANGER Direct Venting Pipe Connections The following types of installation sites (but not limited to the following) will require OUTDOOR AIR for combustion because of chemical exposures: commercial buildings, buildings with indoor swimming pools, furnaces installed in laundry rooms, furnaces in hobby or craft rooms, furnaces installed near chemical storage areas. (USING OUTDOOR COMBUSTION AIR) The direct vent configuration is the preferred installation method.
Air Filters Exhaust Vent Piping IAQ types of air filters may cause higher static, higher temperature rise and erratic furnace operation and, with an ECM drive, can cause blower over speed more noise. Also the consumer may at some time want to add UV treatment, and electrostatic air cleaners or HEPA filters. Thus the return duct should be sized larger than traditionally and also more clearance space allow around the return duct for future equipment.
JOINING PIPE AND FITTINGS CAUTION Acceptable Materials for Combustion Air and Exhaust Vent Pipe FAILURE TO FOLLOW ALL VENTING GUIDELINES MAY RESULT IN ERRATIC FURNACE OPERATION, FREEZE-UP OF THE VENTILATION AIR PIPING, OR SOOTING OF THE FURNACE. The furnace products of combustion include both flue gases and condensate. All venting and drain materials are plastic. Guidelines The combustion air and vent piping and fittings may be comprised of: • Venting may be vertical or horizontal.
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. IMPORTANT After cutting pipe, remove all ragged edges and burrs. This will reduce restriction (pressure drop) throughout the venting and combustion air system. 1. Cut the pipe end square. Chamfer edge of pipe.
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.
TERMINATION OF COMBUSTION AIR AND VENTILATION PIPE USING A CONCENTRIC VENTING KIT The concentric venting terminal has the combustion air intake built into the assembly. If using the concentric vent terminal, there must be a minimum of 12” clearance to grade or anticipated snow level. There are no means available to raise the terminal externally. If planning to use this terminal kit, see Figures 5 and 6. Concentric venting terminal kits may be used for this series furnace.
HORIZONTAL TERMINATION OF COMBUSTION AIR AND EXHAUST VENT Horizontal Combustion Air Termination If the required clearance to grade or anticipated snow level cannot be obtained with the “straight through” configuration, the exhaust pipe may be “periscoped” up to 24” to gain extra height. (Figure 9) In this case, the flue gases may be expelled horizontally. Use the same size pipe as the interior run and count the fittings and length as part of the total vent length.
B A B E C MULTIPLE VENTING VERTICAL TERMINATION OF COMBUSTION AIR AND EXHAUST VENT D F IMPORTANT H When installing multiple furnaces in close proximity, TOP VIEW each requires dedicated combustion A B air and exhaust venting. E Vertical Combustion Air Termination D a pair of 2” medium or The combustion air termination is long sweep 90° elbows pointing downward to prevent rain C from entering the combustion air intake piping.
NON-DIRECT VENT FURNACE INSTALLATIONS (USING INDOOR COMBUSTION AIR) IMPORTANT If the furnace is to be installed in the vicinity of other fuel burning appliances, adequate combustion air must be available for the non-direct vent appliances. See Section 10 of this manual, “Determining Combustion Air.” The furnace, although designed as a direct vent type appliance, may be installed with the intake vent inside the structure. Non-direct vent installations require only an exhaust vent pipe.
Other Then Direct Vent Terminal Clearances A = B = C = D = E F G H = = = = I = J = K = L = M = * ** *** Clearance above grade, veranda, porch, deck, or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft(61 cm) from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Cleara
Direct Vent Terminal Clearances A B C D E F G H I J K L M = Clearance above grade, veranda, porch, deck, or balcony = Clearance to window or door that may be opened = Clearance to permanently closed window = Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 ft(61 cm) from the center line of the terminal = Clearance to unventilated soffit = Clearance to outside corner = Clearance to inside corner = Clearance to each side of center line extended above
CONDENSATE DRAINS The furnace will condense as much as a half pound of water per hour (approximately 2 imperial quarts, 21/2 U.S. quarts or 21/4 liters). It is necessary to make provisions for draining the condensate away. The furnace is supplied with a drain trap assembly. See page 26, Figures 11-14 for possible locations of the drain trap. DRAIN PIPING Condensate from the outlet of the drain trap assembly must be conveyed to a floor drain, sump pit, or, if these are unavailable, to a condensate pump.
HORIZONTAL FLOW LEFT HORIZONTAL FLOW RIGHT CONDENSATE TRAP CONDENSATE TRAP FIGURE 11 FIGURE 12 DOWNFLOW UPFLOW CONDENSATE TRAP CONDENSATE TRAP FIGURE 14 FIGURE 13 26
CONDENSATE DRAIN INSTALLATION 1. 2. 3. 4. 5. 7. Identify which side the condensate drain trap will be installed on the unit. Condensate trap may be mounted on either the left or right side of the unit, when looking at the front. Some installation positions will only allow one option to mount the drain. Using the appropriate template (left vs. right), mark the mounting and drain holes.
Install a manual gas shutoff valve and drip leg as close to the furnace as possible. Some local codes call for the manual gas shutoff valve to be located between 4 to 5 feet above floor level to prevent tampering by small children. Ensure that the valve is readily accessible. GAS SUPPLY WARNING THIS FURNACE IS FACTORY EQUIPPED TO BURN NATURAL GAS ONLY. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector.
Gas piping that has not been pressure tested, from the manual shutoff valve to the furnace gas valve for example, should be leak tested using an electronic combustible gas detector, a commercially prepared leak detector such as Gas Leak Detector® or Search®, or other locally approved method. A leak detector solution can be prepared by mixing a small quantity of dish detergent with water and daubing it onto the gas piping and connections. WARNING NEVER PURGE A GAS LINE INTO THE COMBUSTION CHAMBER.
For USA HIGH ALTITUDE SPECIFICATIONS Rating Plate Input BTU/hr 54,000 72,000 90,000 108,000 Altitude(ft) Low Fire Orifice High Fire Input Output Input Output Natural Gas LP Gas (BTU/hr) (BTU/hr) (BTU/hr) (BTU/hr) (mm)* (mm)** 0-2000 2000-3000 3000-4000 4000-5000 5000-6000 0-2000 2000-3000 3000-4000 4000-5000 5000-6000 0-2000 2000-3000 3000-4000 4000-5000 5000-6000 0-2000 2000-3000 3000-4000 4000-5000 54000 47520 45360 43200 41040 72000 63360 60480 57600 54720 90000 79200 75600 72000 68400 108000 950
SETTING THE MANIFOLD (Outlet) GAS PRESSURE (F92-1003 36G Valve Pressure Check Kit) The manifold outlet pressure is specified on the rating plate. 1. Shut off the gas upstream of valve and move valve switch to OFF. 2. Using the 3/32 inch hex wrench that is included in the valve pressure check kit, rotate outlet pressure tap screw one revolution counter-clockwise. 3. Attach the 5/16 inch hose that is included in the valve pre check kit to the outlet pressure boss of the valve.
IMPORTANT ELECTRICAL SPECIFICATIONS USE COPPER CONDUCTORS ONLY Before proceeding with the electrical connections, ensure that the available electrical supply is compatible with the voltage, frequency, and phase listed on the appliance rating plate. If the junction box must be moved to the right hand side: 1. Unfasten the junction box from the left hand side. 2. Remove the right side panel knockout. 3. Remove the junction box cover hook screw and reinstall it on the opposite side of the box. 4.
WARNING ISOLATION RELAY Make adjustments to the controller with the electrical power off. THERMOSTAT R G Y COOLING CONTACTOR Y W START UP PROCEDURES This furnace is equipped with a hot surface ignition (HSI) device. Each time that the room thermostat calls for heat, the HSI lights the main burners directly. See the lighting instructions on the furnace. G FAN RELAY To Start The Furnace: W HEATING RELAY 115V 1. Remove the burner compartment access door. 2.
6. The circulating fan begins 30 seconds after flame is sensed. 7. Furnace continues to run in this state until a call for second stage heat (W1 and W2) after a call for first stage heat will energize the inducer at high speed and the circulator high heat. The second stage pressure switch contacts will close and energize the second stage gas valve (high fire). 8. When the second stage of the thermostat is satisfied, the inducer motor is reduced to low speed and the second stage gas valve is de-energized.
The formula for determining the furnace input via the gas meter test dial is: Input = Heating Value of Gas X 3000 Time in Sec. for 1 cu. ft. A temperature rise within 35-65 degrees F is acceptable when the furnace is operating with both stages of heat on. If a higher temperature rise is desired, refer to the dip switch settings for “Heating”. This can be adjusted to Nominal-Plus to reduce the air temperature rise or Nominal-minus to increase the air temperature rise.
DIP Switch Configurations Cool Switch Rating Plate Jumper Input BTU/hr Description 54,000 72,000 90,000 108,000 Cool Cool Cool Cool AC Tonnage ADJUST (NORM) ADJUST (-) A 3.0 2.5 B 2.5 2.0 C 2.0 D Heating Rating Plate Jumper Input BTU/hr Rise A 50 B 45 1.5 C 55 1.5 1.0 D 60 A 3.5 3.0 A 50 B 3.0 2.5 B 45 C 2.0 1.5 C 55 D 1.0 1.0 D 60 A 5.0 4.0 A 50 B 3.5 3.0 B 45 C 2.5 2.0 C 55 D 1.5 1.0 D 60 A 5.0 4.0 A 50 B 3.5 3.
1 On 1150 3a A Off 2 S3 70-4 Cool Off 1 1000 2.5 B On 2 On 1 810 2 C On 2 On 1 ADJUSTING BLOWER SPEEDS D 650 1.5 2 On Cooling Mode Switch 1 Off b 1550 4AC Tap A The unit is factory set to provide the highest airflow. Model CFM Off 2 Desc. Bank to Switch Pos.furnace with be made match the Adjustments can Tona smallOn or jumper settings, er cooling coil by changing the1DIP switch 1 Off board. 1350 Refer 3.5b to B located on the integrated ignition control A 3.
5 6 5 6 B C D On On On On B D Off On Off On 30 30 180 30 TABLE 8 MAINTENANCE 6. WARNING DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE. 7. 8. Air Filter The filter should be inspected frequently and cleaned as necessary. We recommend a monthly inspection at first, perhaps coinciding with the arrival of the monthly fuel bill as a reminder.
Electrical WARNING WARNING DISCONNECT THE ELECTRICAL POWER SUPPLY TO THE FURNACE BEFORE ATTEMPTING THIS MAINTENANCE PROCEDURE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR LOSS OF LIFE. ALL WIRING INSIDE THE FURNACE MUST HAVE A MINIMUM TEMPERATURE RATING OF 105C. Troubleshooting All electrical connections should be examined to ensure that they are tight and corrosion free. Repair any connections that have become loose or corroded.
TABLE 9 LED FLASH(ES) INDICATES (FEDDERS UTEC 1170-25 CONTROLLER) CHECK and REPAIR Green Off Internal controller or Room Air Fan failure. DO NOT operate on heat until Fan failure cleared. Roll-out open. Cycle power to reset. 1. Replace Integrated Furnace Control. 2. Rollouts or Fan failure– see 5 Red Flashes. 1 Red Flame sensed with gas valve de-energized. Mis-wiring is probable cause. 2 Red Pressure switch(es) remains open. Combustion Blower cycles until low pressure switch closes.
TABLE 10 : GENERAL TROUBLESHOOTING INTEGRATED FAN CONTROL IF Induced blower does not energize Induced blower does not energize Induced blower is energized AND 1. Induced blower wiring. 3 Flash code does come on 1. Pressure switch stuck closed. 2 Flash code does not come on 2 Flash code comes on Induced blower turns off Pre-purge time has expired HSI element does not glow red within 10 seconds. HSI element i s glowing red.
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User’s Information Manual TABLE OF CONTENTS FURNACE COMPONENTS . . . . . . . . . . . . . . . . . .1 WARNING WHAT TO DO IF YOU SMELL GAS: REGULATOR VENT . . . . . . . . . . . . . . . . . . . . . . .1 • DO NOT TRY TO LIGHT ANY APPLIANCE GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . .1 • DO NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR BUILDING FURNACE OPERATION INFORMATION • LEAVE THE BUILDING IMMEDIATELY TO START THE FURNACE . . . . . . . . . . . . . .
GENERAL SAFETY RULES FURNACE COMPONENTS 1. Combustible materials should not be stored against or around the furnace. Keep the furnace area clear and free from all combustible materials such as newspapers, rags, cardboard, clothing, etc. This applies especially to gasoline and other flammable vapors and liquids. FIGURE 1 FURNACE COMPONENTS Rollout Switch 2. A furnace needs adequate amounts of combustion and ventilation air to operate properly.
FURNACE OPERATION INFORMATION Furnace Shutdown Procedure During the heating season, the operation of the furnace is fully automatic. 1. Set the thermostat to its lowest setting. To Start The Furnace: 3. Turn the appliance manual shutoff valve to the "OFF" position. 1. First read these instructions and safety notices thoroughly. 2. Set the thermostat to the lowest setting. 3. Ensure that all supply air registers and return air grilles are open. 4. Turn off the electric power to the furnace. 2.
MAINTENANCE • The furnace should be well supported on a level floor or by the means used to suspend the furnace in a horizontal configuration. Base support should be physically sound without sagging, cracks, gaps, etc. around the base so as to provide a seal between the support and the base. • Check the furnace for obvious signs of deterioration. • The gas burner should be observed from time to time during the heating season to ensure that the flames are clean and blue.
The furnace achieves its mid-efficiency in two general areas. First, there is no wasteful standing pilot. The furnace consumes no gas in between cycles. Secondly, the furnace is designed to allow very small amounts of excess air in the combustion process. Older furnaces had heat exchangers that were commonly 40% larger than necessary for complete combustion.