Amana Single Stage Gas Furnaces and Accessories Instructions

Amana Single Stage Gas Furnaces and Accessories Instructions

Service and Troubleshooting

This manual is to be used by qualified, professionally trained HVAC technicians only. Goodman does not assume any responsibility for property damage or personal injury due to improper service procedures or services performed by an unqualified person.

Pride and workmanship go into every product to provide our customers with quality products. It is possible, however,
that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.

WARNING

Only personnel that have been trained to install, adjust, service or repair(hereinafter, “service”) the equipment specified in this manual should service the equipment. The manufacturer will not be responsible for any injury or property damage arising from improper service or service procedures. If you service this unit, you assume responsibility for any injury or property damage which may result. In addition, in jurisdictions that require one or more licenses to service the equipment specified in this manual, only licensed personnel should servise the equipment. Improper installation, adjustment, servicing or repair of the equipment specified in this manual, or attempting to install, adjust, service or repair the equipment specified in this manual without proper training may result in product damage, property damage, personal injury or death.

PROP 65 WARNING FOR CALIFORNIA CONSUMERS

WARNING

Cancer and Reproductive Harm – www.P65Warnings.ca.gov

IMPORTANT INFORMATION

IMPORTANT NOTICES FOR CONSUMERS AND SERVICERS RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS
Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual. REVIEW ALL SERVICE INFORMATION IN THE APPROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS.

WARNING

TO PREVENT THE RISK OF PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH, DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE.

WARNING

HIGH VOLTAGE
DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

IMPORTANT INFORMATION

WARNING

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
– DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
– WHATTODOIFYOUSMELLGAS:

• DO NOT TRY TO LIGHT ANY APPLIANCE.
• Do NOT TOUCH ANY ELECTRICAL SWITCH; DO NOT USE ANY PHONE IN YOUR BUILDING.
• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR’S PHONE. FOLLOW THE GAS SUPPLIER’S INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.
  – INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, TURN OFF THE MANUAL GAS SHUTOFF VALVE EXTERNAL TO THE
FURNACE BEFORE TURNING OFF THE ELECTRICAL SUPPLY.

CARBON MONOXIDE POISONING HAZARD

Special Warning for Installation of Furnace or Air Handling Units in Enclosed Areas such as Garages, Utility Rooms or Parking Areas
carbon monoxide producing devices (such as an automobile, space heater, gas water heater, etc.) should not be operated in enclosed areas such as unventilated garages, utility rooms or parking areas because of the danger of carbon monoxide (CO) poisoning resulting from the exhaust emissions. If a furnace or air handler Is Installed in an enclosed area such as a garage, utility room or parking area and a carbon monoxide producing device ls operated therein, there must be adequate, direct outside ventilation. This ventilation is necessary to avoid the danger of CO poisoning which can occur if a carbon monoxide producing device continues to operate in the enclosed area. carbon monoxide emissions can be (re)circulated throughout the structure if the furnace or air handler is operating in any mode.

CO can cause serious illness including permanent brain damage or death.

PRODUCT IDENTIFICATION

The model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information.

PRODUCT IDENTIFICATION

PRODUCT IDENTIFICATION

SYSTEM OPERATION

Safety

WARNING

TO PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE, REFER TO THIS MANUAL. FOR ADDITIONAL ASSISTANCE OR INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

Charge (ESD) Precautions

NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. Use the following precautions during furnace installation and servicing to protect the integrated control module from damage. By putting the furnace, the control, and the person at the same electrostatic potential, these steps will help avoid exposing the integrated control module to electrostatic discharge. This procedure is applicable to both installed and uninstalled (ungrounded) furnaces

1. Disconnect all power to the furnace. Do not touch the integrated control module or any wire connected to the control prior to discharging your body’s electrostatic charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the furnace near the control. Any tools held in a person’s hand during grounding will be discharged.
3.  Service integrated control module or connecting wiring following the discharge process in Step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat Step 2 before touching control or wires.
4. Discharge any static electricity from your body to ground before removing a new control from its container. Follow Steps 1 through 3 if installing the control on a furnace.
   Return any old or new controls to their containers before touching any ungrounded object.

Product Application

This product is designed for use as a residential home gas furnace. It is not designed or certified for use in mobile home, trailer, or recreational vehicle applications. In the U.S.A., this furnace can be used in the following non-industrial commercial applications: Schools, Office buildings, Churches, Retail stores, Nursing homes, Hotels/motels, Common or office areas. In all applications, the furnace must be installed per the installation instructions. Goodman® brand G*ES9* and Amana® brand A*ES9* furnaces are ETL certified. All furnaces are built for use with Natural gas but can be converted for use with LP gas.
(NOTE: If using propane gas, a propane conversion kit is required). Goodman® brand G*ES9* and Amana® brand A*ES9* high efficiency furnaces are dual certified. Dual certification means that the combustion air inlet pipe is optional and the furnace can be vented as a:

• Non-direct vent (single pipe) central forced air furnace in which combustion air is taken from the installation area or from air ducted from the outside or,
• Direct vent (dual pipe) central forced air furnace in which all combustion air supplied directly to the furnace burners through a special air intake system outlined in this manual and the installation instructions.

To ensure proper installation, operation and servicing, thoroughly read the installation and service manuals for specifics pertaining to the installation, servicing and
application of this product. To ensure proper furnace operation, install, operate, maintain and service the furnace in accordance with the installation, operation and service instructions, all local building codes and ordinances. In their absence, follow the latest edition of the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or CAN/CGA B149 Installation Codes, local plumbing or waste water codes, and other applicable codes. A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1)
can be obtained from any of the following:

SYSTEM OPERATION

American National Standards Institute
25 West 43rd Street, 4th Floor
New York, NY 10036
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02169-7471
CSA International
8501 East Pleasant Valley
Cleveland, OH 44131

A copy of the CAN/CGA B149 Installation Codes can be obtained from:
CSA International
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W, 1R3
The rated heating capacity of the furnace should be greater than or equal to the total heat loss of the area to be heated.
The total heat loss should be calculated by an approved method or in accordance with “ASHRAE Guide” or “Manual
J-Load Calculations” published by the Air Conditioning Contractors of America.

Location Requirements and Considerations

WARNING

TO PREVENT POSSIBLE EQUIPMENT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH, THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT.

• Follow the instructions listed below when selecting a furnace location. Refer also to the guidelines provided in the Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.  Centrally locate the furnace with respect to the proposed or existing air distribution system.
• Ensure the temperature of the return air entering the furnace is between 55°F and 100°F when the furnace is heating.
• If the furnace is installed in an application where the typical operating sound level of a furnace is deemed objectionable, an optional sound reduction kit is available. Consult your local distributor for more details.
• Provide provisions for venting combustion products outdoors through a proper venting system. Special consideration should be given to vent/flue pipe routing and combustion air intake pipe when applicable.
• 90% Furnaces: Refer to the Vent/Flue Pipe and Combustion Air Pipe -Termination Locations section in this manual or the installation instructions for appropriate termination locations. Also for 90% furnaces, refer to the Vent/Flue Pipe and Combustion Air Pipe -Termination Locations section in this manual or the installation
  instructions to determine if the piping system from furnace to termination can be accomplished within the guidelines given. NOTE: The length of flue and/
  or combustion air piping can be a limiting factor in the location of the furnace.
• Locate the 90% furnace so that the condensate can be piped at a downward slope away from the furnace to the drain. Do not locate the furnace or its condensate drainage system in any area subject to below freezing temperatures without proper freeze protection. Refer to the Condensate Drain Lines and Trap section in this manual or the installation instructions for further details.
• Set the 90% furnace on a level floor to enable proper condensate drainage. If the floor becomes wet or damp at times, place the furnace above the floor on a concrete base sized approximately 1-1/2” larger than the base of the furnace. Refer to the Horizontal Applications and Considerations section in this manual or the installation instructions for leveling of horizontal furnaces.
• Ensure upflow or horizontal furnaces are not installed directly on carpeting, or any other combustible material. The only combustible material allowed is wood.
•  A special accessory subbase must be used for upright counterflow unit installations over any combustible material (including wood). Refer to subbase instructions
  for installation details. (NOTE: A subbase will not be required if an air conditioning coil is located beneath the furnace between the supply air opening and the
  combustible floor.
• Exposure to contaminated combustion air will result in safety and performance-related problems. Do not install the furnace where the combustion air is exposed to the
  following substances:
  chlorinated waxes or cleaners chlorine-based swimming pool chemicals water softening chemicals deicing salts or chemicals carbon tetrachloride halogen type refrigerants
  cleaning solutions (such as perchloroethylene) printing inks paint removers varnishes hydrochloric acid cements and glues antistatic fabric softeners for clothes dryers
  and masonry acid washing materials Isolate a nondirect furnace from an area contaminated by any of the above substances. This protects the non-direct vent furnace from airborne contaminants. To ensure that the enclosed non-direct vent furnace has an adequate supply of combustion air, vent from a nearby uncontaminated room or from outdoors. Refer to the

SYSTEM OPERATION

Combustion and Ventilation Air Requirements section in this manual or the installation instructions for details.

•  If the furnace is used in connection with a cooling unit, install the furnace upstream or in parallel with the cooling unit coil. Premature heat exchanger failure will result if
  the cooling unit coil is placed ahead of the furnace.
• If the furnace is installed in a residential garage, position the furnace so that the burners and ignition source are located not less than 18 inches (457 mm) above the floor.
  Protect the furnace from physical damage by vehicles.
• If the furnace is installed horizontally, the furnace access doors must be vertical so that the burners fire horizontally into the heat exchanger. Do not install the unit with the
  access doors on the “up/top” or “down/bottom” side of the furnace.

Clearances and Accessibility

Installations must adhere to the clearances to combustible materials to which this furnace has been design certified. The minimum clearance information for this furnace is provided on the unit’s clearance label. These clearances must be permanently maintained. Refer to Specification Sheet for minimum clearances to combustible materials. Clearances must also accommodate an installation’s gas, electrical, and drain trap and drain line connections. If the alternate combustion air intake or vent/flue connections are used on a 90% furnace, additional clearances must be provided to accommodate these connections. Refer to Vent Flue Pipe and Combustion Air Pipe section in this manual or the installation instructions for details. NOTE: In addition to the required clearances to combustible materials, a minimum of 24 inches service clearance must be available in front of the unit. A furnace installed in a confined space (i.e., a closet or utility room) must have two ventilation openings with a total minimum free area of 0.25 square inches per 1,000 BTU/hr of furnace input rating. One of the ventilation openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement

Furnace Suspension

If suspending the furnace from rafters or joist, use 3/8” threaded rod and 2”x2”x1/8” angle iron as shown in the following figure. If the furnace is installed in a crawl space it
must also be suspended from the floor joist or supported by a concrete pad. Never install the furnace on the ground or allow it to be exposed to water. The length of rod will depend on the application and the clearances necessary.

Existing Furnace Removal

NOTE: When an existing furnace is removed from a venting system serving other appliances, the venting system may be too large to properly vent the remaining attached appliances. The following vent testing procedure is reproduced from the American National Standard/National Standard of Canada for Gas-Fired Central Furnaces ANSI Z21.47, latest edition, CSA-2.3b, latest edition Section 1.23.1.

The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:

a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and horizontal pitch, as required by the National Fuel Gas Code, ANSI Z223.1 or the CSA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition;
c. In so 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. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers;
d. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously;
e. Test for draft hood equipped spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle;
f. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use;
g. If improper venting is observed during any of the above tests, the common venting system must be corrected.

SYSTEM OPERATION

Corrections must be in accordance with the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or CSA B149 Installation Codes.
If resizing is required on any portion of the venting system, use the appropriate table in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223.1 and/or CSA B149 Installation Codes.

Thermostat Requirements

A high quality single stage thermostat with a “C” terminal is recommended to control the G*ES9* and A*ES9* furnace.
Thermostat Location In an area having good air circulation, locate the thermostat about five feet high on a vibration-free inside wall. Do not install the thermostat where it may be influenced by any of the following:

• Drafts, or dead spots behind doors, in corners, or under cabinets.
• Hot or cold air from registers.
• Radiant heat from the sun.
• Light fixtures or other appliances.
• Radiant heat from a fireplace.
• Concealed hot or cold water pipes, or chimneys.
• Unconditioned areas behind the thermostat and dehumidistat, such as an outside wall.

COMBUSTION AND VENTILATION AIR REQUIREMENTS

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE FURNACE IS NOT PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF FLUE GASES. MOST HOMES REQUIRE OUTSIDE AIR BE SUPPLIED TO THE FURNACE AREA.

Improved construction and additional insulation in buildings have reduced heat loss by reducing air infiltration and escape around doors and windows. These changes have helped in reducing heating/cooling costs but have created a problem supplying combustion and ventilation air for gas fired and other fuel burning appliances. Appliances that pull air out of the house (clothes dryers, exhaust fans, fireplaces, etc.) increase the problem by starving appliances for air. When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required. However, if this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1 (Section 9.3), or CAN/CGA B149 Installation Codes (Sections 7.2, 7.3, or 7.4), or applicable provisions of the local building codes for determining the combustion air requirements for the appliances.

Most homes will require outside air be supplied to the furnace area by means of ventilation grilles or ducts connecting directly to the outdoors or spaces open to the outdoors such as attics or crawl spaces. The following information on air for combustion and ventilation is reproduced from the National Fuel Gas Code NFPA 54/ANSI
Z223.1 Section 9.3. 9.3* Air for Combustion and Ventilation.

9.3.1 General.
9.3.1.1 Air for combustion, ventilation, and dilution of flue gases for appliances installed in buildings shall be obtained by application of one of the methods covered in 9.3.2 through 9.3.6. Where the requirements of 9.3.2 are not met, outdoor air shall be introduced in accordance with methods covered in 9.3.3 through 9.3.6. Exception No. 1: This provision shall not apply to direct vent appliances.
9.3.1.2 Appliances of other than natural draft design and other than Category 1 vented appliances shall be provided with combustion, ventilation, and dilution air in accordance with the appliance manufacturer’s instructions.
9.3.1.3 Appliances shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air.
9.3.1.4 Where used, a draft hood or a barometric draft regulator shall be installed in the same room or enclosure as the appliance served so as to prevent any difference in pressure between the hood or regulator and the combustion air supply.
9.3.1.5 Makeup air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements.
9.3.2 Indoor Combustion Air. The required volume of indoor air shall be determined in accordance with the method in 9.3.2.1 or
9.3.2.2 except that where the air infiltration rate is known to be less than 0.40 ACH, the method in 9.3.2.2 shall be used. The total required volume shall be the sum of the required volume calculated for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors, and through combustion air openings sized and located in accordance with 9.3.2.3, are considered a part of the required volume.
9.3.2.1* Standard Method. The minimum required volume shall be
50 ft 3 per 1,000/Btu/hour (4.8m3/kW).

SYSTEM OPERATION

9.3.2.2* Known Air Infiltration Rate Method. Where the air infiltration rate of a structure is known, the minimum required volume shall be determined as follows:

1. For appliances other than fan-assisted, calculate using the following
   equation:
   Required Volum e 21 ft3 I other other > ________ _________ ACH 1000 Btu/hr
2.  For fan-assisted appliances, calculate using the following equation:
   15 ft3 I Required Volume fan fan > ________ _________ ACH 1000 Btu/hr
   wher
   I other = all appliances other than fan-assisted input in Btu per hour
   I fan = fan-assisted appliances input in Btu per hour
   ACH = air change per hour (percent of volume of space exchanged per hour, expressed as a decimal)
3. (3) For purposes of this calculation, an infiltration rate greater than 0.60 ACH shall not be used in the equations in 9.3.2.2(1) and 9.3.2.2(2).
   9.3.2.3 Indoor Opening Size and Location. Openings used to connect indoor spaces shall be sized and located in accordance with the following:

(1)* Combining spaces on the same story. Each opening shall have a minimum free area of 1 in.2/1000Btu/hr (2200 mm2/kW) of the total input rating of all appliances in the space but not less than 100 in.2 (0.60m2). One opening shall commence within 12 in. (300 mm) of the top, and one opening shall commence within 12 in. (300 mm) of the bottom, of the enclosure [see Figure A.9.3.2.3(1)]. The minimum dimension of air openings shall be not less than 3 in. (80 mm).

NOTE: Each opening must have a free area of not less than one square inch per 1000 BTU of the total input rating of all equipment in the enclosure, but not
less than 100 square inches.

Figure A.9.2.3.3.(1) All Combustion Air from Adjacent Indoor Spaces through Indoor Combustion Air Openings.

(2) Combining spaces in different stories. The volumes of spaces in different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 in.2/1000 Btu/hr (4400 mm2/ kW) of total input rating of all appliances.
9.3.3 Outdoor Combustion Air. Outdoor combustion air shall be provided through opening(s) to the outdoors in accordance with the method  n 9.3.3.1 or 9.3.3.2. The minimum dimension of air openings shall not be less than 3 in. (80 mm).

9.3.3.1 Two Permanent Openings Method. Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoorsor spaces that freely communicate with the outdoors, as follows:

(1)* Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in.2/4000 Btu/hr (550 min2/kW) of total input rating of all appliances in the enclosure. [See Figure A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).]

Figure A.9.3.3.1(1)(a) All Combustion Air From Outdoors – Inlet Air from Ventilated Crawl Space and Outlet Air to Ventilated Attic.

Figure A.9.3.3.1(1)(b) All Combustion Air From Outdoors through Ventilated Attic.
(2)* Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in.2/2000 Btu/hr (1100
min2/kW) of total input rating of all appliances in the enclosure. [See Figure A.9.3.3.1(2).]

SYSTEM OPERATION

Figure A.9.3.3.1(2) All Combustion Air From Outdoors through Horizontal Ducts

9.3.3.2* One Permanent Opening Method. One permanent openings, commencing within 12 in. (300 mm) of the top of the enclosure, shall be provided. The appliance shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors (see Figure A.9.3.3.2) and shall have a minimum free area of the following:

1. 1 in.2/3000 Btu/hr (700 mm2 per kW) of the total input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in the space
   
   Figure A.9.3.3.2 All Combustion Air From Outdoors through Single Combustion Air Opening.

NOTE: The single opening must have a free area of not less than one square inch per 3000 BTU of the total input rating of all equipment
in the enclosure, but not less than the sum of the areas of all vent connectors in the confined space.

9.3.4 Combination Indoor and Outdoor Combustion Air. The use of a combination of indoor and outdoor combustion air shall be in accordance
with (1) through (3) (see example calculation in Annex J]:

1. Indoor Openings: Where used, openings connecting the interior spaces shall comply with 9.3.2.3.
2. Outdoor Opening(s) Location. Outdoor opening(s) shall be located in accordance with 9.3.3.
3. Outdoor Opening(s) Size. The outdoor opening(s) size shall be calculated in accordance with the following:
   (a) The ratio of the interior spaces shall be the available volume of all communicating spaces divided by the required volume.
   (b) The outdoor size reduction factor shall be 1 minus the ratio of interior spaces.
   (c) The minimum size of outdoor opening(s) shall be the full size of outdoor opening(s) calculated in accordance with 9.3.3, multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in. (80 mm).

9.3.5 Engineered Installations. Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction

9.3.6 Mechanical Combustion Air Supply. Where all combustion air is provided by a mechanical air supply system, the combustion air shall be supplied form outdoors at the minimum rate of 0.35 ft3/min per 1000 Btu/hr (0.034 m3/min per kW) for all appliances located within the space.
9.3.6.1 Where exhaust fans are installed, additional air shall be provided to replace the exhausted air.

9.3.6.2 Each of the appliances served shall be interlocked to the mechanical air supply system to prevent main burner operation where the mechanical
air supply system is not in operation.

9.3.6.3 Where combustion air is provided by the building’s mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.

9.3.7 Louvers, Grilles, and Screens.

9.3.7.1 Louvers and Grilles. The required size of openings for combustion, ventilation, and dilution air shall be based on the net free area of each opening. Where the free area through a design of louver or grille or screen is known, it shall be used in calculating the size opening required to provide the free area specified. Where the louver and grille design and free area are not known, it shall be assumed that wood louvers will have 25 percent free area, and metal louvers and grilles will have 75 percent free area. Nonmotorized louvers and grilles shall be fixed in the open position.

9.3.7.2 Minimum Scree Mesh Size. Screens shall not be smaller than 1/4 in. mesh.
9.3.7.3 Motorized Louvers. Motorized louvers shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main burner operation. Means shall be provided to prevent the main burner form igniting should the louver fail to open during burner startup and to shut down the main burner if the louvers close during burner operation.

9.3.8 Combustion Air Ducts. Combustion air ducts shall comply with
9.3.8.1 through 9.3.8.8.
9.3.8.1 Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance, strength, and rigidity

Exception: Within dwellings units, unobstructed stud and joist spaces shall not be prohibited from conveying combustion air, provided that not more
than one fireblock is removed.

9.3.8.2 Ducts shall terminate in an unobstructed space, allowing free movement of combustion air to the appliances.
9.3.8.3 Ducts shall serve a single space.
9.3.8.4 Ducts shall not serve both upper and lower combustion air openings where both such openings are used. The separation between ducts servicing upper and lower combustion air openings shall be maintained to the source of combustion air.

SYSTEM OPERATION

9.3.8.5 Ducts shall not be screened where terminating in an attic space.
9.3.8.6 Horizontal upper combustion air ducts shall not slope downward toward the source of combustion air.
9.3.8.7 The remaining space surrounding a chimney liner, gas vent, special gas vent, or plastic piping installed within a masonry, metal, or factory built
chimney shall not be used to supply combustion air. Exception: Direct vent appliances designed for installation in a solid fuel- burning fireplace where installed in accordance with the manufacture’s installation instructions.
9.3.8.8 Combustion air intake openings located on the exterior of the building shall have the lowest side of the combustion air intake openings located at least 12 in. (300 mm) vertically from the adjoining grade level

Horizontal Applications and Considerations Horizontal applications, in particular, may dictate many of the installation’s specifics such as airflow direction, ductwork
connections, flue and/or combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace differs only slightly from an upright installation. When installing a furnace horizontally, additional consideration must be given to the following:

Drain Trap and Lines
In horizontal applications the condensate drain trap is secured to the furnace side panel, suspending it below the furnace. A minimum clearance of 5.5” below the furnace must be provided for the drain trap. Additionally, the appropriate downward piping slope must be maintained from the drain trap to the drain location. Refer to Condensate Drain Trap and Lines section in this manual or the installation instructions for further details. If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing. NOTE: The use of insulation and/or heat tape is recommended. Failure to provide proper condensate drainage can result in property damage.

Leveling
Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower. For proper flue pipe drainage, the furnace must be level lengthwise from end to end. The furnace should also be level from back to front or have a slight tilt with the access doors downhill (approximately 3/4”) from the back panel. The slight tilt allows the heat exchanger condensate, generated in the recuperator coil, to flow forward to the recuperator coil front cover. In horizontal installations with the furnace laying on the left hand side, the alternate vent connection may be used. In this configuration the internal elbow is removed. The standard piping connections may also be used in these positions. Refer to Vent/Flue Pipe and Combustion Air Pipe section in the installation instructions for details concerning the conversion to the alternate vent/flue and combustion air connections on the 90% furnace.

The 34.5” single stage furnace is one of the products in our newly redesigned line of shorter chassis furnaces. It is available in 92% / 96% AFUE up flow / horizontal model and a down flow / horizontal model. The up flow / horizontal 34.5” single stage furnace is available in the following models:

*MES920403ANAA    *MES920603BNAA
*MES9S0803BNAA     *MES920804CNAA
*MES920805CNAA     *MES921004CNAA
*MES921005CNAA     *MES921205DNAA
*MES960403ANAA     *MES960603BNAA
*MES960803BNAA     *MES960804CNAA
*MES960805CNAA      *MES961005CNAA
*MES961205DNAA

The down flow / horizontal 34.5” single stage furnace is available in the following models

*CES960403BNAA   *CES960603BNAA  *CES960804CNAA
*CES961005CNAA    *CES961205CNAA

SYSTEM OPERATION

   UPFLOW HORIZONTAL            COUNTERFLOW HORIZONTAL
    LEFT AIR DISCHARGE                 RIGHT AIR DISCHARGE

UPFLOW HORIZONTAL            COUNTERFLOW HORIZONTAL
RIGHT AIR DISCHARGE                LEFT AIR DISCHARGE

NOTE: Alternate “vertical” piping connections can not be used when an upflow 90% furnace is installed with supply air discharging to the right or when a counterflow furnace is installed with supply discharging to the left. In this case, use the standard flue and combustion air piping connections

Alternate Electrical and Gas Line Connections

Furnaces have provisions allowing for electrical and gas line connections through either side panel. In horizontal applications the connections can be made either through the
“top” or “bottom” of the furnace.

Drain Pan
A drain pan must be provided if the furnace is installed above a conditioned area. The drain pan must cover the entire area under the furnace (and air conditioning coil if applicable).

Freeze Protection
If the drain trap and drain line will be exposed to temperatures near or below freezing, adequate measures must be taken to prevent condensate from freezing. NOTE: The use of insulation and/or heat tape is recommended. Failure to provide proper condensate drainage can result in property damage.

Propane Gas and/or High Altitude Installations

WARNING

POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO INSURE SAFE AND PROPER FURNACE OPERATION. ALL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY

This furnace is shipped from the factory configured for natural gas at standard altitude. Propane gas installations require an orifice change to compensate for the energy content
difference between natural and propane gas. High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to
compensate for the natural reduction in the density of both the gas fuel and the combustion air at higher altitude. Refer to the Accessories Charts in this manual or product
Specification Sheet for a tabular listing of appropriate manufacturer’s kits for propane gas and/or high altitude installations. The indicated kits must be used to insure
safe and proper furnace operation. All conversions must be performed by a qualified installer, or service agency.

This manual will refer to the pipe that discharges products of combustion to the outdoors as the “vent” pipe or “flue” pipe. The pipe that supplies air for combustion to the furnace will be referred to as the “intake” pipe or “combustion air” pipe. A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material. This furnace must not be connected to Type B, BW, or L vent or vent connector, and must not be vented into any portion
of a factory built or masonry chimney except when used as a pathway for PVC as described later in this section. Never common vent this appliance with another appliance or use a vent which is used by a solid fuel appliance. It is the responsibility of the installer to follow the manufacturers’

recommendations and to verify that all vent/flue piping and connectors are compatible with furnace flue products. Additionally, it is the responsibility of the installer to ensure
that all piping Dual Certification: Non-Direct/Direct Vent (90%
Furnaces Only) The 90% furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance. A non-direct vent installation requires only a vent/ flue pipe. A direct vent installation requires both a vent/flue pipe and a combustion air intake pipe. Refer to the appropriate section for details concerning piping size, length, number of elbows, furnace connections, and terminations.and connections possess adequate structural integrity and support to prevent flue pipe separation, shifting, or sagging during furnace operation.

WARNING

TO AVOID BODILY INJURY, FIRE OR EXPLOSION, SOLVENT CEMENTS MUST BE KEPT AWAY FROM ALL IGNITION SOURCES (I.E., SPARKS, OPEN FLAMES, AND EXCESSIVE HEAT) AS THEY ARE COMBUSTIBLE LIQUIDS. AVOID BREATHING CEMENT VAPORS OR CONTACT WITH SKIN AND/OR EYES.

Precautions should be taken to prevent condensate from freezing inside the vent/flue pipe and/or at the vent/flue pipe termination. It is our recommendation that all vent/flue piping exposed to temperatures below 35°F for extended periods of time should be insulated with 1/2” thick closed cell foam. Also all vent/flue piping exposed outdoors in excess of the terminations shown in this manual (or in unheated areas) should be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation

The following bullets and diagram describe the restrictions concerning the appropriate location of vent/flue pipe and combustion air intake pipe (when applicable) terminations. Refer to the installation instructions for specific details on termination construction.

• All terminations must be located at least 12 inches above ground level or the anticipated snow level.
• Vent terminations must terminate at least 3 feet above any forced air inlet located within 10 feet.
• NOTE: This provision does not apply to the combustion air intake termination of a direct vent application.
• The vent termination of a non-direct vent application must terminate at least 4 feet below, 4 feet horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.
• The vent termination of a direct vent application must terminate at least 12 inches from any opening through which flue gases may enter a building (door, window, or gravity air inlet).
• The vent termination of vent pipe run vertically through a roof must terminate at least 12 inches above the roof line (or the anticipated snow level) and be at least 12
  inches from any vertical wall (including any anticipated snow build up).

CAUTION

BE SURE NOT TO DAMAGE INTERNAL WIRING OR OTHER COMPONENTS WHEN REINSTALLING COUPLING AND SCREWS.

Vent/Flue Pipe Lengths and Diameters Refer to the following tables for applicable length, elbows, and pipe diameter for construction of the vent/flue pipe system of a
non-direct vent installation. In addition to the vent/flue pipe, a single 90° elbow must be secured to the combustion air intake to prevent inadvertent blockage. The tee or elbows used in the vent/flue termination must be included when determining the number of elbows in the piping system.

*MES9* / *CES9 Direct Vent (2-Pipe) & Non-Direct Vent (1-Pipe) (6 Maximum Allowable Length of Vent/Flue Pipe

1. Maximum allowable limits listed on individual lengths for inlet and flue and NOT a combination.
2. Minimum requirement for each vent pipe is five (5) feet in length and one elbow/ tee.
3. Tee used in the vent/flue termination must be included when determining the number of elbows in the piping system.
4. 2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.
5. Increased Clearance Configurations using (2) 45 deg. Long Sweep elbows should be considered equivalent to one 90 deg. elbow.
6. One 90° elbow should be secured to the combustion air intake connection.

Vent/Flue and Combustion Air Pipe Lengths and Diameters

Refer to the preceding table for applicable length, elbows, and pipe diameter for construction of the vent/flue and combustion air intake pipe systems of a non-direct vent
(single pipe) installation. The number of elbows tabulated represents the number of elbows and/or tees in each (Vent/ Flue & Combustion Air Intake) pipe. Elbows and/or tees used in the terminations must be included when determining the number of elbows in the piping systems. If the combustion air intake pipe is to be installed above a
finished ceiling or other area where dripping of condensate will be objectionable, insulation of the combustion air pipe may be required. Use 1/2” thick closed cell foam insulation such as Armaflex or Insultube where required

Vent/Flue Pipe Terminations The vent/flue pipe may terminate vertically, as through a roof, or horizontally, as through an outside wall. Vertical vent/flue pipe termination should be as shown in the following figures. Refer to Vent/Flue Pipe and Combustion Air Pipe – Termination Locations section in this manual or
the installation instructions for details concerning location restrictions. The penetration of the vent through the roof must be sealed tight with proper flashing such as is used with a plastic plumbing vent.
NOTE: Terminate both pipes in the same pressure zone (same side of roof, no major obstacles between pipes, etc.).

VENT PIPE TERMINATION OPTIONS

Horizontal vent/flue pipe terminations should be as shown in the following figure. Refer to Vent/Flue Pipe and Combustion Air Pipe – Termination Locations section in this manual or the installation instructions for details concerning location restrictions. A 2 3/8” diameter wall penetration is required for 2” diameter pipe while a 3 1/2” diameter hole is required for 3” diameter pipe. To secure the pipe passing through the wall and prohibit damage to piping connections, a coupling should be installed on either side of the wall and solvent cemented to a length of pipe connecting the two couplings. The length of pipe should be the wall thickness plus the depth of the socket fittings to be installed on the inside and outside of the wall. The wall penetration should be sealed with silicone caulking material.

Horizontal Termination (Single Pipe) Above Highest Anticipated Snow Level

Standard Horizontal Terminations (Dual Pipe)

Alternate Horizontal Vent Termination (Dual Pipe)

Combustion Air Intake may also be snorkeled to obtain 12” min ground clearance.
Alternate Vent Termination Above Anticipated Snow Level

SYSTEM OPERATION