Napoleon 9600 Series User manual

W415-0919 / 10.12.10
1
$10.00
INSTALLER: LEAVE THIS MANUAL WITH THE APPLIANCE.
CONSUMER: RETAIN THIS MANUAL FOR FUTURE REFERENCE.
INSTALLATION AND
OPERATING INSTRUCTIONS
Wolf Steel Ltd., 24 Napoleon Rd., Barrie, ON, L4M 4Y8 Canada /
103 Miller Drive, Crittenden, Kentucky, USA, 41030
Phone [phone] • Fax [phone] • www.napoleonheatingandair.com • [email protected]
SAFETY INFORMATION
ELECTRICAL SHOCK, FIRE OR
EXPLOSION HAZARD
Failure to follow safety warnings exactly
could result in serious inquiry, death or
property damage.
Improper servicing could result in
dangerous operation, serious injury, death
or property damage.
- Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
- Before servicing, disconnect all electrical power to
furnace.
- When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.
- Verify proper operation after servicing.
- Do not store or use gasoline or other flammable
vapors and liquids in the vacinity of this or any other
appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbour’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the fire
department.
!WARNING !
CERTIFIED TO ANSI Z21.47b / CSA 2.3b-2008
TWO STAGE NATURAL AND
PROPANE GAS HIGH EFFICIENCY
(CONDENSING) FORCED AIR
FURNACE

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TABLE OF CONTENTS
1.0 INTRODUCTION 3
2.0 SAFETY SYMBOLS AND WARNINGS 4
2.1 SAFETY RULES 5
2.2 CODES 5
2.3 INSTALLATION REQUIREMENTS SPECIFIC TO THE STATE OF MASSACHUSETTS FOR DIRECT VENT, MECHANICAL VENT, AND
DOMESTIC HOT WATER APPLIANCES. 8
3.0 FURNACE SIZING 10
4.0 LOCATION OF UNIT 11
4.1 GENERAL GUIDELINES 11
4.2 OTHER CONSIDERATIONS 12
4.3 INSTALLATION IN UPFLOW, DOWNFLOW OR HORIZONTAL POSITIONS 12
4.4 AIR CONDITIONING 13
5.0 COMBUSTIBLE CLEARANCES 13
6.0 DUCTWORK 14
6.1 DUCTWORK STEPS 15
7.0 VENTING AND COMBUSTION PIPING 15
7.1 ACCEPTABLE MATERIALS IN CANADA 15
7.2 ACCEPTABLE MATERIALS IN UNITED STATES 16
8.0 NON-DIRECT VENT FURNACE INSTALLATIONS USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM) 16
8.1 DETERMINING COMBUSTION AIR 17
8.1.1 CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE 17
8.1.2 CASE 2: FURNACE LOCATED IN A CONFINED SPACE 17
8.1.3 CASE 3: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR FROM ATTIC OR CRAWL SPACE 18
8.1.4 CASE 4: FURNACE LOCATED IN A CONFINED SPACE, OUTDOOR AIR DUCTED HORIZONTALLY 19
8.1.5 CONNECTION TO FURNACE NON-DIRECT VENT 20
9.0 VENTING GUIDELINES 20
9.1 VENT TERMINATION 21
9.2 IN CANADA 22
9.3 IN UNITED STATES 22
9.4 FURNACE VENTING INSTALLATIONS 23
9.4.1 NON-DIRECT VENT INSTALLATION USING INDOOR COMBUSTION AIR (ONE PIPE SYSTEM) 23
9.4.2 DIRECT VENT INSTALLATION USING OUTDOOR COMBUSTION AIR (TWO PIPE SYSTEM) 23
9.4.3 COMBUSTION AIR 23
10.0 TERMINATIONS 24
10.1 COMBUSTION AIR 24
10.2 EXHAUST 24
10.3 CONCENTRIC VENTING KIT 24
10.4 CONCENTRIC VENT TERMINATION INSTALLATION INSTRUCTIONS 24
10.5 LOCATION 25
10.6 MULTIPLE VENTING 25
10.7 IN CANADA 26
10.8 IN UNITED STATES 26
10.9 FURNACE CONNECTION 26
10.9.1 ROUTING OPTIONS 29
10.9.2 EXHAUSTER ROTATION INSTRUCTIONS 29
10.9.3 PREPARATIONS FOR VENT AND DRAINING OPTION 30
11.0 CONDENSATE DRAINS 34
11 .1 DRAIN HOSE INSTALLATION 34
11.1.1 DRAIN PIPING 34
11.2 CONDENSATE NEUTRALIZERS 35
12.0 GAS SUPPLY AND PIPING 36
12.1 GAS SUPPLY 36
12.2 GAS PIPING 36
12.3 GAS INLET PRESSURE 37
12.4 LEAK TESTING 37
12.5 PURGING GAS LINES 37
13.0 CONVERSIONS 38
13.1 CONVERSION STEPS 38
13.2 CHECKING THE INLET GAS PRESSURE 39
13.3 SETTING THE MANIFOLD GAS PRESSURE 40
13.4 CHECKING FURNACE INPUT 41
14.0 ELECTRICAL SPECIFICATIONS 41
14.1 ELECTRICAL WIRING AND CONNECTIONS 41
14.2 120 FURNACE CONNECTION 42
15.0 LOW VOLTAGE WIRING 43
15.1 SINGLE STAGE THERMOSTAT 43
15.2 TWO STAGE THERMOSTAT 43
15.3 THERMOSTAT LOCATION 43
16.0 OPTIONAL ACCESSORIES (FIELD SUPPLIED/INSTALLED) 43
16.1 ELECTRIC AIR CLEANER 43
16.2 POWER HUMIDIFIER 44
16.3 EMERGENCY HEAT MODE 44
17.0 STARTUP PROCEDURES 44
17.1 TO START THE FURNACE 44
17.2 TO SHUT DOWN THE FURNACE 45

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1.0 INTRODUCTION
IMPORTANT:
PLEASE READ THIS MANUAL CAREFULLY
AND KEEP IN A SAFE PLACE FOR FUTURE
REFERENCE BY A SERVICE TECHNICIAN.
This high efficient gas fired two stage condensing furnace is an upflow, downflow, horizontal left and right warm
air furnace suitable for residential and light commercial heating applications with inputs from 45,000 to 120,000
Btu/hr.
This high efficient furnace series is CSA certified as a Category IV indirect or direct vent central forced air
furnace. When installed as a direct vent furnace, all combustion air is supplied to the furnace burners through the
air intake system. (See Section 7, “Ventilation and Combustion Air.”)
All models may be fired by natural or LP gas (propane), and may be field converted from natural gas to LP gas
using Conversion Kit W370-0018.
The furnace is shipped completely assembled except for the condensate drain trap assembly. Please inspect
for damage when the furnace is unpacked.
NOTE: Changes, other than editorial, are denoted by a vertical line in the margin.
17.3 SEQUENCE OF OPERATION 45
18.0 AIR FLOW 46
18.1 TEMPERATURE RISE CHECK 46
18.2 CALCULATING AIR FLOW 47
18.3 ADJUSTING BLOWER SPEEDS ON MODELS EQUIPPED WITH ECM 2.3 BLOWER MOTORS 47
18.4 DEHUMIDIFICATION - ECM 2.3 48
18.5 SETTING BLOWER “ON” AND “OFF” TIMINGS - ECM 2.3 MODELS ONLY 48
18.6 CONTINUOUS FAN OPERATION 48
19.0 MAINTENANCE AND TROUBLESHOOTING 49
19.1 AIR FILTER 49
19.2 LUBRICATION 50
19.3 TERMINATIONS 50
19.4 INTAKE AIR/EXHAUST PIPING 50
19.5 OPERATING TIPS 50
19.6 ANNUAL INSPECTION/SERVICE 51
19.7 TROUBLESHOOTING FLOWCHART 52
19.8 DIAGNOSTIC CODES FOR STATUS LED 53
19.9 FAULT CODE HISTORY 53
20.0 WIRE DIAGRAM FOR TWO STAGE FURNACE WITH ECM 2.3 54
21.0 INSTALLATION CHECKLIST 55
22.0 REPLACEMENT PARTS LIST 56
23.0 SERVICE HISTORY 57
24.0 NOTES 58

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2.0 SAFETY SYMBOLS AND WARNINGS
Understand and pay particular attention to the words DANGER, WARNING, and CAUTION and the following
defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.
DANGER
! !
INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL
RESULT IN DEATH OR SERIOUS INJURY.
INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD
RESULT IN DEATH OR SERIOUS INJURY.
WARNING !
!
INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY
RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT AGAINST
UNSAFE PRACTICES.
CAUTION !
!
IMPORTANT:
READ THE FOLLOWING INSTRUCTIONS COMPLETELY BEFORE INSTALLING!
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.
THIS PRODUCT MUST BE INSTALLED BY A LICENSED PLUMBER OR GAS FITTER
WHEN INSTALLED WITHIN THE COMMONWEALTH OF MASSACHUSETTS.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS, OR
OTHER COMBUSTIBLE MATERIALS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WHAT TO DO IF YOU SMELL GAS
• 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, OR A CEL-
LULAR PHONE FROM A LOCATION WELL AWAY FROM THE BUILDING. FOLLOW THE
GAS SUPPLIER’S INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER, CALL THE FIRE DEPARTMENT.
• DO NOT RE-ENTER THE BUILDING UNTIL AUTHORIZED TO DO SO BY THE GAS
SUPPLIER OR THE FIRE DEPARTMENT.

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IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE
CAN CAUSE INJURY, PROPERTY DAMAGE OR LOSS OF LIFE. REFER TO THIS MANUAL.
INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER,
SERVICE AGENCY OR THE GAS SUPPLIER.
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE
PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF
THIS FURNACE. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING
INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE,
POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE
POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
1. Use this furnace only with type of gas approved for this furnace. Refer to the furnace rating plate.
2. Install this furnace only in dry indoor locations (protected from weather).
3. Provide adequate combustion and ventilation air to the furnace space as specified in Section 7 of this
manual, “Ventilation and Combustion Air.”
4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system
only, as specified in Section 8 of this manual, “Venting and Combustion Air Piping.”
5. 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 as specified in Section 14 of this manual,
“Gas Supply and Piping.”
6. Always install furnace to operate within the furnace’s intended temperature-rise range with a duct
system, which has an external static pressure within the allowable range, listed on the furnace rating
plate, and as specified in Sections 3, 6, and 20 of this manual, “Furnace Sizing,” “Ductwork,” and
“Airflow.”
7. When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside
the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace
casing and terminating outside the space containing the furnace. (Furnace for heating the home located
in the attached garage, for example).
8. A gas-fired furnace for installation in a residential garage must be installed so that the burners and ignitor
are no less than 18” above the floor. The furnace must be located, or protected to avoid physical damage
by vehicles. (See safety warning).
9. This furnace must not be used for temporary heating of buildings under construction.
1. This furnace must be installed:
a. In accordance with all local codes, by-laws and regulations by those authorities having jurisdiction.
b. In Canada, this furnace must be installed in accordance with the current CAN/CGA -B149.1 and .2
Natural Gas and Propane, and the National Electric Code (NEC) NFPA 70.
c. In the United States, this furnace must be installed in accordance with the current ANSI Z223.1 (NFPA
54) National Fuel Gas Code.
2.1 SAFETY RULES
2.2 CODES
WARNING !
!

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2. Electrical connections must be made in accordance with:
a. Any applicable local codes, by-laws and regulations.
b. Canada: current edition of CAN/CSA C22.1, Canadian Electrical Code (Part 1).
c. United States: current edition of ANSI/NFPA 70, National Electrical Code.
Codes and additional information may be obtained from:
Canadian Standards Association American Gas Association
5060 Spectrum Way 400 North Capitol Street, NW, Suite 450
Mississauga, Ontario, L4W 5N6 Washington DC, 20001
Phone: [phone] Phone: [phone]
website: www.csa.ca website: www.aga.org
National Fire Protection Association
1 Batterymarch Park
Quincy, MA, 02169-7471
Phone: [phone]
website: www.nfpa.org
DO NOT INSTALL THIS FURNACE IN A MOBILE HOME! THIS FURNACE IS NOT
APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE,
PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
THE FURNACE CONTAINS FOIL COVERED FIBERGLASS INSULATION. INHALATION OF
FIBERGLASS PARTICLES IS ASSOCIATED WITH RESPIRATORY DISEASE INCLUDING
CANCER.
NATURAL GAS AND PROPANE ARE NORMALLY ODORIZED BY THE FUEL SUPPLIER. IN
SOME CASES, THE ODORANT MAY NOT BE PERCEIVABLE. INSTALLATION OF UL AND
ULC RECOGNIZED FUEL GAS DETECTORS INSTALLED IN ACCORDANCE WITH THEIR
MANUFACTURER’S INSTRUCTIONS IS RECOMMENDED AS AN ADDITIONAL MARGIN OF
SAFETY.
THE EXHAUST GASES FROM THIS FURNACE CONTAIN CHEMICALS WHICH ON
SOME OCCASIONS MAY INCLUDE CARBON MONOXIDE. CARBON MONOXIDE IS AN
ODORLESS, TASTELESS, CLEAR COLORLESS GAS WHICH IS HIGHLY TOXIC. EVEN
LOW CONCENTRATIONS ARE SUSPECTED OF CAUSING BIRTH DEFECTS AND OTHER
REPRODUCTIVE HARM.
UL AND ULC RECOGNIZED CO DETECTORS ARE RECOMMENDED FOR ALL BUILDINGS
EQUIPPED WITH FOSSIL FUEL BURNING APPLIANCES. ALL CO DETECTORS SHOULD
BE INSTALLED IN ACCORDANCE WITH THEIR MANUFACTURER’S INSTRUCTIONS AND
APPLICABLE LOCAL BUILDING CODES.
FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD!
FAILURE TO REPLACE WITH PROPER CONTROL COULD RESULT IN FIRE, EXPLOSION
OR CARBON MONOXIDE POISONING.
REPLACE GAS VALVE ONLY WITH THE SAME MODEL NUMBER OR AS SPECIFIED BY THE
MANUFACTURER.
WARNING !
!

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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” ABOVE THE FLOOR TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS
WHICH MAY BE PRESENT IN THE GARAGE.
THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY
VEHICLES.
FAILURE TO HEED THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING
IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
WARNING
!
!
FIGURE 1 - FURNACE DIMENSIONS AND CLEARANCE TO COMBUSTIBLES
(/(&75,&$/&211(&7
$/7(51$7(
75$3/2&$7,21
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6&+
$/7*$6/,1(
$/7(51$7(&21'(16$7(
75$3/2&$7,21
5(7851$,5
$/7&20%867,21
$,5/2&$7,21
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
&
'
%
(
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'
(
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$/7&20%867,21
$,5/2&$7,21
$/7*$6/,1(6&+
&20%867,21
$,5
$/7(51$7(
$/7(51$7(
)/8(
/2&$7,21
)
$
+9(17
*
TABLE A - FURNACE DIMENSIONS (INCHES)
TOP LEFT SIDE RIGHT SIDE
0
Top
NOTES:
S - Service clearance 24 inches or more.
C - Combustible oor (but not carpet or non-ceramic tile).
All models approved for closet installation.
INPUT Width Depth Height Supply Air Return Air
K/Btu/hr A B C (F x G) (D x E)
45 17½ 29½ 32 7/8 16 x 19½ 14 x 22
60 17½ 29½ 32 7/8 16 x 19½ 14 x 22
80 17½ 29½ 32 7/8 16 x 19½ 14 x 22
100 22½ 29½ 32 7/8 21½ x 19½ 14 x 22
120 22½ 29½ 32 7/8 21½ x 19½ 14 x 22
5 1/16”
UPFLOW DOWNFLOW HORIZONTAL
TOP 0 0 0
PLENUM TOP 1/2 0 1/2
FRONT 0* 0* 0*
BACK 0 0 0
SIDES 0 0 0**
BOTTOM 0*** 0 0
FLUE PIPE 0 0 0
ENCLOSURE CLOSET CLOSET CLOSET
*24” REQUIRED FOR SERVICE
**SUPPLY AIR END / EXTREMITE D’AIR D’APPROVISONNEMENT 1/2” RETURN AIR END
***CERTIFIED FOR CLOSET INSTALATION ON COMBUSTIBLE FLOORING.
TABLE B - MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS
(INCHES)

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For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used
in whole or in part for residential purposes, including those owned or operated by the commonwealth and
where the side wall exhaust vent termination is less than seven feet above finished grade in the area of the
venting, including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS:
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber
or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up
is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber
or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector 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.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl
space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be
installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of
installation, the owner shall have a period of thirty (30) days to comply with the above requirements;
provided, however that during said thirty (30) day period, a battery operated carbon monoxide
detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS:
Each carbon monoxide detector as required in accordance with the above provisions shall comply with
NFPA 720 and be ANS/UL 2034 listed and IAS certified.
3. SIGNAGE:
A metal or plastic identification plate shall be permanently mounted to the exterior of the building at
a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the
horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less
than one-half )1/2) inch in size,
“GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION:
The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve
the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 CMR 5.0(2)(a)1. through 4.:
5. EXEMPTIONS:
The following equipment is exempt from 248 CMR 5.08(2)(a)1. through 4.:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most
current edition of NFPA54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure
separate from the dwelling, building or structure used in whole or in part for residential purposes.
6. (A) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the
manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system
design or venting system components with the equipment, the instructions provided by the manufacturer
for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system
components; and
2. A complete parts list for the venting system design or venting system.
2.3 INSTALLATION REQUIREMENTS SPECIFIC TO THE STATE OF
MASSACHUSETTS FOR DIRECT VENT, MECHANICAL VENT, AND
DOMESTIC HOT WATER APPLIANCES.

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7. INSTALLATION INSTRUCTIONS:
A copy of all installation instructions, and any instructions relating to venting shall remain with the furnace
at the completion of the installation.
FIGURE 2 - FURNACE COMPONENTS
1
2
11
12
4
3
13
6
14
10
16
9
19
5
18
17
8
715
LEGEND
1. Combustion Air Intake Fitting 11. Burner Assembly
2. Flame Roll-Out Switch 12. Igniter (located underneath)
3. Flame Sensor (located underneath) 13. Two Speed Exhauster
4. Two Stage Gas Valve 14. Pressure Switch Assembly
5. Air High Temperature Limit (behind exhauster) 15. Front Manifold Cover Pressure Tap (3)
6. Vent and Drain Assembly 16. PFC “Choke Coil” (required on ¾ and 1 Hp units)
7. Drain for Recovery Coil (3) 17. Door Switch and Junction Box
8. Condensate Trap 18. Blower Motor
9. Two Stage Integrated Furnace Control (IFC) 19. Circulating Air Blower
10. Transformer for 24 VAC

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The maximum hourly heat loss for each heated space shall be calculated in accordance with the procedures
described in the manuals of the Heating, Refrigeration and Air Conditioning Institute of Canada (HRAI), 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 manuals.
In the United States, “Manual J - Load Calculation,” published by the Air Conditioning Contractors of America,
describes a suitable procedure for calculating the maximum hourly heat loss.
If the installation is a retrofit application, do not rely on the capacity of the existing heating equipment as a
method to size the new furnace. Many of the heat transfer multiples listed in earlier versions of load calculation
manuals were much higher than those listed in more recent editions. It is possible that energy saving
measures have been completed since the installation of the existing furnace. This might include additional
insulation in the attic or walls, the application of sprayed foam insulation, the addition of storm windows and
doors, weather-stripping, caulking, etc.
Many of the older furnaces were equipped with large belt drive blower systems, operating at low RPM’s. If
replacing an existing furnace, be sure that the existing ductwork can handle the amount of airflow necessary
for a reasonable temperature rise. Most older gas furnaces operated with a system temperature rise of 70 -
100°F. This furnace is designed to be operated with a system temperature rise (∆T) of High Fire 35 - 65°F, Low
Fire 25 - 55°F. If the furnace selected has an identical output
capacity as the original furnace, a substantial increase in
system air flow will be necessary. See Table 1 and the airflow
characteristics in Section 20 of this manual, “Airflow”.
Existing ductwork should be assessed for its air handling
capabilities. For residential applications, the recommended
air velocity of a supply air trunk duct is 700 feet per minute
(fpm), and should not exceed 900 fpm. These values are slightly lower for flexible ducting. The recommended
air velocity of a return air trunk duct is 600 fpm, and should not exceed 700 fpm. The recommended and
maximum air velocity of a return air branch 600 fpm.
The “Equal Friction Chart,” as published by ASHRAE and HRAI, is the basis for the various air duct calculators
available through heating supply companies. Following the air velocity guide lines, according to the “Equal
Friction Chart,” or a slide rule air duct calculator, a typical 6” round duct has a capacity of approximately 100
cfm.
NOTE:
The return air system is equally as important as the supply air system. An under-sized
return air system will prevent sufficient quantities of air from reaching the supply air
system and will consequently reduce the service life of the furnace and its components.
3.0 FURNACE SIZING
TABLE 1 - RANGE OF TEMPERATURE RISE
Furnace Models Temperature Rise
ALL High Fire (HF) 35 - 65°F
Low Fire (LF) 25 - 55°F

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11
4.0 LOCATION OF UNIT
1. 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.)
2. Select a location as near as possible to the existing or proposed duct system.
3. The furnace location must have provisions for condensate drainage. If a suitable drain is unavailable near
the furnace, a condensate pump must be used. The condensate pump drain tubing must not terminate
outdoors; similar to some air conditioning condensate installations. Be sure to select a condensate pump
that has been approved for furnace condensate applications.
4. The furnace location must permit access for servicing and be within the clearance to combustibles
guidelines as marked on the appliance rating plate.
5. The furnace must be installed on a level surface. It is recommended that the rear of the furnace be
elevated 1/4” higher than the front to facilitate proper condensate drainage.
6. If the furnace is being installed so that the return air will enter through the bottom, the perimeter of the
furnace must be properly supported.
7. When installed in the horizontal position, the furnace may be supported from the bottom, or suspended.
(Figure 3)
FIGURE 3 - SUGGESTED METHOD FOR SUSPENDING HORIZONTAL FURNACE
4.1 GENERAL GUIDELINES

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1. If the furnace is to be located in an area where the combustion air is laden with chemical compounds such
as bromine, chlorine or fluorine, as may be found in swimming pool chemicals, laundry detergents, etc.,
use outdoor air for combustion. These compounds when exposed to flame, form acids which attack the
heat exchanger and other components.
Exposure to the following substances in the combustion air supply (but not limited to the following) will also
require OUTDOOR AIR for combustion:
• Aerosols, particularly CFC based or propelled aerosols
• Air fresheners
• “Airplane Glue” and similar adhesives and cements
• Ammonia, as commonly found in permanent wave solutions used in hair dressing salons
• Anti-static fabric softeners used in clothes dryers
• Carbon tetrachloride
• Chlorinated cleaners and waxes
• Chlorine and bromine based swimming pool chemicals
• De-icing salts or chemicals (rock salt, etc.)
• Dry cleaning fluids such as perchloroethylene
• Fumes from curing polyurethane and similar substances
• Halogen based refrigerants including R-12 and R-22
• Hydrochloric acid, muriatic acid and other acid based masonry washing and curing materials
• Printer’s inks, paint removers, varnishes, varsol, toluene, etc.
• Water softener salt and chemicals
2. If this furnace is to be installed in an area over a finished ceiling or living area, install a field fabricated
auxiliary drain pan under the furnace to protect that area from accidental condensate spills. The auxiliary
pan should be large enough to collect accidentally spilled condensate from the air conditioning evaporator
coil assembly if applicable.
3. If the furnace is installed in an area where freezing may occur, a garage, an attic, a crawl space or any
unconditioned space, steps must be taken to protect the condensate trap and drain line from freezing.
One possible measure could be to use a self-regulating 5 or 6 watt per foot heat tape covered with a jacket
of insulation. Heat tapes are available in plumbing supply houses.
UPFLOW INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed in
accordance with instructions in the appropriate sections of this manual.
HORIZONTAL INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed in
accordance with instructions in the appropriate sections of this manual.
NON-SUSPENDED INSTALLATION: Maintain clearances to combustibles as outlined in Figure 1, Table B. The
furnace must be supported in such a way as to not allow twisting or sagging of the cabinet.
SUSPENDED INSTALLATION: Maintain clearances to combustibles as outlined in Figure 1, Table B. The
furnace may be suspended by field fabricating a cradle of angle iron and threaded rod. Secure the furnace with
2” minimum slotted angle or equivalent as shown in Figure 3. The furnace must be supported in such a way as to
not allow twisting or sagging of the cabinet. Position the supports so as to not interfere with accessing the burner
and blower compartments.
DOWNFLOW INSTALLATION: Vent positioning, pressure switch location and drain locations shall be performed
in accordance with instructions in the appropriate sections of this manual.
The opening in the floor must provide adequate clearances to the combustible material according to the
clearance to combustible as outlined in Figure 1, Table B.
4.2 OTHER CONSIDERATIONS
4.3 INSTALLATION IN UPFLOW, DOWNFLOW OR HORIZONTAL POSITIONS

W415-0919 / 10.12.10
13
IMPORTANT:
• THE FURNACE MUST BE INSTALLED ON A
LEVEL SURFACE. IT IS RECOMMENDED
THAT THE REAR OF THE FURNACE BE
ELEVATED 1/4” HIGHER THAN THE FRONT
TO FACILITATE PROPER CONDENSATE
DRAINAGE.
• IF THE FURNACE AND AIR CONDITIONER
IS LOCATED ABOVE A FINISHED SPACE,
INSTALL A DRAIN PAN UNDERNEATH THE
UNIT.
NOTE
These furnaces are approved for installation
in attics, alcoves, utility rooms, closets
and crawl spaces. If this furnace is to be
installed in a utility room, be sure that it is
located in such a way as to allow access for
servicing or the removal of other appliances
installed in the room (hot water heater, for
example). It is not permissible to use a rear
return on this appliance. Use only side and
end returns.
Figure 1, Table B provides the certified clearances to combustibles and dimensional information. Also see
the appliance rating plate affixed to the furnace for specific model number, serial number and clearance to
combustibles information.
IMPORTANT:
THIS FURNACE REQUIRES A MINIMUM OF 24” OF FRONT CLEARANCE FOR SERVICE
PURPOSES. FOR THIS PURPOSE, SERVICE CLEARANCE TAKES PRECEDENCE OVER
CLEARANCE TO COMBUSTIBLES.
THIS FURNACE IS CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORS. THIS
SHALL BE INTERPRETED AS A WOOD FLOOR ONLY.
THE FURNACE MUST NOT BE INSTALLED DIRECTLY ON CARPETING, OR OTHER
COMBUSTIBLE MATERIAL EXCEPT WOOD.
INSTALLATION ON COMBUSTIBLE MATERIAL CAN RESULT IN FIRE, CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL
COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS
AND LIQUIDS.
THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE
USED AS A CLOSET OR FOR ANY OTHER STORAGE PURPOSE.
WARNING !!
4.4 AIR CONDITIONING
5.0 COMBUSTIBLE CLEARANCES
This furnace may be used as part of an air conditioning system. The furnace wiring and control system is “air
conditioning ready.” There are the following factors to consider:
The air conditioning evaporator coil must be downstream of the heat exchanger. The cooled air passing
over the warmer heat exchanger tubes can cause condensation inside the tubes, resulting in corrosion and
premature failure.
A parallel duct system can be installed to direct the air from the furnace through the evaporator coil only. Use
dampers or other means to bypass the heat exchanger. If (summer/winter) dampers are used, they should be
interlocked to prevent system operation unless the dampers are in the full open or full closed position.

W415-0919 / 10.12.10
14
6.0 DUCTWORK
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.
If air conditioning is to be used with the furnace, the duct system must be capable of delivering the correct
amount of airflow for each system.
The ductwork should be sized and constructed in accordance with accepted industry standards. Duct sizing
and construction information may be obtained from:
• A.C.C.A. (Air Conditioning Contractors of America)
• A.S.H.R.A.E. (American Society of Heating, Refrigeration and Air Conditioning Engineers
• H.R.A.I. (Heating, Refrigerating and Air Conditioning Institute (Canada)
• S.M.A.C.N.A. (Sheet Metal and Air Conditioning Contractors’ National Association (United States)
All of the above professional organizations have duct sizing manuals available.
The total static pressure drop of the air distribution system (including filters) should not exceed 1.0” w.c.
DO NOT ALLOW GAS PIPING TO BE ROUTED THROUGH JOIST SPACES THAT ARE
USED FOR RETURN AIR PURPOSES. DO NOT USE JOIST SPACES FOR RETURN AIR
PURPOSES IF THE JOIST SPACE ALREADY CONTAINS PLUMBING STACKS, CHIMNEY
COMPONENTS, ETC. UNLESS THE PORTION USED FOR RETURN AIR PURPOSES CAN
BE COMPLETELY ISOLATED FROM PORTIONS WITH OTHER USAGES.
NEVER ALLOW THE PRODUCTS OF COMBUSTION FROM THE FLUE TO ENTER THE
RETURN AIR OR SUPPLY AIR DUCTWORK.
ALL RETURN AIR DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO
THE FURNACE WITH SHEET METAL SCREWS. TAPE THE SHEET METAL SEAMS IN THE
VICINITY OF THE FURNACE WITH DUCT TAPE OR SIMILAR MATERIAL.
WHEN THE FURNACE IS MOUNTED ON A PLATFORM WITH RETURN AIR THROUGH THE
BOTTOM, IT MUST BE SEALED AIR TIGHT BETWEEN THE FURNACE AND THE RETURN
AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT
OF THE FURNACE WITHOUT SAGGING, CRACKS OR GAPS AROUND THE BASE,
PROVIDING A SEAL BETWEEN THE SUPPORT AND THE BASE.
FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO
THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING
CARBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR
DEATH.
DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN OR SUPPLY AIR
DUCTWORK TO OR FROM ANY OTHER HEAT PRODUCING DEVICE SUCH AS A
FIREPLACE INSERT, STOVE, ETC. DOING SO MAY RESULT IN FIRE, CARBON MONOXIDE
POISONING, EXPLOSION, PERSONAL INJURY, LOSS OF LIFE, OR PROPERTY DAMAGE.
WARNING !
!

W415-0919 / 10.12.10
15
1. Position the furnace to minimize ductwork length and fittings.
2. Cut open a return air inlet. The choices are furnace bottom, either side, or any combination thereof (i.e.,
two sides or a side and the bottom).In all cases, cut the return air opening the full width of the return air
markers on the side panel.
3. Connect the return air duct or filter fitting to the furnace. The connection should be sealed air tight to prevent
entraining combustion gases from an adjacent fuel burning appliance, or entraining combustion air for this
furnace or adjacent fuel burning appliances.
4. Ensure that there is adequate space and accessibility for air filter removal.
5. If an air conditioning evaporator coil is required, position it on the supply air side of the furnace. Ensure
that no air can bypass the evaporator coil.
6. Connect the supply air plenum to the supply air outlet.
FLEXIBLE DUCT CONNECTORS are an effective device to prevent the telegraphing of mechanical noise from
the furnace to other parts of the home via the ductwork. If using flexible connectors, ensure that the adjoining
duct is independently supported.
DO NOT USE THE REAR PANEL AS A RETURN AIR INLET. THERE IS INSUFFICIENT
ROOM TO PERMIT ADEQUATE AIRFLOW.
WARNING !
!
NOTE: If two return air inlets are used, both must be equipped with filters.
6.1 DUCTWORK STEPS
7.0 VENTING AND COMBUSTION PIPING
7.1 ACCEPTABLE MATERIALS IN CANADA
READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO
PROPERLY VENT OR SUPPLY COMBUSTION AIR TO THIS FURNACE CAN CAUSE CAR-
BON MONOXIDE POISONING, OR AN EXPLOSION OR FIRE, RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
WARNING !
!
Effective August 1, 2007, all vent piping materials and fittings for flue gas venting must be ULC S636 listed
and identified as such on the material. The first 3ft. (900mm) of venting must be readily available for visual
inspection. Specified primers and glues of the certified vent system must be from a single system manufacture,
and not intermixed with other system manufacture’s vent system parts. The components of the certified vent
system must not be interchanged with other vent systems, or unlisted pipe, and or fittings. Follow the venting
manufacturers instructions on installation, cutting, de-burring, cementing, curing and supporting of the venting
system.
This furnace must be vented with ULC S636 certified PVC material with a rating of 65º C or more.
The combustion air piping does not have flue gases traveling through it and may be installed with common
ABS, PVC or CPVC piping or fittings. This piping, fittings, primer and cement will need to be installed as per
the manufacturers instructions including cementing, cutting, curing and supporting the piping.

W415-0919 / 10.12.10
16
7.2 ACCEPTABLE MATERIALS IN UNITED STATES
For United States installations, the combustion air and vent piping and fittings may be comprised of:
• Schedule 40 PVC, ASTM D1785 or CSA B137.3
• PVC-DWV, ASTM D2665 or CSA B181.2
• Schedule 40 CPVC, ASTM F441 or CSA B137.6
• PVC PRIMER AND SOLVENT CEMENT: ASTM D2564
Follow piping manufacturers instructions on proper installation of piping and fittings including cutting, deburring,
priming, cementing, curing and supporting.
8.0 NON-DIRECT VENT FURNACE INSTALLATIONS
USING INDOOR COMBUSTION AIR (ONE PIPE
SYSTEM)
The furnace, although designed as a direct vent type appliance, may be installed with the intake vent inside the
structure.
THIS FURNACE AND ANY OTHER FUEL BURNING APPLIANCE MUST BE PROVIDED
WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE
FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE BROUGHT TO
THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE PERSONAL INJURY, OR DEATH
FROM CARBON MONOXIDE POISONING.
WARNING !
!
Adequate provisions for combustion and ventilation air must be in accordance with CAN/CGA-B149 in Canada,
and ANSI Z223.1 - 1992, section 5.3, “Air for Combustion and Ventilation,” in the United States. Check with
local authorities for any additional building codes bylaws or regulations.
AIR FOR COMBUSTION AND VENTILATION PURPOSES MUST NOT ORIGINATE FROM A COR-
ROSIVE ATMOSPHERE. ANY FURNACE FAILURE CAUSED BY CORROSIVE ELEMENTS IS
EXCLUDED FROM WARRANTY COVERAGE.
CAUTION !
!
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
• Exposure to the following substances in the combustion air supply (but not limited to the following) will
also require OUTDOOR AIR for combustion:
• Aerosols, particularly CFC based or propelled aerosols
• Air fresheners
• “Airplane Glue” and similar adhesives and cements
• Ammonia, as commonly found in permanent wave solutions used in hair dressing salons
• Anti-static fabric softeners used in clothes dryers

W415-0919 / 10.12.10
17
• Carbon tetrachloride
• Chlorinated cleaners and waxes
• Chlorine and bromine based swimming pool chemicals
• De-icing salts or chemicals (rock salt, etc.)
• Dry cleaning fluids such as perchloroethylene
• Fumes from curing polyurethane and similar substances
• Halogen based refrigerants including R-12 and R-22
• Hydrochloric acid, muriatic acid and other acid based masonry washing and curing materials
• Printer’s inks, paint removers, varnishes, varsol, toluene, etc.
• Water softener salt and chemicals
Combustion air must be free of acid forming chemicals such as sulphur, fluorine and chlorine. These elements
are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish
removers, refrigerants, and many other commercial and household products. When burned in a gas flame,
vapors from these products form acid compounds. Acid compounds increase the dew point temperature of the
flue products and are highly corrosive after they condense.
Unconfined space does not necessarily mean that ventilation will not have to be introduced from the outdoors,
particularly in airtight homes. The minimum requirement for unconfined space is a volume of 50 cubic feet for
each 1000 Btu/hr for all fuel burning appliances located within the unconfined area.
If the amount of combustion and ventilation air is insufficient to properly operate the furnace and other fuel
burning appliances within the unconfined area, it will be necessary to supply it from the outdoors based on the
criteria used when calculating the air supply for a confined space.
NOTE
If planning to use the inside air in an unconfined space, remember to test for proper furnace operation (as well
as other fuel burning appliances located within the unconfined space) with respect to adequate combustion and
ventilation air with fireplace dampers open, clothes dryer running, bathroom exhaust fans on, kitchen range hood
on, etc.
8.1 DETERMINING COMBUSTION AIR
8.1.1 CASE 1: FURNACE LOCATED IN A UNCONFINED SPACE
8.1.2 CASE 2: FURNACE LOCATED IN A CONFINED SPACE
A confined space, (any space smaller than the minimums discussed in Case 1), must have two air openings;
one within 12” of the ceiling and the other within 12” of the floor. The air openings must be sized based on
whether the combustion and ventilation air is being taken from indoors or outdoors, the method outdoor air (if
used) is introduced, and taking into account any other fuel burning appliances in the confined space.
If sufficient indoor combustion and ventilation air is available for the furnace and all other fuel burning
appliances, size each opening on the basis of one square inch of free area per 1000 Btu/hr. (Figure 4)
NOTE
Be sure to consider all clothes dryers, bathroom fans, range hoods, etc., when making this calculation.
The minimum requirement for these openings is 100 square inches, even for the furnace models under
100,000 Btu/hr.

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18
In this circumstance, the free area of each of the two combustion and ventilation air openings is based on
a minimum of 1 square inch per 4000 Btu/hr. In this configuration, one opening can originate from the floor
drawing combustion and ventilation air from the ventilated crawl space.
The other opening may communicate freely with a ventilated the attic. If using the attic air, ensure that the
opening is ducted from the ceiling high enough to be above the insulation. The attic must be adequately
vented with soffit vents or gable vents (Figure 5)
As an alternative to creating an opening in the floor to draw air from a crawl space, a duct may be dropped from
the attic terminating 12” above the floor.
The following table shows minimum free areas
and round pipe sizes when drawing combustion air
vertically from the attic or crawl space for the furnace
only. If other fuel burning appliances are present,
their combustion air and ventilation air requirements
must be added to those of the furnace.
NOTE
If using grills to cover the two
openings, factor in the free
area of the grill. Typically, a
sidewall grill will have a free area
approximately 50% of its nominal
size. Consequently, if the required
opening is 10 x 10, it will have to
be doubled if using a sidewall grill
with 50% free area.
IMPORTANT:
IF AN EXHAUST FAN, FIREPLACE, CLOTHES DRYER OR ANY SIMILAR DEVICE IS PRESENT IN THE
INDOOR AREA FROM WHICH THE COMBUSTION AND VENTILATION AIR WILL BE DRAWN, NEGATIVE
PRESSURE COULD BE A PROBLEM IF NATURAL INFILTRATION FROM THE OUTDOORS DOES NOT
MATCH THE RATE AT WHICH AIR IS EXHAUSTED.
TABLE 2 - VERTICAL AIR SUPPLY (CASE 3)
Input Free Area Round Pipe Size
K/Btu/hr Ea. Opening
45 15 in. ² 5 in.
60 15 in. ² 5 in.
80 20 in. ² 6 in.
100 25 in. ² 6 in.
120 30 in. ² 7 in.
FIGURE 4 - COMBUSTION/DILUTION AIR FROM
HEATED INSIDE SOURCES (CASE 2)
8.1.3 CASE 3: FURNACE LOCATED IN A CONFINED SPACE,
OUTDOOR AIR FROM ATTIC OR CRAWL SPACE
FIGURE 5 - OUTSIDE AIR FOR COMBUSTION, ATTIC OR
CRAWL SPACE (CASE 3)

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IMPORTANT:
IF THE ATTIC HAS AN EXHAUST FAN (POWER VENT), IT MAY CREATE A NEGATIVE
PRESSURE SUFFICIENTLY LARGE ENOUGH TO PREVENT THE ATTIC FROM BEING
AN EFFECTIVE SOURCE OF COMBUSTION AND VENTILATION AIR. POWERED ATTIC
FANS DO NOT CUSTOMARILY RUN DURING THE HEATING SEASON; HOWEVER,
SOME ARE CONTROLLED BY A HUMIDISTAT AS WELL AS A THERMOSTAT, WHICH MAY
ALLOW SOME OPERATION DURING THE HEATING SEASON. THE CHOICES ARE (A)
USE THE DIRECT VENT OPTION; (B) OBTAIN OUTDOOR AIR FROM ELSEWHERE; OR
(C) INTERLOCK THE ATTIC EXHAUST FAN WITH THE FURNACE SUCH THAT THE TWO
CANNOT OPERATE SIMULTANEOUSLY.
8.1.4 CASE 4: FURNACE LOCATED IN A CONFINED SPACE,
OUTDOOR AIR DUCTED HORIZONTALLY
Similar to Case 3, outdoor air for combustion and ventilation may be drawn through horizontal ducting. The
free area for each opening is calculated on the basis of a minimum of 1 square inch per 2000 Btu/hr input.
The following table shows minimum free areas and round pipe sizes when drawing combustion air horizontally
from the outdoors for the furnace only. If other fuel burning appliances are present, their combustion air and
ventilation air requirements must be added to those of the furnace.
IMPORTANT:
IF GRILLS ARE USED ON THE OUTSIDE WALL, THEY MUST BE SIZED PROPERLY.
MOST SIDEWALL GRILLS HAVE ONLY 50% FREE AREA. IN THE CASE OF A UNIT
WITH 100,000 BTU/HR INPUT, WHICH REQUIRES A PAIR OF 8” ROUND PIPES TO
OBTAIN SUFFICIENT COMBUSTION AND VENTILATION AIR, THE DUCT COULD BE AN
EQUIVALENT RECTANGULAR DUCT; 8” X 7” FOR EXAMPLE. BASED ON 50% FREE AREA
FOR THE INLET GRILLS, THE ACTUAL GRILL SIZE WOULD HAVE TO BE 14” X 8” OR ITS
EQUIVALENT. A TRANSITION MAY BE USED TO REDUCE TO THE SMALLER DUCT SIZE
IF NECESSARY.
IMPORTANT:
THE OUTDOOR GRILLS MUST BE
INSTALLED IN A LOCATION WHERE THE
WILL NOT BE OBSTRUCTED IN ANY
MANNER.
FIGURE 6 - OUTDOOR AIR FOR COMBUSTION,
HORIZONTAL (CASE 4)
TABLE 3 - HORIZONTAL AIR SUPPLY (CASE 4)
Input Free Area Round Pipe Size
K/Btu/hr Ea. Opening
45 30 in. ² 7 in.
60 30 in. ² 7 in.
80 40 in. ² 8 in.
100 50 in. ² 8 in.
120 60 in. ² 9 in.

W415-0919 / 10.12.10
20
When using indoor air or the non-direct vent configuration,
the combustion air inlet to the furnace must be protected from
blockage. Use a double elbow arrangement if supplying combustion
air through the top, or a downward pointing single elbow if supplying
combustion air through the side. (Figure 7)
FIGURE 7 - NON-DIRECT
COMBUSTION AIR INLET
9.0 VENTING GUIDELINES
FAILURE TO FOLLOW ALL VENTING GUIDELINES MAY RESULT IN ERRATIC FURNACE
OPERATION, FREEZE-UP OF THE EXHAUST AIR PIPING, OR SOOTING OF THE FURNACE.
CAUTION !
!
READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY VENT THIS
FURNACE CAN CAUSE CARBON MONOXIDE POISONING OR AN EXPLOSION OR FIRE RESULTING
IN PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
WARNING !
!
NOTE
• Combustion air intake and exhaust termination should be inspected periodically to ensure they are clear of
obstructions. i.e. vegetation, debris, snow, etc.
• Accumulation of snow around the combustion air intake and exhaust termination may have negative effects
on appliance operation and/or performance. Snow accumulation should be considered when locating
combustion air intake and exhaust terminations.
• Venting may be vertical or horizontal.
• Minimum vent length - 15 total equivalent feet. (See Venting Table)
• Horizontal piping must slope back towards the furnace at a minimum rate of ¼” to the foot, so that condensate
drains towards the furnace.
• Horizontal runs must be supported at least every 3 feet. Horizontal sections must not dip or sag.
• All vent runs through unconditioned space where freezing might occur should be insulated with 1” thick, medium
density, foil-faced Fiberglass insulation. An equivalent “arm-a-flex” or “rub-a-tex” may also be used as long as there
is no heat tape applied to the vent pipe. For horizontal runs where water may collect, wrap the vent pipe with self
regulating 3 or 5 watt heat tape. The heat tape must be CSA, UL, or ULC listed and installed per the manufacturer’s
instructions.
• DO NOT COMMON VENT WITH ANY OTHER APPLIANCE.
• If venting vertically, do not vent up a chimney serving another appliance or install in a chase with a metal or
high temperature plastic pipe from another gas or fuel burning appliance unless the required clearances to
combustibles can be maintained between the furnace venting system and other pipes.
8.1.5 CONNECTION TO FURNACE NON-DIRECT VENT