1 New Low Capacity Gas Furnace

2 Current Situation Multi-family homes is the fastest growing HVAC market Current installations are grossly oversized Existing sizes cause Nuisance pressure switch tripping Cycle-related short run times cause vents to freeze

3 Solution-ICP Low capacity gas furnaces2 new 26,000 BTUH input Single stage ¼-hp w/PSC blower motor (N9MSE) Single stage 1/3-hp w/ Multi-Tap ECM blower motor (F/G9MXE) To serve new construction markets in Apartment Multi-family Low Energy homes

4 ICP® New Low Capacity ModelsN9MSE A2 F(G)9MXE A2 95% AFUE 2 tons nominal cooling in. W.C. 675 nominal heating CFM 1/4 HP PSC blower motor (new) 4 speed taps 2 burner/2 cell heat exchanger 13,000 btuh per burner 14 3/16-in. casing 95% AFUE 2 ½ tons nominal cooling in. W.C. 605 nominal heating CFM 1/3 HP Multi-Tap ECM blower motor (new) 5 speed taps 2 burner/2 cell heat exchanger 13,000 btuh per burner 14 3/16-in. casing

5 Installation SimilaritiesCurrent to 4-way multipoise 90%furnaces Footprint Location requirements Duct connections Electrical requirements 15 amp circuit/14ga. wire Gas piping requirements Vent requirements New table for 26K models Condensate connections

6 Major Differences Inducer Choke Pressure SwitchesMulti-hole design Pressure Switches New set points Gas Valve & Manifold Pressure Lower set point & operating range 2-pipe venting Not considered “Direct Vent” Can be single pipe or VCA option Dedicated Conversion Kits Not approved for Mobile Home use

7 Inducer Inlet Choke 3-hole design Hole I.D. is 9.7 mm (3/8-in.)Same overall OD as other chokes Inducer service kit Single stage Includes inlet choke No outlet choke required

8 Pressure Switches Inducer Housing Pressure SwitchSquare tube Faces backward Max Make 0.25-in. W.C. Min Break 0.10-in. W.C. Collector Box Pressure Switch Round tube Faces forward

9 Gas Valve Uses a unique Low Capacity regulator springLower natural gas manifold pressure range 1.3-in. W.C. to 1.8-in. W.C. Lower propane manifold pressure 5.5-in. W.C. Certified for this model only Special color label Note the nominal regulator setting of 1.5-in. W.C.

10 ¼ HP PSC Blower Motor 4 speed taps As shipped: 25 µF 370 VAC capacitorBlack (high) Yellow (medium high) Blue (medium low) Red (low) As shipped: Black (cooling) Blue (heating) Yellow (spare) Red (spare) 25 µF 370 VAC capacitor 2 Brown leads

11 1/3 HP Multi-Tap Blower Motor5 speed taps Grey (high) Yellow (medium high) Orange (medium) Blue (medium low Red (low) Green (common) As shipped: Grey (cooling) Blue (heating) Red (continuous fan) Yellow (spare) Orange (spare)

12 Max length (before deductions)Venting 3 options 2-pipe Single pipe Ventilated Combustion Air Max length (before deductions) 1 ½-in., 70 ft ft. 2-in., 200 ft ft. Approved for ULC S636 pipe (Canada)

13 Pipe Diameter (inches)Vent Tables Input Altitude (feet) Pipe Diameter (inches) 1 ½-in. 2-in. 2 ½-in. 3-in. 4-in. 26,000 BTUH Only 0-2000 70 200 NP 2001 to 3000 65 190 3001 to 4000 60 175 4001 to 4500 55 160 4501 to 5000 5001 to 6000 50 145 6001 to 7000 45 135 7001 to 8000 40 120 8001 to 9000 35 110 9001 to 10,000 30 95 NP means Not Permitted

14 Alberta/Saskatchewan clearances may not applyTerminations 2-in Concentric 3-in not recommend Standard 2-pipe Standard single pipe Alberta/Saskatchewan clearances may not apply Input less than 35,000 BTUH Final ruling required You must verify code requirements with the authority having local jurisdiction

15 Similar to current products Same minimum inlet gas pressuresStart-up Similar to current products Same minimum inlet gas pressures 4.5-in. W.C. for natural gas 12.0-in. W.C. for propane Manifold pressure ranges are lower 1.3-in. to 1.8-in. W.C. for natural gas #44 orifices (0 to 2000 ft.) 5.5-in. to 5.2-in. W.C. for propane 1.25 mm orifices (0 to 10,000 ft.)

16 Startup-Check Inlet Gas PressureRemove the inlet pressure tap plug (3/16-in. hex wrench) Install manometer fitting & manometer Install inlet pressure tap plug after checking inlet gas pressure.

17 Startup-Check Inlet Gas PressureWith manometer connected to inlet pressure tap: Turn gas supply ON Verify inlet gas pressure above 4.5-in. W.C. (natural gas) Set furnace to call for heat After ignition Verify inlet gas pressure does not drop below 4.5-in. W.C. Do not operate the furnace for more than about a minute After checking the inlet pressure Remove manometer Install the 1/8-in. pipe plug in the gas valve

18 Startup-Check Manifold PressureRemove the outlet pressure tap plug (3/16-in. hex wrench) Install manometer fitting & manometer Install outlet pressure tap plug after checking manifold pressure.

19 Startup-Adjust Manifold PressureWith manometer connected to outlet pressure tap: Set furnace to call for heat After ignition and the burner stabilizes The manifold pressure range for natural gas: 1.3-in. W.C. to 1.8-in. W.C. (Refer to table in installation instructions) To adjust the manifold pressure Remove cap that conceals gas valve regulator adjustment screw Turn adjusting screw counterclockwise (out) to decrease manifold pressure clockwise (in) to increase manifold pressure Replace gas valve regulator seal cap Verify manifold pressure is correct

20 Startup-Adjust Manifold PressureAfter adjusting the manifold pressure Terminate the call for heat Turn gas off/gas valve switch to OFF/power off Remove the manometer Install the 1/8-in. pipe plug in the outlet tap of the gas valve Turn furnace gas on/valve switch ON/power on Set room thermostat to call for heat Check pressure tap plug for gas leaks when main burners ignite Check for correct burner flame. Observe unit operation through 2 complete heating cycles

21 Check Temperature RiseBlower door must be installed when taking temperature rise reading Leaving blower door off affects temperature measurements Changes the duct static pressure and airflow This furnace must operate within the temperature rise ranges specified on the furnace rating plate

22 Temperature Rise Information25-55 14-31 Temperature Rise Minimum Mid-Point Maximum Fahrenheit 25° 40° 55° Celsius 14° 22° 31° Min/Max temperature rise is shown on the unit rating plate. Mid-point of the rise range (shown above) is the ideal rise range point

23 Check Temperature RiseDetermine the air temperature as follows: Place thermometers in return and supply ducts As close to furnace as possible Away from line-of-sight of the heat exchanger When thermometer readings stabilize Subtract return air temperature from supply air temperature to determine temperature rise

24 Adjust Temperature RiseAdjust blower speed to change temperature rise Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise Change blower speeds at control board

25 Blower Speed Tap LocationsPSC Models Neutral (white) to 3/16” L2 terminal marked “BLW” Speed taps to ¼” spade terminals on top of relay Unused taps to ¼” spade terminals labeled “Spare” on edge of control board

26 Blower Speed Tap LocationsPSC models 115 VAC motor speed taps connect to the terminals on the relay. “COOL” & “HEAT” are marked on control board (red box). Motor neutral (white) connects to the 3/16 terminal marked “BLW” at the Neutral block (yellow box) Spare terminals connect to spade terminals on the edge of the control board (blue box)

27 Blower Speed Tap LocationsTap Select ECM models 24 VAC speed taps to 24V MTR TAPS Green wire to COM Neutral (white) to L2 block terminals 115 VAC (black) to terminal BL-1

28 Blower Speed Tap LocationsTap Select ECM models 24 VAC motor speed taps connect to the terminals on the furnace control board

29 Blower Speed Tap LocationsTap Select ECM models 115 VAC motor lead (black) connect to BL-1 Motor Neutral lead (white) connects to Neutral-L2

30 Condensate drain connected? Accessories installed? Other Tasks Filter installed? Filter(s) are external to the casing Condensate drain connected? Check for condensate drainage Accessories installed? Gas piping checked for leaks? Installation book left with furnace? Supply registers open/return grills not blocked? Outer doors installed?

31 Conversion to Propane NAHA01201LP includes: 1.25 mm orificesRegulator spring Spare spring-Regulator spring change not required Mixer screws with drill bit Low Gas Pressure Switch Brass fittings Wires Conversion Labels

32 Remove the manifold NOTE: Use a back−up wrench on the gas valvePrevent the valve from rotating on the manifold or damaging the mounting to the burner box Disconnect the gas pipe from gas valve and remove pipe from the furnace casing Disconnect: Wires from gas valve Hot Surface Igniter Flame Sensor Support the manifold and remove the four (4) screws that secure the manifold assembly to the burner box and set aside. Note the location of the green/yellow wire ground wire for re−assembly later

33 Remove the burner Slide one−piece burner assembly out of slots on sides of burner box Remove the flame sensor from the burner assembly

34 Remove the natural gas orificesRemove the #44 orifices Discard orifices

35 Install the orifices Inspect the 1.25 mm orifice for chips or debrisInstall mm orifices There are enough orifices in each kit for largest furnace Do not use Teflon® tape or pipe dope Finger−tighten orifices At least one full turn to prevent cross−threading, Tighten with wrench Discard extra orifices NOTE: DO NOT reinstall the manifold at this time

36 Pre-Adjust the Gas ValveGreen labeled gas valve ONLY! DOES NOT need regulator spring replaced Kit includes an regulator extra spring Regulator must be pre-adjusted for propane applications Extra Gas Valve Regulator Spring

37 Pre-Adjust the Gas ValveRemove the brass cap for the gas−valve regulator Turn the regulator adjustment screw clockwise 1.5 full turns This will adjust the valve closer to the propane set point If the regulator spring is removed Re-install the spring and the adjustment screw Turn the adjusting screw clockwise (in) 11.5 full turns This will increase the manifold pressure closer to the propane set point Do not install the brass regulator seal caps at this time Pre-adjust the regulator by turning the adjustment screw clockwise 1.5 full turns

38 Install Low Gas Pressure SwitchNOTE: Install the Low Gas Pressure Switch before installing the manifold on the burner assembly Remove the 1/8-in. NPT pipe plug from the gas valve inlet pressure tap Do not discard plug NOTE: Use pipe dope approved for use with Propane Gas

39 Install Low Gas Pressure SwitchNecessary fittings are supplied in the kit There are extra fittings in the kit LGPS is included it the kit CONTACTS OPEN ON PRESSURE FALL AT 7.20” W.C. +/- 0.70” W.C. CONTACT CLOSE ON INCREASING PRESSURE NO MORE THAN 10.20” W.C.

40 LGPS Fittings Black iron street ell Male x Female x Female TeeMale into inlet tap Points outward Male x Female x Female Tee Male end into street ell Female ends point Outward To your left Brass hex nipple Inserts into tee Brass Street ell Connects to hex nipple Male end connects to LGPS 1 2 3 4 Manometer connection. Install inlet pressure tap plug after checking inlet gas pressure.

41 Install Low Gas Pressure SwitchUse pipe dope sparingly Install: Black iron street ell F x M x F Tee Open end of Tee points outward Connect inlet manometer fitting Brass hex nipple Brass street ell Tighten each fitting with a small wrench Install LGPS Tighten with a small wrench Terminals point outward If unit is to be started at a later date, install plug removed from inlet pressure tap and install in place of manometer fitting

42 LGPS Pressure Switch WiresThere are 2 orange wires in the kit The straight terminals (1) connect to the LGPS The male spade terminal (2) connects to the orange wire of the low pressure switch harness The flag terminal (3) connects to the terminal on the low pressure switch 2 1 3

43 LGPS Pressure Switch WiresBefore installing the manifold Connect the straight terminal from each orange wires to each terminals on the switch

44 Install the Mixer ScrewsUse only the parts in the bag marked: “REQUIRED FOR THE CONVERSION OF CONDENSING GAS FURNACES TO PROPANE GAS” Locate the dimple on each burner venturi tube. If you cannot locate the dimple Refer to Figure in the instructions for the location of the mixer screw

45 Install the Mixer ScrewsUse only the parts in the bag marked: “REQUIRED FOR THE CONVERSION OF CONDENSING GAS FURNACES TO PROPANE GAS” Bag includes: 7/64th drill bit (7) Mixer screws

46 Install the Mixer ScrewsDrill a 7/64−in (2.8 mm) hole in each dimple Install a mixer screw in each drilled hole As straight as possible Perpendicular to the gas flow stream The screw head should be flush with the top of the burner venturi

47 Install the Mixer ScrewsInstall a mixer screws As straight as possible perpendicular to the gas flow stream The screw head should be flush with the top of the burner venturi

48 Re-assemble Burner Note the notch on front corner of burnerBurner slides in slots in burner box Slide burner forward Notched area should be fully seated forward

49 Install Manifold Insert manifold Install the 4 mounting screwsVerify orifices are captured by the burner mounting rings Install the 4 mounting screws Re-connect: Green ground wire HSI Flame Sensor Route HSI harness OVER manifold Route Flame Sensor harness UNDER manifold

50 Modify Pressure Switch WiringRoute the LGPS wires down to the LPS Disconnect the orange wire from the LPS (1) Connect the flag terminal (2) to the terminal on the LPS Connect the male spade terminal (3) to the orange wire (1) removed from the LPS 3 1 2

51 Modify Pressure Switch WiringFlag terminal (2) connected to the terminal on the LPS Male spade terminal (3) connected to the orange wire (1) removed from the LPS Secure wires with wire tie included in the kit 3 1 2

52 Startup-Check Inlet Gas PressureWith manometer connected to inlet pressure tap: Turn gas supply ON Verify inlet gas pressure above 12.0-in. W.C. (propane) Set furnace to call for heat After ignition Verify inlet gas pressure does not drop below 12.0-in. W.C. Do not operate the furnace for more than about a minute After checking the inlet pressure Terminate the call for heat Remove the manometer Install the 1/8-in. pipe plug in the brass tee

53 Startup-Check Inlet Gas PressureInstall inlet pressure tap plug after checking manifold pressure Manometer connection at LGPS

54 Startup-Adjust Manifold PressureWith manometer connected to outlet pressure tap: Set furnace to call for heat After ignition and the burner stabilizes Verify the manifold pressure (see conversion rating plate) To adjust the manifold pressure Remove cap that conceals gas valve regulator adjustment screw Turn adjusting screw counterclockwise (out) to decrease manifold pressure clockwise (in) to increase manifold pressure Replace gas valve regulator seal cap Verify manifold pressure is correct

55 Startup-Adjust Manifold PressureAfter adjusting the manifold pressure Terminate the call for heat Turn gas off/gas valve switch to OFF/power off Remove the manometer Install the 1/8-in. pipe plug in the outlet tap of the gas valve Turn furnace gas on/valve switch ON/power on Set room thermostat to call for heat Check pressure tap plug for gas leaks when main burners ignite Check for correct burner flame Observe unit operation through 2 complete heating cycles

56 Startup-Check Manifold PressureRemove the outlet pressure tap plug (3/16-in. hex wrench) Install manometer fitting & manometer Install outlet pressure tap plug after checking manifold pressure

57 Check Temperature RiseBlower door must be installed when taking temperature rise reading Leaving blower door off affects temperature measurements Changes the duct static pressure and airflow This furnace must operate within the temperature rise ranges specified on the furnace rating plate

58 Temperature Rise Information25-55 14-31 Temperature Rise Minimum Mid-Point Maximum Fahrenheit 25° 40° 55° Celsius 14° 22° 31° Min/Max temperature rise is shown on the unit rating plate. Mid-point of the rise range (shown above) is the ideal rise range point.

59 Check Temperature RiseDetermine the air temperature as follows: Place thermometers in return and supply ducts As close to furnace as possible Away from line-of-sight of the heat exchanger When thermometer readings stabilize Subtract return air temperature from supply air temperature to determine temperature rise

60 Adjust Temperature RiseAdjust blower speed to change temperature rise Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise Change blower speeds at control board

61 Blower Speed Tap LocationsPSC Models

62 Blower Speed Tap LocationsTap Select ECM models 24 VAC speed taps to 24V MTR TAPS Green wire to COM Neutral (white) to L2 block terminals 115 VAC (black) to terminal BL-1

63 Blower Speed Tap LocationsTap Select ECM models 24 VAC motor speed taps connect to the terminals on the furnace control board

64 Blower Speed Tap LocationsTap Select ECM models 115 VAC motor lead (black) connect to BL-1 Motor Neutral lead (white) connects to Neutral-L2

65 Apply Labels-English Apply to inside of door Note label shows:Model number Orifice size (1.25 mm) Manifold pressure (4.5-in. W.C.)

66 Apply Labels-French Apply to inside of door Note label shows:Model number Orifice size (1.25 mm) Manifold pressure

67 Apply Labels-French/EnglishApply to inside of door Fill in: Date conversion was performed Company name Company address

68 Apply Labels-French/EnglishApply to gas valve Shown larger than actual size

69 Operate the furnace through 2 heating cycles Before You Leave Operate the furnace through 2 heating cycles Verify gas and electric are still on Perform final gas leak check Final inspections of installation Including accessories and filter installed Install outer doors Thermostat set correctly

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