Tempstar F9MAE User Manual

Printed in U.S.A. 440 01 4300 02 12/5/2013
INSTALLATION INSTRUCTIONS
Modulating Gas Valve, Variable Speed Motor
35” Tall High Efficiency Condensing Gas Furnace
(F/G)9MAE
These instructions must be read and understood completely before attempting installation.
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and NOTE
The signal words DANGER, WARNING,
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and
throughout this manual and other manual that may
apply to the product.
DANGER − Immediate hazards which will result in
severe personal injury or death.
WARNING − Hazards or unsafe practices which
could result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
NOTE − Used to highlight suggestions which will
result in enhanced installation, reliability, or
operation.
!
WARNING
Signal Words in Manuals
The signal word CAUTION is used throughout
this manual in the following manner:
!
CAUTION
Signal Words on Product Labeling
Signal words are used in combination with
colors and/or pictures or product labels.
The signal word WARNING is used throughout
this manual in the following manner:
Safety−alert symbol
When you see this symbol on the unit and in
instructions or manuals, be alert to the
potential for personal injury.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 3..............................
INTRODUCTION 4.........................................
CODES AND STANDARDS 4................................
ELECTROSTATIC DISCHARGE PRECAUTIONS PROCEDURE 5
DIMENSIONS 6...........................................
LOCATION 7..............................................
LOCATION RELATIVE TO COOLING EQUIPMENT 8...........
AIR FOR COMBUSTION AND VENTILATION 9................
CONDENSATE TRAP 10.....................................
INSTALLATION 17..........................................
UPFLOW INSTALLATION 17.................................
DOWNFLOW INSTALLATION 18..............................
HORIZONTAL INSTALLATION 20.............................
FILTER ARRANGEMENT 23.................................
AIR DUCTS 26.............................................
GAS PIPING 27.............................................
ELECTRICAL CONNECTIONS 28.............................
J−BOX INSTALLATION 29...................................
VENTING 33...............................................
SPECIAL VENTING REQUIREMENTS
FOR INSTALLATIONS IN CANADA 33........................
DIRECT VENT / 2−PIPE SYSTEM 35..........................
VENTILATED COMBUSTION AIR SYSTEMS 35................
TERMINATION REQUIREMENTS FOR
THE PROVINCES OF ALBERTA AND SASKATCHEWAN 37.....
MAXIMUM EQUIVALENT VENT LENGTH 51...................
MAXIMUM ALLOWABLE EXPOSED VENT LENGTHS 54........
Use of the AHRI Certified TM Mark indicates a
manufacturer’s participation in the program.
For verification of certification for individual
products, go to www.ahridirectory.org .
INSTALLER: Affix these instructions on or adjacent to the
furnace.
CONSUMER: Retain these instructions for future
reference.
Portions of the text and tables are reprinted from NFPA 54 /ANSI Z223.1−2012, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington, DC
20001. This reprinted material is not the complete and official position of the NFPA or ANSI, on the referenced subject, which is represented only by the standard in its entirety.

Tempstar F9MAE Specifications

General

Brand	Tempstar
Model	F9MAE
Category	Furnace
Language	English

Summary

Safety Labeling and Signal Words

Signal Words in Manuals

Explains the use and meaning of signal words like WARNING and CAUTION in manuals.

Signal Words on Product Labeling

Describes how signal words are used on product labels for hazard identification.

Required Notice for Massachusetts Installations

Important

Highlights critical compliance requirements for installations in Massachusetts.

Safety Considerations

WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Details critical hazards related to fire, explosion, electrical shock, and CO poisoning.

WARNING FIRE HAZARD

Warns about fire hazards associated with combustible materials and solvents.

CAUTION FURNACE RELIABILITY HAZARD

Alerts to potential unit component damage due to improper handling or installation.

CAUTION CUT HAZARD

Warns about personal injury risks from sharp sheet metal edges and burrs.

Codes and Standards

Safety

Lists safety standards for US and Canadian installations.

General Installation

References national codes for general installation practices in US and Canada.

Duct Systems

US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA)

References standards for duct system design and installation.

Acoustical Lining and Fibrous Glass Duct

US and CANADA: current edition of SMACNA, NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Specifies standards for acoustical lining and fibrous glass duct materials.

Gas Piping and Gas Pipe Pressure Testing

U.S.A.: NFPA 54/ANSI Z223.1-2012, NFGC; Chapters 5, 6, 7, and 8 and national plumbing codes.

Lists US codes and standards for gas piping installation and testing.

CANADA: CAN/CSA-B149.1-2010, Parts 4, 5, 6 and 9.

Lists Canadian codes and standards for gas piping installation and testing.

In the state of Massachusetts:

Details specific Massachusetts regulations for gas piping installations.

Electrical Connections

U.S.A.: National Electrical Code (NEC) ANSI/NFPA 70-2011

References the US National Electrical Code for electrical connections.

CANADA: Canadian Electrical Code CSA C22.1

References the Canadian Electrical Code for electrical connections.

Condensate Drain Connection

US: National Standard Plumbing Code 2009, Section 8.7.

References US plumbing code for condensate drain connections.

Canada: National Plumbing Code of Canada 2010 in Canada.

References Canadian plumbing code for condensate drain connections.

Electrostatic Discharge (ESD) Precautions Procedure

CAUTION FURNACE RELIABILITY HAZARD

Warns about potential damage to electronic controls from ESD.

Dimensions

Location

CAUTION PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Warns about premature furnace failure due to improper location or installation.

WARNING CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD

Alerts to CO poisoning risk and component damage from corrosive atmospheres.

General

Provides general guidelines for furnace location and installation requirements.

Location Relative to Cooling Equipment

WARNING FIRE, INJURY OR DEATH HAZARD

Warns about hazards when installing furnace in garages or hazardous atmospheres.

WARNING FIRE HAZARD

Warns against improper furnace orientation affecting safety controls.

Air for Combustion and Ventilation

Introduction

Provides an overview of air requirements for furnace operation.

Direct Vent (2–Pipe) Applications

Explains air requirements for direct vent (2-pipe) furnace installations.

Ventilated Combustion Air Applications

Details air supply needs for ventilated combustion air systems.

CAUTION FURNACE CORROSION HAZARD

Warns about furnace damage from contaminated combustion air.

WARNING CARBON MONOXIDE POISONING HAZARD

Alerts to CO poisoning risk from negative pressure or inadequate makeup air.

CONDENSATE TRAP

CAUTION FROZEN AND BURST WATER PIPE HAZARD

Warns about risks of freezing and burst pipes in furnace installation areas.

CAUTION PROPERY DAMAGE HAZARD

Alerts to property damage from plugged condensate drains or failed pumps.

Condensate Trap – Upflow Orientation

Describes condensate trap configuration for upflow furnace orientation.

Condensate Trap – Downflow Orientation

Condensate Trap – Downflow Orientation

Details condensate trap relocation for downflow furnace orientation.

Condensate Trap – Horizontal Orientation

Condensate Trap – Horizontal Orientation

Explains condensate trap repositioning for horizontal furnace orientations.

CAUTION CUT HAZARD

Condensate Drain Connection

CAUTION FROZEN AND BURST WATER PIPE HAZARD

Warns about risks of freezing and burst pipes in furnace installation areas.

CAUTION PROPERY DAMAGE HAZARD

Alerts to property damage from plugged condensate drains or failed pumps.

For Right Side Condensate Drain

For Right Side Condensate Drain

Provides step-by-step instructions for right-side condensate drain routing.

For Left Side Condensate Drain Connection

For Left Side Condensate Drain Connection

Details steps for routing condensate drain on the left side of the furnace.

Supply Air Connections

Return Air Connections

WARNING FIRE HAZARD

Warns against improper return air duct connection to the furnace back.

Bottom Return Air Inlet

Explains how to use or remove the bottom closure panel for return air.

Side Return Air Inlet

Describes the use of side return air inlets for upflow and horizontal configurations.

Leveling Legs (If Desired)

Provides instructions for installing leveling legs for furnace support.

Air Ducts

General Requirements

Outlines general design and sizing requirements for duct systems.

Return Duct Sizing

Guides on proper sizing of return ductwork and filter selection.

Ductwork Acoustical Treatment

Discusses requirements for acoustical lining or fibrous ductwork.

GAS PIPING

WARNING FIRE OR EXPLOSION HAZARD

Warns of fire or explosion risks during gas piping installation and testing.

CAUTION FURNACE DAMAGE HAZARD

Alerts to potential furnace damage from improper gas pipe connections.

Gas Entry

ELECTRICAL CONNECTIONS

WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Warns of severe hazards from improper electrical servicing or operation.

WARNING ELECTRICAL SHOCK HAZARD

Highlights shock hazard related to blower door switch and wiring.

WARNING ELECTRICAL SHOCK AND FIRE HAZARD

Stresses the importance of proper grounding to prevent electrical hazards.

J-Box Installation

WARNING FIRE OR ELECTRICAL SHOCK HAZARD

Warns of fire or shock hazard if disconnect switch is mounted improperly.

115-V Wiring

FIRE HAZARD

Electrical Box on Furnace Casing Side

Power Cord Installation in Furnace J-Box

BX Cable Installation in Furnace J-Box

24-V Wiring

Thermostats and Control Settings

Accessories (See Figure 38 and Figure 39)

Alternate Power Supplies

VENTING

Special Venting Requirements for Installations in Canada

Outlines specific venting requirements for installations in Canada.

Venting Systems

WARNING CARBON MONOXIDE POISONING HAZARD

Warns of CO poisoning risk from improper vent termination or system configuration.

Direct Vent / 2-Pipe System

Explains requirements for direct vent (2-pipe) system terminations.

Ventilated Combustion Air Systems

Details requirements for ventilated combustion air system terminations.

Locating the Vent Termination

General

Provides guidelines for selecting appropriate vent termination locations.

Sidewall Terminations

Discusses considerations for sidewall vent termination installations.

Concentric Vent

Details installation requirements for concentric vent termination kits.

Termination Requirements for the Provinces of Alberta and Saskatchewan

Specifies unique vent termination rules for Alberta and Saskatchewan.

Size the Vent and Combustion Air Pipes

General

Guides on selecting appropriate pipe diameters based on furnace input and altitude.

Optional Combustion Air Inlet Moisture Trap

Explains the installation and use of an optional moisture trap for air inlets.

Configure the Furnace

WARNING CARBON MONOXIDE POISONING HAZARD

Warns of CO risk due to improper routing or sealing of vent pipes.

Install the Vent and Combustion Air Pipes

Provides instructions for routing and installing vent and combustion air pipes.

Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter

WARNING CARBON MONOXIDE POISONING HAZARD

Warns of CO poisoning risk from improper pipe sealing or use of cement.

Installing the Vent Termination

Roof Terminations

Details requirements for vent terminations through roofs.

Concentric Vent

Guides installation of concentric vent termination kits.

Two-Pipe (Direct Vent)Terminations

Specifies requirements for direct vent (2-pipe) termination installations.

Inducer Outlet Restrictor

Venting System Length Calculations