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HEATING A COOLING
58PAV Upflow Induced-Combustion Furnaces
Installation, Start-Up, and Operating Instructions
Sizes 035-125,
NOTE: Before beginning the installation, READ THESE
INSTRUCTIONS CAREFULLY AND COMPLETELY.
SAFETY CONSIDERATIONS
Installation and servicing of heating equipment can be haz ardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance func tions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in the literature, tags, and labels attached to or shipped with the unit and other safety precautions that may apply.
Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code NFPA No. 54-1988/ANSI Z223.1-1988. In Canada, refer to the cur rent edition of the National Standard of Canada CAN/CGAB149.1- and .2-M86 Natural Gas and Propane Gas Installa tion Codes. Wear safety glasses and work gloves. Have fire extinguisher available duriag startup and adjustment pro cedures and service calls.
Recognize safety information: This is the safety-alert sym bol AA. When. VI you see this symbol on the furnace and in instructions or manuals, be alert to the potential for per sonal injury.
Understand the signal word—DANGER, WARNING, or CAUTION. These words are used with the safety-alert sym bol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard that could result in personal injury or death. CAUTION is used to identify unsafe practices, which would result in minor personal injury or product and prop erty damage.
Table 1—Minimum Clearances From
Combustible Materials (In Ins.)
These instructions cover minimum requirements and con form to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residentieil construction practices.
We require these instructions as a minimum for a safe installation.
INTRODUCTION
The design of the upflow gas-fired furnace is A.G.A./CGA certified for natural and propane gas and for instaUation on combustible flooring, in alcoves, attics, basements, closets, or utility rooms. The design of this furnace line is not A.G.A./CGA certified for installation in mobile homes, rec reation vehicles, or outdoors.
Before instalhng the furnace, refer to the current edition of the National Fuel Gas Code NFPA No. 54-1988/ANSI Z223.1-1988. Canadian installations must be installed in accordance with CAN/CGA.B149 Installation Codes and aU authorities having jurisdiction. For further information, the National Fuel Gas Code is available from National Fire Protection Association Inc. Batterymarch Park, Quincy, MA 02269, American Gas Association, 1515 Wilson Boule vard, Arlington, VA 22209, or from Literature Distribution.
Installation must conform to the regulations of the serving gas supplier and the local building, heating, and plumbing codes in effect in the area in which the installation is made, or in the absence of local codes, with the requirements of the National Fuel Gas Code.
Size |
035 and 055 |
075 thru 125 |
Sides—Single-Wall Vent |
1 |
0 |
Type B-1 Double-Wall Vent |
0 |
0 |
Back |
0 |
0 |
Top of Plenum |
1 |
1 |
Vent Connector—Single-Wall Vent |
6 |
6 |
Type B-1 Double-Wall |
1 |
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Vent |
1 |
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Front—Single-Wall Vent |
6 |
6 |
Type B-1 Double-Wall Vent |
3 ■ |
3 |
Service |
30 |
30 |
A CAUTION
Application of this furnace should be indoors with spe cial attention given to vent sizing and material, gas input rate, air temperature rise, and unit sizing. Improper installation or misapplication of the furnace can require excessive servicing or cause premature component failure.
This furnace is designed for a minimum continuous return
NOTES: |
air temperature of 60 degrees F DB or an intermittent oper |
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1. Provide 30-in. front clearance for servicing. An open door in front of the |
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furnace can meet this requirement. |
ation down to 55 degrees F DB such as when used with a |
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thermostat night setback. Return air temperature must not |
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2. A minimum clearance of 3 ins. must be provided in front of the furnace |
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for combustion air and proper operation. |
exceed a maximum of 85 degrees F DB. |
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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations.
Book] 1 I 4 |
PC 101 Catalog No. 565-913 |
Printed in U.S.A. |
Form58PA-1SI Pg 1 |
5-90 |
Replaces: New |
Tab 16a i 8a |
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RETURN AIR.
Fig. 1 —Dimensional Drawing
A WARNING
Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poison ing, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier or your distributor or branch for information or assistance. The qualified installer or agency must use only factory authorized and fisted kits or accessories when modifying this product. A failure to foUow this warning can cause electrical shock, fire, personal injury, or death.
For accessory installation details, refer to the applicable instruction literature.
NOTE: Remove aU shipping brackets and materials before operating the furnace.
I. LOCATION
A. General
A CAUTION
Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are adhered to, in addition to eiU local codes and ordinances.
Do not use this furnace during construction when adhe sives, sealers, and/or new carpets are being installed. If the fm-nace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine when burned with combustion air form acids which will cause corrosion of the heat exchangers and metal vent system. Some of these com pounds are: paneling and dry waU adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction process.
Locate the furnace close to the chimney/vent and as near the center of the air distribution system as possible. The furnace should be installed as level as possible.
When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.
Provide ample space for servicing and cleaning. Always comply with the minimum fire protection clearemces shown on the unit rating plate. This furnace shall not be installed directly on carpeting, tüe, or any combustible material other than wood flooring.
Table 2—Dimensions (In Ins.)
Size |
A |
D |
E |
Vent Conn |
Ship. Wt |
035-EC |
14-3/16 |
12-9/16 |
12-11/16 |
4 |
116 |
035-GC |
14-3/16 |
12-9/16 |
12-11/16 |
4 |
118 |
055-EC |
14-3/16 |
12-9/16 |
12-11/16 |
4 |
126 |
055-GC |
14-3/16 |
12-9/16 |
12-11/16 |
4 |
128 |
075-GC |
17-1/2 |
15-7/8 |
16 |
4 |
143 |
075-JC |
21 |
19-3/8 |
19-1/2 |
4 |
147 |
090-GC |
17-1/2 |
15-7/8 |
16 |
4 |
153 |
090-JC |
21 |
19-3/8 |
19-1/2 |
4 |
159 |
090-LC |
24-1/2 |
22-7/8 |
23 |
4 |
176 |
110-JC |
21 |
19-3/8 |
19-1/2 |
5 |
171 |
110-LC |
24-1/2 |
22-7/8 |
23 |
5 |
186 |
125-LC |
24-1/2 |
22-7/8 |
23 |
5 |
196 |
B. Location With Respect to Cooling Equipment
The coofing coil must be installed parallel with, or on the downstream side of, the furnace to avoid condensation in the heat exchangers. When installed parallel with a furnace, dampers or other means used to control the flow of air must prevent chilled air from entering the unit. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full-heat or fuU-cool position.
C. Hazardous Locations
When the furnace is installed in a residential garage, it must be installed so that the burners and ignition source are located no less them 18-ins. above the floor. Also, the fur nace should be protected from physical damage by vehicles.
When a furnace is installed in public garages, airplane han gars, or other buildings having hazardous atmospheres, the unit must be installed in accordance with the recommended good practice requirements of the National Fire Protection Association, Inc.
II. AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1-1988, or applicable provisions of the local building codes.
Canadian installations must be installed in accordance with CAN/CGA.B149 Installation Codes, and aU authorities hav ing jurisdiction.
A CAUTION
Air for combustion must not be contaminated by halo gen compounds, which include fluoride, chloride, bro mide and iodide.
These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.
AU fuel burning equipment must be supplied with air for combustion of the fuel. Sufficient air MUST be provided to insure there wfll not be a negative pressure in the equipment room or space. In addition, a positive seal MUST be made between the furnace cabinet and the return-air duct puUing air from the burner area and draft safeguard opening.
A CAUTION
The operation of exhaust fans, kitchen ventilation fans, clothes dryers, or fireplaces could create a negative pressure condition at the furnace. Make up air must be provided for the ventilation devices, in addition to that required by the furnace.
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Combustion air requirements are determined by whether |
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the fiunace is in an UNCONFINED or CONFINED space. |
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A confined space is a space whose volume is less than 50 |
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cubic ft per 1000 Btu per hour of the total output rating for |
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aU appliances installed in that space. |
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A. Unconfined Space |
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An unconfined space must have at least 50 cubic ft for each |
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1000 Btuh of input for all the appliances (i.e. furnaces, |
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clothes dryer, water heaters, etc.) in the space. |
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For Example: |
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58PAV Furnace |
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Minimum Sq Ft |
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with |
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Input Btuh |
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7-1/2 Ft Ceiling |
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44,000 |
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293 |
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66,000 |
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440 |
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88,000 |
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587 |
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110,000 |
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733 |
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132,000 |
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880 |
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154,000 |
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1026 |
If the unconfined space is of unusually tight construction, air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the out doors. Combustion and ventilation openings must be sized the same as for a confined space. A minimum opening hav ing a total of not less than 1 square in. per 5000 Btuh of total input rating for all equipment must be provided. Return air must not be taken from the room, unless an equal or greater eimount of air is supplied to the room.
B. Confined Space
A confined space MUST have two permanent openings, one within 12-ins. of the ceiLing, and the other within 12-ins. of the floor. See Fig. 2.
NOTE: In deterniining the free area of an opening, the blocking effect of the louvers, grilles and screens must be considered. If the free area of a louver or grille design is unknown, it may be assumed that wood louvers have a 20 percent free area and metal louvers or grilles have a 60 per cent free area. Screens, when used, must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed.
The size of the openings depend upon whether the air comes from inside or outside of the structure.
SUPPLY |
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AIR |
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r~Hn |
VENT TO ROOF |
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12 MAX |
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^ 1 SQ INCH |
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PER 1000 |
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I BTUH* |
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INTERIOR |
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HEATED |
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SPACE |
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-6 MIN |
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(FRONT) |
A89012
♦Minimum opening size is 100 square ins. tMinimum of 3 ins. when type-B vent is used.
1. All air from inside the structure
Each opening MUST have at least 1 square in. of free area per 1000 Btuh of the total input for all equipment within the confined space, but not less than 100 square ins. per opening. See Fig. 2.
For Example:
58PAV Furnace |
Free Area per Opening |
Input Btuh |
(square ins.) |
44,000 |
100 |
66,000 |
100 |
88,000 |
100 |
110,000 |
110 |
132,000 |
132 |
154,000 |
154 |
If the building is of unusually tight construction, a perma nent opening directly communicating with the outdoors shall be provided. This opening shall have a minimum free area of 1 square in. per 5000 Btuh of total input rating for all equipment in the enclosure.
If the furnace is installed on a raised platform to provide a return air plenum, and return air is taken directly from the hallway or space adjacent to the furnace, aU air for combus tion must come from outdoors.
2.All air from outdoors
a. If combustion air is taken from outdoors through vertical ducts, the openings and ducts MUST have at least one square inch of free area per 4000 Btuh of the total input for aU equipment within the con fined space. See Fig. 3.
For Example:
58PAV Furnace |
Free Area per Opening |
Round Pipe |
input Btuh |
(square ins.) |
(ins. dia) |
44,000 |
11.0 |
4 |
66,000 |
16.5 |
5 |
88,000 |
22.0 |
6 |
110,000 |
27.5 |
6 |
132,000 |
33.0 |
7 |
154,000 |
38.5 |
7 |
b.If combustion air is taken from the outdoors through horizontal ducts, the openings and ducts MUST have at least one square in. of free area per 2000 Btuh of the
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1 |
so INCH PER |
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4000 BTUH |
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DUCTS |
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TO ROOF- |
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I'. ".I |
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MAX 12 |
SUPPLY |
D |
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1 |
SQ INCH PERT |
AIR |
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A A VENT |
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2000 BTUH |
T TO ROOF |
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DUCTS TO |
A |
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OUTS DE |
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1 |
SQ INCH PER |
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i 2 MAX |
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2000 BTUH ^ |
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MAX 12 |
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1 SQ INCH |
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RETURN AIR j |
,^PER 4000 |
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BTUH |
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DUCT |
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TO OUTSIDE |
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USE ANY OF THE FOLLOWING |
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COMBINATIONS OF |
OPENINGS: |
A89013 |
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A&B C&D D&E |
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Fig. 2 |
Fig-3 |
total input for all equipment within the confined space.
For Example:
58PAV Furnace |
Free Area per Opening |
Round Pipe |
Input Btuh |
(square ins.) |
(ins. dia) |
44,000 |
22.0 |
6 |
66,000 |
33.0 |
7 |
88,000 |
44.0 |
8 |
110,000 |
55.0 |
9 |
132,000 |
66.0 |
10 |
154,000 |
77.0 |
10 |
When ducts are used, they must be of the same cross sec tional area as the free area of the openings to which they connect. The minimum dimension of rectangular ducts must not be less than 3-ins. See Fig. 3.
The front bracket(s) are installed on the bottom front plate as shown in Fig. 5, once the bottom enclosure has been removed. Rotate filter supports 180 degrees so filter will rest on support emd reinstall. (Do not reinstall in 17-1/2-in. casing.) Install the filter retaining rod (small U-shaped end) in the rear bracket, and the front of the filter retainer rod as shown in Fig. 5. Two sets of hardware are needed for fur naces in 24-1/2-in. casings using one filter for bottom return. All hardware is provided for filter installation.
A WARNING
Never operate unit without a filter or with filter access door removed. A failure to follow this warning can cause a fire, personal injury, or death.
A WARNING
Do not install the furnace on its back; safety control operation will be adversely affected. Never connect return-air ducts to the back of the furnace. A failure to follow this warning can cause a fire, personal injury, or death.
III. FILTER ARRANGEMENT
The factory-supphed filter(s) is shipped in the blower com partment. Deterrnine location for the filter and move filter retaining hardware, if necessary, before attaching the return-air duct. After the return-air duct has been connected to the furnace, install the filter(s) inside the furnace blower compartment. See Fig. 4 for side return apphcation and Fig. 5 for bottom return application.
A bottom closure panel is factory-installed in the bottom of the furnace. When bottom return inlet is desired, remove and discard the enclosure panel.
Filter retaining brackets, supports, and retainers are fac tory assembled and shipped installed for side return appUcation, with one set of all required hardware provided. See Fig.
4. For bottom return appHcations, remove the brackets (front and back) and supports from each side. The back bracket(s) are installed in the rear of the furnace casing (dimples are provided to mark mounting screw locations).
Fig. 4—Side Filter Arrangement
Table 3—Filter Information
Furnace |
Fiiter Size* |
Fiiter |
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Casing Width |
Side Return |
Bottom Return |
Type |
14-3/16 |
(1)16x25x1 |
(1)14x25x1t |
Cleanable |
17-1/2 |
(1)16x25x1 |
(1)16x25x1t |
Cleanable |
21 |
(1)16x25x1 |
(1)20 x 25x1t |
Cleanable |
24-1/2 |
(2)16x25x1 |
(1)24 x 25x1t |
Cleanable |
*Filter can be field-modified by cutting to the desired size. Aiternate sizes can be ordered from your Distributor or Deaier.
fFactory provided with the furnace.
Fig. 5—Bottom Filter Arrangement
IV. LEVELING LEGS (If Required)
When the furnace is used with side inlet(s), and leveling legs are required, refer to Fig. 6, and install field-supplied corrosion-resistant 5/16-in. machine bolts and nuts.
NOTE; The maximum length of the bolt should not exceed 1-1/2 ins.
1.Lay furnace on its back, locate and drill 5/16-in. diame ter hole in each bottom corner of furnace as shown in Fig. 6.
2.Install nut on bolt and install bolt and nut in hole. (Install flat washer if desired.)
3.Install another nut on other side of furnace base. (Install flat washer if desired.)
4.Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.
V.GAS PIPING
Gas piping must be installed in accordance with national and local codes. Refer to the current edition of the National Fuel Gas Code. Canada installations must be installed in accordance with CAN/CGA.B149 Installation Codes, and all authorities having jurisdiction.
The gas supply line should be a separate line running directly from the gas meter to the furnace, if possible. Refer to Table 4 for the recommended gas pipe size. Risers must be used to connect to the furnace and the meter.
Table 4—Maximum Capacity of Pipe*
Nominal |
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Iron Pipe |
Internal |
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Length of Pipe, Ft |
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Size |
Diameter |
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Ins. |
Ins. |
10 |
20 |
30 |
40 |
50 |
1/2 |
0.622 |
175 |
120 |
97 |
82 |
73 |
3/4 |
0.824 |
360 |
250 |
200 |
170 |
151 |
1 |
1.049 |
680 |
465 |
375 |
320 |
285 |
1-1/4 |
1.380 |
1400 |
950 |
770 |
660 |
580 |
1-1/2 |
1.610 |
2100 |
1460 |
1180 |
990 |
900 |
*Cubic ft of gas per hour, for gas pressures of 0.5 psig (14 ins. wc) or less, and a pressure drop of 0.5 in. wc (based on a 0.60 specific gravity gas). Ref; Table C-4 NFPA 54-1988.
Fig. 7—Typical Gas Pipe Arrangement
made, purge the lines and check for leakage with regulated gas supply pressure.
Install a sediment trap in the riser leading to the furnace. The trap can be installed by connecting a tee to the riser leading from the furnace. Connect a capped nipple into the lower end of the tee. The capped nipple should extend below the level of the gas controls. See Fig. 7.
Apply joint compound (pipe dope) sparingly and only to the male threads of each joint. The compound must be resistant to the action of propane gas.
A WARNING
Never purge a line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap-and- water solution to check for leakage. A failure to follow this warning can cause a fire, explosion, personal injury, or death.
An accessible manual shut-off valve shall be installed upstream of the furnace gas controls and within 6 ft of the furnace. A 1/8-in. NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the furnace and downstream of the manual shut-off valve. Place ground joint union between the gas control manifold and the manual shut-off valve.
A WARNING
Use the proper length of pipes to avoid stress on the gas control manifold. A failure to follow this warning can cause a gas leak resulting in a fire, explosion, per sonal injury, or death.
A CAUTION
If a flexible connector is required or allowed by the authority having jurisdiction, black iron pipe shall be installed at the gas valve and extend a minimum of 2- ins. outside the furnace casing.
Piping should be pressure-tested in accordance with local and national plumbing and gas codes before the furnace has been attached. If the pressure exceeds 0.5 psig (14 in. wc), the gas supply pipe must be disconnected from the furnace and capped before the pressure test. If the test pressure is equal to or less than 0.5 psig (14 in. wc), close the manual shut-off valve located on the gas valve before the test. It is recommended that the ground joint union be loosened before pressure testing. After all connections have been
A CAUTION
Use a backup wrench when connecting the gas pipe to the furnace to avoid damaging gas controls.
VI. ELECTRICAL CONNECTIONS A. 115-Volt Wiring
Refer to the unit rating plate or Table 5 for equipment elec trical requirements. The control system requires an earth ground for proper operation.
A CAUTION
Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.
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