Bryant 120 User Manual

312A

2 --- S t a ge D e lux e I n d u ce d --- C o m b u s ti o n 4---Way Multipoise Furnace

Installation, Start--up, Operating and

Service and M a int e nanc e

Instructions Series 120/C

SAFETY CONSIDERATIONS 2........................

INTRODUCTION 3..................................

CODES AND STANDARDS 5..........................

Safety 5...........................................

General Installation 5................................

Combustion and Ventilation Air 5......................

Duct Systems 5.....................................

Acoustical Lining and Fibrous Glass Duct 5...............

Gas Piping and Gas Pipe Pressure Testing 5...............

Electrical Connections 5..............................

Venting 5.........................................

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE 5.....................................

LOCATION 6.......................................

AIR FOR COMBUSTION AND VENTILATION 8.........

INSTALLATION 10..................................

UPFLOW INSTALLATION 10......................

DOWNFLOW INSTALLATION 11...................

HORIZONTAL INSTALLATION 11..................

FILTER ARRANGEMENT 15.......................

AIR DUCTS 15...................................

GAS PIPING 18..................................

ELECTRICAL CONNECTIONS 21..................

VENTING 26....................................

START--UP, ADJUSTMENT, AND SAFETY CHECK 35.....

General 35........................................

Start--Up Procedures 35..............................

Adjustments 36.....................................

Check Safety Controls 40.............................

Checklist 41.......................................

SERVICE AND MAINTENANCE PROCEDURES 45.....

Introdution 46....................................

Care and Maintenance 46...........................

Sequence of Operation 51...........................

Wiring Diagrams 54...............................

Troubleshooting 54................................

ama

ISO 9001:2000

CERTIFIED

REGISTERED

NOTE: Read the entire instruction manual before starting the installation.

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1--2006E, 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.

28-7/8"

25-1/4"

22-9/16"

JUNCTION BOX LOCATION

WIRE ENTRY

3-15/16"

LEFT HAND GAS

ENTRY

7/8" DIA. ACCESSORY

21-5/8"

BOTTOM INLET

24"

CASING

1-11/16"

24-7/8"

5-1/2"

4-13/16"

8-9/16"

ALTERNATE

JUNCTION BOX

VENT OUTLET

5 PLACES (TYP)

3-3/4"

2-7/16" 1-5/16"

1-1/8"

13/16"

LOCATIONS (TYP)

5-1/2"

11/16"

AIRFLOW

19"

OUTLET

1/2" DIA. K.O.THERMOSTAT WIRE ENTRY

1-3/4" DIA.RIGHT HAND GAS ENTRY

7/8" DIA. K.O. WIRE ENTRY

7/8" DIA. ACCESSORY

1-1/2"

22-1/16"

SIDE INLET

13/16"

11/16"

14-7/8"

1-1/4"

312A

26-1/8"

(FLUE COLLAR)

5-15/16"

7/8" DIA

ACCESSORY

NOTES:

1. Two additional 7/8-in. diameter holes are located in the top plate.

2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a. For 800 CFM-16-in. round or 14 1/2 x 12-in. rectangle. b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle. c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

1/2" DIA THERMOSTAT

33-5/16"

11/16"

NOTES:

1. Two additional 7/8---in. diameter holes are located in the top plate.

2. Minimum return --- air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a. For 800 CFM---16--- in. round or 14 1/2 x 12--- in. rectangle. b. For 1200 CFM---20 ---in. round or 14 1/2 x 19 1/2--- in. rectangle. c. For 1600 CFM---22 ---in. round or 14 1/2 x 22--- in. rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific u se of single side inlets. The use of both sideinlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airfl ow requirements above 1800 CFM.

Fig. 1 -- Dimensional Drawing

7-3/4"

9-5/8"

11-1/2"

A04037

SAFETY CONSIDERATIONS

WARNING

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

Failure to follow this warning could result in dangerous operation, serious injury, death, or property damage.

Improper installation, adjustment, alteration, service, maintenance, or use could cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factory--authorized and listed kits or accessories when modifying this product.

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure.

Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions 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 literature, on tags, and on labels attached to or shipped with furnace and other safety precautions that may apply. These instructions cover minimum requirements and conform 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 residential construction practices. We require these instructions as a minimum for a safe installation.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

Wear safety glasses and work gloves. Have fire extinguisher available during start--up and adjustment procedures and service calls.

This is the safety--alert symbol

. When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify hazards which may result in minor personal injury or

Table 1 – Dimensions (In.)

FURNACE SIZE

045--- 08/024045 14--- 3/16 12--- 9/16 12--- 11/16 9--- 5/16 4 116 16 045--- 12/036045 14--- 3/16 12--- 9/16 12--- 11/16 9--- 5/16 4 119 16 070--- 08/024070 14--- 3/16 12--- 9/16 12--- 11/16 9--- 5/16 4 120 16 070--- 12/036070 14--- 3/16 12--- 9/16 12--- 11/16 9--- 5/16 4 124 16 070--- 16/048070 17--- 1/2 15--- 7/8 16 11 --- 9/16 4 138 16 090--- 14/042090 17--- 1/2 15--- 7/8 16 11 --- 9/16 4 136 16 090--- 16/048090 21 19--- 3/8 19 --- 1/2 13---5/16 4 151 20 090--- 20/060090 21 19--- 3/8 19 --- 1/2 13---5/16 4 156 20 110--- 12/036110 17--- 1/2 15--- 7/8 16 11 --- 9/16 4 144 16 110--- 16/048110 21 19--- 3/8 19 --- 1/2 13---5/16 4 158 20 110--- 22/066110 21 19--- 3/8 19 --- 1/2 13---5/16 4 163 20 135--- 16/048135 21 19--- 3/8 19 --- 1/2 13---5/16 4† 163 20 135--- 22/066135 24--- 1/2 22--- 7/8 23 15 --- 1/16 4† 174 24 155--- 20/060155 24--- 1/2 22--- 7/8 23 15 --- 1/16 4† 181 24

* 5” or 6” vent connector may be required in some cases. { 135 and 155 size furnaces require five---inch or larger vents. Use a 4---5 or 4---6 inch vent adapter between furnace and vent connector.

CABINET

WIDTH

(IN.)

SUPPLY--- AIR

WIDTH (IN.)

RETURN---AIR

WIDTH (IN.)

product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate 2. Install this furnace only in a

2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified in “Air for Combustion and Ventilation” section.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.

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 the “Gas Piping” section.

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, as specified in the “Start--Up, Adjustments, and Safety Check” section. See furnace rating plate.

7. When a furnace is installed so that 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. See “Air Ducts” section.

8. A gas-- fired furnace for installation in a residential garage must be installed as specified in the warning box in the “Location” section.

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

10. These Multipoise Gas--Fired Furnaces are CSA (formerly A.G.A. and C.G.A.) design--certified for use with natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory--shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required

C.L. TOP AND

BOTTOM FLUE

COLLAR (IN.)

FLUE

COLLAR*

(IN.)

SHIP WT. (LB)

11. See Fig. 2 for required clearances to combustible construction.

12. Maintain a 1--in. clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used. See Fig. 2 for clearance to combustible construction information.

INTRODUCTION

The Series 120/C 4--way multipoise Category I fan--assisted furnace is CSA (formerly A.A.A.. and C.G.A.) design--certified. A Category I fan--assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory--shipped for use with natural gas. This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors.

These furnaces shall not be installed directly on carpeting, tile, or any other combustible material other than wood flooring. For downflow installations, a factory accessory floor base must be used when installed on combustible materials and wood flooring. This special base is not required when this furnace is installed on the manufacturer’s coil assembly, or when the manufacturer’s coil box is used. See Fig. 2 for clearance to combustible material information.

This furnace is designed for minimum continuous return--air temperature of 60_F db or intermittent operation down to 55_F db such as when used with a night setback thermostat. Return-- air temperature must not exceed 80_F db. Failure to follow these return-- air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 3.)

For accessory installation details, refer to the applicable instruction literature.

NOTE: Remove all shipping brackets and materials before operating the furnace.

to convert furnace for use with propane gas.

FILTER

MEDIA CABINET SIZE (IN.)

312A

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES

This forced air furnace is equipped for use with

natural gas at altitudes 0-10,000 ft (0-3,050m).

An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications.

This furnace is for indoor installation in a building constructed on site.

This furnace may be installed on combustible

flooring in alcove or closet at minimum clearance as indicated by the diagram from combusitble material.

This furnace may be used with a Type B-1 Vent

and may be vented in common with other gas fired appliances.

Cette fournaise à air pulsé est équipée pour utilisation avec gaz naturel et altitudes comprises entre 0-3,050m (0-10,000 pi).

Utiliser une trousse de conversion, fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz naturel.

This furnace is approved for UPFLOW, DOWNFLOW, and HORIZONTAL installations.

Cette fournaise est approuvée pour l 'installation HORIZONTALE et la circulation d 'air VERS LE HAUT et VERS LE BAS.

Clearance arrows do not change with furnace orientation.

Les fléches de dégagement

l 'orientation de la fournaise.

TOP / PLE NUM

DESSUS / CHAMBRE D'AIR

Cette fournaise est prévue pour être installée dans un bâtiment construit sur place.

Cette fournaise peut être installée sur un plancher combustible dans une alcôve ou dans un garde-robe en respectant le minimum d'espace libre des matériaux combustibles, tel

indiqué sur le diagramme.

Cette fournaise peut être utilisée avec un

évacuation de Type B-1 ou connectée

conduit d au conduit ommun d 'autres appareils à gaz.

Vent Clearance to combustibles:

For Single Wall vents 6 inches (6 po). For Type B-1 vent type 1 inch (1 po).

Dégagement de l´évent avec combustibles:

Pour conduit d´évacuation à paroi simple 6 po (6 inches). Pour conduit d

BOTTOM

DESSOUS

†

évacuation de Type B-1 1 po (1 inch).

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DOWNFLOW POSITIONS:

Installation on non-combusibible floors only.

†

For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,

Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

18 inches front clearance required for alcove.

Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible

between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists, studs or framing.

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS

DE CONSTRUCTION COMBUSTIBLES

POUR LA POSITION COURANT DESCENDANT:

Pour l´installation sur plancher non combustible seulement.

†

installation sur un plancher combustible seulement quand on utilise la base spéciale, pièce

Pour l

nº KGASB0201ALL, l nº KCAKC.

Dans une alcôve, on doit maintenir un dégagement à l

La poistion indiquée concerne le côté d

position horizontale.

Le contact n

est permis qu´entre les lignes formées par les intersections du dessus et des

deux côtés de la cherrise de la fournaise et les solives, montant sous cadre de charpente.

ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de serpentin, pièce

entrée ou de retour quand la fournaise est dans la

avant de 18 po (450mm).

327590-101 REV. C

ne change pas avec

24"

MIN

Clearance in inches Dégagement (po).

MIN

Fig. 2 -- Clearances to Combustibles

A04123

A04036

Fig. 3 -- Return Air Temperature

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with

regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

In the United States and Canada, follow all codes and standards for the following:

Step 1 — Safety

S US: National Fuel Gas Code (NFGC) NFPA 54--2006/ANSI

Z223.1--2006 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

S CANADA: CSA B149.1--00 National Standard of Canada

Natural Gas and Propane Installation Code (CAN/CSA--B149.1--05)

Step 2 — General Installation

S US: Current edition of the NFGC and the NFPA 90B. For

copies, contact the National Fire Protection Association Inc., Batterymarch Park,Quincy, MA 02269; (www.NFPA.org) or for only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington DC 20001 (www.AGA.org.)

S CANADA: CAN/CSA--B149.1--05. For a copy, contact

Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada Step

Step 3 — Combustion and Ventilation Air

S US: Section 8.3 of the NFGC, Air for Combustion and

Ventilation

S CANADA: Part 7 of CAN/CSA--B149.1--05, Venting Systems

and Air Supply for Appliances

Step 4 — Duct Systems

S US and CANADA: Air Conditioning Contractors Association

(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Step 5 — Acoustical Lining and Fibrous Glass Duct

S US and CANADA: current edition of SMACNA and NFPA

90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Step 6 — Gas Piping and Gas Pipe Pressure Testing

S US: NFGC; chapters 5, 6, and 7 and National Plumbing Codes S CANADA: CAN/CSA--B149.1--05 Parts 4, 5, 6 and 9 and

Appendices A, B, E and H.

Step 7 — Electrical Connections

S US: National Electrical Code (NEC) ANSI/NFPA 70--2006 S CANADA: Canadian Electrical Code CSA C22.1

Step 8 — Venting

S US: NFGC; chapters 12 and 13 S CANADA: CAN/CSA--B149.1--05 Part 8 and Appendix C

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or service of furnace may cause premature furnace component failure.

Electrostatic discharge can affect electronic components. Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body with static electricity (for example; DO NOT move or shuffle your feet, do not touch ungrounded objects, etc.).

4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) mayalsobeusedtopreventESDdamage.

312A

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

312A

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration. Some assembly and modifications are required when used in any of the four applications shown in Fig. 4.

NOTE: For high--altitude installations, the high--altitude conversion kit MUST be installed at or above 5500 ft above sea level. Obtain high--altitude conversion kit from your area authorized distributor.

This furnace must: S be installed so the electrical components are protected from

water.

S not be installed directly on any combustible material other than

wood flooring (refer to SAFETY CONSIDERATIONS).

S be located close to the chimney or vent and attached to an air

distribution system. Refer to Air Ducts section.

S be provided ample space for servicing and cleaning. Always

comply with minimum fire protection clearances shown on the furnace clearance to combustible construction label.

WARNING

CARBON MONOXIDE POISONING AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury or death, and furnace damage.

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

Fig. 4 -- Multipoise Orientations

The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:

S Commercial buildings S Buildings with indoor pools S Laundry rooms S Hobby or craft rooms, and S Chemical storage areas

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for

combustion:

S Permanent wave solutions S Chlorinated waxes and cleaners S Chlorine based swimming pool chemicals S Water softening chemicals S De-- icing salts or chemicals S Carbon tetrachloride S Halogen type refrigerants S Cleaning solvents (such as perchloroethylene) S Printing inks, paint removers, varnishes, etc. S Hydrochloric acid S Cements and glues S Antistatic fabric softeners for clothes dryers

S Masonry acid washing materials

All fuel--burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal mu st be made between the furnace cabinet and the return--air duct to prevent pulling air from the burner area and from draft safeguard opening.

WARNING

FIRE, INJURY OR DEATH HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC or CAN/CSA--B149.1--05. (See Fig. 5.)

Fig. 6 -- Prohibit Installation on Back

CAUTION

A02054

18-IN. MINIMUM

TO BURNERS

A93044

Fig. 5 -- Installation in a Garage

WARNING

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect return-- air ducts to the back of the furnace. (See Fig. 6.)

PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may cause premature component failure. This gas furnace may be used for construction heat provided that:

--The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame roll--out and/or drawing combustion products into the structure.

--The furnace is controlled by a thermostat. It may not be ”hot wired” to provide heat continuously to the structure without thermostatic control.

--Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

--The temperature of the return air to the furnace is maintained between 55_F(13_C) and 80_F(27_C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

--The air temperature rise is within the rated rise range on the furnace rating plate, and the gas input rate has been set to the nameplate value.

--The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

--The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

--Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting according to these installation instructions.

312A

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the furnace. 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 full--cool position.

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

U.S. installations: Section 8.3 of the NFGC, Air for Combustion and Ventilation, and applicable provisions of the local building codes.

Canadian installations: Part 8 of the CAN/CSA--B149.1--05, Venting Systems and Air Supply for Appliances and all authorities having jurisdiction.

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

312A

Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans 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. Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make--up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

S Spaces having less than 50 cubic feet per 1,000 Btuh require the

Outdoor Combustion Air Method.

S Spaces having at least 50 cubic feet per 1,000 Btuh may use the

Indoor Combustion Air, Standard or Known Air Infiltration Method.

Outdoor Combustion Air

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horihorizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

a. One opening MUST commence within 12 in. (300 mm)

of the ceiling and the second opening MUST commence within 12 in. (300 mm) of the floor.

b. Size openings and ducts per Fig. 7 and Table 2.

c. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btuh (1,100 mm2/kW) of combined input for all gas appliances in the space per Fig. 7 and Tab le 2.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch of free area per 4,000 Btuh (550 mm2/kW) for combined input of all gas appliances in the space per Fig. 7 and Table 2.

3. ONE OUTDOOR OPENING requires:

a. 1 square inch offreearea per 3,000 Btuh (734 mm2/kW)

for combined input of all gas appliances in the space per Tab le 2 a nd

b. Not less than the sum of the areas of all vent connectors

in the space.

Method

Table 2 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING

FURNACE

INPUT

(BTUH)

44,000 22 6 14.7 5 11 4 66,000 33 7 22 6 16.5 5

88,000 44 8 29.3 7 22 6 110,000 55 9 36.7 7 27.5 6 132,000 66 10 44 8 33 7 154,000 77 10 51.3 9 38.5 8

FURNACE WATER HEATER TOTAL INPUT

110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening 88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

(1 SQ. IN./2,000 BTUH)

(1,100 SQ. MM/KW)

Free Area of

Opening and Duct

(Sq. In.)

Round Duct

(in. Dia)

(1 SQ. IN./3,000 BTUH)

(734 SQ. MM/KW)

Free Area of

Opening and Duct

(sq. In.)

Round Duct

(in. Dia)

TWO OPENINGS OR VERTICAL

Free Area of

Opening and Duct

(Sq. In.)

DUCTS

(1 SQ. IN./4,000 BTUH)

(550 SQ. MM/KW)

Round Duct

(In. Dia)

DUCTS

OUTDOORS

1 SQ IN. PER 4000 BTUH*

CIRCULATING AIR

DUCTS

VENT THROUGH ROOF

12″ MAX

1 SQ IN. PER 2000 BTUH*

DUCTS

OUTDOORS

1 SQ IN. PER 2000 BTUH*

12″ MAX

CIRCULATING AIR DUCTS

Minimum dimensions of 3 in.

Use any of the following

NOTE:

combinations of openings: A & B C & D D & E F & G

AIR DUCTS

CIRCULATING

OPENINGS SHALL BE

OF COMBUSTION AIR

CLEARANCE IN FRONT

VENT THROUGH ROOF

AT LEAST 3 IN.

OUTDOORS

DUCT

12″ MAX

1 SQ IN. PER 4000 BTUH*

Fig. 7 -- Air for Combustion, Ventilation and Dilution for

Outdoors

12″ MAX

1 SQ IN.

PER 4000

BTUH*

OUTDOORS

1 SQ IN.

PER

4000

BTUH*

12″ MAX

A03174

12" MAX

1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. with minimum dimensions of 3 in.

†

Minimum of 3 in. . when type-B1 vent is used.

UNCONFINED SPACE

6" MIN (FRONT)

1 SQ IN. PER 1000 BTUH* IN DOOR

OPENINGS SHALL BE AT LEAST 3 IN.

OR WALL

CLEARANCE IN FRONT OF COMBUSTION AIR

†

12" MAX

A03175

Fig. 8 -- Air for Combustion, Ventilation, and Dilution from

Indoors

312A

The opening shall commence within 12 in. (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion Air Known --Air--Infiltration Rate

E NFPA & AGA Standard and

Methods

Indoor air is permitted for combustion, ventilation, and dilution, if the Standard or Known--Air--Infiltration Method is used.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in death and/or personal injury.

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in accordance with this instruction manual.

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space.

Table 3 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN--- ASSISTED TOTAL

ACH

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

Table 3--Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI

Z223.1--2006/NFPA 54--2006, 9.3.2.2:

1. For other than fan-- assisted appliances, such as a draft hood--equipped water heater:

312A

Volume

2. For fan--assisted applicances such as this furnace:

Volume

If:

= combined input of all other than fan--assisted

other

= combined input of all fan--assisted appliances in

fan

ACH = air changes per hour (ACH shall not exceed 0.60.)

The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if:

a. There are no closable doors between rooms.

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW) of the total input rating of all gas appliances in the space, but not less than 100 in.2 (0.06 m2). One opening shall commence within 12 in. (300 mm) of the ceiling and the second opening shall commence within 12 in. (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). (See Fig.

8.)

c. Combining space on different floor levels. The volumes

of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in.2/1,000 Btuh (4,400 mm2/kW) of total input rating of all gas appliances.

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1--in.2/4,000 Btuh of total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight

(1,000s BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

SpaceVolume(ft3)

21ft

Other

Fan

appliances in Btuh/hr

Btuh/hr

ACH

15ft ACH

other

1000 Btu/hr

fan

1000 Btu/hr

A04002

A04003

Combination of Indoor and Outdoor

1. Indoor openings shall compy with the Indoor

2. Outdoor openings shall be located as required in the

3. Outdoor openings shall be sized as follows:

UPFLOW INSTALLATION

Bottom Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom

2. Rotate bottom filler panel downward to release holding

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when only side return air is used.

NOTE: Side return--air openings can be used in UPFLOW and most HORIZONTAL configurations. Do not use side return--air openings in DOWNFLOW configuration.

FAN--- ASSISTED TOTAL

(1,000s BTUH GAS INPUT RATE)

construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section. Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a

continuous, sealed vapor barrier. Openings are gasketed or sealed and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole plates and floors, between wall-- ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.

Air

Combustion Air Method below and,

Outdoor Combustion Air Method mentioned previously

and,

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The minimumdimension of air openingsshallbenot lessthan 3in.(80mm).

INSTALLATION

Inlet

filler panel. (See Fig. 9.)

tabs.

Inlet

A02098

Fig. 9 -- Removing Bottom Closure Panel

Leveling Legs (If Desir

ed)

In upflow position with side return inlet(s), leveling legs may be used. (See Fig. 10.) Install field--supplied, 5/16 X 1--1/2 in. (max) corrosion --resistant machine bolts, washers and nuts.

NOTE: Bottom closure must be used when leveling legs are used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see item 1 in Bottom Return Air Inlet section in Step 1 above.

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace. (See Fig. 10.)

2. For each leg, install nut on bolt and then 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.

5. Reinstall bottom closure panel if removed.

⁄16″

1 3⁄4″

⁄4″

⁄16″

⁄4″

A02071

Fig. 10 -- Leveling Legs

DOWNFLOW INSTALLA

TION

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the following 3 accessories are used:

S Special Base, KGASB S Cased Coil Assembly Part No. CD5 or CK5 S Coil Box Part No. KCAKC

1. Determine application being installed from Table 4.

2. Construct hole in floor per Table 4 and Fig. 11.

3. Construct plenum to dimensions specified in Table 4 and Fig. 11.

4. If downflow subbase, KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

NOTE: It is recommended that the perforated supply--air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory --supplied cased coil or coil box. To remove the supply--air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 14.)

Bottom Return Air

Inlet

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLA

TION

The furnace can be installed horizontally in an attic or crawl space on either the left--hand (LH) or right--hand (RH) side. The furnace can be hung from floor joists, rafters or trusses or installed on a non--combustible platform, blocks, bricks or pad.

WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Suspended Furnace Support

The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown. (See Fig. 15 and

16.) Secure angle iron to bottom of furnace as shown. Heavy--gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x .--in. screw into the side and 2 #8 x .--in. screw in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.)

If the screws are attached to ONLY the furnace sides and not the bottom, the straps must be vertical against the furnace sides and not pull away from the furnace sides, so that the strap attachment screws are not in tension (are loaded in shear) for reliable support.

Platform Furnace

Support

Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in. clearance requirement on side, set furnace on non--combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended from the floor joists, the ground

312A

underneath furnace must be level and the furnace set on blocks or bricks.

Roll--Out Pr

otection

Provide a minimum 17--3/4 in. X 22 in. piece of sheet metal for flame roll--out protection in front of burner area for furnaces closer than 12 inches above the combustible deck or suspended furnaces closer than 12 inches to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. with the door removed.

The bottom closure panel on furnaces of widths 17--1/2 in. and larger may be used for flame roll--out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper orientation of roll--out shield.

Bottom Return Air

Inlet

312A

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air

Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) are used without a bottom return air inlet.

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A096285

Fig. 12 -- Furnace, Plenum, and Subbase installed on a

Combustible Floor

PLENUM

OPENING

FLOOR

Fig. 11 -- Floor and Plenum Opening Dimensions

A096283

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A04140

Fig. 13 -- Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

FURNACE

CASING

WIDTH

14–3/16

17–1/2

24--- 1/2

Table 4 – Opening dimensions (In.)

APPLICATION

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring

(KGASB subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

Downflow applications on combustible flooring

(KGASB subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

Downflow applications on combustible flooring

(KGASB subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring

(KGASB subbase not required)

Downflow applications on Combustible flooring

(KGASB subbase required)

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box

(KGASB subbase not required)

PLENUM OPENING FLOOR OPENING

A B C D

12--- 11/16 21--- 5/8 13---5/16 22--- 1/4

12--- 9/16 19 13--- 3/16 19--- 5/8

11--- 13/16 19 13 --- 7/16 20 ---5/8

12--- 5/16 19 13--- 5/16 20

16 21--- 5/8 16 ---5/8 22---1/4

15--- 7/8 19 16---1/2 19 --- 5/8

15--- 1/8 19 16---3/4 20 --- 5/8

15--- 1/2 19 16---1/2 20

19--- 1/2 21 --- 5/8 20--- 1/8 22 --- 1/4

19--- 3/8 19 20 19--- 5/8

18--- 5/8 19 20---1/4 20 --- 5/8

19 19 20 20

23 21--- 1/8 23 ---5/8 22---1/4

22--- 7/8 19 23---1/2 19 --- 5/8

22--- 1/8 19 23---3/4 20 --- 5/8

22--- 1/2 19 23---1/2 20

312A

UPFLO

90û

120û

MIN

W OWNFLOW

YES

NOT RECOMMENDED

120û MIN

Fig. 14 -- Duct Flanges

YES

NOT RECOMMENDED

HORIZONTAL

90û

120û

MIN

YES

NOT RECOMMENDE

A02329

OUTER DOOR ASSEMBLY

" THREADED ROD

4 REQ.

312A

8" MIN FOR DOOR REMOVAL

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS REQ. PER ROD

Fig. 15 -- Horizontal Unit Suspension

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x TYPICAL FOR 2 SUPPORTS

1" SQUARE, 1 OR UNI-STRUT MAY BE USED

" x 1

" x

" ANGLE IRON

" SCREWS

METHOD 2 USE (42) #8 x 3/4 SHEET METAL SCREWS TYPICAL FOR EACH STRAPS.THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

A02345

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (42) #8 x 3/4 SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

Fig. 16 -- Horizontal Suspension with Straps

A03176

LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS, STUDS, OR FRAMING.

GAS ENTRY

TYPE-B VENT

17 3/4

″ OVER ALL

4 3/4

″ UNDER DOOR

1″ UNDER FURNACE

EXTEND OUT 12″ OUT FROM FACE OF DOOR

17 3/4

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

SEDIMENT

TRAP

UNION

SHEET METAL

Fig. 17 -- Typical Attic Installation

Not all horizontal furnaces are approved for side return air connections. (See Fig. 20.)

FILTER

ARRANGEMENT

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, or death.

Never operate a furnace without a filter or with filter access door removed.

There are no provisions for an internal filter rack in these furnaces. An external filter rack is required.

This furnace is shipped with a factory--supplied Media Filter Cabinet. The Media Filter Cabinet uses either a factory--supplied standard 1--inch filter or 4--inch wide Media Filter which can be purchased separately.

Refer to the instructions supplied with Media Cabinet for assembly and installation options.

DUCTS

AIR

General Requir

ements

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table 5--Air Delivery CFM (With Filter).

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.

6″ MIN*

″

30-IN. MIN WORK AREA

* WHEN USED WITH SINGLE WALL VENT CONNECTIONS

312A

A03177

Secure ductwork with proper fasteners for type of ductwork used. Seal supply-- and return--duct connections to furnace with code approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration.

Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1--in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Tr NOTE: Metal duct systems that do not have a 90_ elbow and 10

ft of main duct to the first branch take--off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Supply Air

Connections

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

Upflow and Horizontal

Connect supply--air duct to flanges on furnace supply--air outlet. Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supply--outlet--air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing side to attach supply air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace main casing.

eatment

Furnaces

Table 5 – Air Delivery -- CFM (With Filter)*

312A

FURNACE

SIZE

045--- 08 /

024045

045--- 12 /

036045

070--- 081 /

024070

070--- 12 /

036070

070--- 16 /

048070

090--- 14 /

042090

090--- 16 /

048090

090--- 20 /

060090

110--- 12 /

036110

110--- 16 /

048110

RETURN---AIR

INLET

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

Both Side or 1 Side & Bottom

1Side Only

Bottom or

Side(s)

Bottom or

Side(s)

SPEED

High

M e d ---

High

M e d --- L ow

Low

High

M e d ---

High Me-

dium

M e d --- L ow

Low

High

M e d ---

High

M e d --- L ow

Low

High

M e d ---

High Me-

dium

M e d --- L ow

Low

High

M e d ---

High Me-

dium

M e d --- L ow

Low

High

M e d ---

High

M e d --- L ow

Low

High

M e d ---

High

M e d --- L ow

Low

High

M e d ---

High Me-

dium

M e d --- L ow

Low

High

M e d ---

High Me-

dium

M e d --- L ow

Low

High

M e d ---

High Me-

dium

M e d --- L ow

Low

High

M e d ---

High

M e d --- L ow

Low

High

M e d ---

High Me-

dium

M e d --- L ow

Low

EXTERNAL STATIC PRESSURE (IN. WC)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1120

930 820 725

1465 1295 1150 1030

860

1140

915 795 690

1440 1180 1015

885 695

1840 1610 1460 1260 1065

1650 1515 1385 1205

2060 1710 1470 1260 1030

2380 2185 1905 1595 1340

2485 2175 1845 1540 1280

2420 2160 1850 1530 1290

1625 1510 1360 1195

2055 1750 1545 1300 1050

1075

890 785 690

1400 1260 1120 1010

835

1105

885 770 665

1400 1165 1020

885 700

1790 1575 1430 1240 1040

1600 1485 1360 1180

2000 1695 1475 1365 1025

2295 2115 1865 1565 1310

2415 2130 1815 1515 1250

2345 2110 1815 1490 1250

1575 1470 1335 1180

1990 1725 1525 1290 1045

1020

850 750 655

1325 1210 1085

980 810

1055

855 740 630

1355 1150 1010

880 700

1730 1535 1400 1215 1015

1535 1440 1320 1160

1930 1665 1450 1245 1020

2205 2045 1815 1530 1280

2330 2070 1770 1475 1220

2265 2045 1765 1455 1220

1515 1415 1295 1155

1910 1670 1490 1275 1015

960 805 700 605

1250 1155 1040

945 780

1010

825 700 590

1300 1125

990 865 690

1670 1485 1360 1180

985

1465 1380 1260 1120

1835 1585 1390 1225

990

2105 1960 1740 1485 1225

2230 2000 1720 1435 1190

2165 1960 1710 1420 1190

1445 1355 1250 1115

1815 1605 1445 1235

975

895 750 650 555

1175 1090

985 895 745

955 785 655 550

1240 1085

965 845 670

1605 1435 1315 1145

955

1385 1300 1195 1065

1755 1480 1335 1165

940

2005 1875 1670 1430 1170

2135 1930 1655 1385

115

2070 1885 1635 1375

115

1355 1285 1180 1065

1695 1515 1355 1165

935

815 680 585 495

1085 1015

920 835 700

885 725 600 475

1170 1030

925 815 640

1530 1370 1260

110 915

1285 1220 1120 1005

1620 1390 1230 1090

890

1900 1770 1590 1355 1120

2030 1840 1580 1335 1105

1960 1790 1560 1320 1110

1260 1185 1100

980

1575 1400 1260 1085

880

720 600 505 405

980 930 835 765 635

815 655 510 415

1090

970 875 770 600

1450 1305 1205 1040

875

1175 1115 1025

925

1490 1245 1120

995 810

1775 1655 1490 1275 1040

1920 1740 1500 1270 1035

1850 1695 1480 1250 1040

1165 1070

985 860

1425 1255 1135 1005

815

605 500 400 305

860 830 740 685 555

715 530 420 340

1000

890 800 700 540

1370 1230 1130

985 825

1055

990 915 810

1315 1110 1005

880 720

1650 1535 1390 1160

955

1790 1620 1395 1175

945

1720 1570 1380 1160

950

990 890 810 740

1230 1120 1020

895 715

455 345 235

--- ---

725 700 620 570 445

545 420 325 245

890 785 700 605 460

1275 1145 1055

915 765

895 830 710 630

1115

955 855 750 615

1510 1400 1245 1055

850

1645 1495 1270 1045

845

1570 1445 1250 1055

835

785 725 670 605

1090

975 880 750 610

340 195

--- ---

560 545 510 345 260

390 280

--- ---

745 645 560 475 345

1170 1055

965 835 695

645 600 565 510

910 775 690 600 500

1335 1240 1110

920 750

1485 1345 1090

915 745

1420 1305 1110

905 740

595 530 475 410

910 785 750 620 515

High

M e d ---

Bottom Only

110--- 22 /

066110

*A filter is required for each return---air inlet. Airflow performance included 1---in. washable filter media such as contained in factory---authorized accessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.

--- --- Indicates unstable operating conditions.

Bottom Sides or

1 Side & Bottom

1Side Only

High Me-

dium

M e d --- L ow

Low

High

M e d ---

High High

M e d ---

High Me-

dium

M e d --- L ow

Low

2530 2225 1895 1565 1320

--- ---

2205

2485 2155 1830 1520 1275

2460 2190 1885 1555 1295

--- ---

2175

2430 2135 1830 1505 1260

2380 2135 1865 1535 1265

2415 2120

2360 2100 1810 1490 1240

2285 2075 1820 1505 1235

2330 2065

2270 2040 1780 1470 1210

2200 1995 1770 1465 1205

2235 1975

2175 1970 1730 1430 1180

2085 1910 1700 1410 1160

2125 1900

2070 1885 1665 1385 1135

1970 1805 1610 1350 1105

1995 1790

1950 1790 1595 1330 1090

1835 1695 1520 1265 1035

1860 1685

1825 1680 1505 1250 1025

1695 1565 1410 1175

950

1735 1580

1685 1560 1395 1165

930

1545 1430 1290 1050

870

1605 1460

1535 1420 1275 1055

840

312A

Table 5 -- Air Delivery -- CFM (With Filter)* (Cont.)

FURNACE

SIZE

135--- 16 /

048135

135--- 22 /

066135

312A

155--- 20 /

060155

--- --- Indicates unstable operating conditions.

RETURN---AIR

INLET

Bottom

Side(s)

Bottom

Only

Bottom Sides

1 Side & Bottom

1SideOnly

Bottom Only

Both Sides Or 1

Side & Bottom

1SideOnly

SPEED