Bryant 140/E series Installation, Start-up, Operating And Service And Maintenance Instructions
311AAV/JAV
SINGLE--STAGE DELUXE, INDUCED--COMBUSTION
4--WAY MULTIPOISE GAS FURNACE
Installation, Start--up, Operating and
Service and Maintenance Instructions
Series 140/E
SAFETY CONSIDERATIONS 2........................
INTRODUCTION 4..................................
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 PRECAUTIONS
PROCEDURE 5.....................................
LOCATION 6.......................................
INSTALLATION 11..................................
Upflow Installation 11..............................
Downflow Installation 11...........................
Horizontal Installation 13...........................
Filter Arrangement 14..............................
Air Ducts 14.....................................
Gas Piping 17....................................
115--V Wiring 22..................................
J--Box Relocation 23..............................
Electrical Connection to J--Box 23.....................
Electrical Box on Furnace Casing Side 23...............
Power Cord Installation in Furnace J--Box 23............
BX Cable Installation in Furnace J--Box 23..............
24--V Wiring 24...................................
Accessories
Venting 28.......................................
General Venting Requirements 28.....................
Masonry Chimney Requirements 28...................
Appliance Application Requirements 29................
Additional Venting Requirements 31...................
Sidewall Venting 31................................
START--UP, ADJUSTMENT, AND SAFETY CHECK 36.....
General 36.......................................
Start--up Procedures 36.............................
Adjustments 36...................................
Check Safety Controls 39...........................
Checklist 39......................................
SERVICE AND MAINTENANCE PROCEDURES 45.......
Introduction 45...................................
Electrical Controls and Wiring 45.....................
Care and Maintenance 46...........................
Cleaning and/or Replacing Filter 46...................
Sequenceof Operation 50...........................
Blower Motor and Wheel 46.........................
Cleaning Heat Exchanger 47.........................
Sequenceof Operation 49...........................
Wiring Diagrams 50...............................
Troubleshooting 50
................................
Accessory List 54.................................
PARTS REPLACEMENT INFORMATION GUIDE 55.......
ISO 9001:2000
REGISTERED
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NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1--2009E, 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.
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.
311AAV
!
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.
!
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.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory--authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
include in literature and attached to the unit. Consult local
building codes, the current editions of the National Fuel Gas
Code (NFGC) NFPA 54/ANSI Z223.1 and the National
Electrical Code (NEC) NFPA 70.
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit 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 hazards
which could result in personal injury or death. CAUTION is
used to identify unsafe practices which may result in minor
personal injury or 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 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 listed accessory gas conversion kit is required to convert furnace for use with propane gas.
11. See Fig. 2 for required clearances to combustible construction.
12. Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914
mm) 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 re-
.
quired when this furnace is installed on manufacturer’s
Coil Assembly Part No. CNPV, CNRV, CAR and CAP, or
when Coil Box Part No. KCAKC is used. See Fig. 2 for
clearance to combustible construction information.
2
A
B
[736.9]
29
Ø7/8
[22.2]
ACCESSORY
5 15/16
[150.7]
28.39
[721.2]
Ø7/8
[22.2]
ACCESSORY
14 7/8
[337.3]
(BOTH SIDES)
Ø7/8
[22.2]
ACCESSORY
Ø7/8
[22.2]
ACCESSORY
Ø1 3/4
[44.5]
GAS ENTRY
Ø1/2
[12.7]
THERMOSTAT WIRE ENTRY
22 1/16
[560]
SIDE INLET
(BOTH SIDES)
11 7/16
[290.7]
9 11/16
[245.4]
[197.8]
7 13/16
Ø7/8
[22.2]
J.BOX PROVISION
Ø7/8
[22.2]
JUNCTION BOX
LOCATION
Ø1 3/4
[44.5]
GAS ENTRY
1 15/16
[49.2]
1
[25.4]
1 1/4
[31.8]
29 9/16
[750.7]
1 15/16
[49.2]
5 5/8
[143.3]
5 7/16
[138.5]
6 13/16
[172.3]
Ø1/2
[12.7]
THERMOSTAT WIRE ENTRY
19
[481.7]
OUTLET
D
21.6
[549.5]
BOTTOM INLET
C
33 1/4
[843.9]
9 9/16
[243.3]
3/4
[19.1]
5 7/8
[148.5]
3 7/16
[86.8]
9 7/8
[250.7]
27 3/4
[704.7]
2 5/16
[59]
FRONT OF CASING
TOP OF CASING
4 13/16
[122.2]
27 3/4
[704.7]
5 7/8
[148.5]
8 5/8
[219]
5 1/2
[140.3]
8 7/16
[213.5]
FRONT OF CASING
TOP OF CASING
6.1
[155.7]
2 1/16
[51.6]
5.1
5.1
[130.5]
1.7
[43.5]
Ø7/8
[22.2]
ACCESSORY (2)
AIR FLOW
AIR FLOW
BOTTOM RETURN
WIDTH
AIR FLOW
KNOCK OUTS FOR
VENTING(5
PLACES)
[130.5]
2 1/16
[51.6]
1.7
[43.5]
Ø7/8
[22.2]
ACCESSORY (2)
FRONT OF CASING
8 5/8
[219]
6 13/16
FRONT OF CASING
1 15/16
[49.2]
5 15/16
[150.7]
5 1/2
[140.3]
8 7/16
[213.5]
9 7/8
[250.7]
27 3/4
[704.7]
33 1/4
[843.9]
NOTES:
1. Two additional 7/8---in. (22 mm) 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.
AIR FLOW
ACCESSORY
THERMOSTAT WIRE ENTRY
ACCESSORY
21.6
[549.5]
BOTTOM INLET
28.39
[721.2]
29
[736.9]
Ø7/8
[22.2]
Ø7/8
[22.2]
Ø1/2
[12.7]
6.1
[155.7]
3 7/16
[86.8]
5 7/8
[148.5]
2 5/16
[59]
TOP OF CASING
Ø7/8
[22.2]
JUNCTION BOX
LOCATION
Ø1 3/4
[44.5]
GAS ENTRY
AIR FLOW
A
BOTTOM RETURN
WIDTH
TOP OF CASING
3/4
[19.1]
29 9/16
[750.7]
27 3/4
[704.7]
KNOCK OUTS FOR
VENTING(5
PLACES)
[148.5]
5 7/16
[138.5]
4 13/16
[122.2]
9 9/16
[243.3]
J.BOX PROVISION
ACCESSORY
5 7/8
[172.3]
[143.3]
1 15/16
[49.2]
Ø7/8
[22.2]
Ø7/8
[22.2]
5 5/8
AIR FLOW
19
[481.7]
OUTLET
Ø1/2
[12.7]
THERMOSTAT WIRE ENTRY
Ø1 3/4
[44.5]
GAS ENTRY
Ø7/8
[22.2]
ACCESSORY
22 1/16
[560]
SIDE INLET
(BOTH SIDES)
7 13/16
[197.8]
14 7/8
[337.3]
(BOTH SIDES)
[25.4]
9 11/16
[245.4]
1 1/4
[31.8]
a. For 800 CFM---16 ---in. (406 mm) round or 14 1/2 x 12---in. (368 x 305 mm) rectangle.
b. For 1200 CFM--- 20---in. (508 mm) round or 14 1/2 x 19 1/2 ---in. (368 x 495 mm) rectangle.
c. For 1600 CFM--- 22---in. (559 mm) round or 14 1/2 x 22 1/16 ---in. (368 x 560mm) 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 sideinlets,
a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
11 7/16
[290.7]
A10290
311AAV
A
FURNACE SIZE
045---08/024045 14---3/16 (360) 12---9/16 (319) 9---5/16 (237) 12--- 11/16 (322) 4 (102) 107 (47) 16 (406)
CABINET WIDTHBOUTLET WIDTH
045---12/036045 14---3/16 (360) 12---9/16 (319) 9---5/16 (237) 12--- 11/16 (322) 4 (102) 107 (49) 16 (406)
070---08/024070 14---3/16 (360) 12---9/16 (319) 9---5/16 (237) 12--- 11/16 (322) 4 (102) 111 (50) 16 (406)
070---12/036070 14---3/16 (360) 12---9/16 (319) 9---5/16 (237) 12--- 11/16 (322) 4 (102) 115 (52) 16 (406)
070---16/048070 17---1/2 (445) 15---7/8 (403) 11 ---9/16 (294) 16 (406) 4 (102) 126 (57) 16 (406)
090---14/042090 17---1/2 (445) 15---7/8 (403) 11 ---9/16 (294) 16 (406) 4 (102) 127 (58) 16 (406)
090---16/048090 21 (533) 19---3/8 (492) 13 ---5/16 (338) 19 ---1/2 (495) 4 (102) 140 (64) 20 (508)
090---20/060090 21 (533) 19---3/8 (492) 13 ---5/16 (338) 19 ---1/2 (495) 4 (102) 146 (66) 20 (508)
110---12/036110 17---1/2 (445) 15---7/8 (403) 11 ---9/16 (294) 16 (406) 4 (102) 135 (61) 16 (406)
110---16/048110 21 (533) 19---3/8 (492) 13 ---5/16 (338) 19 ---1/2 (495) 4 (102) 146 (66) 20 (508)
110---22/066110 21 (533) 19---3/8 (492) 13 ---5/16 (338) 19 ---1/2 (495) 4 (102) 152 (69) 20 (508)
135---16/048135 21 (533) 19---3/8 (492) 13 ---5/16 (338) 19 ---1/2 (495) 4 (102)* 149 (68) 20 (508)
135---22/066135 24---1/2 (622) 22---7/8 (581) 15 ---1/16 (383) 23 (584) 4 (102)* 163 (74) 24 (610)
155---20/060155 24---1/2 (622) 22---7/8 (581) 15 ---1/16 (383) 23 (584) 4 (102)* 170 (77) 24 (610)
*135 and 155 size furnaces require a 5 or 6 ---in. (127 or 152 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for
complete installation requirements.
Fig. 1 -- Dimensional Drawing
Table1–Dimensions
C
TOP &
BOTTOM FLUE
COLLAR
3
D
BOTTOM
INLET WIDTH
ACCESSORY
VENT
CONNECTION
SIZE
SHIP WT
LB. (KG)
FILTER
MEDIA
CABINET SIZE
IN. (MM)
INTRODUCTION
Series 140/E 4--way multipoise Category I fan--assisted furnace is
CSA 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. This furnace is designed for
minimum continuous return--air temperature of 60_F(16_C) db
311AAV
or intermittent operation down to 55_F(13_C)db such as when
used with a night setback thermostat. Return--air temperature
must not exceed 80_F(27_C) 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.
A10269
Fig. 2 -- Clearances to Combustibles
4
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, follow all codes and standards for the
following:
Safety
S National Fuel Gas Code (NFGC) NFPA 54--2009/AN-
SI Z223.1--2009 and the Installation Standards, Warm
Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
(27º C)
0
60
(16º C)
A05004
Fig. 3 -- Return Air Temperature
General
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).
Combustion and Ventilation
Section 9.3 of the NFGC, NFPA 54/ANSI Z223.1--2009 Air for
Combustion and Ventilation.
Duct
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.
Acoustical Lining and Fibrous Glass
Current edition of SMACNA and NFPA 90B as tested by UL
Standard 181 for Class I Rigid Air Ducts
Gas Piping and Gas Pipe Pressure T
NFPA 54/ANSI Z223.1--2009 Chapters 5, 6, 7, and 8 and
National Plumbing Codes.
Installation
Air
Systems
Duct
esting
Electrical
National Electrical Code (NEC) ANSI/NFPA 70--2008.
enting
V
NFGC NFPA 54/ANSI Z223.1--2009 ; chapters 12 and 13.
Connections
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
maybe 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. 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.
311AAV
5
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
BURNER SECTION, AND
311AAV
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.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death, and unit component 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.
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 forupflow applications.
Downflow installations require use of a factory--approved floor base or coil assembly when installed on
combustible materials or wood flooring (refer to
SAFETY CONSIDERATIONS).
S be located as 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
label.
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 must be
made between the furnace cabinet and the return--air duct to
prevent pulling air from the burner area and from draft safeguard
opening.
6
18-IN. (457.2 mm)
MINIMUM TO BURNERS
Fig. 5 -- Installation in a Garage
A93044
A02054
Fig. 6 -- Prohibit Installation on Back
!
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 (457 mm) 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. (See Fig.
5.)
!
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.)
!
CAUTION
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Improper use or installation of this furnace may cause
premature furnace component failure.
This gas furnace may be used for heating buildings under
construction 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 rollout 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.
311AAV
7
Table 2 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors
FURNACE
INPUT
(BTUH)
44,000 22 (14194) 6 (152) 14.7 (9484) 5 (127) 11 (7096) 4 (102)
66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)
88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152)
110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152)
132,000 66 (42580) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)
154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)
TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS
(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)
Free Area of Opening
and Duct
Sq. In. (Sq. mm)
Round Duct
Dia.
In. (mm)
Free Area of Opening
and Duct
Sq. In. (Sq. mm)
Round Duct
Dia.
In. (mm)
Free Area of Opening
and Duct
Sq. In. (Sq. mm)
EXAMPLES: Determining Free Area
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
311AAV
88,000
+ 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts
Table 3 – Minimum Space Volumes for100% Combustion, Ventilation, and Dilution from Indoors
OTHER THAN FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
ACH
0.60
0.50
0.40
0.30
0.20
0.10
0.00
NP = Not Permitted
30 40 50 44 66 88 110 132 154
1,050
(29.7)
1,260
(35.6)
1,575
(44.5)
2,100
(59.4)
3,150
(89.1)
6,300
(178.3)
NP NP NP NP NP NP NP NP NP
1,400
(39.6)
1,680
(47.5)
2,100
(59.4)
2,800
(79.2)
4,200
(118.9)
8,400
(237.8)
1,750
(49.5)
2,100
(59.4)
2,625
(74.3)
3,500
(99.1)
5,250 (148.6)
10,500
(297.3)
SpaceVolumeFt3(M3)
1,100
(31.1)
1,320
(37.3)
1,650
(46.7)
2,200
(62.2)
3,300
(93.4)
6,600
(186.8)
1,650
(46.7)
1,980
(56.0)
2,475
(70.0)
3,300
(93.4)
4,950
(140.1)
9,900
(280.3)
FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
2,200
(62.2)
2,640
(74.7)
3,300
(93.4)
4,400
(124.5)
6,600
(186.8)
13,200
(373.7)
2,750
(77.8)
3,300
(93.4)
4,125
(116.8)
5,500
(155.7)
8,250
(233.6)
16,500
(467.2)
3,300
(93.4)
3,960
(112.1)
4,950
(140.1)
6,600
(186.8)
9,900
(280.3)
19,800
(560.6)
Round Duct
Dia.
In. (mm)
3,850
(109.0)
4,620
(130.8)
5,775
(163.5)
7,700
(218.0)
11,550
(327.0)
23,100
(654.1)
8
!
CAUTION
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
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.
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:
S Section 9.3 of the NFGC NFPA 54/ANSI
Z223.1--2009 , Air for Combustion and Ventilation,
and applicable provisions of the local building codes.
!
WARNING
2. Fig. 7 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air opening, to the outdoors.
e. One opening MUSTcommence within 12--in. (300 mm)
of the ceiling and the second opening MUST commence
within 12--in. (300 mm) of the floor.
f. Size openings and ducts per Fig. 7 and Table 2.
2
g. TWO HORIZONTAL DUCTS require1--in.
per 2,000 Btuh (1,100 mm
2
/kW) of combined input for
of freearea
all gas appliances in the space per Fig. 7 and Table 2.
h. TWO OPENINGS OR VERTICAL DUCTS require
2
of free area per 4,000 Btuh (550 mm2/kW) for
1--in.
combined input of allgas appliancesin the spaceperFig.
7 and Table 2.
3. ONE OUTDOOR OPENING requires:
2
a. 1--in.
of free area 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.
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.
1 SQ IN.
DUCTS
TO
O UTDOORS
PER 4000
BTUH*
311AAV
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 horizontal or vertical duct(s) or opening(s) directly
communicating with the outdoors or spaces that freely
communicate with the outdoors.
Method
(305mm)
12 ″ MAX
1 SQ IN.
PER 2000
BTUH*
DUCT S
TO
OUTDOORS
1 SQ IN.
PER 2000
BTUH*
(305mm)
12 ″ MAX
CIRCULA TING AIR DUCT S
*Minimum dimensions of 3 ---in. (76 mm.)
Use any of the following combinations of openings:
A&BC&DD&EF&G
B
AIR DUCTS
C IRCULA TING
A
OF COMB USTION AIR
CLEARANCE IN FRONT
D
VENT
THR OUGH
R OOF
(76mm)
AT LEAST 3 IN .
OPENINGS SHALL BE
OUTDOORS
C
DUCT
TO
E
12 ″ MAX
(305mm)
F
1 SQ IN .
BTUH*
1 SQ IN .
BTUH*
G
1 SQ IN.
PER 4000
BTUH*
12 ″
MAX
PER
4000
OUTDOORS
PER
4000
12 ″
MAX
Fig. 7 -- Air for Combustion, Ventilation, and Dilution for
Outdoors
Indoor Combustion Air -- NFPA & AGA
Standard and Known--Air--Infiltration Rate Methods
(305mm)
(305mm)
A03174
9
Indoor air is permitted for combustion, ventilation, and dilution,
if the Standard or Known--Air--Infiltration Method is used.
!
WARNING
CIRCULATING AIR
DUCTS
VENT THROUGH ROOF
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
311AAV
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 were determined by using
the following equations from the National Fuel Gas Code ANSI
Z223.1--2009/NFPA 54--2009, 9.3.2.2:
1. For other than fan--assisted appliances, such as a draft
hood--equipped water heater:
Volume
Other
=
21ft
ACH
3
I
other
1000 Btu/hr
2. For fan--assisted appliances such as this furnace:
Volume
Fan
=
15ft
ACH
3
I
fan
1000 Btu/hr
If:
Iother = combined input of all other than fan--assisted appliances
in Btuh/hr
Ifan = combined input of all fan--assisted appliances in Btuh/hr
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 closeable doors between rooms.
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1 in.
mm2/kW) of the total input rating of all gas appliances
in the space, but not less than 100 in.
2
/1,000 Btuh (2,000
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 least3--in. (80 mm). (SeeFig.
8.)
A04002
A04003
12" MAX
(305mm)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
INTERIOR
HEATED
SPACE
CIRCULATING AIR DUCTS
* Minimum opening size is 100 sq in. (64516 sq. mm)with minimum dimensions
of3in.(76mm)
†Minimumof3in.(76mm)whentype-B1ventisused.
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
(152mm)
Ü
12" MA X
(305mm)
A03175
Fig. 8 -- Air for Combustion, Ventilation, and Dilution from
Indoors
c. Combining space on different floor levels. Thevolumes
of spaces on different floor levels shall be considered as
communicating spaces if connected by one or morepermanent openings in doors or floors having free area of
at least 2 in.
2
/1,000 Btuh (4,400 mm2/kW) of totalinput
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 AirMethod,infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases.
However, in buildings with unusually tight construction,
additional air MUST be provided using the methods describedintheOutdoor Combustion Air Method section.
Unusually tight construction is defined as construction with:
a. Walls and ceilings exposed to the outdoors have a con-
tinuous, 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.
Combination of Indoor and Outdoor
Air
1. Indoor openings shall comply with the Indoor Combustion Air Method below and,
10
Bottom
Closure Panel
Bottom Filler Panel
A10273
Fig. 9 -- Removing Bottom Closure Panel
2. Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previously and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air Meth-
od below.
b. Outdoor opening sizereductionFactoris1 minus the Ra-
tio in a. above.
c. Minimum size of Outdoor openings shall be the size re-
quiredin OutdoorCombustion Air Methodabove multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80
mm).
INSTALLATION
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 two 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
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.
Leveling Legs (If Desir
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.
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).
Inlet
Inlet
ed)
5/
16
″
(8mm)
(8mm)
5/
16
″
1 3 / 4 ″
(44mm)
3
/ 4 ″
1
(44mm)
(8mm)
5
/
16
″
(8mm)
5/
16
″
1
(44mm)
3/
4 ″
3/
1
4 ″
(44mm)
Fig. 10 -- Leveling Legs
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.
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. CNPV, CNRV, CAP, or
CAR
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. CAPVP, CAPMP, and
CNPVP 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
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 two 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
11
Inlet
311AAV
A89014
A
PLENUM
OPENING
B
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
D
FLOORING
FLOOR
OPENING
C
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
311AAV
A96285
Fig. 11 -- Floor and Plenum Opening Dimensions
A96283
Fig. 12 -- Furnace, Plenum, and Subbase Installed on a
Combustible Floor
FURNACE
APPROVED
COIL ASSEMBLY
OR
COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
Fig. 13 -- Furnace, Plenum, and Coil Assembly or
Coil Box Installed on a Combustible Floor
A08556
12
Table 4 – Opening Dimensions -- IN. (mm)
FURNACE
CASING
WIDTH
14–3/16
(360)
17–1/2
(445)
21
(533)
24---1/2
(622)
APPLICATION
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB sub-
base required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR, or CAP Coil Assembly or KCAKC coil box
(KGASB subbase not required)
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB sub-
base required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR, or CAP Coil Assembly or KCAKC coil box
(KGASB subbase not required)
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on combustible flooring (KGASB sub-
base required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR, or CAP Coil Assembly or KCAKC coil box
(KGASB subbase not required)
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required)
Downflow applications on Combustible flooring (KGASB sub-
base required)
Downflow Applications on Combustible Flooring with CNPV,
CNRV, CAR, or CAP Coil Assembly or KCAKC coil box
(KGASB subbase not required)
PLENUM OPENING FLOOR OPENING
A B C D
12---11/16
(322)
12---9/16
(319)
11---13/16
(284)
12---5/16
(319)
16
(406)
15---7/8
(403)
15---1/8
(384)
15---1/2
(394)
19---1/2
(495)
19---3/8
(492)
18---5/8
(473)
19
(483)
23
(584)
22---7/8
(581)
22---1/8
(562)
22---1/2
(572)
21---5/8
(549)
19
(483)
19
(483)
19
(483)
21---5/8
(549)
19
(483)
19
(483)
19
(483)
21---5/8
(549)
19
(483)
19
(483)
19
(483)
21---1/8
(537)
19
(483)
19
(483)
19
(483)
13---5/16
(338)
13---3/16
(335)
13---7/16
(341)
13---5/16
(338)
16---5/8
(422)
16---1/2
(419)
16---3/4
(425)
16---1/2
(419)
20---1/8
(511)
20
(508)
20---1/4
(514)
20
(508)
23---5/8
(600)
23---1/2
(597)
23---3/4
(603)
23---1/2
(597)
22---1/4
(565)
19---5/8
(498)
20---5/8
(600)
20
(508)
22---1/4
(565)
19---5/8
(498)
20---5/8
(600)
20
(508)
22---1/4
(565)
19---5/8
(498)
20---5/8
(600)
20
(508)
22---1/4
(565)
19---5/8
(498)
20---5/8
(600)
20
(508)
311AAV
HORIZONTAL INSTALLATION
!
WARNING
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING 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.
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.
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 3/4--in. screws into the side
and 2 #8 x 3/4--in. screws 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 noncombustible
blocks, bricks or angle iron. For crawl space installations, if the
furnace is not suspended from the floor joists, the ground
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--in. (305 mm) above the combustible deck or
suspended furnaces closer than 12--in. (305 mm) to joists. The
sheet metal MUST extend underneath the furnace casing by 1--in.
(25 mm) with the door removed.
The bottom closure panel on furnaces of widths 17--1/2 in. (445
mm) 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
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 two screws holding bottom filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
13
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws. Side Return Air
Inlet
Side Return Air
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) is used without a bottom return air inlet.
Not all horizontal furnaces are approved for side return air
connections.
FILTER
CARBON MONOXIDE AND 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.
311AAV
There are no provisions for an internal filter rack in these
furnaces.
A field--supplied accessory external filter rack is required.
Refer to the instructions supplied with the external filter rack for
assembly and installation options.
DUCTS
AIR
General Requir
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.
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.
Inlet
ARRANGEMENT
!
WARNING
ements
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration. Ductwork
passing through unconditioned space should be insulated and
sealed to enhance system performance. When air conditioning is
used, a vapor barrier is recommended.
Maintain a 1--in. (25 mm) clearance from combustible materials
to supply air ductwork for a distance of 36 in. (914 mm)
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 degree elbow
and 10 ft. (3 M) 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
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 airstream. The cover attachment shall prevent leaks.
Upflow and Horizontal Furnaces
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.
NOTE: For horizontal applications, the top--most flange may be
bent past 90 degrees to allow the evaporator coil to hang on the
flange temporarily while the remaining attachment and sealing of
the coil are performed.
Downflow
Connect supply--air duct to supply--air outlet on furnace. Bend
flange inward past 90_ with wide duct pliers. (See Fig. 14.) The
supply--air duct must be connected to ONLY the furnace
supplyoutlet or air conditioning coil casing (when used). When
installed on combustible material, supply--air duct must be
connected to ONLY the factory--approved accessory subbase or a
factory--approved air conditioning coil casing. DO NOT cut main
furnace casing to attach supply side air duct, humidifier, or other
accessories. All accessories MUST be connected to duct external
to furnace casing.
Connections
Furnaces
eatment
14
UPFLOW DOWNFLOW HORIZONTAL
90°
120°
MIN
YES
YES
NO
120°
MIN
Fig. 14 -- Duct Flanges
1
/ 4
4 REQ.
90°
YES
YES
120°
MIN
NO
" (6mm) THREADED ROD
YES
YES
NO
311AAV
A02020
OUTER DOOR
A S SEMBLY
8" (203mm)
FOR DOOR REMOVAL
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
MIN
1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm)
ANGLE IRON OR UNI-STRUT MAY BE USED
Fig. 15 -- Horizontal Unit Suspension
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3
/4" (19mm) SCREWS
3 #8 x
TYPICAL FOR 2 SUPPORTS
A10130
15
METHOD 2
USE (4) #8 x 3/4 (19 mm) SHEET
METAL SCREWS FOR EACH
STRAP. THE STRAPS
SHOULD BE VERTICAL
AGAINST THE FURNACE
SIDES AND NOT PULL AWAY
FROM THE FURNACE
SIDES.
311AAV
METHOD 1
FOLD ALL STRAPS UNDER
FURNACE AND SECURE WTH
(4) #8 x 3/4 (19 mm) SHEET METAL SCREWS
(2 SCREWS IN SIDE AND 2 SCREWS
IN BOTTOM).
A10131
Fig. 16 -- Horizontal Suspension with Straps
LINE CONT A CT ONL Y PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE T OP AND TW O SIDES OF THE FURNA CE
JA CKET AND BUILDING JOISTS ,
STUDS , OR FRAMING.
SHEET
MET AL
GAS
ENTR Y
17 3 / 4 ″
22
(559mm)
″
6 ″
(451mm)
M IN
TYPE-B
VENT
(152mm)
*
30-IN . (76 2mm)
MIN WORK AREA
17 3 / 4 ″
(451mm)
4 3 / 4 ″
(121mm)
1 ″
(25mm)
EXTEND OUT 12 ″
OVERALL
UNDER DOOR
UNDER FURNACE
(305mm)
FR OM FA CE OF DOOR
* WHEN USED W ITH
SINGLE W ALL VEN T
CONNECTIONS
EQUIPMENT MANU AL
SHUT -OFF GAS VA LV E
SEDIMENT
TRAP
UNION
A10164
Fig. 17 -- Typical Attic Installation
16
PIPING
Connections
!
WARNING
!
WARNING
!
WARNING
!
CAUTION
Return Air
FIRE HAZARD
Failure to follow this warning could cause personal injury,
death and/or property damage.
Never connect return--air ducts to the back of the furnace.
Follow instructions below.
Downflow Furnaces
The return--air duct must be connected to return--air opening
(bottom inlet) as shown in Fig. 19. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and most
horizontal furnaces. (See Fig. 19.) Bypass humidifier connections
should be made at ductwork or coil casing sides exterior to
furnace.
Upflow and Horizontal Furnaces
The return--air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. 18 and 20. Bypass humidifier may be
attached into unused return air side of the furnace casing. (See
Fig. 18 and 20.)
Not all horizontal furnaces are approved for side return air
connections. (See Fig. 20.)
GAS
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Never purge a gas line into a combustion chamber. 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.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury,death, and/or property damage.
Use proper length of pipe to avoid stress on gas control
manifold and a gas leak.
FURNACE OVERHEAT HAZARD
Failure to follow this caution may result in property
damage.
Connect gas pipe to gas valve using a backup wrench to
avoid damaging gas controls and burner misalignment.
Gas piping must be installed in accordance with national and
local codes. Refer to current edition of NFGC.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a
separate line running directly from meter to furnace.
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously served another gas
appliance. Black iron pipe shall be installed at the furnace
gas control valve and extend a minimum of 2 in. (51 mm)
outside the furnace.
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36--in. (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T--handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
Refer to Table 6 for recommended gas pipe sizing. Risers must be
used to connect to furnace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of 1 hanger
every 6 ft. (2 M) Joint compound (pipe dope) should be applied
sparingly and only to male threads of joints. Pipe dope must be
resistant to the action of propane gas.
An accessible manual equipment shutoff valve MUST be
installed external to furnace casing and within 6 ft. (2 M) of
furnace. A 1/8--in. (3 mm) NPT plugged tapping, accessible for
test gauge connection, MUST be installed immediately upstream
of gas supply connection to furnace and downstream of manual
equipment shutoff valve.
NOTE: The furnace gas control valve inlet pressure tap
connection is suitable to use as test gauge connection providing
test pressure DOES NOT exceed maximum 0.5 psig (14--In.
W.C.) stated on gas control valve. (See Fig. 47.)
Some installations require gas entry on right side of furnace (as
viewed in upflow). (See Fig. 21.)
Install a sediment trap in riser leading to furnace as shown in Fig
22. Connect acapped nipple into lower end of tee. Capped nipple
should extend below level of furnace gas controls. Place a ground
joint union between furnace gas control valve and exterior
manual equipment gas shutoff valve. A 1/8--in. NPT plugged
tapping, accessible for test gauge connection, MUST be installed
immediately upstream of gas supply connection to furnace and
downstream of manual equipment shutoff valve.
Piping should be pressure and leak tested in accordance with
NFGC, local, and national plumbing and gas codes before the
furnace has been connected. After all connections have been
made, purge lines and check for leakage at furnace prior to
operating furnace.
If pressure exceeds 0.5 psig (14--In. W.C.), gas supply pipe must
be disconnected from furnace and capped before and during
supply pipe pressure test. If test pressure is equal to or less than
0.5 psig (14--In. W.C.), turn off electric shutoff switch located on
furnace gas control valve and accessible manual equipment
shutoff valve before and during supply pipe pressure test. After
all connections have been made, purge lines and check for
leakage at furnace prior to operating furnace.
The gas supply pressure shall be within the maximum and
minimum inlet supply pressures marked on the rating plate with
the furnace burners ON and OFF.
311AAV
17
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