Carrier 58DLX13510016, 58DLX13510022, 58DLX11010012, 58DLX11010016, 58DLX11010022 Installation Guide

...

Installation, Start-up, Operating and

Service and Maintenance Instructions

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

UpfJow 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 CaMe 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

Sequence of Operation ........................... 50

Blower Motor and Wheel ......................... 46

Cleaning Heat Exchanger ......................... 47

Sequence of Operation ........................... 49

Wiring Diagrams ............................... 50

Troubleshooting ................................ 50

PARTS REPLACEMENT INFORMATION GUIDE ....... 54

Always Ask For

Use of tile AIIR[ Cmlified 1-,i Mark indicates a manulilcturer's pallicipation in the program, lot

verification (if cellification lbr individual products, go to www.ahridireclory.org.

ISO9001

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

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1-2012©, with permission of National Fire Protection

Association, Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the

complete and official position of the NFPA or ANSI on the referenced subject, which is represented only by the standard in

its entirety.

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING

HAZARD

Failure to follow this warning could result in dangerous operation, serious iniury, 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 iniury 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.

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.

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 iniury, 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 iniury. 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 iniury or death. WARNING signifies hazards which could result in personal iniury or death. CAUTION is

used to identify unsafe practices which may result in minor personal iniury 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 spe- cified 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. Con- nect this furnace to an approved vent system only, as spe-

cified in the "Venting" section of these instructions.

5. Never test for gas leaks with an open flame. Use a com- mercially 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 in- tended 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 con-

taining the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating out-

side the space containing the furnace. See "Air Ducts" sec- tion.

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 in- structions.

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 install- ation 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 con- version kit is required to convert furnace for use with pro-

pane gas.

11. See Fig. 2 for required clearances to combustible construc- tion.

12. Maintain a 1-in. (25 mm) clearance from combustible ma- terials to supply air ductwork for a distance of 36 in. (914

mm) horizontally from the furnace. See NFPA 90B or loc- al code for further requirements.

13. These furnaces SHALL NOT be installed directly on car- peting, tile, or any other combustible material other than

wood flooring. In downflow installations, factory access- ory floor base MUST be used when installed on combust-

ible 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.

f_7/8

1/16

[4a_1

_de

57/S--

° 12

[!;_;t

27 @/4

_@/4 [1Z/1

, --TOP O_¢.A_NG

[14a_

_ 21.6

BOTTOM_

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. 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 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.

A B C D ACCESSORY

FURNACE SIZE BOTTOM FLUE iNLET WIDTH CONNECTION LB. (KG) MEDIA

045- 08/024045 045-12/036045 070- 08/024070

070-12/036070 070-16/048070 090-14/042090 090-16/048090 090- 20/060090

110-12/036110 110-16/048110 110-22/066110 135-16/048135 135-22/066135 155-20/060155 22-7/8 (581)

"135 and 155 size furnaces require a 5 or 6-in. (127 or 152 complete installation requirements.

CABINET WIDTH OUTLET WIDTH TOP & BOTTOM SHIP WT

14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 107 (47) 16 (406) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 107 (49) 16 (406) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 111 (50) 16 (406) 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 115 (52) 16 (406)

17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 126 (57) 16 (406) 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 127 (58) 16 (406)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 140 (64) 20 (508) 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66) 20 (508)

17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 135 (61) 16 (406)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66) 20 (508) 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 152 (69) 20 (508)

21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102)* 149 (68) 20 (508) 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102)* 163 (74) 24 (610) 24-1/2 (622) 15-1/16 (383) 23 (584) 4 (102)* 170 (77) 24 (610)

mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for

_gfN

VENT FILTER

COLLAR SIZE CABINET SIZE

I N_N

IN. (MM)

A10290

Fig. 1 - Dimensional Drawing

INTRODUCTION

Series 150/F 4-way nmltipoise 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

naininmm continuous return-air temperature of 60°F (16 °C) db

MINIMUMiNCHESCLEARANCETO COMBUSTIBLECONSTRUCTION

This forced air furnace is

improperadjustment, alteration, service, maintenance, or installationcan cause

seriousinjuryor death,

Read and follow instructions and precautions in User's information Manual

provided with this furnace, installation

and service must be performed by a

qualified service agency or the gas

supplier,

Check entire gas assembly for leaks after lighting this appliance.

iNSTALLATION

1. This furnace must be installed in accordance with the manufacturer's

instructions and local codes. In the absence of local codes, follow the National

Fuel Gas Code ANSI Z223.1 / NFPA54 or CSA B-149. 1 Gas InstNlation Code.

2. This furnace must be installed so there are provisions for combustion and ventilation

air. See manufacturer's installation information provided with this appliance.

OPERATION

This furnace is equipped with manual reset limit switch(es) in burner compartment to

protect against overheat conditions that can result from inadequate combustion air supply or blocked vent conditions.

1. Do not bypass limit switches.

2. If a limit opens, call a quallified serviceman to correct the condition

and reset limit switch.

equipped for use with natural gas at Ntitudes 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 combustible material.

This furnace may be used with

a Type B-1 Vent and may be vented in common with other

gas fired appliances.

DOWNFLOWPOSiTiONS:

Installation on non-combustible floors only. For Installation on combustible flooring only when installed on special

base, Part No. KGASB0201ALL or NAHA01101SB, Coil Assembly, Part No. CAR, CAP, CNPV, CNRV, END4X, ENW4X, WENC, WTNC,

WENW OR WTNW. 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.

Fig. 2 - Clearances to Combustibles

or intermittent operation down to 55°F (13°C)db such as when used with a night setback thermostat. Return-air temperature nmst 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.

This furnace is approved for UPFLOW, DOWNFLOW, and

HORIZONTAL installations.

Clearancearrows donotchangewith

furnaceorientation.

Clearancein inches

Vent Clearance to combustiNes:

For SingleWall vents6 inches(6 po). ForType B=I venttype I inch(1 po).

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

IIIIIIIIIIIIIIIIIIIIIIIIIII

336996-101 REV. C

A10269

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation nmst 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

• National Fuel (;as Code (NFGC) NFPA 54-2012/AN- SI Z223.1-2012 and the Installation Standards, Warm

Air Heating

and Air Conditioning Systems ANSI/NFPA 90B

ii !I

II I

A05004

Fig. 3 - Return Air Temperature

General Installation

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 Air

Section 9.3 of the NFGC, NFPA 54/ANSI Z223.1-2012 Air for Combustion and Ventilation.

Duct Systems

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 Lininq and Fibrous Glass Duct

Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Gas Pipinq and Gas Pipe Pressure Testinq

NFPA 54/ANSI Z223.1-2012 Chapters 5, 6, 7, and 8 and National Plumbing Codes.

Electrical Connections

National Electrical Code (NEC) ANSI/NFPA 70-2011. Venting

NFGC NFPA 54/ANSI Z223.1-2012 ; chapters 12 and 13.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

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 fur- nace 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 un- grounded 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 (ungroun- ded) furnaces.

6. Before removing a new control from its container, dis- charge your body's electrostatic charge to ground to pro-

tect the control from damage. If the control is to be in- stalled in a furnace, follow items 1 through 4 before

bringing the control or yourself in contact with the fur- nace. Put all used and new controls into containers before

touching ungrounded objects.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

THE BLOWER IS LOCATED

TOTHE RIGHT OFTHE

BURNER SECTION, AND

AIR CONDiTiONED AiR IS

DISCHARGED TO THE LEFT.

AIRFLOW

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDiTiONED AIR IS

DISCHARGED UPWARD.

HORIZONTAL LEFT

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

_AIRFLOW

Fig. 4 - Multipoise Orientations

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.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal iniury 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:

• be installed so the electrical components are protected from water.

• not be installed directly on any combustible material other than wood flooring for upflow applications. Downflow installations require use of a factory-ap-

proved floor base or coil assembly when installed on combustible materials or wood flooring (refer to SAFETY CONSIDERATIONS).

• be located as close to the chimney or vent and attached to an air distribution system. Refer to Air Ducts section.

• be provided ample space for servicing and cleaning.

Always comply with minimum fire protection clear-

ances shown on the furnace clearance to combustible label.

HORIZONTAL RIGH-'_AIR FL_OW

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDiTiONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

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

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• 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:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• 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.

18qN. (457.2 mm)

MINIMUM TO BURNERS

Fig. 5 - Installation in a Garage

A93044

BACK

A02054

Fig. 6 - Prohibit Installation on Back

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.)

FIRE HAZARD

Failure to follow this warning could result in personal iniury, 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.)

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.

Table 1 - Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

FURNACE (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)

iNPUT Free Area of Opening Round Duet Free Area of Opening Round Duet Free Area of Opening Round Duet

(BTUH) and Duet Dia. and Duet Dia. and Duet Dia.

Sq. In. (Sq. turn) In. (turn) Sq. In. (Sq. turn) In. (turn) Sq. In. (Sq. turn) In. (turn)

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)

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 88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

Table 2 - Minimum Space Volumes for 100 % Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

(1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

ACH Space Volume Ft3 (M3)

0.60 (29.7) (39.6) (49.5) (31.1) (46.7) (62.2) (77.8) (93.4) (109.0)

0.50 (35.6) (47.5) (59.4) (37.3) (56.0) (74.7) (93.4) (112.1 ) (130.8)

0.40 (44.5) (59.4) (74.3) (46.7) (70.0) (93.4) (116.8) (140.1 ) (163.5)

0.30 (59.4) (79.2) (99.1) (62.2) (93.4) (124.5) (155.7) (186.8) (218.0)

0.20 (89.1) (118.9) 5,250 (148.6) (93.4) (140.1) (186.8) (233.6) (280.3) (327.0)

0.10 (178.3) (237.8) (297.3) (186.8) (280.3) (373.7) (467.2) (560.6) (654.1)

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

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

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

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

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

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

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

FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace damage.

Air for combustion nmst 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 nmst 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 nmst 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:

• Section 9.3 of the NFGC NFPA 54/ANSI Z223.1-2012, Air for Combustion and Ventilation,

and applicable provisions of the local building codes.

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 MUST commence within 12-in. (300 ram)

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

f. Size openings and ducts per Fig. 7 and Table 1.

g. TWOHORIZONTALDUCTSrequire 1-in.2offreearea

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

h. TWO OPENINGS OR VERTICAL DUCTS require

1-in. 2 of free area per 4,000 Btuh (550 mm2/kW) for combined input of all gas appliances in the space per Fig.

7 and TaMe 1.

3. ONE OUTDOOR OPENING requires:

a. 1-in. 2 of free area per 3,000 Btuh (734 mm2/kW) for

combined input of all gas appliances in the space per Table 1 and

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

in the space.

The opening shall commence within 12-in. (300 ram) of the ceiling. Appliances in the space shall have clearances of at least

l-in. (25 ram) from the sides and back and 6-in. (150 ram) from the front. The opening shall directly conmmnicate 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.

DUCTS --J / \ PER 4000

TO _ / _, BTUH*

/C- 1 SQ IN.

OUTDOORSI "_'&.. _&

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.

• Spaces having less than 50 cubic feet per 1,000 Btuh

require the OUTDOOR COMBUSTION AIR METHOD.

• 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 Method

1. Provide the space with sufficient air for proper combus- tion, ventilation, and dilution of flue gases using perman- ent horizontal or vertical duct(s) or opening(s) directly

communicating with the outdoors or spaces that freely communicate with the outdoors.

I I J

iii j i} /

(3osmm)12"MA_/I I D III 2"(3osmm)

1SQ_N.i I _ IVENT I I LJ MAX

PER2000T IBI _) ITHROUGH I I FN_

BTUH* _ D ROOF T

oc_ PER

OUTDOORS / II

i!iiiiil _'Hii_ _ { ii ii

......... ] ] iDUCTS OO

E 1SQIN.

; PER

4000.

_,_ J I _N-_

PER2000_ :lAli _ 'G _ t___f

BTUH* f It _

__ __ • J

(3o_mm)_2"MAX C _' I_ (30_mm)

i , , i ! 12"MAX I _, 'r _ I 1 (305mm) ' ]"

CIRCULATING AIR DUCTS

*Minimum dimensions of 3-in, (76 mm.) Use any of the following combinations of openings:

A&BC&DD&EF&G

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

Indoor Combustion Air - NFPA & AGA Standard and Known-Air-Infiltration Rate Methods

DUCTr x 1 SQ IN.

] TO PER 4000

OUTDOORS BTUH*

Outdoors

A03174

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

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 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 deternfined per Table 2 or Equations 1 and 2. Deternfine the minimum required volume for each appliance in the space and add the volumes together to get the total nfininmm

required volume for the space. Table 2-Minimum Space Volumes were deternfined by using

the following equations from the National Fuel Gas Code ANSI Z223.1-2012/NFPA 54-2012, 9.3.2.2:

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

Volume - 21ft3 _ [ °ther

Other ACH 000 Btu/hr

A04002

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

Volume _ 15ft 3 _ I fan

Fan ACH 000 Btu/hr

A04003

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.2/l,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 ram) of the ceiling and the second opening shall commence within

12-in. (300 ram) of the floor. The nfininmm dimension of air openings shall be at least 3-in. (80 ram). (See Fig.

8.)

1 1

I I

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. (64516 sq, mm)with minimum dimensions of 3 in. (76 mm)

1-Minimum of 3 in. (76 mm) when type-B1 vent is used.

I I

:305mm)

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

UNCONFINED SPACE

6" MIN (152mm) (FRONT)0

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

L 12" MAX (3O5mm)

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

Indoors

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 per- manent openings in doors or floors having free area of

at least 2 in.2/l,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 conmmnicates with the outdoors provided there are

adequate permanent ventilation openings directly to out- doors 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,in- filtration should be adequate to provide air for combus- tion, permanent ventilation and dilution of flue gases.

However, in buildings with unusually tight construction, additional air MUST be provided using the methods de-

scribed 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 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 Combus- tion Air Method below and,

A03175

Bottom Closure Panel

Bottom Filler Panel

A10273

Fig. 9 - Removing Bottom Closure Panel

2. Outdoor openings shall be located as required in the Out- door 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 size reduction Factor is I minus the Ra-

tio in a. above.

c. Mininmm size of Outdoor openings shall be the size re-

quired in Outdoor Combustion Air Method above nmlti- plied by reduction Factor in b. above. The n_ininmm di-

mension of air openings shall be not less than 3 in. (80 mm).

INSTALLATION

UPFLOW INSTALLATION Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed m 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 bot- tom filler panel. (See Fig. 90

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 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.

Levelin_ Le_s (If Desired) 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).

(8ram)

] 8/4'

(44ram)

l:)

1 3/4"

(44mm)

(8mm)

5/16"

(8mm)

(44mm) 1 3/4"

(44mm) I 3/4'_

A89014

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 INSTALLATION NOTE: For downflow applications, this furnace is approved for

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

• Special Base, KGASB

• Cased Coil Assembly Part No. CNPV, CNRV, CAP, or CAR

• Coil Box Part No. KCAKC

1. Determine application being installed from Table 3.

2. Construct hole in floor per Table 3 and Fig. 11.

3. Construct plenum to dimensions specified in Table 3 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 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 bot- tom 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

FURNACE

(OR COIL CASING

WHEN USED)

Fig. 11 - Floor and Plenum Opening Dimensions

A96283

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

/,_ COMBUSTIBLE

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

FLOORING \

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Combustible Floor

A96285

COMBUSTIBLE _\

FLOORING

\\\\_

SHEET METAL _

PLENUM

FLOOR

OPENING

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

Coil Box Installed on a Combustible Floor

A08556

Table 3 - Opening Dimensions - IN. (mm)

FURNACE

CASING

APPLICATION

WIDTH

Upflow Applications on Combustible or Noncombustible Floor- 12-11/16 21-5/8 13-5/16 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 12-9/16 19 13-3/16 19-5/8

14-3/16 Downflow applications on combustible flooring (KGASB sub- 11 - 18/16 19 18- 7/16 20- 5/8

(360) base required) (284) (483) (341) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 16 21 -5/8 16-5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 15-7/8 19 16-1/2 19-5/8

17-1/2 Downflow applications on combustible flooring (KGAS B su b- 15-1/8 19 16-3/4 20-5/8

(445) base required) (384) (483) (425) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 19-1/2 21-5/8 20-1/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 19-3/8 19 20 19-5/8

21 Downflow applications on combustible flooring (KGASB sub- 18-5/8 19 20-1/4 20-5/8

(533) base required) (473) (483) (514) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

Upflow Applications on Combustible or Noncombustible Floor- 23 21 - 1/8 28- 5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 22-7/8 19 28-1/2 19-5/8

24-1/2 Downflow applications on Combustible flooring (KGAS B su b- 22-1/8 19 28- 3/4 20-5/8

(622) base required) (562) (483) (603) (600)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

ing (KGASB subbase not required) (322) (549) (338) (565)

subbase not required) (819) (483) (335) (498)

(KGASB subbase not required) (819) (483) (338) (508)

ing (KGASB subbase not required) (406) (549) (422) (565)

subbase not required) (403) (483) (419) (498)

(KGASB subbase not required) (394) (483) (419) (508)

ing (KGASB subbase not required) (495) (549) (511) (565)

subbase not required) (492) (483) (508) (498)

(KGASB subbase not required) (483) (483) (508) (508)

ing (KGASB subbase not required) (584) (537) (600) (565)

subbase not required) (581) (483) (597) (498)

(KGASB subbase not required) (572) (483) (597) (508)

PLENUM OPENING FLOOR OPENING

A B C D

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

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

19 19 20 20

22-1/2 19 28-1/2 20

HORIZONTAL INSTALLATION

FIRE, EXPLOSION, AND CARBON MONOXIDE

POISONING HAZARD

Failure to follow this warning could result in personal iniury, 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 Protection 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 ram) above the combustible deck or suspended furnaces closer than 12-in. (305 ram) to joists. The

sheet metal MUST extend underneath the furnace casing by 1-in. (25 ram) with the door removed.

The bottom closure panel on furnaces of widths 17-1/2 in. (445 ram) 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 bot- tom 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

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) is used without a bottom return air inlet.

Not all horizontal furnaces are approved for side return air connections.

FILTER ARRANGEMENT

CARBON MONOXIDE AND POISONING

HAZARD Failure to follow this warning could result in personal

iniury, 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.

A field-supplied accessory external filter rack is required. Refer to the instructions supplied with the external filter rack for

assembly and installation options. AIR DUCTS

General Requirements 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 4-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 ternfinating 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.

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 ram) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914 ram)

horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Treatment

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 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 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, hunfidifier, 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 Furnaces 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 nmst 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, hunfidifier, or other

accessories. All accessories MUST be connected to duct external to furnace casing.

UPFLOW DOWNFLOW HORIZONTAL

[ ......

YES

Fig. 14 - Duct Flanges

YES

NO NO

_/4"(6mm) THREADED ROD 4 REQ.

YES

A02020

ASSEMBLY

8" (203mm) MtN

FOR DOOR REMOVAL

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

1" (25ram) 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 #8 x3/4'' (19mm) SCREWS

TYPICAL FOR 2 SUPPORTS

A10130

22 GAUGE GALVANIZED STRAPS TYPICAL

FOR 4 STRAPS

OUTER DOOR ASSEMBLY

Fig. 16 - Horizontal Suspension with Straps

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.

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH

(4) #8 x 3/4 (t9 ram) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2SCREWS

IN BOTTOM).

ENTRY VENT

BACK OF FURNACE

METHOD 2 USE (4) #8 x 3/4 (19 ram) SHEET

METAL SCREWS FOR EACH STRAR THE STRAPS

SHOULD BE VERTICAL AGAINST THE FURNACE

SIDES AND NOT PULL AWAY FROM THE FURNACE

SIDES.

17 3/4" (451 mm)OVERALL 4 3/4" (121mm) UNDER DOOR 1" (25mm) UNDER FURNACE

EXTEND OUT 12" (305mm) FROM FACE OF DOOR

A10131

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

SEDIMENT UNION

TRAP

Fig. 17 - Typical Attic Installation

_0-1N.(762mm)

MIN WORK AREA

*WHEN USED WITH

SINGLE WALL VENT CONNECTIONS

A10164

Return Air Connections

FIRE HAZARD

Failure to follow this warning could cause personal iniury, 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 PIPING

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. A fire or explosion may result causing property damage, personal injury or loss of

life.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury,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.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal iniury, 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 li- censed 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 5 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 a capped 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.

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