Carrier 58MTB100F10116, 58MTB100F10120, 58MTB120F10120, 58MTB060F10112, 58MTB080F10112 Installation Guide

...

Installation, Start-up, and Operating Instructions

Sizes 060-120, Series 110

Visit www.Carrier.com

NOTE: Read the entire instruction manual before starting the installation. Please retain these instructions with the furnace

after installation for future reference.

NOTE: This furnace can be installed as a (2-pipe) direct vent or (1-pipe) non-direct vent condensing gas furnace.

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ISO 9001:2000

Special Venting Requirements for Installations in Canada

Installation in Canada must conform to the requirements of CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC $636. The special vent

fittings and accessory concentric vent termination kits and accessory external drain trap have been certified to ULC $636 for

use with those IPEX PVC vent components which have been certified to this standard. In Canada, the primer and cement must

be of the same manufacturer as the vent system - IPEX System 636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and IPEX System 636(1) TM , PVC Cement for Flue Gas Venting, rated

Class IIA, 65 deg C. must be used with this venting system - do not mix primers and cements from one manufacturer with a vent

system from a different manufacturer. Follow the manufacturer's instructions in the use of primer and cement and never use primer

or cement beyond its expiration date. The safe operation, as defined by ULC $636, of the vent system

is based on following these installation instructions, the vent system manufacturer's installation instructions, and proper use of primer and cement. All fire stop and roof flashing used with this

system must be UL listed material. Acceptability under Canadian standard CSA B149 is dependent upon full compliance with all installation instructions. Under this standard, it is recommended

that the vent system be checked once a year by qualified service personnel.

The authority having jurisdiction (gas inspection authority, municipal building department, fire department, etc) should be

consulted before installation to determine the need to obtain a permit.

Consignes sp_ciales pour l'installation de ventillation au Canada

Uinstallation faite au Canada doit se conformer aux exigences du code CSA B149. Ce syst_me de ventillation doit se composer de

tuyaux, raccords, ciments et appr_ts conformes au ULC $636. La tuyauterie de ventillation des gaz, ses accessoires, le terminal

concentrique mural ainsi que l'ensemble du drain de condensat ext_rieur ont _t_ certifies ULCS 636 pour l'application des composantes IPEX PVC qui sont certifi_es fi ce standard. Au

Canada l'appr_t et le ciment doivent _tre du m_me manufacturier

que le syst_me de ventillation - IPEX Syst_me 636, Appr_t PVC/CPVC. Mauve Violette pour conduit en _vacuation des gaz et IPEX Syst_me 636(1) TM, ciment pour PVC pour conduit en

_vacuation des gaz, _valu_ CLASSE IIA, 65 deg. C. doit _tre utilis_ avec ce syst_eme d'_vacuation - ne pas m_langer l'appr_t

et le ciment d'un manufacturier avec le syst_me de ventillation d'un autre manufacturier. Bien suivre les indications du

manufacturier lors de l'utilisation de l'appr_t et du ciment et ne pas utiliser ceux-ci si la date d'expiration est atteinte.

Uop_ration s_curitaire, tel que d_finit par ULC $636, du syst_me de ventilation est bass sur les instructions d'installation suivantes,

ainsi que l'usage appropri_ de l'appr_t et ciment. Tout arr_t feu et

solin de toit utilis_s avec ce syst_me doivent _tre des mat_riaux list,s UL. Uacceptation du standard Canadien CSA B419 est

directement reli_ fi l'installation conforme aux instructions ci- haut mentionn_es. Le standard Canadien recommande 1'

inspection par un personel qualifi_ et ce, une fois par annie. Les autorit_es ayant juridiction (inspecteurs de gas, inspecteurs

en bfitiments, d@artement des incendies, etc) devraient _tre consult_es avant l'installation afin de d_terminer si un permis est requis.

(1) System 636 is a trademark of IPEX Inc.

Required Notice for Massachusetts Installations

IMPORTANT

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:

5.08: Modifications to NFPA-54, Chapter 10

2) Revise 10.8.3 by adding the following additional requirements: a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used

in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,

including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an

alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is

installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for

the installation of hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard

wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner

shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a

minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "(}AS

VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve

the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in

accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

(1.) The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of

NFPA 54 as adopted by the Board; and

(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from

the dwelling, building or structure used in whole or in part for residential purposes.

c. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

d. MANUFACTURER REQUIREMENTS - (}AS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When

the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be

satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled

equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers

and Gas Fitters, 239 Causeway Street, Boston, MA 02114. 617-727-9952.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS .......................... 3

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

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

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

Combustion and Ventilation Air ........................ 7

Duct Systems ...................................... 7

Acoustical Lining and Fibrous Glass Duct ................ 7

Gas Piping and Gas Pipe Pressure Testing ................ 7

Electrical Connections ............................... 7

Venting ........................................... 8

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ... 8

INTRODUCTION .................................... 8

APPLICATIONS ..................................... 8

General ........................................... 8

Upflow Applications ................................. 8

Downflow Applications ............................. 10

Horizontal Left (Supply-Air Discharge) Applications ...... 12

Horizontal Right (Supply-Air Discharge) Applications ..... 13

LOCATION ........................................ 16

General .......................................... 16

Furnace Location Relative to Cooling Equipment ......... 17

Hazardous Locations ............................... 17

Furnace Location and Application ..................... 17

AIR FOR COMBUSTION AND VENTILATION .......... 18

INSTALLATION .................................... 21

Leveling Legs (If Desired) ........................... 21

Installation in Upflow and Downflow Applications ....... 21

Installation in Horizontal Applications ................. 21

Air Ducts ......................................... 21

General Requirements ............................. 21

Ductwork Acoustical Treatment ..................... 23

Supply Air Connections ........................... 23

Return Air Connections ............................ 24

Filter Arrangement ................................. 25

Bottom Closure Panel ............................... 26

Gas Piping ........................................ 26

Electrical Connections .............................. 27

115-v Wiring .................................... 27

24-v Wiring ..................................... 29

Accessories ..................................... 29

Removal of Existing Furnaces from

Common Vent Systems .............................. 30

Combustion Air and Vent Pipe Systems ................. 30

Condensate Drain .................................. 45

General ........................................ 45

Application ..................................... 45

Condensation Drain Protection ...................... 46

START-UR ADJUSTMENTS, AND SAFETY CHECK ..... 46

General .......................................... 46

Prime Condensate Trap With Water .................... 47

Purge Gas Lines ................................... 47

Sequence of Operation .............................. 47

Two-Stage Heating With Single-Stage Thermostat

(Adaptive Mode) ................................. 48

Two-Stage Heating With Two-Stage Thermostat

(Non-Adaptive Heating Mode) ...................... 48

Cooling Mode ................................... 49

Thermidistat Mode ............................... 49

Continuous Blower Mode .......................... 53

Heat Pump Mode ................................. 53

Component Self-Test .............................. 53

Operate Furnace ................................. 54

Furnace Restart .................................. 54

Set Gas Input Rate ................................ 54

Set Temperature Rise .............................. 59

Adjust Blower Off Delay (Heat Mode) ................ 60

Set Thermostat Heat Anticipator ..................... 60

Check Safety Controls .............................. 60

Checklist ......................................... 61

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SAFETY CONSIDERATIONS

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.

A93041

FURNACERELIABILITYHAZARD

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.

hnproper 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. In Canada, refer to the current editions of the National Standards of Canada CAN/CSA-B149.1 and .2 Natural Gas and Propane

Installation Codes, and Canadian Electrical Code CSA C22.1

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.

ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental

pollution. Remove and recycle all components or materials (i.e., oil,

refrigerant, control boards, etc.) before unit final disposal.

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.

The model 58MTB, 2-Stage, 4-way Multipoise, Gas-Fired, Category IV, condensing furnace is available in model sizes

ranging in high-stage gas input rates of 60,000 to 120,000 Btuh.

This furnace is CSA (formerly AGA and CGA) design-certified for natural and propane gases (see furnace rating plate) and for

installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. This furnace is factory-shipped for use with natural gas. A CSA listed gas conversion kit is required to

convert furnace for use with propane gas.

See Fig. 3 for required clearances to combustibles.

This furnace SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. For

downflow installations, a factory accessory floor base must be used when installed on combustible materials and wood flooring.

Special base is not required when this furnace is installed on the

manufacturer's coil assembly or when the manufacturer's coil box is used. The design of the 58MTB furnace is not CSA certified for installation in mobile homes, recreational vehicles, or outdoors. This furnace is suitable for installation in a structure

built on site or a manufactured building completed at final site. This furnace is designed for continuous return-air minimum

temperature of 60°F (16°C) db 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 limits may affect reliability

of heat exchangers, motors and controls. (See Fig. 4.) This furnace is shipped with the drain and pressure tubes

connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGHT,

or HORIZONTAL LEFT (supply-air discharge direction)

applications as shown in Fig. 1. See details in Applications

section. Install this furnace only in a location and position as specified in

LOCATION and INSTALLATION sections of these instructions. Always provide adequate combustion and ventilation air as

specified in section Combustion Air and Vent Pipe Systems of these instructions to furnace.

Combustion products must be discharged outdoors. Connect this

furnace to an approved vent system only, as specified in the

Combustion Air and Vent Piping sections of these instructions.

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 of these instructions.

Always install furnace to operate within the furnace's intended rise range with a duct system which has an external static

pressure within the allowable range, as specified in the SET TEMPERATURE RISE section of these instructions and furnace

rating plate. 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.

A gas-fired furnace for installation in a residential garage must be installed as specified in the Hazardous Locations section of these

instructions. The furnace may be used for construction heat provided that the

furnace installation and operation complies with:

• The furnace is permanently installed with all electrical wiring, piping, air filters, 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 firing 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.

This furnace is shipped with the following materials to assist in proper furnace installation. These materials are shipped in the

main blower compartment.

Installer Packet includes:

Installation, Startup, and Operating Instructions Service and Maintenance Instructions

User's Information Manual

Warranty Certificate

Loose Parts Bag includes: Quantity

Pressure tube extension 1 Collector Box or condensate trap extension tube 1

Inducer housing drain tube 1 1/2-in CPVC street elbow 2

Drain tube coupling 1 Drain tube coupling grommet 1

Condensate trap hole filler plug 3

Vent and combustion-air intake hole filler plug 2

Combustion-air intake pipe perforated disk assembly 1 Gas line grommet 1

Vent pipe grommet 1

Combustion-air pipe grommet 1 Power entry hole filler plug 2

Vent Pipe Extension 1"

CODES AND STANDARDS

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

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

all authorities having jurisdiction.

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

Step 1 - Safety

• US: National Fuel (;as Code (NFGC) NFPA 54-2006/ANSI Z223.1-2006 and the Installation Standards, Warm Air Heating

and Air Conditioning Systems ANSI/NFPA 90B

• CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-05

Step 2 - General Installation

• US: NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park,

Quincy, MA 02269; or for only the NFGC contact the

American Gas Association, 400 N. Capitol, N.W., Washington DC 20001

• A manufactured (Mobile) home installation must conform with

the Manufactured Home Construction and Safety Standard,

Title 24 CFR, Part 3280, or when this standard is not applicable, the Standard for Manufitctured Home Installation

(Manufactured Home Sites, Communities, and Set-Upsg,

ANSI/NCS A225.1, and/or CAN/CSA-Z240, MH Series

Mobile Homes

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke

(Toronto), Ontario, M9W 1R3, Canada.

*ONLY supplied with some furnaces.

The furnace shall be installed so that the electrical components are protected from water.

For accessory installation detail, refer to the accessory installation instruction.

NOTE: Remove all shipping materials before operating furnace.

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A05053

NSTALLATION

e This forced air fumace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 fL

(0- Z135m).

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

• This famace is for indoor installation in a building constructed on site. This furnace may be installed in a manufactured (mobile) home when stated on rating plate and using factory authorized kit..

• This furnace may be instated on combustible floodng in alsove or closet at Minimum Inches Clearance To Combustible Construction as described below.

e This _mace requires a special venting system. Refer to the installation instructions for parts list and method of installation. In the US this furnace is for use with

schedule=40 PVC, PVC-DWV, CPVC, or AB,S-DWV pipe, and must not be vented in common with other gas-fired appliances. In Canada, refer to installation instructions for vent materiaN. Construction through which vent/air intake pipes may be installed is maximum 24 inches (610 ram), minimum 3/4 inches (19 mm) thickness (including

roofing materials).

e Cette foumaise _ air puls6 est 6quip6e pour utilisation avec gaz naturem et altitudes comprises entre 0 - 3,050m (0 - 10,000 pi),except6 queles foumaises de 140 taifle

sont pour altitudes comprises entre 0 - 2,135m (0 - 7,000pi).

® Utiiiser une trousse de conversion, foumie par le fabdcent, pour passer au gaz propane ou pour certaines installations au gaz natureL e Cette foumaise _ air pulse est pour installation a Fintedeur dans un b_timent construit sur place. Cette foumaise a air puNe peut 6tre install6e dans une maison

prCfabdqu6e (maison mobile) si prescrit par la plaque signal6tique et si'l on utilise une trousse specifi6e par le fabricent.

• C.ette foumaise pout 6tre install6e sur un piancher combustible dans un enfoncement ou un pmacerd en observant les D6gagernent Minimum En Pouces Avec EI6ments De Construction Combustibles.

• Cette foumaise n6cessite un syst_me d'6vacuation sp6cial. La m6thode d'instaliation et la liste des pi_ces n6cessaires figurent dana les instructions d'installation. Aux Etats-Unis, cette foumaise dolt s'utiliser avec la tuyautede des nomenclatures 40 PVC, PVC-DWV, CPVC, ou ,ABS-DWV et elle ne peut pas _tre ventii6e conjointment

avec d'autres appareils & gaz. Au Canada, referer aux instructions d'installation pour lax matedaux a ventiler. Epaisseur de la construction au travers de laquene il est possible de faire passer les tuyaux d'aeration (admission/evacuation): 24 po (610 mm) maximum, 3/4 pc (19mm) minimum (y compds la toiture).

For up&3w and downflow applications, furnace must be installed level, or pitched within 1/2" (12.7ram) of level. For a LEVEL 0" ( 0 ) TO _,. MIN 114"(6.35mm) TO horizontal appllaatiorl, the furnace must be pitched mirlimum 1/4" (6.35mm) to maximum of 1/2" (12.7mm) forward for 1/2" (12.7mm) MAX t ¢_L-_-_ 1/2" (12.7mm)MAX

proper drainage. See Installation Manual for IMPORTANT unit support details on horizontal applications.

Pour des applications de flux ascendant et descendant, la foumaise doit ¢¢e install6e de niveau ou indin6e _ T ............ !

pas plus de 1/2" (12.7mm) du niveau. Pour une applicetion hodzontale, lafoumaise dolt &,Ire inclin6e enli'e minimum UPFLOW OR F_0RONT_) 1/4" (6.35mm) et maximum 1/2" (12.7ram) du niveau pour ledrainage appropn6. En cas d'installation en position DOWN FLOW

hodzootale, consulter les renseignements mMPORTANTS sur le support dans le manuel d'instaHation. HORIZONTAL

MINIMUMINCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSiTiONS:

Minimum front clearance for service 24 inches (610mm).

t 1 140 size furnaces require I inch back clearance to combustible materials.

DOWNFLOW POSITIONS:

t For installation on combustible 11oors only when instated on special base No. KGASB0201ALL or

NAHA01101SB, CoilAssembly, Part No. CAR, CAP, CNPV, CNRV or Coil Casing, Part No. KCAKC,

or WENC or WTNC.

HORIZONTAL POSITIONSi

Line contact is permissible only between lines formed by intersections of top and two sides of

furnace jacket, and building joists, studs, or framing.

§ Clearance shown is for air inlet and air curet ends.

O 120 and 140 size furnaces require 1 inch bottom clearance to combustible materials.

DEGAGEMENT MNfl_UM EN POUCESAVEC I_LleMENTSDECONSTRUCTION COMBUSTIBLES

POUR TOUS LES POSITIONS:

D@jagement avant minimum de 24 po (610mm ) pour l'entretien.

1- t Pour les foumaises de 140 taifle, 1 pc (25mm) d6gagement des mat6riaux combustibles est

requis au-arriere.

POUR LA POSITION COURANT DESCENDANT:

1 Pour Ilnstaflation sur le plancher cembustible seulement quand on utilise la base sp_ciale, piece

n° KGASB0201ALL ou NAHA01101SB, I'ensemble serpentin, pi_:e n ° CAR, CAP, CNPV, CNRV, ou le carter de serpentin, piece n ° KCAKC ou WENC ou WTNC.

POUR LA POSmON HORIZONTALE:

Le contact n'est permis qOentre les lignes form6es par les intersec_ons du dessus et des deuxottes de la chemise de la foumaise, et des solives, des montants ou de la charpente du

batiment.

§ La distance indiqu_e conceme I'extr_mit6 du tuyau d'ardv_e d'air et I'extr_mit_ du tuyau de sortie d'aic Pour les foumaises de 120 et 140 taifie, 1 pc (25mm) d6gagement des materiaux combustibles

est requis au-dessous.

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

Cette foumaise est approuv_e pour I'installation HORIZONTALE et la circulation d'air VERS LE HAUT et VERS LE BAS.

Clearance arrows Les _hes de degagement do not change with ne change pas avec

furnace orientation, gen_rateur d'air chaud.

Clearanceininches 0 (pc) D_Jagement D6gagement(pc). d'_ventaveccombustibles.

I'orientation de la

Vent clearance to

combustibles 0".

Step 3 - Combustion and Ventilation Air

• US: Section 9.3 of the NFPA 54/ANSI Z223.1-2006, Air for Combustion and Ventilation

• CANADA: Part 8 of the CAN/CSA-B149.1-05, Venting Systems and Air Supply for Appliances

Step 4 - Duct Systems

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

Step 5 - Acoustical Lining and Fibrous Glass Duct

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

Step 6 - Gas Piping and Gas Pipe Pressure Testing

• US: NFPA 54/ANSI Z223.1-2006; chapters 5, 6, 7, and 8 and

national plumbing codes.

• CANADA: CAN/CSA-B149.1-05 Parts 4, 5, and 6, A, B, E, G, and H.

In the state of Massachusetts:

• This product must be installed by a licensed plumber or gas fitter.

• When flexible connectors are used, the maximum length shall

not exceed 36 in. (914 mm)

• When lever type gas shutoffs are used they shall not exceed 36 in.

014 mm).

• The use of copper tubing for gas piping is not approved by the

state of Massachusetts.

Step 7 - Electrical Connections

• US: National Electrical (?ode (NEC) ANSI/NFPA 70-2008

• CANADA: Canadian Electrical (?ode CSA (722.1

Step 8 - Venting

• US: NFPA 54/ANSI Z223.1-2006 Chapters 12 and 13.

• CANADA: CAN/CSA-B149.1-05 Part 8 and Appendix C

MAX80°F (27° C)

INTRODUCTION

The model 58MTB 4-way multipoise, Gas-Fired, Category IV, condensing furnace is available in model sizes ranging from input

capacity of 60,000 to 120,000 Btuh as a direct vent (2-pipe)

application as well as a non-direct vent (1-pipe) application.

APPLICATIONS

FRONT

MIN 60°F (16o C)

Fig. 4 - Return-Air Temperature

A05004

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

UNIT DAMAGE HAZARD Failure to follow this caution may result in damage to unit

components. Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR

ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY'S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in

hand during grounding will be 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 (moving or shuffling feet, touching

ungrounded objects, etc.).

4. If you touch ungrounded objects, 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) may also be used to prevent ESD damage.

MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor property damage.

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling.

Step 1 - General

Some assembly and modifications are required for furnaces

installed in any of the 4 applications shown in Fig. 1. All drain

and pressure tubes are connected as shown in Fig. 6. See appropriate application instructions for these procedures.

Step 2 - Upflow Applications

In an upflow application, the blower is located below the burner section, and conditioned air is discharged upwards.

CONDENSATE TRAP LOCATION (FACTORY-SHIPPED ORIENTATION)

The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications. A factory-supplied

tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment. See Condensate

Trap Tubing (Factory-Shipped Orientation) section for drain tube extension details. (See Fig. 5.)

CONDENSATE TRAP TUBING (FACTORY-SHIPPED ORIENTATION)

NOTE: See Fig.6 or tube routing label on main furnace door to confirm location of these tubes.

1. Collector Box Drain, Inducer Housing Drain, Relief Port, and Pressure Switch Tubes

These tubes should be factory attached to condensate trap and pressure switch ready for use in upflow applications.

These robes can be identified by their connection location and also by a color label on each tube. These tubes are

identified as follows: collector box drain tube (blue label), inducer housing drain tube (violet label or molded), relief

port tube (green label), and pressure switch tube (pink label).

2. Condensate Trap Drain Tube The condensate trap drain connection must be extended

for field attachment by doing the following:

f. Determine location of field drain connection. (See Fig.

2 or 6)

NOTE: If internal filter or side Filter/Media Cabinet is used, drain tube should be located to opposite side of casing from

return duct attachment to assist in filter removal.

g. Remove and discard casing drain hole plug button

from desired side.

h. Install drain tube coupling grommet (factory-supplied

in loose parts bag) in selected casing hole.

i. Slide drain tube coupling (factory-supplied in loose

parts bag) through grommet ensuring long end of coupling faces blower.

BLOWERSRELF ACE ,--"CONDENSATE

,---CONDENSATE\ / TRAP

/TRAP(INSIDE) "k / FURNACE-7

\ / S,Dy

FIELD 261/4 1 /2

ALTERNATEDRAIN CONN TUBELOCATION

CONDENSATETRAP-- SIDE VIEW FRONT VIEW

DRAINTUBE LOCATION

UPFLOW APPLICATIONS EXTERNAL UPFLOW APPLICATIONS

DRAIN 667 mm 38 mm

DOWNFLOW AND ALTERNATE

SLOT oO SO2fW-7

11/2 3Smm /

71/8

__!/4 45 mm

GUIDES (WHEN USED)

181

RNACE

DOOR

102

FIELD

DRAIN

CONN

END VIEW FRONT VIEW

1/40D COLLECTOR BOX TO TRAP RELIEF PORT

1/2OD

INDUCER HOUSING

DRAIN CONNECTION

5/80D COLLECTOR BOX

DRAIN CONNECTION

SCREW HOLE FOR

UPFLOW OR DOWN-

FLOW APPLICATIONS

(OPTIONAL)

1/2-1N. PVC OR CPVC

-- FURNACE SIDE

146mm _4 146mm

26 /4 667mm 3/4 19mm

HORIZONTAL

APPLICATIONS

FRONT VIEW SIDE VIEW

Fig. 5 - Condensate Trap

j. Cement 2 factory-supplied 1/2-in. (13 mm) street CPVC

elbows to the rigid drain tube connection on the condensate trap. (See Fig. 6.) These elbows must be cemented together and cemented to condensate trap drain

connection.

NOTE: Failure to use CPVC elbows may allow drain to kink and prevent draining.

k. Connect larger diameter drain tube and clamp (factory

supplied in loose parts bag) to condensate trap and clamp securely.

1. Route tube to coupling and cut to appropriate length.

In. Attach tube to coupling and clamp securely. CONDENSATE TRAP LOCATION (ALTERNATE UPFLOW ORIENTATION)

An alternate location for the condensate trap is the left-hand side of casing. (See Fig. 2 and 7.)

NOTE: If the alternate left-hand side of casing location is used, the factory-connected drain and relief port tubes must be

disconnected and modified for attachment. See Condensate Trap Tubing (Alternate Upflow Orientation) section for tubing

attachment. To relocate condensate trap to the left hand side, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

A93026

CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury

or death. Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

4. Install condensate trap into left-hand side casing hole by inserting tube connection stubs through casing hole and

rotating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING (ALTERNATE

UPFLOW ORIENTATION) NOTE: See Fig.7 or tube routing label on main furnace door to

confirm location of these tubes.

1. Collector Box Drain Tube Connect collector box drain tube (blue label) to

condensate trap.

NOTE: On 17-1/2 in. (445 mm) wide furnaces ONLY, cut tube between corrugated sections to prevent kinks from occurring.

PLUG

CAP

COLLECTOR

DRAIN TUBE (BLUE

&WHITE STRIPED)

COLLECTOR

TUBE (PINK)

PLUG

COLLECTOR BOX

DRAIN TUBE (BLUE

&WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK) N

CAP

COLLECTOR BOX

TUBE (GREEN)

INDUCER

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR

DRAIN TUBE (BLUE)

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIE LD-INSTALLED FIELD- IN STALLED

FACTORY-SUPPLIED FACTORY-SUPPLIED

%-IN. (13 mm) CPVC STREET DRAIN TUBE

Fig. 6 - Factory-Shipped Upflow Tube Configuration

2. Inducer Housing Drain Tube

3. Relief Port Tube

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and procedures.

ELBOWS (2) FOR COUPLING (RIGHT

LEFT DRAIN OPTION DRAIN OPTION)

(Shown with Blower Access Panel Removed)

a. Remove and discard LOWER (molded) inducer

housing drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label

and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to the

condensate trap.

c. Determine appropriate length, cut, and connect tube.

d. Clamp tube to prevent any condensate leakage.

a. Connect relief port tube (green label) to

condensate trap.

b. Extend this tube (if required) by splicing to small

diameter tube (factory-supplied in loose parts bag).

c. Determine appropriate length, cut, and connect tube.

A01030

COLLECTOR BOX --

TUBE (GREEN)

COLLECTOR BOX --

DRAIN TUBE (BLUE)

O O

CONDENSATETRAP.,.-,.*,,,.b__

INDUCER J

HOUSING

DRAIN TUBE

(VIOLET)

A01031

Fig. 7 - Alternate Upflow Configuration and Trap Location

PRESSURE SWITCH TUBING

The LOWER collector box pressure tube (pink label) is factory connected to the High Pressure Switch and should not require

any modification.

NOTE: See Fig.6 or 7 or tube routing label on main furnace door to check for proper connections.

UPPER COLLECTOR BOX AND INDUCER HOUSING (UNUSED) DRAIN CONNECTIONS

Upper Collector Box Drain Connection Attached to the UPPER collector box drain connection is a

factory-installed corrugated, plugged tube (blue and white striped label). This tube is plugged to prevent condensate leakage in this

application. Ensure this tube is plugged.

NOTE: See Fig.6 or 7 or tube routing label on main furnace door to check for proper connections.

Upper Inducer Housing Drain Connection Attached to the UPPER (unused) inducer housing drain

connection is a cap and clamp. This cap is used to prevent condensate leakage in this application. Ensure this connection is capped.

NOTE: See Fig.6 or 7 or tube routing label on main furnace door to check for proper connections.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

Step 3 - Downflow Applications

In a downflow furnace application, the blower is located above the burner section, and conditioned air is discharged downwards.

CONDENSATE TRAP LOCATION

The condensate trap must be removed from the factory-installed blower shelf location and relocated in selected application

location as shown in Fig. 2, 8, or 9.

DRAIN TUBE (BLUE)

COLLECTOR

TUBE (GREEN)

COLLECTOR

EXTENSION TUBE

COLLECTOR

TUBE (PINK)

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX_

EXTENSION TUBE

TRAP

INDUCER HOUSING

DRAIN TUBE (VIOLET)

Fig. 8 - Downflow Tube Configuration

(Left-Hand Trap Installation)

A01023

O O

'DRAIN TUBE 8

COUPLING "_

Fig. 9 - Downflow Tube Configuration

(Right-Hand Trap Installation)

DRAIN TUBE (BLUE)

BOX

TUBE (PINK)

)R BOX

TUBE (GREEN)

)R BOX

EXTENSION TUBE

BOX DRAIN TUBE (BLUE & WHITE STRIPED)

)R BOX

EXTENSION TUBE INDUCER HOUSING

DRAIN TUBE

(VIOLET)

TRAP

)R BOX

EXTENSION DRAINTUBE

A01024

To relocate condensate trap from the blower shelf to desired location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2, 8, or 9.)

4. Install casing hole filler cap into blower shelf hole where trap was removed.

CARBON MONOXIDE POISONING HAZARD

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

Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

5. Install condensate trap into desired casing hole by inserting tube connection stubs through casing hole and

rotating until tabs snap into locking position.

CONDENSATE TRAP TUBING NOTE: See Fig. 8 or 9 or robe routing label on main fi_rnace

door to check for proper connections. Relocate robes as described below.

1. Collector Box Drain Tube

a. Remove factory-installed plug from LOWER collector

box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector

box drain tube (blue label) which was connected to condensate trap.

c. Connect LOWER collector box drain connection to

condensate trap.

(3.) Condensate Trap Located on Left Side of Casing

a. Connect LOWER collector box drain tube (blue

and white striped label) to condensate trap.

Tube does not need to be cut.

b. Clamp tube to prevent any condensate leakage.

(4.) Condensate Trap Located on Right Side of Casing

a. Install drain tube coupling (factory-supplied in

loose parts bag) into collector box drain tube (blue and white striped label) which was

previously plugged.

b. Connect larger diameter drain tube

(factory-supplied in loose parts bag) to drain tube coupling, extending collector box drain

tube for connection to condensate trap.

c. Route extended collector box drain tube

directly from collector box drain to condensate

trap as shown in Fig. 9. d. Determine appropriate length and cut. e. Connect to condensate trap.

f. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

d. Use inducer housing drain tube (violet label and

factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to the

condensate trap.

e. Connect inducer housing drain connection to

condensate trap.

(1.) Condensate Trap Located on Left Side of Casing

a. Determine appropriate length and cut.

b. Connect tube to condensate trap.

c. Clamp tube to prevent any condensate leakage.

(2.) Condensate Trap Located on Right Side of Casing

a. Route inducer housing drain tube (violet label)

directly from inducer housing to condensate trap as shown in Fig. 9.

b. Determine appropriate length and cut.

c. Connect tube to condensate trap.

d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and procedures.

PRESSURE SWITCH TUBING One collector box pressure tube (pink label) is factory connected

to the High Pressure Switch for use when furnace is installed in upflow applications. This tube MUST be disconnected and used

for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the

High Pressure Switch in DOWNFLOW or HORIZONTAL RIGHT applications

NOTE: See Fig. 8 or 9 or robe routing label on main furnace door to check for proper connections.

1. Disconnect collector box pressure tube (pink label) attached to High Pressure Switch.

2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port

connection by splicing to small diameter tube (factory-supplied in loose parts bag).

3. Connect collector box pressure tube (green label) to High Pressure Switch connection labeled COLLECTOR BOX.

4. Extend collector box pressure tube (pink label) which was previously connected to High Pressure Switch by splicing to remaining small diameter tube (factory-supplied in

loose parts bag).

5. Route this extended robe (pink label) to condensate trap relief port connection.

Determine appropriate length, cut, and connect tube.

7. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section

recommendations and procedures.

for

Step 4 - Horizontal Left (Supply-Air Discharge)

Applications

In a horizontal left furnace application, the blower is located to the right of the burner section, and conditioned air is discharged

to the left.

CONDENSATE TRAP LOCATION

The condensate trap must be removed from the factory-installed blower shelf location and relocated in selected application

location as shown in Fig. 2 or 10. To relocate condensate trap from the blower shelf to desired

location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

CARBON MONOXIDE POISONING HAZARD

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

Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

4. Install condensate trap into left-hand side casing hole by inserting tube connection stubs through casing hole and

rotating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING

NOTE: See Fig. 10 or tube routing label on main furnace door to check for proper connections.

1. Collector Box Drain Tube a. Install drain tube coupling (factory-supplied in loose

parts bag) into collector box drain tube (blue label) which was previously connected to condensate trap.

b. Connect large diameter drain tube and clamp

(factory-supplied in loose parts bag) to drain tube coupling, extending collector box drain tube.

c. Route extended tube (blue label) to condensate trap

and cut to appropriate length.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer

housing drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label

and factory-supplied in loose parts bag) to connect

LOWER inducer housing drain connection to the condensate trap.

c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage.

PLUG--

AUXILIARY

CONDENSATE

"J" BOX COLLECTORBOX

_t I CAP

TRAP

COLLECTC \ DRAINTUBE (VIOLET)

BOX EXTENSION \\

DRAINTUBE \_'- COLLECTOR BOX

COLLECTOR BOX

DRAINTUBE (BLUEAND WHITE STRIPED)

_ O

\ DRAINTUBE (BLUE)

EXTE.S,O. O E

DRAINTUBE COUPLING _

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040,060, AND 080 HEATING INPUT FURNACES

Fig. 10 - Horizontal Left Tube Configuration

COLLECTOR BOXTUBE (PINK)

UCER HOUSING

A01029

3. Relief Port Tube a. Extend collector box tube (green label) which was

previously connected to the condensate trap by splicing to small diameter tube (factory-supplied in loose parts

bag).

b. Route extended collector box pressure tube to relief

port connection on the condensate trap.

c. Determine appropriate length, cut, and connect tube.

d. Clamp tube to prevent any condensate leakage.

CONDENSATE TRAP FIELD DRAIN ATTACHMENTS

Refer to Condensate Drain section for recommendations and procedures. PRESSURE SWITCH TUBING

The LOWER collector box pressure tube (pink label) is factory connected to the High Pressure Switch for use when furnace is

installed in UPFLOW applications. This tube MUST be disconnected, extended, rerouted, and then reconnected to the

pressure switch in HORIZONTAL LEFT applications for 060 and 080 heating input furnaces.

NOTE: See Fig. 10 or tube routing label on main furnace door to check for proper connections. Modify tube as described below:

1. Disconnect collector box pressure tube (pink label)

attached to High Pressure Switch.

2. Use smaller diameter tube (factory-supplied in loose parts

bag) to extend tube disconnected in item 1.

3. Route extended tube: a. Behind inducer housing.

b. Between blower shelf and inducer housing.

4. Determine appropriate length, cut, and reconnect tube to High Pressure Switch connection labeled

COLLECTOR BOX.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

CONSTRUCT A WORKING PLATFORM Construct working platform where all required furnace clearances

are met. (See Fig. 3 and 11 or 12.)

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation.

The condensate trap MUST be installed below furnace. See Fig. 5 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (2 M)(See Table 13.)

NOTE: A 12-in. (305 mm) minimum offset pipe section is recommended with short (5 to 8 ft or 2 to 3 M)) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12 or 43.)

Step 5 - Horizontal Right (Supply-Air Discharge)

Applications

In a horizontal right furnace application, the blower is located to the left of the burner section, and conditioned air is discharged to

the right.

MAN1

SHUTOFF

GAS VALVE

SEDIMENT TRAP

COMBUSTION -

INTAKE

(146 mm)

CONDENSATE

TRAP

30" (762 mm)MIN

DRAIN

A 12-1N. (305 mm) MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH

SHORT (5 TO 8 FT / 1.5 TO 2.4 M) VENT SYSTEMS TO REDUCE EXCESSIVE

CONDENSATE DROPLETS FROM EXITING THE VENT PIPE.

ACCESS OPENING

FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.

Fig. 11 - Attic Location and Working Platform for Direct Vent (2-Pipe) Applications

MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor property damage.

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling.

NOTE: The auxiliary junction box (J-Box) MUST be relocated to opposite side of furnace casing. (See Fig. 13.) See Electrical

Connection section for J-Box relocation. CONDENSATE TRAP LOCATION

The condensate trap must be removed from the factory-installed blower shelf location and relocated in selected application

location as shown in Fig. 2 or 13. To relocate condensate trap from the blower shelf to desired

location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

A93031

CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury

or death. Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated to prevent combustion products being drawn in from appliances in the

equipment room.

4. Install condensate trap into right-hand side casing hole by inserting tube connection stubs through casing hole and

rotating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING

NOTE: See Fig. 13 or tube routing label on main furnace door to check for proper connections.

1. Collector Box Drain Tube: a. Remove factory-installed plug from LOWER collector

box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector

box drain tube (blue label) which was previously connected to condensate trap.

c. Connect LOWER collector box drain tube (blue and

white striped label) to condensate trap. Tube does not need to be cut.

d. Clamp tube to prevent any condensate leakage.

A 3-1N.(76mm) MINIMUM CLEARANCE TO COMBUSTION-AIR INTAKE

IS REQUIRED.

COMBUSTION

INTAKE

A 12-IN. (305mm) MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH

SHORT (5 TO 8 FT / 1.5 TO 2.4M) VENT CONDENSATE DROPLETS FROM

EXITING THE VENT PIPE.

30-1N.(762mm) MIN WORKAREA

IN. (146mm)

MAN[

SHUTOFF

GAS VALVE

SEDIMENT TRAP

DRAIN

CONDENSATE

ACCESS OPENING

FOR TRAP

TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.

Fig. 12 - Attic Location and Working Platform for Non-Direct Vent (1-pipe) Applications

TO REDUCE EXCESSIVE

A96184

2. Inducer Housing Drain Tube: a. Remove factory-installed cap and clamp from LOWER

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

d. Use inducer housing drain extension tube (violet label

and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to

condensate trap.

e. Determine appropriate length, cut, and connect tube to

condensate trap.

f. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube:

Refer to Pressure Switch Tubing section for connection procedure.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT Refer to Condensate Drain section for recommendations

and procedures. PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to the High Pressure Switch for use when furnace is installed in

UPFLOW applications. This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector

box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the High Pressure Switch in DOWNFLOW or HORIZONTAL

RIGHT applications.

NOTE: See Fig. 12 or tube routing label on main furnace door to check for proper connections. Relocate tubes as described below.

1. Disconnect collector box pressure tube (pink label) attached to High Pressure Switch.

2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port

connection by splicing to small diameter tube (factory-supplied in loose parts bag).

3. Connect collector box pressure tube (green label) to High

Pressure Switch connection labeled COLLECTOR BOX.

4. Use remaining smaller diameter tube (factory-supplied in

loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to High Pressure Switch. Route this extended tube (pink label) to

condensate trap relief port connection.

5. Determine appropriate length, cut, and connect tube.

6. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

CONSTRUCT A WORKING PLATFORM

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 11 or 12.)

PLUG

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAINTUBE(VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 13 - Horizontal Right Tube Configuration

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TU BE (GREEN)

BOX EXTENSION TUBE

COLLECTOR BOXTUBE (PINK)

"J" BOX RELOCATED HERE

TRAP

A01028

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation.

The condensate trap MUST be installed below furnace. See Fig. 5 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: Combustion-air pipe (when applicable) and vent pipe(s) are restricted to a minimum length of 5 ft. (2 M). (See Table 13.)

NOTE: A 12-in. (305 mm) minimum offset pipe section is recommended with short (5 to 8 ft or 2 to 3 M) vent systems. This

recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12 or 43.)

LOCATION

Step 1 - General

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 (refer to SAFETY CONSIDERATIONS).

• be located so combustion-air and vent pipe maximum lengths are not exceeded. Refer to Table 13.

• be located where available electric power and gas supplies meet specifications on the furnace rating plate.

• be attached to an air distribution system and be located as close to the center of the distribution system as possible. Refer to Air

Ducts section.

• be provided with ample space for servicing and cleaning. Always comply with minimum fire protection clearances

shown on the furnace clearance to combustibles label.

NOTE: For upflow/downflow applications install furnace so that it is level or pitched forward within 1/2-in. (13 mm) for proper furnace operation. For horizontal applications pitch 1/4-in. (6 mm) minimum to 1/2-in. (13 mm) maximum forward to ensure proper condensate drainage from secondary heat exchangers. (See Fig. 14.)

When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the

furnace, return air must also be handled by ducts sealed to furnace casing. The ducts terminate outside the space containing

the furnace to ensure a negative pressure condition will not occur within equipment room or space.

FIRE, INJURY OR DEATH HAZARD

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

Do not install furnace on its back. (See Fig. 15.) Safety control operation will be adversely affected. Never connect return-air

ducts to back of furnace.

UPFLOW OR DOWNFLOW

F FRONT

I_"MAX

(6to13mm)

HORIZONTAL

A02146

Fig. 14 - Proper Condensate Drainage

UNIT DAMAGE HAZARD

This gas fllmace may be used for construction heat provided that:

-The furnace is permanently installed with all electrical

wiring, piping, air filters, 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 firing 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.

- After construction is complete, verify furnace operating

conditions including ignition, input rate, temperature rise and venting, according to the manufacturer's instructions.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in minor property or unit damage.

If this furnace is installed in an unconditioned space where the ambient temperatures may be 32°F (0°C)or lower, freeze protection measures must be taken. (See Fig. 16.)

BACK

A93043

Fig. 15 - Prohibit Installation on Back

Step 3 - Hazardous Locations

FIRE, EXPLOSION, INJURY OR DEATH HAZARD

Improper location or inadequate protection could result in fire or explosion.

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 in.

(457 mm) above the floor. The furnace must be located or protected to avoid physical 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 current edition of the NFGC or NSCNGPIC. (See Fig. 17.)

Step 4 Furnace Location and Application

DIRECT VENT (2-PIPE) APPLICATION

Furnace may be located in a confined space without special provisions for dilution or ventilation air.

Step 2 - Furnace Location Relative to Cooling

Equipment

The cooling coil must be installed parallel with or on downstream side of furnace to avoid condensation in heat exchanger. When installed parallel with a furnace, dampers or other means used to

control flow of air shall be adequate to prevent chilled air from entering furnace. If dampers are manually operated, they must be equipped with a means to prevent operation of either unit unless

the damper is in full-heat or full-cool position.

32° F/0 ° C MINIMUM INSTALLED AMBIENT OR FREEZE

PROTECTION REQUIRED

A07911

Fig. 16 - Freeze Protection

18-1N.(457.2mm)

MINIMUMTOBURNERS

A93044

Fig. 17 - Installation in a Garage

NON-DIRECT VENT (1-PIPE) APPLICATION

UNIT DAMAGE HAZARD Failure to follow this caution may result in intermittent

unit operation. Do not install furnace in a corrosive or contaminated

atmosphere. Make sure all combustion and circulating air

requirements are met.

Refer to the AIR FOR COMBUSTION AND VENTILATION section for details.

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air

must be provided in accordance with:

• U.S. Installations: Section 9.5 of the NFPA 54/ANSI Z223.1-2006, Air for Combustion and Ventilation and

applicable provisions of the local building codes.

• Canadian Installations: Part 8 of the CAN/CSA-B149.1-05, Venting Systems and Air Supply for Appliances and all

authorities having jurisdiction.

FURNACE CORROSION HAZARD Failure to follow this warning could result in reduced furnace

component life. Air for combustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and iodide. These elements could 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.

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.

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 the Carbon Monoxide Poisoning Hazard warning in the 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

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.

Fig. 18 illustrates how to provide TWO OUTDOOR

OPENINGS, one inlet and one outlet combustion and

ventilation air openings to the outdoors.

a. One opening MUST commence within 12 in.(305 mm)

of the ceiling and the second opening MUST commence within 12 in. (305 mm) of the floor.

b. Size openings and ducts per Fig. 18 and Table 1. c. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btt h (1,100 mm /kW) of combined input for all gas appliances in the space per Fig. 18 and

Table 1.

Table1 - Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

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

FURNACE (1SQ. INJ2,000 BTUH)(1,100SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/K3/V) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

INPUT Free Area of Round Duct Free Area of Opening Round Duct Free Area of Opening Round Duct

(BTUH) Opening and Duct Dia. and Duct Dia. and Duct Dia.

44,000 22 (14194) 6 (152) 14.7 (9494) 5 (127) 11 (7097) 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 (17741) 6 (152) 132,000 66 (42581) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (198) 154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24838) 8 (203)

EXAMPLE: 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

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

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) (148.6) (93.4) (140.1) (186.8) (233.6) (280.3) (327.0)

O.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

d. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch of free area per 4,000 Btuh (550 mm2/kW) for combined input of all gas appliances in the space per Fig. 18 and Table 1.

3. ONE OUTDOOR OPENING requires: a. 1 square inch of free area per 3,000 Btuh (734 mm2/kW)

for combined input of all gas appliances in the space per Table 1 and 13.

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

connectors in the space. The opening shall commence within 12 in. (305 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. (152 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.

CARBON MONOXIDE POISONING HAZARD Failure to supply outdoor air via grilles or ducts 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.

Sq. In. (mm) In. (mm) Sq. In (mm) In. (mm) Sq. In (mm) In. (mm)

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

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

30 ! 40 ! 50 44 ! 66 ! 88 ! 110 ! 132 ! 154

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 5,250 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

Standard and Known-Air-Infiltration Rate Methods

Indoor combustion air is permitted for combustion, ventilation,

and dilution, if the Standard or Known-Air-Infiltration Rate

Method is used. The Standard Method:

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

installed in the space and

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

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of

ACH and shall be determined per Table 2 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 2 - Minimum Space Volumes were determined by using

the following equations from the National Fuel Gas Code ANSI

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

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