Carrier 58MXA 170 Series Installation, Start-up, And Operating Instructions Manual

0 (0)

Deluxe 4–Way Multipoise Fixed-Capacity

Direct Vent Condensing Gas Furnace

Visit www.carrier.com

Installation, Start-Up, and Operating Instructions

Sizes 040-140, Series 170

Condensate Trap Freeze Protection..................................11

Construct a Working Platform..........................................11

Horizontal Right (Supply-Air Discharge)

Applications ............................................................................11

Condensate Trap Location ................................................11

Condensate Trap Tubing...................................................11

Condensate Trap Field Drain Attachment........................13

Pressure Switch Tubing.....................................................13

Condensate Trap Freeze Protection..................................13

Construct a Working Platform..........................................13

LOCATION..................................................................................13

General....................................................................................13

A93040

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

This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

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

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

CODES AND STANDARDS........................................................3

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........5

APPLICATIONS............................................................................6

General......................................................................................6

Upflow Applications.................................................................6

Condensate Trap Location (Factory-Shipped

Orientation)..........................................................................6

Condensate Trap Tubing (Factory-Shipped

Orientation)..........................................................................6

Condensate Trap Location (Alternate Upflow

Orientation)..........................................................................6

Condensate Trap Tubing (Alternate Upflow

Orientation)..........................................................................6

Condensate Trap Field Drain Attachment..........................7

Pressure Switch Tubing.......................................................7

Upper Collector Box and Inducer Housing

(Unused) Drain Connections...............................................7

Condensate Trap Freeze Protection....................................7

Downflow Applications............................................................8

Condensate Trap Location ..................................................8

Condensate Trap Tubing.....................................................8

Condensate Trap Field Drain Attachment..........................9

Pressure Switch Tubing.......................................................9

Condensate Trap Freeze Protection..................................10

Horizontal Left (Supply-Air Discharge)

Applications ............................................................................10

Condensate Trap Location ................................................10

Condensate Trap Tubing...................................................10

Condensate Trap Field Drain Attachments ......................11

Pressure Switch Tubing.....................................................11

Furnace Location Relative to Cooling

Equipment ...............................................................................14

Hazardous Locations...............................................................14

INSTALLATION.........................................................................15

Leveling Legs (If Desired).....................................................15

Installation in Upflow and Downflow

Applications ............................................................................15

Installation in Horizontal Applications..................................16

Air Ducts.................................................................................17

General Requirements .......................................................17

Ductwork Acoustical Treatment .......................................17

Supply Air Connections....................................................17

Return Air Connections.....................................................17

Filter Arrangement..................................................................18

Bottom Closure Panel.............................................................19

Gas Piping...............................................................................19

Electrical Connections............................................................20

115–v Wiring.....................................................................20

24–v Wiring.......................................................................22

Accessories ........................................................................22

Direct Venting.........................................................................22

Removal of Existing Furnaces from Common

Vent Systems.....................................................................22

Combustion-Air and Vent Piping .....................................22

Vent Extension Pipe..........................................................27

Concentric Vent and Combustion-Air

Termination Kit Installation..............................................29

Multiventing and Vent Terminations................................33

Condensate Drain....................................................................34

General...............................................................................34

Application.........................................................................34

Condensation Drain Protection .........................................35

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

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

Prime Condensate Trap With Water......................................36

Purge Gas Lines......................................................................37

Sequence of Operation............................................................37

Heating Mode....................................................................37

Cooling Mode....................................................................40

Thermidistat Mode ............................................................40

Continuous Blower Mode .................................................41

58MXA

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4 Tab 6a 8a

PC 101 Catalog No. 535–80136 Printed in U.S.A. Form 58MXA-17SI Pg 1 9-04 Replaces: 58MXA-16SI

Heat Pump Mode...............................................................41

Component Test.................................................................41

Adjustments.............................................................................42

Set Gas Input Rate ............................................................42

Set Temperature Rise........................................................48

Adjust Blower Off Delay (Heat Mode)............................49

Set Thermostat Heat Anticipator ......................................49

Check Safety Controls............................................................49

Check Primary Limit Control ...........................................49

Check Pressure Switch......................................................49

Checklist..................................................................................50

AIRFLOW

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

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

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

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply.

These instructions cover the minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

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

UPFLOW

HORIZONTAL

RIGHT

AIRFLOW

HORIZONTAL

LEFT

DOWNFLOW

AIRFLOW

Fig. 1—Multipoise Orientations

SAFETY CONSIDERATIONS

UNIT 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.

A93041

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 and gloves when handling parts.

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 these signal words: DANGER, WARNING, CAUTION, and NOTE. 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.

The 58MXA Multipoise Condensing Gas-Fired Furnaces are C.S.A. (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. The furnace is factory-shipped for use with natural gas. A C.S.A. listed gas conversion kit is required to convert furnace for use with propane gas.

See Fig. 3 for required clearances to combustibles. Maintain a 1-in. clearance from combustible materials to supply air

ductwork for a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code for further requirements.

CODES AND STANDARDS

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

The 58MXA 040 through 120 size units are C.S.A. design-certified for use in manufactured (mobile) homes when factory accessory conversion kit is used. The 140 size unit is NOT design-certified for use in manufactured (mobile) homes. These furnaces are suitable for installation in a structure built on site or a manufactured building completed at final site. The design of this furnace line is NOT C.S.A. design-certified for installation in recreation vehicles or outdoors.

This furnace is designed for continuous return-air minimum temperature of 60 °F db or intermittent operation down to 55°F db such as when used with a night setback thermometer. Return-air temperature must not exceed 85°F db. Failure to follow these return air limits may affect reliability of heat exchangers, motors and controls. (See Fig. 4.)

These furnaces are 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.

This furnace must be installed with a direct-vent (combustion air and flue gas) system and a factory accessory termination kit. In a direct-vent system, all air for combustion is taken directly from the outdoor atmosphere and flue gases are discharged to the outside atmosphere. See furnace and factory accessory vent-air intake termination kit instructions for proper installation.

These furnaces are 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 Vent and combustion-air pipe support 2 Condensate trap hole filler plug 3 Vent and combustion-air intake hole filler plug 2 Combustion-air pipe perforated disk assembly 1

Vent Pipe Extension 1*

* ONLY supplied with some furnaces.

For accessory installation details, refer to accessory installation instructions.

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 Gas Code (NFGC) NFPA 54-2002/ANSI Z223.1-2002 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) CAN/CGA -B149,1

-and.2 M-00

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

• CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada.

Step 3—Combustion and Ventilation Air

• US: Section 5.3 of the NFGC, Air for Combustion and Ventilation

• CANADA: Part 7 of the NSCNGPIC, 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 American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34.

Step 5—Acoustical Lining and Fibrous Glass Duct

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

Step 6—Gas Piping and Gas Pipe Pressure Testing

• US: NFGC; chapters 2, 3, 4, and 9 and national plumbing codes

→

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 inches.

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

• CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E, and H.

Step 7—Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70-2002

• CANADA: Canadian Electrical Code CSA C22.1

INTRODUCTION

The model 58MXA 4-way multipoise, Gas-Fired, Category IV, direct-vent condensing furnace is available in model sizes ranging in input capacities of 40,000 to 138,000 Btuh.

⁄

A02149

⁄

19"

⁄

OUTLET

⁄

AIRFLOW

2-IN. COMBUSTION-

⁄

TYP

TRAP LOCATION

⁄

CONDENSATE DRAIN

OUTLET

⁄2-IN. DIA

GAS CONN

AIR CONN

(DOWNFLOW &

OR ALTERNATE

-IN. DIA GAS CONN

⁄

HORIZONTAL RIGHT)

⁄8-IN. DIA

POWER CONN

⁄2-IN. DIA

THERMOSTAT ENTRY

⁄

2-IN. VENT CONN

⁄

SIDE INLET

⁄

" TYP

⁄

(UPFLOW)

BOTTOM INLET

HANGING

CONDENSATE

DRAIN LOCATION

FOR HORIZONTAL

DIMPLE LOCATORS

⁄

-in. rectangle.

INLET

x 19

x 23

x 12-in. rectangle.

return air openings for airflow requirements above 1800 CFM at 0.5 W.C. ESP.

Dimensions (in.)

Fig. 2—Dimensional Drawing

040-08 17-1/2 15-7/8 16

040-12 17-1/2 15-7/8 16

060-08 17-1/2 15-7/8 16

060-12 17-1/2 15-7/8 16

060-16 17-1/2 15-7/8 16

080-12 17-1/2 15-7/8 16

080-16 17-1/2 15-7/8 16

080-20 21 19-3/8 19-1/2

100-16 21 19-3/8 19-1/2

100-20 21 19-3/8 19-1/2

120-20 24-1/2 22-7/8 23

UNIT SIZE A D E

140-20 24-1/2 22-7/8 23

⁄

⁄8-IN. DIA

CONDENSATE DRAIN

TRAP LOCATION

(DOWNFLOW &

HORIZONTAL LEFT)

⁄

-IN. COMBUSTION2

AIR CONN

POWER CONN

-IN. DIA

⁄

GAS CONN

-IN. VENT CONN 2

⁄

TYP

⁄

TYP

⁄

TYP

⁄

TYP

⁄

TYP

LOCATION

(ALTERNATE

UPFLOW)

SIDE INLET

⁄

TYP

CONDENSATE

DRAIN TRAP

⁄8-IN. DIA

ACCESSORY

POWER ENTRY

ENTRY

⁄

⁄2-IN. DIA THERMOSTAT

CONDENSATE

⁄

DRAIN LOCATION

(UPFLOW)

" TYP

⁄

SIDE INLET

1" E

c. For 1600 CFM–22-in. round or 14

b. For 1200 CFM–20-in. round or 14

see flex duct manufacturer’s recommendations for equivalent diameters.

a. For 800 CFM–16-in. round or 14

2. Minimum return-air opening at furnace:

NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,

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

d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data

This forced air furnace 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 ft.

INSTALLATION

(0 - 2,135m). 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 in a manufactured (mobile) home when stated on rating plate and using factory authorized kit.. This furnace may be installed on combustible flooring in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below. This furnace requires a special venting system. Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC, PVC-DWV, CPVC, or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).

Cette fournaise à air pulsé est équipée pour utilisation avec gaz naturel et altitudes comprises entre 0 - 3,050m (0 - 10,000 pi),excepté queles fournaises de 140 taille sont pour altitudes comprises entre 0 - 2,135m (0 - 7,000pi). Utiliser une trousse de conversion, fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz naturel. Cette fournaise à air pulsé est pour installation à l´intérieur dans un bâtiment construit sur place. Cette fournaise à air pulse peut être installée dans une maison préfabriquée (maison mobile) si prescrit par la plaque signalétique et si l' on utilise une trousse specifiée par le fabricant. Cette fournaise peut être installée sur un plancher combustible dans un enfoncement ou un placard en observant les Dégagement Minimum En Pouces Avec

Éléments De Construction Combustibles.

Cette fournaise nécessite un système d´évacuation spécial. La méthode d´installation et la liste des pièces nécessaires figurent dans les instructions d´installation. Cette fournaise doit s´utiliser avec la tuyauterie des nomenclatures 40 PVC, PVC-DWV, CPVC, ou ABS-DWV et elle ne peut pas être ventilée conjointment avec d´autres appareils à gaz. Épaisseur de la construction au travers de laquelle il est possible de faire passer les tuyaux d'aération (admission/évacuation): 24 po (600 mm) maximum, 3/4 po (19mm) minimum (y compris la toiture).

For upflow and downflow applications, furnace must be installed level, or pitched within 1/2" of level. For a horizontal application, the furnace must be pitched minimum 1/4" to maximum of 1/2" forward for proper drainage. See Installation Manual for IMPORTANT unit support details on horizontal applications.

Pour des applications de flux ascendant et descendant, la fournaise doit être installée de niveau ou inclinée à pas plus de 1/2" du niveau. Pour une application horizontale, la fournaise doit être inclinée entre minimum 1/4" et maximum 1/2" du niveau pour le drainage approprié. En cas d´installation en position horizontale, consulter les renseignements IMPORTANTS sur le support dans le manuel d´installation.

LEVEL (0") TO

1/2" MAX

UPFLOW OR DOWNFLOW

FRONT

MIN 1/4" TO 1/2" MAX

FRONT

HORIZONTAL

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSITIONS:

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

†

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

DOWNFLOW POSITIONS:I

†

For installation on combustible floors only when installed on special base No. KGASB0201ALL, Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

HORIZONTAL POSITIONS::

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

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS DE CONSTRUCTION COMBUSTIBLES

POUR TOUS LES POSITIONS:U

Dégagement avant minimum de 610mm (24 po) pour l´entretien.

Pour les fournaises de 140 taille, 1 po (25mm) dégagement des matériaux combustibles est

†

requis au-arriere.

POUR LA POSITION COURANT DESCENDANT:

†

Pour l´installation sur le plancher combustible seulement quand on utilise la base spéciale, pièce nº KGASB0201ALL, l pièce nº KCAKC.

POUR LA POSITION HORIZONTALE:

Le contact n deuxcôtés de la chemise de la fournaise, et des solives, des montants ou de la charpente du bátiment. La distance indiquée concerne l

air.

Pour les fournaises de 120 et 140 taille, 1 po (25mm) dégagement des matériaux combusitbles est requis au-dessous.

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

est permis qúentre les lignes formées par les intersections du dessus et des

extrémité du tuyau d´arrivée d´air et l´extrémité du tuyau de sortie

→

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

UNIT DAMAGE HAZARD

→

Failure to follow this caution may damage furnace 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.

Fig. 3—Clearances to Combustibles

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

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

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

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

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

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

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

Clearance arrows do not change with furnace orientation.

†

Clearance in inches Dégagement (po).

Les fléches de dégagement

ne change pas avec

générateur d´air chaud.

TOP/PLENUM

DESSUS/CHAMBRE D´AIR

BOTTOM

†

DESSOUS

Vent clearance to combustibles 0".

0 (po) Dégagement

d´évent avec combustibles.

orientation de la

328066-201 REV. B LIT TOP

MIN

A04110

A93042

Fig. 4—Return-Air Temperature

controls into containers before touching ungrounded objects.

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

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.

APPLICATIONS

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

An upflow furnace application is where furnace blower is located below combustion and controls section of furnace, 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 tubes 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:

a. 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.

b. Remove and discard casing drain hole plug button from

desired side.

c. Install drain tube coupling grommet (factory-supplied in

loose parts bag) in selected casing hole.

d. Slide drain tube coupling (factory-supplied in loose parts

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

e. Cement 2 factory-supplied 1/2-in. 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.

f. Connect larger diameter drain tube and clamp (factory-

supplied in loose parts bag) to condensate trap and clamp

securely. g. Route tube to coupling and cut to appropriate length. h. 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.

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.

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.

BLOWER SHELF

CONDENSATE TRAP (INSIDE)

ALTERNATE DRAIN TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

FURNACE DOOR

FIELD

DRAIN

CONN

EXTERNAL UPFLOW APPLICATIONS

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

WIRE TIE GUIDES (WHEN USED)

CONDENSATE TRAP

FURNACE

SIDE

FURNACE DOOR

FIELD

DRAIN

CONN

FURNACE SIDE

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

⁄4 OD COLLECTOR BOX TO TRAP RELIEF PORT

⁄2 OD INDUCER HOUSING DRAIN CONNECTION

⁄8 OD COLLECTOR BOX DRAIN CONNECTION

SCREW HOLE FOR UPFLOW OR DOWNFLOW APPLICATIONS (OPTIONAL)

⁄2-IN. PVC OR CPVC

HORIZONTAL

APPLICATIONS

FRONT VIEW SIDE VIEW

Fig. 5—Condensate Trap

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

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

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.

3. Relief Port Tube 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.

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

procedures.

A93026

PRESSURE SWITCH TUBING The LOWER collector box pressure tube (pink label) is factory

connected to the 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 recommenda-

tions and procedures.

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄2-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE TRAP

DRAIN TUBE

DRAIN OPTION)

A94163

Fig. 6—Factory-Shipped Upflow Tube

Configuration (Shown with Blower Access Panel

Removed)

Step 3—Downflow Applications

A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, 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.

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.

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

CONDENSATE

TRAP

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

Fig. 7—Alternate Upflow Configuration and Trap

Location

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.

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 tube routing label on main furnace door

to check for proper connections. Relocate tubes 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 con-

densate trap. (1.) 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.

A94164

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX EXTENSION TUBE

CONDENSATE

TRAP

INDUCER HOUSING

DRAIN TUBE (VIOLET)

DRAIN TUBE COUPLING

PLUG CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (PINK)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED)

COLLECTOR BOX EXTENSION TUBE

INDUCER HOUSING DRAIN TUBE (VIOLET)

CONDENSATE TRAP

COLLECTOR BOX EXTENSION DRAIN TUBE

A94165

Fig. 8—Downflow Tube Configuration (Left-Hand

Trap Installation)

(2.) 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.

A94166

Fig. 9—Downflow Tube Configuration (Right-Hand

Trap Installation)

(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 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 pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications. NOTE: See Fig. 8 or 9 or tube routing label on main furnace door to check for proper connections.

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

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).

AUXILIARY "J" BOX

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040, 060, AND 080 HEATING INPUT FURNACES

Fig. 10—Horizontal Left Tube Configuration

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

4. Extend collector box pressure tube (pink label) which was previously connected to pressure switch by splicing to remaining small diameter tube (factory-supplied in loose parts bag).

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

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

7. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda-

tions and procedures.

Step 4—Horizontal Left (Supply-Air Discharge) Applications

A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace, 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.

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

CARBON MONOXIDE POISONING HAZARD

→

Failure to follow this warning could result in personal injury or death. Casing filler cap must be installed in blower shelf hole when condensate trap is relocated.

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.

COLLECTOR BOX TUBE (GREEN)

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOX DRAIN TUBE (BLUE)

A00215

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.

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

ously 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 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.

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 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. c. Behind inducer motor bracket. d. Between inducer motor and pressure switch.

4. Determine appropriate length, cut, and reconnect tube to pressure switch connection labeled COLLECTOR BOX.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda-

tions and procedures. CONSTRUCT A WORKING PLATFORM

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

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. (See Table 7.)

NOTE: A 12-in. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11 or 34.)

Step 5—Horizontal Right (Supply-Air Discharge) Applications

A horizontal right furnace application is where furnace blower is located to the left of combustion and controls section of furnace, and conditioned air is discharged to the right.

PROPERTY DAMAGE

NOTE: In Canada, installations shall be in accordance with current NSCNGPIC Installation Codes and/or local codes.

NOTE: The junction box (J-Box) MUST be relocated to opposite side of furnace casing. (See Fig. 12.) 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 12.

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 when condensate trap is relocated.

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. 12 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.

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

inducer housing drain connection.

MANUAL

SHUTOFF

GAS VALVE

COMBUSTION – AIR

SEDIMENT TRAP

INTAKE

⁄

″

CONDENSATE TRAP

VENT

30″ MIN WORK AREA

DRAIN

A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) 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

CAP

PLUG

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

A93031

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

AUXILARY “J” BOX RELOCATED HERE

CONDENSATE TRAP

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 12—Horizontal Right Tube Configuration

A00214

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 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 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 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. Route extended collector box pressure tube behind inducer motor bracket then between inducer motor and pressure switch.

4. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.

5. Use remaining smaller diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch.

6. Route this extended tube (pink label) to condensate trap relief port connection.

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

8. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda-

tions and procedures. CONSTRUCT A WORKING PLATFORM

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

UNIT MAY NOT OPERATE

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 7.)

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 7.

• 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.

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

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 ducts sealed to furnace casing. The ducts terminate outside the space containing the furnace to ensure there will not be a negative pressure condition within equipment room or space.

LEVEL (0″)

⁄2″ MAX

UPFLOW OR DOWNFLOW HORIZONTAL

FRONT

MIN

⁄2″ MAX

⁄4″

FRONT

A02146

Fig. 13—Furnace Location for Proper Condensate

Drainage

NOTE: For upflow/downflow applications install furnace so that

it is level or pitched forward within 1/2-in. for proper furnace operation. For horizontal applications pitch 1/4-in. minimum to 1/2-in. maximum forward to ensure proper condensate drainage from secondary heat exchangers. (See Fig. 13.)

FRONT

BACK

B A C K

FRONT

Fig. 14—Prohibit Installation on Back

FIRE HAZARD

→

Failure to follow this warning could result in fire of designed unit operation injury, or death. Do not install furnace on its back. Safety control operation will be adversely affected. Never connect return-air ducts to back of furnace. (See Fig. 14.)

→

UNIT DAMAGE HAZARD

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

-The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame 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 no less than 55°F, 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.

A93043

18-IN. MINIMUM

TO BURNERS

Fig. 16—Installation in a Garage

UNIT DAMAGE HAZARD

Failure to follow this caution may result in minor property or unit damage. If furnace is installed in an unconditioned space where the ambient temperatures may be 32°F or lower, freeze protection measures must be taken. (See Fig. 15.)

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

Step 3—Hazardous Locations

32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED

Fig. 15—Freeze Protection

A93044

A93058

FIRE, EXPLOSION, INJURY OR DEATH HAZARD

→

Improper location or inadequate protection could result in fire or explosion. When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18 in. above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with NFGC or NSCNGPIC. (See Fig. 16.)

INSTALLATION

Step 1—Leveling Legs (If Desired)

When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 17.) Install field-supplied, corrosion-resistant 5/16-in. machine bolts and nuts.

⁄16″

1. Determine application being installed from Table 1.

2. Construct hole in floor per dimensions specified in Table 1 and Fig. 18.

3. Construct plenum to dimensions specified in Table 1 and Fig.

18.

4. If downflow subbase (KGASB) is used, install as shown in Fig. 19. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No. KCAKC is used, install as shown in Fig. 20.

PLENUM

OPENING

⁄16″

1 3⁄4″

⁄4″

⁄16″

⁄4″

1 3⁄4″

A89014

Fig. 17—Leveling Legs

NOTE: The maximum length of bolt should not exceed 1-1/2 in.

1. Position furnace on its back. Locate and drill a 5/16–in. diameter hole in each bottom corner of furnace. (See Fig. 17.) Holes in bottom closure panel may be used as guide locations.

2. For each hole, install nut on bolt and then install bolt and nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.

NOTE: Bottom closure must be used when leveling legs are used. See Bottom Closure Panel section.

Step 2—Installation in Upflow and Downflow Applications

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when special base (available from manufacturer) Part No. KGASB0201ALL is used. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is used.

FLOOR

OPENING

A96283

Fig. 18—Floor and Plenum Opening Dimensions

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 19—Furnace, Plenum, and Subbase Installed

on a Combustible Floor

NOTE: Remove furnace perforated, discharge duct flanges when

they interfere with mating flanges on coil on downflow subbase. To remove furnace perforated, discharge duct flange, use wide

FURNACE

CASING

WIDTH

17-1/2

24-1/2

Table 1—Opening Dimensions (in.)

APPLICATION

Upflow Applications 16 24–1/8 16–5/8 24–3/4

Downflow Applications on Non-Combustible Flooring 15-7/8 19 16-1/2 19-5/8

Downflow Applications on Combustible Flooring Using

KGASB Subbase