Carrier 58PHA-PHX User Manual

58PHA/PHX Performance Boost 80 4 --- Wa y M u l ti p o ise Induced---Combustion Gas Furnace Input Capacities: 45,000 thru 135,000 Btuh

Installation, Start---up, Operating and

Service and Maintenance Instructions Series 100/A

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

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

CODES AND STANDARDS 4..........................

Safety 4........................................

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

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

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

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

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

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

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

ELECTROSTATIC DISCHARGE PRECAUTIONS

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

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

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

Upflow Installation 10..............................

Downflow Installation 11...........................

Horizontal Installation 13...........................

Filter Arrangement 14..............................

Air Ducts 14.....................................

Gas Piping 17....................................

115--V Wiring 22..................................

START--UP, ADJUSTMENT, AND SAFETY CHECK 36.....

General 36.......................................

Start--up Procedures 36.............................

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

Check Safety Controls 39...........................

Checklist 40......................................

SERVICE AND MAINTENANCE PROCEDURES 43.......

Introduction 43...................................

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

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

Wiring Diagrams 51...............................

Troubleshooting 51................................

ama

ISO 9001:2000

CERTIFIED

REGISTERED

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

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1--2006E, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject, which is represented only by the standard in its entirety.

(FLUE COLLAR)

(

7/8" DI A

ACCESSORY

(664mm)

26-1/8"

(22mm)

5-15/16" (135mm)

33-5/16"

(846mm)

(733mm)

28-7/8"

(641mm)

25-1/4"

22-9/16"

(573mm)

JUNCTION BOX LOCATION

1/2" (13 mm) DIA.

THERMOSTAT WIRE ENTRY

3-15/16" (84mm) LEFT HAND GAS

ENTRY

7/8" (22mm) DIA. ACCESSORY

24-7/8"

(632mm)

13/16"

(21mm)

4-13/16"

(122mm)

8-9/16"

(217mm)

ALTERNA T E

JUNCTION BOX

LOCATIONS (TYP)

VENT OUTLE T

5 PLACES (TYP)

(140mm)

5-1/2"

2-7/16" (62mm)

1-5/16" (33mm)

1-1/8"

(29mm)

AIRFLOW

19"

(483mm)

OUTLE T

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

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

(22mm)

7/8" DIA. ACCESSORY

(22mm)

(13mm)

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

(44mm)

13/16"

(21mm)

11/16"

(17mm)

14-7/8"

(378mm)

7-3/4"

(197mm)

9-5/8"

(244mm)

11-1/2"

(292mm)

11/16"

(17mm)

58PHA

NOTES:

1. Two additional 7/8 ---in. (22 mm) diameter holes are located in the top plate.

2. Minimum return ---air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a. For 800 CFM ---16 ---in. (406 mm) round or 14 1/2 x 12 ---in. (368 x 305 mm) rectangle. b. For 1200 CFM--- 20 ---in. (508 mm) round or 14 1/2 x 19 1/2 ---in. (368 x 495 mm) rectangle. c. For 1600 CFM--- 22 ---in. (559 mm) round or 14 1/2 x 22 1/16 ---in. (368 x 560mm) rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both sideinlets,a combination of 1 side and the bottom, or the bottom only will ensure a dequate return air openings for airflow requiremen ts above 1800 CFM.

(549mm)

21-5/8"

BOTTOM INLE T

24"

CASING

610mm)

1-11/16" (43mm)

5-1/2"

(140mm)

11/16"

(17mm)

3-3/4"

(95mm)

1-1/2"

(560mm) 22-1/16"

SIDE INLE T

(38mm)

1-1/4"

(32mm)

(25mm)

Fig. 1 -- Dimensional Drawing

Table1–Dimensions

C.L. TOP AND

BOTTOM FLUE

COLLAR

IN. (MM)

FLUE

COLLAR*

IN. (MM)

SHIP WT (LB / KG)

FURNACE SIZE

CABINET

WIDTH

IN. (MM)

SUPPLY--- AIR

WIDTH

IN. (MM)

RETURN--- AIR

WIDTH

IN. (MM)

045---08/024045 14---3/16 (360) 12---9/16 (319) 12---11/16 (322) 9---5/16 (237) 4 (102) 114 (52) 16 (406) 070---16/048070 17--- 1/2 (445) 15---7/8 (403) 16 (406) 11---9/16 (294) 4 (102) 136 (62) 16 (406) 090---16/048090 21 (533) 19---3/8 (492) 19 --- 1/2 (495) 13- -- 5/16 (338) 4 (102) 150 (68) 20 (508) 110---20/060110 21 (533) 19---3/8 (492) 19 --- 1/2 (495) 13- -- 5/16 (338) 4 (102) 162 (73) 20 (508) 135---20/060135 24--- 1/2 (622) 22---7/8 (581) 23 (584) 15---1/16 (383) 4 (102) 173 (78) 24 (610)

* 5 in. or 6 in. (127 or 152 mm) vent connector may be required in some cases.

A04037

FILTER MEDIA

CABINET

SIZE

IN. (MM)

SAFETY CONSIDERATIONS

WARNING

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

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

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

CAUTION

FURNACE RELIABILITY HAZARD

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

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

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory--authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions include in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC) NFPA 70.

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.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

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

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

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

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

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Gas Piping” section.

6. Always install furnace to operate within the furnace’s intended temperature--rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Start--Up, Adjustments, and Safety Check” section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating

outside the space containing the furnace. See “Air Ducts” section.

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

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

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

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

12. Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 inches (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

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

INTRODUCTION

Series 100/A 4 --way multipoise Category I fan--assisted furnace is CSA design--certified. A Category I fan--assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory--shipped for use with natural gas.

This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors. This furnace is designed for minimum continuous return--air temperature of 60_F(16_C)db 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 85_F(29_C) db. Failure to follow these return--air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 3).

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

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

58PHA

Fig. 2 -- Clearances to Combustibles

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:

A08471

Safety

S USA: National Fuel Gas Code (NFGC) NFPA

54--2006/ANSI Z223.1--2006 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

S CANADA: CSA B149.1--05 National Standard of

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

Max 85ºF/ 29ºC

Min 60ºF / 16ºC

Fig. 3 -- Return Air Temperature

A02055

S CANADA: CAN/CSA--B149.1--05 Parts 4, 5, and 6

Appendices A, B, E, and H.

Electrical

Connections

S US: National Electrical Code (NEC) ANSI/NFPA

70--2008.

S CANADA: Canadian Electrical Code CSA C22.1.

enting

S US: NFGC NFPA 54 / ANSI Z223.1--2006; Chapters

12 and 13.

S CANADA: CAN/CSA--B149.1--05 Part 8 and

Appendix C.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

CAUTION

General

Installation

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

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

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

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

Combustion and Ventilation

Air

S US: NGFC NFPA54/ANSI Z223.1 --2006 Section 9.3,

Air for Combustion and Ventilation.

S CANADA: Part 8 of CAN/CSA--B149.1--05, Venting

Systems and Air Supply for Appliances.

Duct

Systems

S US and CANADA: Air Conditioning Contractors

Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2005 Fundamentals Handbook Chapter 35 or 2004 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Acoustical Lining and Fibrous Glass

Duct

S US and CANADA: current edition of SMACNA and

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

Gas Piping and Gas Pipe Pressure T

esting

S US: NFGC NFPA54/ANSI Z223.1-- 2006; chapters 5,

6, 7, and 8 and National Plumbing Codes.

FURNACE RELIABILITY HAZARD

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

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

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

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

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

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

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

58PHA

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

58PHA

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

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

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

LOCATION

GENERAL

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

This furnace must:

S be installed so the electrical components are protected

from water.

S not be installed directly on any combustible material

other than wood flooring (refer to SAFETY CONSIDERATIONS).

S be located as close to the chimney or vent and attached

to an airdistribution system. Refer to Air Ducts section.

S be provided ample space for servicing and cleaning.

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

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

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

Fig. 4 -- Multipoise Orientations

CARBON MONOXIDE POISONING HAZARD

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

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

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

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

WARNING

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

S Masonry acid washing materials

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

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 5 -- Installation in a Garage

WARNING

ELECTRICAL OPERATION HAZARD

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

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

CAUTION

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may cause premature furnace component failure.

This gas furnace may be used for heating buildings under construction provided that:

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

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

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

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

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

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

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

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

58PHA

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

TWO HORIZONTAL DUCTS

FURNACE INPUT

(BTUH)

44,000 22 (14193) 6 (152) 14.7 (9484) 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 (17742) 6 (152) 132,000 66 (42581) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)

Free Area of Opening

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

(1,100 SQ. MM/KW)

and Duct

(sq.in./sq.mm)

Round Duct

Diameter (in./mm)

SINGLE DUCT OR OPENING

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

(734 SQ. MM/KW)

Free Area of Open-

ing and Duct

(sq.In./sq.mm)

Round Duct

Diameter

(in. / mm)

TWO OPENINGS OR VERTICAL

Free Area of

Opening and Duct

(sq.In./sq.mm)

DUCTS

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

(550 SQ. MM/KW)

Round Duct

Diameter

(In./mm)

EXAMPLES: Determining Free Area

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

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

Table 3 – Minimum Space volumes for 100% combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN--- ASSISTED TOTAL

ACH*

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

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

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

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

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

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

0.00 NP NP NP NP NP NP NP NP

*Air Changes/Hour

(1,000’S BTUH GAS INPUT RATE

30 40 50 44 66 88 110 132

SpaceVolume(ft.3)

FAN---ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

WARNING

FIRE HAZARD

58PHA

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

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

Fig. 6 -- Prohibit Installation on Back

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

Air for combustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and

iodide. These elements can corrode heat exchangers and

shorten furnace life. Air contaminants are found in aerosol

sprays, detergents, bleaches, cleaning solvents, salts, air

fresheners, and other household products.

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full-- heat or full-- cool position.

A02054

AIR FOR COMBUSTION AND

VENTILATION

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

S U.S. installations: Section 9.3 of the NFGC

NFPA54/ANSI Z223.1--2006, Air for Combustion and Ventilation, and applicable provisions of the local building codes.

WARNING

CARBON MONOXIDE POISONING HAZARD

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

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make--up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make--up air is available.

S Canadian installations: Part 8 of the

CAN/CSA--B149.1--05, Venting Systems and Air Supply for Appliances, and all authorities having jurisdiction.

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

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

require the OUTDOOR COMBUSTION AIR METHOD.

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

may use the INDOOR COMBUSTION AIR, STANDARD or KNOWN AIR INFILTRATION

METHOD.

Outdoor Combustion Air

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

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

Method

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

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

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

c. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btuh (1,100 mm

/kW) of combined input for all gas appliances in the space per Fig. 7 and Tab l e 2 .

d. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch of free area per 4,000 Btuh (550 mm

/kW) for combined input of all gas appliances in the space per Fig. 7 and Table 2.

3. ONE OUTDOOR OPENING requires:

a. 1 square inch of free areaper 3,000 Btuh (734 mm

/kW) for combined input of all gas appliances in the space per Tab l e 2 an d

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

in the space.

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

1 SQ IN. PER 4000 BTUH*

1 SQ IN .

BTUH*

12 ″ MAX

PER

4000

(305mm)

1 SQ IN. PER 2000 BTUH*

12 ″ MAX

DUCTS

O UTDOORS

AIR DUCTS

C IRCULA TING

VENT THR OUGH R OOF

WARNING

CARBON MONOXIDE POISONING HAZARD

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

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

The Standard Method:

1. The space has n o 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 p er hour (ACH).

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space. Table 3 --Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223.1-- 2006/NFPA 54-- 2006, 9.3.2.2:

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

Volume

Other

21ft ACH

other

1000 Btu/hr

58PHA

DUCT S

OUTDOORS

1 SQ IN. PER 2000 BTUH*

(305mm)

12 ″ MAX

CIRCULA TING AIR DUCT S

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

A&B, C&D, D &E, F&G

(76mm)

AT LEAST 3 IN .

OPENINGS SHALL BE

OF COMB USTION AIR

CLEARANCE IN FRONT

DUCT

OUTDOORS

12 ″ MAX

(305mm)

1 SQ IN .

BTUH*

1 SQ IN. PER 4000 BTUH*

OUTDOORS

PER 4000

12 ″

(305mm)

MAX

A03174

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

Outdoors

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

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

A04002

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

Volume

Fan

15ft ACH

fan

1000 Btu/hr

A004003

If: Iother = combined input of all other than fan--assisted appliances in Btuh/hr Ifan = combined input of all fan--assisted appliances in Btuh/hr ACH = air changes per hour (ACH shall not exceed 0.60.)

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

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

a. There are no closable doors between rooms.

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in.

/kW) of the total input rating of all gas appliances

mm in the space, but not less than 100 in.

/1,000 Btuh (2,000

(0.06 m2). One opening shall commence within 12” (300 mm) of the ceiling and the second opening shall commence within 12” (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). (See Fig. 8.)

c. Combining space on different floor levels. The volumes

of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area

of at least 2 in.

/1,000 Btuh (4,400 mm2/kW) of total

input rating of all gas appliances.

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

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section.

Unusually tight construction is defined as construction with:

a. Walls and ceilings exposed to the outdoors have a

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

58PHA

*Minimum opening size is 100 in.2with minimum dimensions of 3 in. ( 76 mm).

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

CIRCULATING AIR

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

DUCTS

VENT THROUGH ROOF

12" MAX

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

UNCONFINED SPACE

(152mm)

6" MIN (FRONT)

1 SQ IN. PER 1000 BTUH* IN DOOR

OPENINGS SHALL BE AT LEAST 3 IN.

OR WALL

CLEARANCE IN FRONT OF COMBUSTION AIR

12" MA X

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

Indoors

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

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

Combination of Indoor and Outdoor

Air

1. Indoor openings shall comply with the Indoor Combustion Air Method below and,

2. Outdoor openings shall be located as required in the Outdoor Combustion Air Method menioned previously and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air Method below.

/4,000 Btuh of

(305mm)

A03175

A02098

Fig. 9 -- Removing Bottom Closure Panel

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80 mm).

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

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

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

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air

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

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

Leveling Legs (If Desir

In upflow position with side return inlet(s), leveling legs may be used. (See Fig. 10.) Install field--supplied, 5/16 x 1--1/2 in. (8 x 38 mm) (max) corrosion--resistant machine bolts, washers and nuts.

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

To install leveling legs:

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

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

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

Inlet

ed)

(8mm)

(44mm)

16″

1 3/ 4″

(8mm)

16″

/ 4″

(44mm)

PLENUM

OPENING

(8mm)

/ 16″

(8mm)

16″

(44mm)

4″

A89014

(44mm)

Fig. 10 -- Leveling Legs

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

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLA

TION

NOTE: For downflow applications, this furnace is approved for

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

S Special Base, KGASB S Cased Coil Assembly Part No. CNPV, CNRV, CAP, or

CAR

S Coil Bo x Part No. KCAKC

1. Determine application being installed from Table 4.

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

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

4. If downflow subbase, KGASB is used, install as shown in Fig. 1 2. If Coil Assembly Part No. CNPV, CNRV, CAP and CNR or Coil Box PartNo. KCAKC is used, install as shown in Fig. 13.

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

Bottom Return Air

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

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws

Inlet

FLOOR

OPENING

Fig. 11 -- Floor and Plenum Opening Dimensions

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

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

on a Combustible Floor

58PHA

A96283

A96285

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

58PHA

A08556

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

Coil Box Installed on a Combustible Floor

Table 4 – Opening Dimensions -- In. (mm)

FURNACE

CASING

WIDTH

14–3/16

(360)

17–1/2

(445)

(533)

24---1/2

(622)

APPLICATION

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

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

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

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

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

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

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on Combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

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

(KGASB subbase not required)

PLENUM OPENING FLOOR OPENING

A B C D

12---11/16

(322)

12---9/16

(319)

11---13/16

(284)

12---5/16

(313)

(406)

15---7/8

(403)

15---1/8

(384)

15---1/2

(394)

19---1/2

(495)

19---3/8

(492)

18---5/8

(473)

(483)

(584)

22---7/8

(581)

22---1/8

(562)

22---1/2

(572)

21---5/8

(549)

(483)

21---5/8

(549)

(483)

21---5/8

(549)

(483)

21---1/8

(537)

(483)

13---5/16

(338)

13---3/16

(335)

13---7/16

(341)

13---5/16

(338)

16---5/8

(422)

16---1/2

(419)

16---3/4

(425)

16---1/2

(419)

20---1/8

(511)

(508)

20---1/4

(514)

(508)

23---5/8

(600)

23---1/2

(597)

23---3/4

(603)

23---1/2

(597)

22---1/4

(565)

19---5/8

(498)

20---5/8

(600)

(508)

22---1/4

(565)

19---5/8

(498)

20---5/8

(600)

(508)

22---1/4

(565)

19---5/8

(498)

20---5/8

(600)

(508)

22---1/4

(565)

19---5/8

(498)

20---5/8

(600)

(508)

58PHA

HORIZONTAL INSTALLATION

WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

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

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

Suspended Furnace

Support

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

16.) Secure angle iron to bottom of furnace as shown. Heavy--gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x 3/4--in. (19 mm) screws into the side and 2 #8 x 3/4--in. (19 mm) screws in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.) If the screws are attached to ONLY the furnace sides and not the bottom, the straps must be vertical against the furnace sides and not pull away

from the furnace sides, so that the strap attachment screws are not in tension (are loaded in shear) for reliable support.

Platform Furnace

Support

Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in. (25 mm) clearance requirement on side, set furnace on noncombustible blocks, bricks or angle iron. For crawl space installations, if the furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

Roll-- Out Pr

otection

Provide a minimum 17--3/4 in. x 22 in. (451 mm x 559 mm) piece of sheet metal for flame roll--out protection in front of burner area for furnaces closer than 12 inches (305 mm) above the combustible deck or suspended furnaces closer than 12 inches (305 mm) to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. (25 mm) with the door removed. The bottom closure panel on furnaces of widths 17--1/2 in. (445 mm) and larger may be used for flame roll--out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper orientation of roll--out shield.

Bottom Return Air

Inlet

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

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws. Side Return Air Inlet

Side Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) is used without a bottom return air inlet. Not all horizontal furnaces are approved for side return air connections. (See Fig. 20).

FILTER

CARBON MONOXIDE AND POISONING HAZARD

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

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

58PHA

There are no provisions for an internal filter rack in these furnaces.

Deluxe furnaces are shipped with a factory supplied Media Filter Cabinet. The Media Filter Cabinet uses either the factory--supplied standard 3/4--in. (19 mm) filter or a 4 --in. (102 mm) wide Media Filter which can be purchased separately.

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

DUCTS

AIR

General Requir

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table 5--AIR DELIVERY--CFM (With Filter). When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. Secure ductwork with proper fasteners for type of ductwork used. Seal supply-- and return--duct connections to furnace with code approved tape or duct sealer.

Inlet

ARRANGEMENT

WARNING

ements

NOTE: Flexible connections should be used between ductwork

and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated and sealed to enhance system performance. When air conditioning is used, a vapor barrier is recommended. Maintain a 1-- in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Tr

NOTE: Metal duct systems that do not have a 90 degree elbow

and 10 ft. (3 M) of main duct to the first branch take--off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Supply Air

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

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

NOTE: For horizontal applications, the top-- most flange may be bent past 90 degrees to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed.

Downflow

Connect supply--air duct to supply--air outlet on furnace. Bend flange inward past 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing (when used). When installed on combustible material, supply--air duct must be connected to ONL Y the accessory subbase KGASB0201ALL or a factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace casing.

Connections

Furnaces

eatment

UPFLOW DOWNFLOW HORIZONTAL

120°

MIN

90°

YES

120°

MIN

YES

Fig. 14 -- Duct Flanges

/ 4 " (6mm) THREADED ROD

4 REQ.

120°

MIN

90°

YES

58PHA

A02020

OUTER DOOR A S SEMBLY

MIN

8" (203mm) FOR DOOR REMOVAL

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

Fig. 15 -- Horizontal Unit Suspension

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH

/4" (19mm) SCREWS

3 #8 x TYPICAL FOR 2 SUPPORTS

1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm) ANGLE IRON OR UNI-STRUT MAY BE USED

A05027

METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

58PHA

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH

(4) #8 x 3/4 (19 mm) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

A03176

Fig. 16 -- Horizontal Suspension with Straps

LINE CONT A CT ONL Y PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE T OP AND TW O SIDES OF THE FURNA CE JA CKET AND BUILDING JOISTS , STUDS , OR FRAMING.

EQUIPMENT MANU AL

SHUT -OFF GAS VA LV E

SEDIMENT

TRAP

UNION

SHEET MET AL

GAS ENTR Y

17 3 / 4 ″

(559mm)

″

(451mm)

6 ″ M IN

TYPE-B VENT

(152mm)

Fig. 17 -- T ypical Attic Installation

17 3 / 4 ″ 4 3 / 4 ″ 1 ″

(25mm)

EXTEND OUT 12 ″ FR OM FA CE OF DOOR

30-IN . (762mm) MIN WORK AREA

(451mm)

(121mm)

OVERALL

UNDER DOOR

UNDER FURNACE

(305mm)

* WHEN USED W ITH SINGLE W ALL VEN T CONNECTIONS

A03177

PIPING

Connections

WARNING

CAUTION

Return Air

FIRE HAZARD

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

Never connect return--air ducts to the back of the furnace. Follow instructions below

Downflow Furnaces The return--air duct must be connected to return--air opening (bottom inlet) as shown in Fig. 19. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most horizontal furnaces. (See Fig. 19.) Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

Upflow and Horizontal Furnaces The return--air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 18 and 20. Bypass humidifier may be attached into unused return air side of the furnace casing. (See Fig. 18 and 20.) Not all horizontal furnaces are approved for side return air connections. (See Fig. 20.)

GAS

FIRE OR EXPLOSION HAZARD

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

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

FIRE OR EXPLOSION HAZARD

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

Use proper length of pipe to avoid stress on gas control manifold and a gas leak.

FURNACE OVERHEAT HAZARD

Failure to follow this caution may result in property damage.

Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls and burner misalignment.

WARNING

FIRE OR EXPLOSION HAZARD

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

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance. Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in.(51 mm) outside the furnace.

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S., the CAN/CSA--B149.1 --05 in Canada.

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 inches (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T --handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

Refer to Table 6 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. (2 M). Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. (2 M) of furnace. A 1/8--in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

NOTE: The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14--in. wc) stated on gas control valve. (See Fig. 52.)

Some installations require gas entry on right side of furnace (as viewed in upflow.) (See Fig. 21.)

Install a sediment trap in riser leading to furnace as shown in Fig

22. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve. A 1/8 --in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

58PHA

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