Carrier 58STX, 58STA User Manual

0 (0)

58STA/58STX

Induced-Combustion

4-Way Multipoise Furnace

Installation, Start-up, Operating, and

Service and Maintenance Instructions

-Series 120

The 58STA/STX 4-way Multipoise Gas Furnaces feature Carrier's QuieTech TM noise reduction system for incredibly quiet induced draft operation. Applications are easy with 4-way multipoise

design, through-the-furnace downflow venting, 13 different venting options, and a door designed for easy service access. An inner blower door is provided for tighter sealing in sensitive applications.

The 58STA/STX furnaces are approved for use with natural or propane gas, and the 58STX is also approved for use in Low NOx Air Quality Management Districts.

STANDARD FEATURES

QuieTech noise reduction system

- Microprocessor based control center

Adjustable heating air temperature rise Adjustable cooling airflow

LED diagnostics and self test feature

- 4-way Multipoise furnace, 13 vent applications

- Inner blower door

- Hot surface ignition (HSI)

Draft safeguard switch to ensure proper furnace venting

All models are Chimney-Friendly when used with

accessory vent kit

- Heat pump compatible

- Residential installations eligible for consumer financing

through the Retail Credit Program

- Twinning in Upflow, Downflow and Horizontal LIMITED WARRANTY

20-year warranty on "Super S TM''heat exchanger

5-year parts warranty on all other components

Catalog No: 535-80149 Form No. 58ST-13Sl 5-05

Installation,

Service and

Single-Stage

Induced-Combustion

4-W

Cancels: II 310A-45-4/IM-PG8J-04

A 11310,A-45-5/IM-PG 8J-0=5

Start-up, upera lng, ana

Maintenance Instructions

Series 120/C

NOTE: Read the entire instruction manual bet\_re starting the

installation. This symbol --+ indicates a change since the last issue.

---> Portions of the text and tables are reprinted froll] NFPA 54/ANSI Z223.1-2002'c3, 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.

TABLE OF CONTENTS

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

INTRODUCTION .......................................................................... 4

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

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

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

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

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

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

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

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

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

LOCATION .................................................................................... 5

General ...................................................................................... 5

Location Relative to Cooling Equipment ................................ 7

AIR FOR COMBUSTION AND VENTILATION ...................... 7

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

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

Bottom Return Air Inlet .................................................... 10

Side Return Air Inlet ......................................................... 10

Leveling Legs (If Desired) ................................................ 10

Downflow Installation ............................................................ 10

Bottom Return Air Inlet .................................................... 11

Horizontal Installation ............................................................ 11

Suspended Furnace Support .............................................. 11

Platt\mn Furnace Support ................................................. 11

Roll-Out Protection ............................................................ 11

Bottom Return Air Inlet .................................................... 11

Side Return Air Inlet ......................................................... 11

Filter Arrangement .................................................................. 11

Air Ducts ................................................................................. 11

General Requirements ....................................................... 11

Ductwork Acoustical Treatment ....................................... 12

Supply Air Connections .................................................... 12

Return Air Connections ..................................................... 14

Gas Piping ............................................................................... 15

Electrical Connections ............................................................ 19

115-V Wiring ..................................................................... 19

J-Box Relocation ............................................................... 20

Electrical Connection to J-Box ......................................... 21

Power Cord Installation in Furnace J-Box ....................... 21

BX Cable Installation in Furnace J-Box .......................... 22

EFFICIENCY RATING CERTIFIED

area

ISO 9001:2000

24-V Wiring ....................................................................... 22

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

Venting .................................................................................... 22

General Venting Requirements ......................................... 23

Masom T Chimney Requirements ...................................... 23

Appliance Application Requirements ............................... 24

Additional Venting Requirements ..................................... 26

Sidewall Venting ............................................................... 26

START-UP, ADJUSTMENT, AND SAFETY CHECK ............ 27

General .................................................................................... 27

Start-Up Procedures ................................................................ 27

Adjustments ............................................................................. 31

Check Safety Controls ............................................................ 34

Checklist .................................................................................. 35

SERVICE AND MAINTENANCE PROCEDURES .................. 35

Introduction ............................................................................. 35

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

Electrical Controls and Wiring ......................................... 36

Care and Maintenance ............................................................ 37

Cleaning and/or Replacing Air Filter ............................... 37

Blower Motor and Wheel .................................................. 37

Cleaning Heat Exchanger .................................................. 40

Sequence of Operation ............................................................ 44

Wiring Diagrams ..................................................................... 45

Troubleshooting ...................................................................... 45

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

Book 1I 4 PC 101 Catalog No. See Cover Printed in U.S.A. Form 58ST-13SI Pg 1 5-05 Replaces: 58ST-12SI Tab 6a 8a

5-15/16"

33-5/16"

11/16"_

-- 28-7/8"--

25-1/4"

22-9/16" _

LOCATION

JUNCTION BOX-_

1/2" DIA THERMOSTAT

WIRE ENTRY_

3-15/16" J

LEFT HAND GASJ

ENTRY

7/8" DIA. ACCESSORY-_

21-5/8"

BOTTOM INLET

24"

CASING

1-11/16"

24-7/8"

-1/2"

AIRFLOW

-- 13/16"

OUTLET

ENTRY

LOCATIONS (TYP)

5 PLACES (TYP)

5-1/2"

_ 11/16"

22-1/16"

SiDE INLET

-1

14-7/8"

1-1/4"

7-3/4"

26-1/8"

(FLUE COLLAR)

ACCESSORY

7/8" DIA 1

NOTES:

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

2. Minimum return-air openings ar 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. round or 14 1/2 x 12-in. rectangle. b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle. c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

--> Fig. l mDimensional Drawing

SAFETY CONSIDERATIONS

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

Failure to l\_llow this warning could result in dangerous operation, serious injmT, death, or property damage. hnproper installation, adjustment, alteration, service, mainte- nance, or use can cause carbon monoxide poisoning, explo- sion, fire, electrical shock, or other conditions which may cause personal injmT or property damage. Consult a qualified service agency, local gas supplier, or your distributor or branch t\_r int\_rnaation or assistance. The qualified service agency must use only factolT-authorized and listed kits or accessories when modifying this product.

FURNACE RELIABILITY HAZARD hnproper installation or misapplication of furnace may re-

quire excessive servicing or cause premature component I:ailure.

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.

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 pert\_rm 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 furnace and other safety precautions that may apply.

These instructions cover mininmm 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 residen- tial construction practices. We require these instructions as a

mininmm t\_r a safe installation.

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.

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

This is the safety-alert symbol/!X •When you see this symbol on the furnace and in instructions or manuals, be alert to the potential

t\_r personal injmT. Understand the signal words DANGER, WARNING, and CAU-

TION. These words are used with the safety-alert symbol. DAN- GER identifies the most serious hazards which will result in severe

personal injury or death. WARNING signifies a hazard which could result in personal injmy or death. CAUTION is used to identity hazards which may result in minor personal injury or product and property damage. NOTE is used to highlight sugges- tions which will result in enhanced installation, reliability, or operation.

1. Use only with type of gas approved t\_r 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.

A04037

iNSTALLATiON

MiNiMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES

This forced air furnace is equipped for use with Thisfurnace is approvedfor UPFLOW, DOWNFLOW, and

natural gas at altitudes 0-10,000 ft (0-3,050m). HORIZONTAL installations.

An accessory kit, supplied by the Cette foumaiseestapprouvee pour I 'installationHORIZONTALE manufacturer, shall be used to convert to propane et lacirculationd 'airVERS LE HAUT etVERS LE BAS. gas use or may be required for some natural gas

applications. Clearance arrows /'_1 Lesflechesdedecjagement

This furnace is for indoor installation in a donot change with _ _ I ne change pas avec building constructed on site.

This furnace may be installed on combustible

as indicated by the diagram from combusitble

fiooring in alcove or closet at minimum clearance _B.A_cK_.. j i_-

material.

This furnace may be used with a Type B-1 Vent ._'_R E .Q _15_._ co j_/ and may be vented in common with other gas _" "_- _,_-__,,'f V

fired appliances. -.,._., i._,_ _o_._

pour utilisation avec gaz naturel et altitudes comprises entre 0-3,050m (0-10,000 pi).

Cette foumaise a air pulse est 6quipde _cb9 _ __%

Utiliser une trousse de conversion, foumie par le fabricant, pour passer au gaz propane ou pour / _0" ,,..,,,,'_ _ , f>,,,,, ' 3'_ "_

certaines installations au gaz naturel. \ /

Cette foumaise est prevue pour 6tre _ _ _ installee dens un b_timent construit sur place. 2 W _/ Clearancein inches

Cette foumaise peut 6tre installee sur _ / Degagement (pc). un plancher combustible dens une alcdve ou _-- t"'/

dens un garde-robe en respectant le minimum d'espace libre des materiaux combustibles, tel Vent Clearance to combustibles:

qu'indique sur le diagramme. ForSingleWallvents 6 inches(6 pc).

Cette foumaise peut 6tre utilisee avec un conduit d'evacuation de Type B-1 ou connectee Pour conduitd'evacuation a paroisimple6 pc (6 inches).

au conduit ommun d 'autres appareils a gaz. Pourconduitd'evacuation deType B-1 1pc (1 inch).

furnaceorientation. ____I I'orientationde la fournaise.

ForType B-1 venttype 1 inch(1 pc).

Degagement de I'event avec combustibles:

MINIMUMINCHES CLEARANCETO COMBUSTIBLE CONSTRUCTION

DOWNFLOW POSITIONS:

1- Installation on non-combusibible floors only.

For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,

Coil Assembly, Part No. CD5 or CKS, or Coil Casing, Part No. KCAKC.

18 inches front clearance required for alcove. Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible

between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists, studs or framing.

BEGAGEMENTMINIMUM EN POUCESAVEC €=LI_MENTS

DECONSTRUCTION COMBUSTIBLES

POUR LA POSITIONCOURANTDESCENDANT:

1- Pour Hnstallation sur plancher non combustible seulement.

Pour I'installation sur un plancher combustible seulement quand on utilise la base speciale, piece

no KGASB0201ALL, I'ensemble serpentin, piece no CD5 ou CK5, ou le carter de serpentin, piece

no KCAKC. Dens une alcdve, on dolt maintenir un degagement a I'avant de 18 pc (450mm). La poistion indiquee conceme le cdte d'entree ou de retour quand la foumaise est dens la

position horizontale. Le contact n'est permis qu'entre les lignes formees par les intersections du dessus et des

deux cdtes de la cherrise de la foumaise et les solives, montant sous cadre de charpente.

327590-101 REV. C

--> Fig. 2_Clearances to Combustibles

A04123

Table lmDimensions (iN.)

FURNACE A SUPPLY-AIR RETURN-AIR

SiZE CABINET WIDTH WIDTH WIDTH

045-081024045 14-3/16 12-9/16 12-11/16 9-5/16 4 104 045-121036045 14-3/16 12-9/16 12-11/16 9-5/16 4 107

070-081024070 14-3/16 12-9/16 12-11/16 9-5/16 4 111 070-121036070 14-3/16 12-9/16 12-11/16 9-5/16 4 115 070-161048070 17-1/2 15-7/8 16 11-9/16 4 126 090-141042090 17-1/2 15-7/8 16 11-9/16 4 127

090-161048090 21 19-3/8 19-1/2 13-5/16 4 140 090-201060090 21 19-3/8 19-1/2 13-5/16 4 146 110-121036110 17-1/2 15-7/8 16 11-9/16 4 135 110-161048110 21 19-3/8 19-1/2 13-5/16 4 146

110-221066110 21 19-3/8 19-1/2 13-5/16 4 152 135-16/048135 21 19-3/8 19-1/2 13-5/16 4 149 135-221066135 24-1/2 22-7/8 23 15-1/16 4 163 155-201060155 24-1/2 22-7/8 23 15-1/16 4 170

* 5"or 6" vent connector may be required insome cases.

Provide adequate combustion and ventilation air to the furnace

space as specified in "Air t\_r Combustion and Ventilation" section.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in

the "Venting" section of these instructions.

5. Never test t_r gas leaks with an open flame. Use a commer- cially available soap solution made specifically t\_r the detec-

D E

(iN.) (iN.) (iN.)

13. These furnaces SHALL NOT be installed directly on carpet- ing, tile, or any other combustible material other than wood

flooring. In downflow installations, factoiT accessoi T 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. See Fig. 2 t\_r clearance to combustible construction int\_rmation.

tion 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 speci-

fied 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 t_r installation in a residential garage nmst

be installed as specified in the warning box in the "Location" section.

--->

9. The furnace is not to be used t_r temporm T heating of

buildings or structures under construction. See page 7 caution box regarding the heating of buildings under construction.

10. These Multipoise Gas-Fired Furnaces are CSA (t_rmerly A.G.A. and C.G.A.) design-certified t\_r use with natural and

--->

This Series 120/C 4way multipoise Categoi T 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 t\_rce products of combustion through the combus- tion chamber and/or heat exchanger. The furnace is factory- shipped t_r use with natural gas. A CSA (A.G.A. and C.G.A.) listed gas conversion kit is required to convert furnace t_r use with propane gas. This furnace is not approved t\_r installation in mobile homes, recreational vehicles, or outdoors.

This furnace is designed t\_r mininmm confumous return-air temperature of 60°F db or intermittent operation down to 55°F db such as when used with a night setback thermostat. Return-air temperature must not exceed 85°F db. Failure to t\_llow these return-air temperature limits may affect reliability of heat exchang- ers, motors, and controls. (See Fig. 3.)

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

NOTE: Remove all shipping brackets and materials bet_re oper-

ating the furnace.

propane gases (see furnace rating plate) and t_r installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factolT-shipped t\_r use with natural gas. A CSA listed gas conversion kit is required to convert furnace t\_r use with propane gas.

11. See Fig. 2 t\_rrequired clearances to combustible construction.

12. Maintain a 1-in. clearance fiom combustible materials to

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

of the serving gas supplier, local building, heating, plmnbing, and other codes. In absence of local codes, the installation must

comply with the national codes listed below and all authorities having jurisdiction.

supply air ductwork t\_r a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code t\_r further

requirements.

C.L. TOP AND FLUE

BOTTOM COLLAR* SHiP WT. (LB)

FLUE COLLAR (iN.)

INTRODUCTION

CODES AND STANDARDS

°ii- _ MAX 85°F

_I I MING0°F

A02055

Fig. 3mReturn Air Temperature

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: CSA B149.1-00 National Standard of Canada Natural Gas and Propane Installation Codes (NSCNGPIC)

Step 2--General Installation

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

copies, contact the National Fire Protection Association Inc., BattmTmarch 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).

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

CSA International, 178 Rexdale Boulevard, Etobicoke (Tor- onto), Ontario, Mgw 1R3 Canada

Step a--Combustion and Ventilation Air

--€, US: Section 8.3 of the NFGC, Air I\)r Combustion and Ventilation

, CANADA: Part 7 of NSCNGPIC, Venting Systems and Air

Supply I\)r Appliances

Step 4--Duct Systems

--€, US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Con-

tractors National Association (SMACNA), or American Soci- ety of Heating, Refiigeration, and Air Conditioning Engineers

(ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Step 5--Acoustical Lining and Fibrous Glass Duct

, US and CANADA: current edition of SMACNA and 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 5, 6, 7, and 12 and National Plmnbing Codes

, CANADA: NSCNGPIC Parts 3, 4, and 5, and Appendices A,

B, E and H.

Step 7--Electrical Connections

, US: National Electrical Code (NEC) ANSI/NFPA 702002 , CANADA: Canadian Electrical Code CSA C22.1

--->Step 8--Venting , US: NFGC; chapters 10 and 13

, CANADA: NSCNGPIC Part 7 and Appendix C

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE

FURNACE RELIABILITY HAZARD hnproper installation or service of furnace may cause prema-

ture furnace component failure. Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will pre- vent 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.

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 DIS- CHARGING YOUR BODY'S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surt:ace 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 smwice 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

surt:ace of the furnace again before touching control or wires.

Use this procedure for installed and uninstalled (ungrounded)

furnaces.

Before removing a new control fiom its container, discharge

your body's electrostatic charge to ground to protect the

control fiom damage. If the control is to be installed in a furnace, follow items 1 through 4 bet\)re bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

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

LOCATION

GENERAL Some assembly and modifications are required when used in any

of the four applications shown in Fig. 4. This furnace must:

, be installed so the electrical components are protected flom

water.

, not be installed directly on any combustible material other than

wood flooring (refer to SAFETY CONSIDERATIONS).

, be located close to the chinmey or vent and attached to an air

distribution system. Refer to Air Ducts section.

, be provided ample space for smwicing and cleaning. Always

comply with mininmm fire protection clearances shown on the furnace clearance to combustible construction label.

THE BLOWER IS LOCATED

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

TO THE RIGHT OF THE t

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

Fig. 4mMuitipoise 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 t\mnd 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.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

HORIZONTAL RIGHT

q IAIRFLOW

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

THE BLOWER IS

DISCHARGED TO THE RIGHT.

A02097

All fuel-burning equipment must be supplied with air t\_r 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 fiom the burner area and fiom draft safeguard

opening.

---5 The t\_llowing types of furnace installations may require OUT- DOOR AIR for combustion due to chemical exposures:

. Commercial buildings . Buildings with indoor pools . Lanndi T rooms

. Hobby or craft rooms, and

• Chemical storage areas

---5 If air is exposed to the tMlowing substances, it should not be used for combustion air, and outdoor air may be required for combus-

tion: . Permanent wave solutions . Chlorinated waxes and cleaners

. Chlorine based swimming pool chemicals . Water softening chemicals . De-icing salts or chemicals

. Carbon tetrachloride . Halogen type refrigerants

. Cleaning solvents (such as perchloroethylene) . Printing inks, paint removers, varnishes, etc. . Hydrochloric acid . Cements and glues . Antistatic t;abric softeners t\_r clothes dlTers . Masom T acid washing materials

18-1N. MINIMUM

TO BURNERS

A93044

Fig. 5mlnstallation in a Garage

FIRE, INJURY OR DEATH HAZARD hnproper location or inadequate protection could result in fire or explosion. When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 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 NSCNGPIC. (See Fig. 5.)

-__>

PERSONALINJURY AND/OR PROPERTY DAMAGE

HAZARD

Improper use or installation of this furnace may cause

premature furnace component t:ailure.

This gas furnace may be used I\)r 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 &awing combustion products into the

structure.

-The furnace is controlled bya 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 &Twall dust into combustion air, which can cause fouling and plugging of furnace components.

-The temperature of the return air to the furnace is main- rained 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 intermit- tent 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 nmst be either changed or thoroughly

cleaned prior to occupancy.

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

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

-__>

FIRE, INJURY OR DEATH HAZARD Failure to t\)llow this warning could result in unsafe furnace operation. DO NOT install the furnace on its back or hang furnace with control compartment facing downward. Safety control opera- tion will be adversely affected. Never connect return-air ducts to back of furnace. (See Fig. 6.)

LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil nmst be installed parallel with, or on the

downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or

other flow control nmst prevent chilled air from entering the furnace. If the dampers are manually operated, they nmst be equipped with means to prevent operation of either unit unless the damper is in the full-heat or full-cool position.

BACK S

FR(

A02054

Fig. 6mProhibit Installation on Back

AIR FOR COMBUSTION AND VENTILATION

Provisions t\)r adequate combustion, ventilation, and dilution air nmst be provided in accordance with:

, U.S. installations: Section 8.3 of the NFGC, Air for Combus-

tion and Ventilation, and applicable provisions of the local building codes.

, Canadian installations: Part 7 of the NSCNGPIC, Venting

Systems and Air Supply t\)r Appliances, and all authorities having jurisdiction.

FURNACE CORROSION HAZARD Failure to t\)llow this caution may result in furnace damage.

Air for combustion nmst not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and

shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air

ffesheners, and other household products.

---> CARBON MONOXIDE POISONING HAZARD Failure to t\)llow this warning could result in personal injury

or death. The operation of exhaust t:ans, kitchen ventilation tans,

clothes dwers, attic exhaust tans 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 Hazard warning in venting section of these instruc- tions to determine if an adequate amount of make-up air is

available.

--->The requirements for combustion and ventilation air depend upon

whether or not the furnace is located in a space having a volmne of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

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

the OUTDOOR COMBUSTION AIR METHOD.

, Spaces having at least 50 cubic feet per 1,000 Bmh may use the

INDOOR COMBUSTION AIR, STANDARD or KNOWN- AIR INFILTRATION METHOD.

--€

FURNACE

(BTUH)

110,000 132,000

154,000

iNPUT

44,000 66,000 88,000

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

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

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

Free Area of

Opening and Duct

(Sq. In.)

22 33 44 55 66

(1,100 SQ. MM/KW)

Round Duct

(in. Dia)

6 7 8 9

10 10

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

Free Area of

Opening and Duct

(sq In.)

14.7 22

29.3

36.7 44

51.3

(734 SQ. MM/KW)

Round Duct

(in. Dia)

5 6 7 7 8

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

Free Area of

Opening and Duct

(Sq In.)

16.5 22

27.5 33

38.5

(550 SQ. MM/KW)

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 T FAN-ASSISTED TOTAL

Round Duct

(in. Dia)

4 5 6 6 7

ACH 30 I 40 I 50 44 !66 ! 88 I 110 I 132 1154

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

---> Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent hori- zontal or vertical duct(s) or opening(s) directly communicat- ing with the outdoors or spaces that tieely communicate with

the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPEN- INGS, one inlet and one outlet combustion and ventilation air

opening, to the outdoors. a. One opening MUST commence within 12" (300 mm) of

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

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

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

Space Volume (ft3)

b. Not less than the stun 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 mln) from the sides and back and 6" (150 mm) Iiom the Iiont. The opening shall directly conmmnicate with the outdoors or shall conmmnicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that tieely communicate with the

outdoors.

Indoor Combustion Air(c) 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.

c. TWO HORIZONTAL DUCTS require 1 square inch of

tiee area per 2,000 Btuh (1,100 mn12/kW) of combined input for all gas appliances in the space per Fig. 7 and Table

2. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch of tiee area per 4,000 Btuh (550 mn12/kW) for combined input of all gas appliances in the space per Fig.

7 and Table 2.

3. ONE OUTDOOR OPENING requires:

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

in death and/or personal injury. Many homes require air to be supplied tiom outdoors t\_r furnace combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in accordance with this instruction manual.

a. 1 square inch of tiee area per 3,000 Btuh (734 mm2/kW)

for combined input of all gas appliances in the space per Table 2 and

1 SQ IN. PER 4000

BTUH*

OUTDOORS

D 1:

o9 VENT MAX

F+

_r_ 1SC

o r_ PE

BTL

!M O _'C_ i 1BCIN.

_ 40( _'; BTL

PER 2000 BTU_

12"MJ_Xj

CIRCULATING AIR DUCTS

*Minimum dimensions of 3 in. NOTE: Use any of the following

combinations of openings: A&B C&D D&E F&G

i 12" MAX

c M

TO PER 4000

OUTDOORS BTUH*

--> Fig. 7mAir for Combustion, Ventilation and Dilution for Outdoors

1SQ IN.

A03174

CIRCULATING AIR

DUCTS

VENT THROUGH ROOF

I I

I I I I

I I

INTERIOR

HEATED

SPACE

I I

_< 12" MAX

F-Z __- 1 SQ IN.

m__ PER 1000

O R WAL L

oOo_ BTUH*INDOOR

O_ UNCONFINED

..J SPACE

=_J

o< O2-r 6" MIN

LL CO (FRONT)t

2O3

o- 1 SQ IN. _+ PER1000

_ %- BTUH* IN DOOR

ORWALL

L12" MAX

I I

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. with

minimum dimensions of 3 in.

tMinimum of 3 in. when type-B1 vent is used.

--> Fig. 8mAir for Combustion, Ventilation and Dilution from Indoors

A03175

The Standard Method:

1. The space has no less volmne than 50 cubic feet per 1,000 Btuh of the maximmn input ratings t\_r all gas appliances installed in the space and

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

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

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

ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimmn required volmne for each appliance in the

space and add the volumes together to get the total mininmm required volmne t\_r the space.

Table 3-Minimum Space Volmnes were determined by using the t\_llowing equations from the Nutional Fllel Gas ('ode AN57

Z223.1-2002/NFPA 54-2002,8.3.2.2:

1. For other than fan-assisted appliances, such as a draft

hood-equipped water heater:

Volume _ 21ft 3 (" [other "_

Other ACH _000 Btu/hr!

A04002

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

Volume Fan AOH _!.000 Btu/hrj

: 15ft3_" I .... -_

A04003

If:

lothe 1 = combined input of all other than fan-assisted appli-

ances in Btu/hr

If++,+= combined input of all fan-assisted appliances in Btu/hr

ACH = air changes per hour (ACH shall not exceed 0.60.)

--€ The t\_llowing requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space it'. a. There are no closable doors between rooms.

b. Combining spaces on same floor level. Each opening shall

have free area of at least 1in.2/1,000 Bmh (2,000 mm2/kW) of the total input rating of all gas appliances in the space, but not less than 100 in.2 (0.06 m2). One opening shall commence within 12" (300 mm) of the ceiling and the second opening shall commence within 12" (300 mm) of the floor. The n_inimum 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 perma- nent openings in doors or floors having tiee area of at least 2 in.2/1,000 Btuh (4,400 mm2/kW) of total input rating of all gas appliances.

An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having

free area of at least 1-in.2/4,000 Bmh of total input rating t\_r

all gas appliances in the space.

In spaces that use the Indoor Combustion Air Method,

infiltration should be adequate to provide air t\_r 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 continu-

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

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include joints

around window and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations I\_r 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 mentioned previously and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided by

required volume I\)r Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

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

111m).

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, pert\_rm the following:

1. Tilt or raise furnace and remove 2 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 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.

t 1

I BOTTOM CLOSURE

PANEL

Fig. 9mRemoving Bottom Closure Panel

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 Desired) In upflow position with side return inlet(s), leveling legs may be

used. (See Fig. 10.) Install field-supplied, 5/16 X 1-1/2 in. (max) corrosion-resistant machine bolts, washers and nuts.

NOTE: Bottom closure must be used when leveling legs are used.

It may be necessm T 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.)

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

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLATION

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the t\_llowing 3 accessories are used:

, Special Base, KGASB , Cased Coil Assembly Part No. CD5 or CK5

, Coil Box Part No. KCAKC

1. Determine application being installed from Table 3.

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

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

11.

4. Ifdownflow subbase, KGASB is used, install as shown in Fig.

12. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part

No. KCAKC is used, install as shown in Fig. 13.

NOTE: It is recommended that the pert\_rated supply-air duct flanges be completely folded over or removed from furnace when installing the furnace on a factolT-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 t\_rth until it breaks off. Be careful of sharp edges. (See Fig. 14.)

A02098

1 3/4_

A02071

Fig. 10=Leveling Legs

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,

pert\_rm the following:

1. Tilt or raise furnace and remove 2 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.

HORIZONTAL INSTALLATION

Platt\_rm Furnace Support Construct working platform at location where all required furnace

clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in. clearance requirement on side, set furnace on non-combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended fiom the floor joists, the ground under-

neath furnace must be level and the furnace set on blocks or bricks. Roll-Out Protection

Provide a minimum 17-3/4" X 22" piece of sheet metal for flame roll-out protection in front of burner area for furnaces closer than

12 inches above the combustible deck or suspended furnaces closer than 12-in. to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. with the door removed.

The bottom closure panel on furnaces of widths 17-1/2 in. and larger may be used I\_r flame roll-out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper

orientation of roll-out shield.

Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in

bottom return-air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, perform the t\_llowing:

1. Tilt or raise furnace and remove 2 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 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 linlet.

Not all horizontal furnaces are approved for side return air connections (See Fig. 20.)

FILTER ARRANGEMENT

-__>

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Failure to t\_llow this warning could result in dangerous operation, serious injm% death or property damage. Do not install the furnace on its back or hang furnace with control COlnpamnent facing downward. Safety control opera- tion will be adversely affected. Never connect return-air ducts

to the back of the furnace.

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

Suspended Furnace Support The furnace may be supported under each end with threaded rod,

angle iron or metal plumber's strap as shown. (See Fig. 15 and 16.) Secure angle iron to bottom of furnace as shown. Heavy-gauge sheet metal straps (plumber's straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling

out, use 2 #8 x 3A-in. screws into the side and 2 #8 x 3A-in. screws in the bottom of the furnace casing t\_r 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) l\_r reliable support.

FIRE, CARBON MONOXIDE AND POISONING HAZARD

Failure to tMlow this warning could result in fire, personal injuw, or death. Never operate a furnace without a filter or with filter access

door removed.

There are no provisions t\_r an internal filter rack in these furnaces. A field-supplied accessoi T external filter rack is required.

This furnace requires KGAFR0301ALL 1" external filter rack or a suitable field-supplied substitute, such as the Media Cabinet.

Refer to the instructions supplied with external filter rack t\_r assembly and installation options.

AIR DUCTS General Requirements

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air 51!,stems Design Guide- lines reference tables available from your local distributor. The duct system should be sized to handle the required system design

Table 4reOpening Dimensions (in.)

FURNACE

CASING

WIDTH

Upflow Applications on Combustible or Noncombustible 13-5/16

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring 13-3/16

14-3/16 Downflow applications on combustible flooring (KGASB 13-7/16

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 13-5/16

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

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring 16-1/2 19-5/8

17-1/2 Downflow applications on combustible flooring (KGASB 16-3/4 20-5/8

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 16-1/2 20

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required) 20-1/8 22-1/4

Downflow Applications on Noncombustible Flooring 20 19-5/8

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

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 20 20

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required) 23-5/8 22-1/4

Downflow Applications on Noncombustible Flooring 23-1/2 19-5/8

24-1/2 Downflow applications on Combustible flooring (KGASB 23-3/4 20-5/8

Downflow Applications on Combustible Flooring with CD5 or

CK5 Coil Assembly or KCAKC coil box (KGASB subbase 23-1/2 20

APPLICATION

(KGASB subbase not required)

subbase required)

not required)

(KGASB subbase not required)

subbase required)

not required)

(KGASB subbase not required)

subbase required)

not required)

(KGASB subbase not required)

subbase required)

not required)

PLENUM OPENING

A B

12-11/16 21-5/8

12-9/16 19

11-13/16 19

12-5/16 19

16 21-5/8

15-7/8 19

15-1/8 19

15-1/2 19

19-1/2 21-5/8

19-3/8 19

18-5/8 19

19 19

23 21-1/8

22-7/8 19

22-1/8 19

22-1/2 19

FLOOR OPENING

22-1/4

19-5/8

20-5/8

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 can7 air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the

furnace. Secure ductwork with proper t:asteners t\)r type of ductwork used.

Seal supply- and return-duct connections to furnace with code approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork pass-

ing through unconditioned space should be insulated and sealed to enhance system perfom_ance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1-in. clearance from combustible materials to supply air ductwork t\_ra distance of 36 in. horizontally tiom the furnace. See

NFPA 90B or local code t\_r further requirements.

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow and 10 ft 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 t\_r Class 1 Rigid air

ducts. Supply Air Connections

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size

that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted t\)r sampling the air

strealn. The cover attachment shall prevent leaks. Upflow and Horizontal Furnaces Connect supply-air duct to flange 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 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.

Fig. 11--Floor and Plenum Opening Dimensions

A96283

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

-- FLOOR -- OPENING

A96285

Fig. 12mFurnace, Plenum, and Subbase installed on

a Combustible Floor

.-->

FURNACE

CD5 OR CK5

COiL ASSEMBLY

OR KCAKC

COiL BOX

_ COMBUSTIBLE

FLOORING ",

SHEET METAL

PLENUM

FLOOR

OPENING

X..-.../

A04140

Fig. 13mFurnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor

Downflow Furnaces Connect supply-air duct to supply-air outlet on furnace. Bend

flange inward past 90° with wide duct pliers. (See Fig. 14.) The supply-air duct must be connected to ONLY the furnace supply- outlet or air conditioning coil casing (when used). When installed on combustible material, supply-air duct must be connected to ONLY the accessol T subbase, KGASB0201ALL, or t:actory ap-

proved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accesso-

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

UPFLOW

I _L

DOWNFLOW

HORIZONTAL

120_ MIN

PREFERRED

PREFERRED PREFERRED PREFERRED

PERMITTED PERMITTED PERMITTED

PREFERRED

Fig. 14inDuct Flanges

V4"THREADED ROD

4 REQ.

I I

I I I

A02329

SSEMBLY

L_.

8" MIN FOR DOOR REMOVAL

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

--> Fig. 15mHorizontal Unit Suspension

Return Air Connections

FIRE HAZARD Failure to tMlow this warning could cause a fire, personal

injury , or death.

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 pem_itted t\_r only upflow and most

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WITH 3 #8 x 3/4" SCREWS

TYPICAL FOR 2 SUPPORTS

1" SQUARE, 1//4" x ll/4 '' x/Is" ANGLE IRON

OR UNI-STRUT MAY BE USED

horizontal furnaces. 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 to unused side return air side of the furnace casing. (See Fig. 18 and 20.)

Not all horizontal furnaces are approved t1_r side return air connections. (See Fig. 20.)

A05027

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