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HEATING & COOLING
58SX040 Deluxe'Gas-Fired Condensing Furnaces
Application Data
Installation Guidelines — Procedures
INTRODUCTIOIM
Portions of the following instructions have been adopted in part from the National Fuel Gas Code (NFPA 54-1984/ANSI Z223 1-1984) copyrighted by the National Fire Protection Association and American Gas Association. For further details, consult this publication, or the current edition available from National Fire Protection Association, Inc., Batterymarch Park, Quincy, M A 02269, or American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209.
These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept pace with changing residential construction prac tices. Carrier requires these standard procedures as a minimum for a safe installation.
Refer also to regulations of the local gas supplier as well as to local building, heating, plumbing, or other codes in effect in area in which installation is made.
A WARNING
Never store items such as the following on, near, or in contact with the furnace
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning compounds; plastic items or containers; gasoline, kerosene, cigarette lighter fluid, dry-cleaning fluids, or other volatile fluids.
3 Paint thinners and other painting compounds.
4. Paper bags or other paper products.
CONTENTS |
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Page |
INSPECTION ................................................................. |
I |
LOCATION OF FURNACE AND AIR FOR |
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VENTILATION ............................................................ |
1,2 |
GAS PIPING................................................................... |
2 |
COMBUSTION-AIR, VENT, AND |
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CONDENSATE PIPING ............................................... |
2-5 |
ELECTRICAL CONNECTIONS ..................................... |
5 |
START-UP, ADJUSTMENT, AND |
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SAFETY CHECK .......................................................... |
6,7 |
INSPECTION
Available power supply must meet specifications on furnace rating plate and on all motors in the equipment
Check the available gas supply to see that it conforms to the gas specification on the AGA rating plate.
LOCATION OF FURNACE AND
AIR FOR VENTILATION
Locate the furnace as near the center of the air distribu tion system as possible.
Provide ample space for servicing and cleaning. Always comply with the minimum fire protection clearances shown on the unit rating plate This furnace must NOT be installed directly on carpeting, tile, or any combustible material other than wood flooring.
A CAUTION
Do not install furnace in unconditioned space that could experience temperatures of 32 F or lower.
NOTE: For proper furnace operation, the furnace must be installed within 1/2 in of level.
When furnace supply ducts deliver air to areas outside the space containing the furnace, return air ducts must also be sealed to furnace casing and must terminate outside the space containing the furnace. Otherwise, a negative pressure condition could develop within equip ment room or space
Furnace Location Relative to Cooling Equip ment — Install cooling coil in parallel with, or on downstream side of, furnace to reduce potential for condensation in heat exchanger. When a coil is installed in parallel with a furnace, dampers or other means used to control airflow must prevent chilled air from entering furnace. For manual damper operation, equip dampers with a means of preventing operation of either unit unless damper is in the full-heat or full-cool position.
Special Locations — When installing furnace in a lesidential garage, protect it from physical damage by vehicles. Furnaces installed in public garages, airplane hangars, or other buildings having hazardous atmos pheres must comply with requirements of the National Fire Protection Association, Inc.
Ventilation Air — Requirements depend upon whether the furnace is located in an “unconfined” or “confined” space:
Unconfined space — A space whose volume is not less than 50 cu ft/1000 Btuh of the total input rating of all appliances installed in the space Rooms are considered a part of the unconfined space when they communicate through openings not furnished with doors with the space in which the appliances are installed.
No special ventilating means are required for furnaces installed in unconfined spaces
Confined space — A space whose volume is less than 50 cu ft/1000 Btuh of the total input ratings of all appliances installed in that space.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 11 |
PC 101 |
Catalog No 515-806 |
Printed in U S.A |
Form 58SX-3XA |
Pg 1 |
2-85 |
Replaces: New |
Tab 6a
For casing ventilation purposes, provide the confined space with 2 permanent openings, one within 12 in. of top and one within 12 in. of bottom of enclosure. Each opening shall have a minimum free area of one sq in / 1000 Btuh of total input rating of all equipment in enclosure, but not less than 100 sq inches
Openings must freely communicate with interior areas whose volume, when combined with tbe volume of the confined space, meet the criteria for an unconfined space. This can be accomplished through installation of either permanent openings or louvered doors.
LOUVERS AND GRILLES — When calculating the free area, consider the blocking effect of louvers, grilles, or screens protecting openings Screen mesh size must equal or exceed 1/4 inch Use the free area through the design of the louver or grille, when known, to calculate the opening size required to provide free area specified. If free area is not known, assume that wood louvers will have a 20 to 25% free area, while metal louvers and grilles will have a 60 to 75% free area. Construct all louvers and grilles providing combustion or dilution air so that they cannot be closed
GAS PIPING
Gas piping must be installed in accordance with national and local codes.
Run a separate gas supply line directly from the meter to the furnace, if possible Table 1 shows recommended gas pipe siziijg. Slope all pipe 1 /4 inch in 15 ft to prevent traps. Slope all horizontal runs away from meter and toward risers. Use risers to connect lines to furnace and meter.
Apply joint compounds (pipe dope) sparingly and only to male threads of joints Consult local gas supplier for compound recommendations.
NOTE Use only compounds resistant to the action of LP (propane) gas.
Install a sediment trap in the riser leading to the furnace to trap dirt and condensate. Connect a tee to the riser leading to the furnace, keeping straight-through section of tee vertical. Connect a capped nipple into lower end of tee, so that nipple extends below level of gas controls (Fig. I).
Where a gum filter is required by local codes, install it in accordance with their requirements.
An accessible manual shutoff valve must be installed upstream of furnace gas controls and within 6 ft of furnace. A 1/8-in. NPT plugged tapping, accessible for test-gage connection, must also be installed immediately upstream of gas supply connection to furnace and down stream of manual shutoff valve.
Install a ground joint union between gas control manifold and manual gas sbutoff valve (Fig 1).
Table 1 — Maximum Capacity of Pipe*
NOMINAL |
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INTERNAL |
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LENGTH OF PIPE (ft) |
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IRON |
PIPE |
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DIAMETER |
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SIZE (In.) |
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(in.) |
10 |
20 |
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30 |
40 |
50 |
|
'/2 |
|
|
0.622 |
175 |
120 |
|
97 |
82 |
73 |
Ÿ4 |
|
|
0.824 |
360 |
250 |
|
200 |
170 |
151 |
1 |
|
|
1.049 |
680 |
465 |
|
375 |
320 |
285 |
1V4 |
|
1.380 |
1400 |
950 |
|
770 |
660 |
580 |
|
IV2 |
|
1 610 |
2100 |
1460 |
|
1180 |
990 |
900 |
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‘Cubic ft |
of gas |
per hour, for |
gas pressures |
of 0 5 psig (14 |
in wg) |
||||
or less, and a pressure drop of 0 5 in wg (based on a 0 60 specific gravity gas)
Fig. 1 — Ground Joint Union and Sediment Trap
Protect all segments of the piping system against physical and thermal damage. Support all piping with appropriate straps or hangers (one hanger every 6 ft minimum). For pipe sizes larger than I/2 in., follow recommendations of national codes.
A CAUTION
If a flexible connector is required or allowed by the authority having jurisdiction, black iron pipe must be installed at the gas valve and extend a minimum of 2 in. outside the furnace casing
Pressure-test piping in accordance with local and national plumbing and gas codes before attaching furnace. Crack ground joint union before pressure testing If pressure exceedsO.5 psig( 14 in. wg), disconnect gas supply line from furnace before performing pressure test If test pressure is equal to or less than 0.5 psig (I4in. wg), close manual shutoff valve located on gas valve before testing
After final connection to the furnace has been made, purge lines and check for leakage with regulated gas supply pressure
A WARNING
Never purge line into combustion chamber. Never use matches, candles, flame, or other sources of ignition to check for gas leakage. Use a soap-and- water solution to check for leaks.
COMBUSTION-AIR, VENT, AND
CONDENSATE PIPING
Construct all combustion-air and vent pipes for this unit of schedule40 PVC, PVC-DWV, or ABS-DWV pipe. The accessory vent terminal kit described below must be used in constructing the vent terminal for this unit. Pipes must terminate through either roof or sidewall; roof termination is preferable Locate sidewall terminations to prevent damage to shrubs or siding materials. Table 2 gives clearance requirements.
When a previously common-vented system (furnace and water heater) is converted to water heater only, vent system may be drastically oversized for water heater. Consult National Fuel Gas Code for proper sizing and revise vent system if necessary.
A WARNING
Do NOT install unit so that indoor air is used for combustion
A CAUTION
Combustion air must not be taken from inside the structure because that air frequently is contaminated by halogens, which include fluoiides, chlorides, bromides, and iodides. These elements are found in aerosols, deteigents, bleaches, cleaning solvents, salts, air fresheners and other household products. Vapors from these products are highly corrosive to gas-fired furnaces, even in extremely low concentra tions (as low as 0 5 ppm).
Maintain a minimum ol .'16in between com bustion-air inlet and clothes-dryer vent
Locate combustion-air inlet as far as possible from swimming pool and swimming pool pump house
A CAUTION
When the vent pipe is exposed to temperatures below freezing — that is, when it passes through an un heated space or when a chimney is used as a raceway
— the pipe must be insulated with 1/2-in thick Armaflex insulation.
A CAUTION
When the combustion-air pipe is installed above a suspended ceiling, the pipe must be insulated with 1/2-in Armaflex insulation
The combustion-air pipe should also be insulated in warm, humid spaces such as basements.
Table 2 — Combustion-Air and
Vent Terminal Clearances
LOCATION |
CLEARANCE |
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Dryer vent |
3 |
ft |
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From plumbing vent stack |
3 |
ft |
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From any opening where vent gases could |
12 in. |
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enter building |
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Above grade and anticipated snow depth |
12 in. |
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Above grade when adjacent to public |
7 |
ft |
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walkway |
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Combustion-Air and Vent Piping — The schedule-40 PVC pipe and fittings must conform to American National Standards Institute (ANSI) stand ards and American Society for Testing and Materials (ASTM) standards D1785, D2661, or D2665. PVC pipe cement and primer must conform to ASTM D2235 or D2564. See 'Table 3 for pipe sizing and Fig. 3, 4 and 5 for exterior piping arrangements
A WARNING
Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well venti lated areas. Do NOT breathe vapors. Avoid contact with the skin or eyes.
A WARNING
All combustion-air and vent pipes must be airtight and watertight Pipes must terminate exactly as shown in Fig. 3 through 5
Furnace is shipped from factory assembled for righthand vent pipe connection. When left-hand vent connec tion is desired, remove cap from left-hand side of inducer outlet box and install over hole in right-hand side of box.
Remove plastic plug from left-hand casing side panel and install plug in unused hole in the right-hand casing side panel
Install the tuning valve in the vertical riser of the vent pipe 18 in. above the elbow, as shown in Fig 2
To install piping.
1. Attach factory-supplied flexible coupling to furnace combustion-air inlet connection and secure with stainless steel hose clamp. Ensure that factorysupplied, perforated metal combustion-air disc is installed in the flexible coupling
2 Working from furnace to outside, cut PVC pipe to required length(s).
3.Deburr inside and outside of pipe
4.Chamfer outside edge of pipe for better distribution of primer and cement
5.Clean and dry all surfaces to be joined.
6 Check dry fit of pipe and mark insertion depth on pipe.
NOTE: All pipe should be cut, prepared, and pre assembled before any joint is permanently cemented.
Table 3 — Pipe Diameter (in.)
PIPE |
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NUMBER OF 90° ELBOWS |
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LENGTH |
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(See Notes) |
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(H) |
1 |
2 |
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3 |
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4 |
5 |
5 |
2 |
2 |
|
2 |
|
2 |
2 |
10 |
2 |
2 |
|
2 |
|
2 |
2 |
15 |
2 |
2 |
|
2 |
|
2 |
2 |
20 |
2 |
2 |
|
2 |
|
2 |
2 |
25 |
2 |
2 |
|
2 |
|
2 |
2 |
30 |
2 |
2 |
|
2 |
|
2 |
2 |
35 |
2 |
2 |
|
2 |
|
2 |
2 |
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NOTES
1.Assume two 45° elbows equal one 90° elbow.
2.Pipe lengths are “up to and Including” the tabulated values
3.Diameters listed are for schedule-40 PVC, PVC-DWV or ABS-DWV pipe
4Long radius elbows are desirable
5Elbows and pipe sections supplied in vent terminal kit should not be included in count
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