Carrier 59MN7A, 59TP6A Series 2 Installation, Start-up, Operating And Service And Maintenance Instructions

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59MN7A Modulating 4---Way Multipoise Condensing Gas Furnace Series 200

Installation, Start---up, Operating and

Service and Maintenance Instructio ns

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

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

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

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 4...

ACCESSORIES 4.....................................

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

AIR FOR COMBUSTION AND VENTILATION 9..........

CONDENSATE TRAP 11...............................

Upflow 11........................................

Downflow 11.....................................

Horizontal 11......................................

CONDENSATE DRAIN 15.............................

INSTALLATION 18...................................

Upflow 18........................................

Downflow 18.....................................

Horizontal 19......................................

Filter Arrangement 19...............................

AIR DUCTS 28.......................................

Ductwork Acoustical Treatment 28.....................

GAS PIPING 32......................................

ELECTRICAL CONNECTIONS 33.......................

115--V Wiring 33...................................

J--Box Installation 34................................

24--V Wiring 34....................................

Accessories 34.....................................

Alternate Power Supplies 35..........................

VENTING 40........................................

Special Venting Requirements for Installations in Canada 40.

Materials 41.......................................

Venting Systems 41.................................

Locating Vent Termination 42.........................

Size the Vent and Combustion Air Pipes 42...............

Combustion Air and Vent Piping Insulation Guidelines 43...

Configure the Furnace 44............................

Installing the Vent Termination 46......................

Venting System Length Calculations 50.................

START--UP, ADJUSTMENT, AND SAFETY CHECK 64......

Select Setup Switch Positions 64........................

Prime Condensate Trap 64.............................

Purge Gas Lines 65...................................

Adjustments 66......................................

Check Safety Controls 69..............................

Checklist 69........................................

SERVICE AND MAINTENANCE PROCEDURES 79........

Cleaning Heat Exchangers 85...........................

SEQUENCE OF OPERATION 92........................

PARTS REPLACEMENT GUIDE 97......................

TABLE

Loose Parts Bag Contents 6..............................

Minimum Clearances to Combustible Materials 6.............

Minimum Free Area Required 10.........................

Minimum Space Volumes 10.............................

Filter Size Information 22...............................

Opening Dimensions 24................................

Air Delivery CFM 29...................................

Maximum Capacity of Pipe 33...........................

Electrical Data 35......................................

Vent Termination Kit for Direct Vent (2--Pipe) Systems 42......

Combustion--Air Vent Pipe, Fitting & Cement Material.. 47.....

Maximum Allowable Exposed Vent Lengths Insulation 48......

Maximum Equivalent Vent Length 49......................

Deductions from Maximum Equivalent Vent Length 49........

Altitude Derate Multiplier for U.S.A. 74....................

Blower Off Delay Setup Switch 74........................

Gas Rate 74..........................................

Orifice Size and Manifold Pressure 75.....................

CERTIFIED

Use of the AHRI Certified manufacturer’s participation in the program. For verification of certification for individual products, go to www.ahridirectory.org.

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1--2009E, 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.

Mark indicates a

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Required Notice for Massachusetts Installations

IMPORTANT

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

5.08: Modifications to NFPA--54, Chapter 10

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

whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back--up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors

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

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

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

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

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

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one--half (1/2) inch in size, ”GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

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

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

NFPA 54 as adopted by the Board; and

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

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

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

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

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

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

d. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When

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

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

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

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

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

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

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

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SAFETY CONSIDERATIONS

WARNING

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

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

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified 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.

WARNING

FIRE HAZARD

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

Solvents, cements and primers are combustible. Keep away from heat, sparks and open flame. Use only in well--ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.

CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

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.

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

personnel should install, repair, or service heating equipment.

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

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 up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

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 included in literature and attached to the unit.

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.

This is the safety--alert symbol . When you see this symbol on the furnace 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 a hazard which could result in personal injury or death. CAUTION is used to identify hazards which may result in minor personal injury or product and property damage. NOTE and NOTICE are used to highlight suggestions which will result in enhanced installation, reliability, or operation.

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 in the “Venting” 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 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 (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to convert furnace for use with propane gas.

11. See Table 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 in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

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13. These furnaces SHALL NOT be installed directly on carpeting, combustible 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. CNRV, CNPV, CAP, or CAR or when Coil Box Part No. KCAKC is used. See Table 2 for clearance to combustible construction information.

INTRODUCTION

The 4--way multipoise Category IV condensing furnace is CSA design--certified for both direct--vent (2-pipe) and ventilated combustion air venting installations. See Fig. 2. The furnace is factory--shipped for use with natural gas. The furnace can be converted in the field for use with propane gas when a factory-supplied conversion kit is used. Refer to the furnace rating plate for conversion kit information.

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(15_C) db or intermittent operation down to 55_F(13_C) db such as when used with a night setback

59MN7A

thermostat. Return-air temperature must not exceed 80_F(27_C) db. Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls. See Fig. 3.

The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air--Conditioning Engineers; or other approved engineering methods. Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely.

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

NOTE: Remove all shipping materials, loose parts bag, and literature before operating the furnace. See Table 1.

CODES AND STANDARDS

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

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

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

Safety

S US: National Fuel Gas Code (NFGC) NFPA 54--2009/ANSI

Z223.1--2009 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

S CANADA: National Standard of Canada, Natural Gas and

Propane Installation Code (NSCNGPIC) CAN/CSA B149.1--2010

General Installation

S US: NFGC and the NFPA 90B. For copies, contact the National

Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC contact the American Gas Association, 400 N. Capitol, N.W., Washington DC 20001

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

CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada

Combustion and Ventilation Air

S US: Section 9.3 of the NFPA54/ANSI Z223.1--2009 Air for

Combustion and Ventilation

S CANADA: Part 8 of the CAN/CSA B149.1--2010, 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

Acoustical Lining and Fibrous Glass Duct

S US and CANADA: current edition of SMACNA, NFPA 90B as

tested by UL Standard 181 for Class I Rigid Air Ducts

Gas Piping and Gas Pipe Pressure Testing

S US: NFPA 54/ANSI Z223.1--2009 NFGC; Chapters 5, 6, 7, and 8

and national plumbing codes. CANADA: CAN/CSA--B149.1--2010, Parts 4, 5, 6, and 9.

In the state of Massachusetts:

S This product must be installed by a licensed plumber or gas fitter. S When flexible connectors are used, the maximum length shall

not exceed 36 in. (914 mm).

S When lever typegas shutoffs are used they shall be T--handle

type.

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

state of Massachusetts.

Electrical Connections

S US: National Electrical Code (NEC) ANSI/NFPA 70--2011 S CANADA: Canadian Electrical Code CSA C22.1

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

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

1. Disconnect all power to the furnace. Multiple disconnects

may be required. DO NOT TOUCH THE CONTROL

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

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

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surface of the furnace again before touching control or wires.

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

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

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

ACCESSORIES

See Product Data Sheet for a list of accessories for this product.

LOCATION

General

These furnaces are shipped with materials to assist in proper furnace installation. These materials are shipped in the main blower compartment. See Table 1 for loose parts bag contents.

This furnace must:

S be installed so the electrical components are protected from

water.

S not be installed directly on any combustiblematerial other than

wood flooring (refer to SAFETY CONSIDERATIONS).

S be located close to the chimney or vent and attached to an air

distribution system. Refer to Air Ducts section.

S be provided ample space for servicing and cleaning. Always

comply with minimum fire protection clearances shown in Tabl e 2 or on the furnace clearance to combustible construction label.

CAUTION

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may result in 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.

WARNING

CARBON MONOXIDE POISONING / COMPONENT DAMAGE 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.

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 S Chemical storage areas

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

S Permanent wave solutions S Chlorinated waxes and cleaners S Chlorine based swimming pool chemicals S Water softening chemicals S De--icing salts or chemicals S Carbon tetrachloride S Halogen 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 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

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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.

WARNING

FIRE, INJURY OR DEATH 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 in. (457 mm) 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 NFPA 54/ANSI Z223.1--2009 or CAN/CSA B149.2--2010. See Fig. 5.

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Table 1 – Factory--Supplied Installation Parts

DESCRIPTION QUANTITY

AirIntakePipeFlange 1

Vent Pipe Flange 1

Coupling Flange Gaskets 2

Sharp Tip Screws (Vent and Inlet Flanges) 10

Vent Pipe Coupling 1

Vent Pipe Coupling Clamps 2

Rubber Drain Elbow 1

Drain Tube Clamps 4

1 / 2 --- i n . C P V C t o 3 / 4 --- i n . P V C P i p e A d a p t e r 1

Gas Line Grommet 1

Junction Box Cover 1

Junction Box Base 1

Green Ground Screw 1

Blunt Tip Screws (Junction Box) 3

Thermostat Wire Grommet 1

Drain Extension Tube (Z --- pipe) (Provided separately in furnace) 1

WARNING

FIRE HAZARD

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. 4.

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.

Table 2 – Minimum Clearances to Combustible Materials for All Units

POSITION CLEARANCE

Rear 0(0mm)

Front (Combustion air openings in furnace and in structure) 1in.(25mm)

Required for service *24 in. (610 mm)

All Sides of Supply Plenum *1 in. (25 mm)

Sides 0(0mm)

Vent 0(0mm)

Top of Furnace 1in. (25mm)

* Consult local building codes.

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29 1/2

[749.3]

28 3/4

[730.5]

[678.1]

26 11/16

26 3/8

[669.9]

[557.4]

21 15/16

21 1/16

[535.8]

20 5/8

[522.7]

AIR FLOW

[76.2]

1 3/4

[44.5]

AIR INTAKE

7/8

GAS CONN

[22.2]

REV

SHT

23 3/8

7/8

[22.2] POWER CONN

[63.5]

[101.6]

[889.0]

SIDE INLET

28 3/8

[720.4]

[757]

29 13/16

7/8

[22.2]

28 5/8

7/8

[22.2]

THERMOSTAT ENTRY

[420.9]

16 9/16

[442.3]

17 7/16

[458.6]

18 1/16

20 1/4

[513.9]

[609.7]

[726.9]

7/8

[22.2]

2 1/2

[76.2 ]

21 5/8

[592.0]

[549.5]

BOTTOM INLET

6 1/16

[154.0]

11/16

[17.5]

26 5/16

1 5/16

[33.3]

[668.8]

SD5024-4

PART NUMBER

NEXT SHEET

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NOTES:

1. Doors may vary by model.

2. Minimum return-air openings at furnace, based on metal duct. If ex duct is used,

see ex 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. Return air above 1800 CFM at 0.5 in. w.c. ESP on 24.5" casing, requires one of the following

congurations: 2 sides, 1 side and a bottom or bottom only. See Air Delivery table in this

document for specic use to allow for sucient airow to the furnace.

3. Vent and Combustion air pipes through blower compartment must

use accessory “Vent Kit - Through the Cabinet”. See accessory list for

current part number.

[58.4]

6 15/16

[176.1]

2 3/10

[76.2]

VENT

[76.2]

AIR INTAKE

[170.1]

6 11/16

TOP VIEW

[678.1]

26 11/16

26 3/8

[670.0]

25 1/8

[638.7]

23 5/16

[592.9]

20 5/8

[522.7]

19 1/8

OUTLET WIDTH

[76.2]

AIR INTAKE

[485.8]

AIR FLOW

5/8

[15.8]

1 3/4

AIR FLOW

[44.5]

GAS CONN

[76.2]

VENT

7/8

[22.2]

[101.6]

CONDENSATE DRAIN TRAP

LOCATION

7/8

32 5/8

28 3/16

7/8

[22.2] POWER CONN

2 1/2

[63.5]

7/8

[22.2]

[829.5]

[715.9]

[22.2]

28 5/8

[726.4]

23 7/16

SIDE INLET

[639.1]

25 3/16

[595.6]

22 15/16

20 1/4

[513.9]

[420.9]

16 9/16

14 13/16

7/8

[22.2]

THERMOSTAT ENTRY

[581.9]

[439.2]

17 5/16

[376.3]

WIDTH

BOTTOM RETURN

NOTE: ALL DIMENSIONS IN INCH [MM]

11/16

[17.5]

SEE NOTE #3

[668.8]

26 5/16

[534.0]

[558.3] (BOTH SIDES)

[25.4]

1 (BOTH SIDES)

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FURNACE SIZE

060--- 14 080--- 14 164.0 (73.8)

A B C D

CABINET WIDTH OUTLET WIDTH

17--- 1/2 (445) 15---7/8 (403) 16 (406) 8--- 3/4 (222)

060--- 20 080--- 20 168.5 (76.6)

21 (533) 19--- 3/8 (492) 19--- 1/2 (495) 10--- 1/2 (267) 100--- 22 178.5 (80.3) 120--- 22 24--- 1/2 (622) 22---7/8 (581) 23 (584) 12--- 1/4 (311) 202.5 (91.1)

BOTTOM

INLET WIDTH

Fig. 1 -- Dimensional Drawing

AIR INTAKE

SHIP WT.

LB (KG)

154.0 (69.3)

158.5 (72.0)

A12267

Page 8

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

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

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

59MN7A

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A12181

Fig. 2 -- Multipoise Orientations

80 / 27˚C

SUPPLY AIR

/ 16˚C

A10490

Fig. 3 -- Freeze Protection and Return Air Temperature

BACK POSITIONED

DOWNWARD

BACK POSITIONED

UPWARD

Fig. 4 -- Prohibited Installations

AIR RETURN

CUT IN BACK

A12182

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 5 -- Installation in a Garage

Page 9

AIR FOR COMBUSTION AND

VENTILATION

Introduction

Direct Vent (2--pipe) Applications

When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required. However, other gas appliances installed in the space with the furnace may require outside air for combustion. Follow the guidelines below to insure that other gas appliances have sufficient air for combustion.

Ventilated Combustion Air Applications

When the furnace is installed using the ventilated combustion air option, the attic or crawlspace must freely communicate with the outdoor to provide sufficient air for combustion. The combustion air pipe cannot be terminated in attics or crawlspaces that use ventilation fans designed to operate during the heating season. If ventilation fans are present in these areas, the combustion air pipe must terminate outdoors as a Direct Vent/ 2-Pipe system.

All air for combustion is piped directly to the furnace from a space that is well ventilated with outdoor air (such as an attic, crawl space, or equipment closet) and the space is well isolated from the living space or garage. In addition, other gas appliances installed in the space with the furnace may require outside air for combustion. Follow the guidelines below to insure that the roof or crawlspace walls have sufficient free area to provide sufficient air for combustion and ventilation for the furnaces. The guidelines below can be used to insure that other gas appliances have sufficient air for combustion.

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

S U.S.A. Installations: Section 9.3 of the NFPA 54/ANSI

Z223.1--2009 , Air for Combustion and Ventilation and applicable provisions ofthe local building codes.

S Canada: Part 8 of the CAN/CSA--B149.1--2010, Venting

Systems and Air Supply for Appliances.

Outdoor Combustion Air Method

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. 6 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

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. 6 and Table 3.

c. TWO HORIZONTAL DUCTS require 1 sq.in. (645 sq.

mm) of free areaper 2,000 Btuh (1,100mm binedinputforall gas appliances in the spaceperFig.6 and Tab le 3.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

sq. in. (645 sq. mm) of free area per 4,000 Btuh (550

/kW) for combined input of all gas appliances in the

mm space per Fig. 6 and Table 3.

3. ONE OUTDOOR OPENING requires:

a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh (734

/kW) for combined input of all gas appliances in the

mm space per Fig. 6 and Table 3.

b. Not less than thesum of the areasof all vent connectors in

the space.

The opening shall commence within 12 in. (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (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.

/kW) of com-

59MN7A

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.

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 the Carbon Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount ofmake--up air is available.

Page 10

Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

TWO HORIZONTAL DUCTS

FURNACE

INPUT

(BTUH)

40,000*

60,000

80,000 100,000 120,000

140,000*

*Not all families have these models.

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

(1,100 SQ. MM/KW)

Free Area of

Opening and Du ct

Sq. In (Sq. mm)

20 (12904) 5 (127) 14 (8696) 5 (127) 10 (6452) 4 (102)

30 (19355) 6 (152) 20 (13043) 5 (127) 15 (9678) 5 (127)

40 (25807) 7 (178) 27 (17391) 6 (152) 20 (12904) 5 (127)

50 (32258) 8 (203) 34 (21739) 7 (178) 25 (16130) 6 (152)

60 (38709) 9 (229) 40 (26087) 7 (178) 30 (19355) 6 (152)

70 (45161) 10 (254) 47 (30435) 8 ( 203) 35 (22581) 7 (178)

Round Duct

In. (mm) Dia

FURNACE WATER HEATER TOTAL INPUT

100,000 + 30,000 = (130,000 divided by 4,000) = 32.5 Sq. In. for each two Vertical Ducts or Openings

60,000 + 40,000 = (100,000 divided by 3,000) = 33.3 Sq. In. for each Single Duct or Opening

80,000 + 30,000 = (110,000 divided by 2,000) = 55.0 Sq. In. for each two Horizontal Ducts

Table 4 – Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors

OTHER THAN FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

59MN7A

NP = Not Permitted

ACH

0.60

0.50

0.40

0.30

0.20

0.10

0.00

30 40 50 40 60 80 100 120 140

1,050 (29.7)

1,260 (35.6)

1,575 (44.5)

2,100 (59.4)

3,150 (89.1)

6,300

(178.0)

NP NP NP NP NP NP NP NP NP

1,400 (39.6)

1,680 (47.5)

2,100 (59.4)

2,800 (79.2)

4,200

(118.9)

8,400

(237.8)

1,750

(49.5)

2,100 (59.4)

2,625 (74.3)

3,500 (99.1)

5,250

(148.6)

10,500 (297.3)

SINGLE DUCT OR OPENING

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

(734 SQ. MM/KW)

Free Area of

Opening and Du ct

Sq. In (Sq. mm)

Round Duct

In. (mm) Dia

EXAMPLES: Determining Free Area

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

SpaceVolumeFt3(M3)

1,400 (39.6)

1,680 (47.5)

2,100 (59.4)

2,800 (79.2)

4,200

(118.9)

8,400

(237.8)

1,500 (42.5)

1,800 (51.0)

2,250 (63.7)

3,000 (84.9)

4,500

(127.3)

9,000

(254.6)

2,000

(56.6)

2,400

(67.9)

3,000

(84.9)

4,000

(113.2)

6,000

(169.8)

12,000

(339.5)

TWO OPENINGS OR

VERTICAL DUCTS

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

Free Area of Open-

2,500 (70.8)

3,000 (84.9)

3,750

(106.1)

5,000

(141.5)

7,500

(212.2)

15,000 (424.4)

(550 SQ. MM/KW)

ing and Duct

Sq. In (mm)

3,000 (84.9)

3,600

(101.9)

4,500

(127.3)

6,000

(169.8)

9,000

(254.6)

18,000 (509.2)

Round Duct

In. (mm) Dia.

3,500

(99.1)

4,200

(118.9)

5,250

(148.6)

7,000

(198.1)

10,500 (297.1)

21,000 (594.1)

*Minimum dimensions of 3‐in. (76mm)

NOTE: Use any of the following combinations of openings:

Fig. 6 -- Air for Combustion, Ventilation, and Dilution for Outdoors

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

L12F012

Page 11

CONDENSATE TRAP

Condensate Trap--Upflow Orientation

When the furnace is installed in the upflow position, it is not necessary to relocate the condensate trap or associated tubing. Refer to Fig. 7 for upflow condensate trap information. Refer to Condensate Drain section for information how to install the condensate drain.

Condensate Trap--Downflow Orientation.

When the furnace is installed in the downflow position, the condensate trap will be initially located at the upper left corner of the collector box, as received from the factory. See the top image in Fig. 8. When the furnace is installed in the downflow orientation, the condensate trap must be relocated for proper condensate drainage. See the bottom image in Fig. 8.

To Relocate the Condensate Trap:

S Orient the furnace in the downflow position. S Fig. 8 shows the condensate trap and tubing before and after

relocation. Refer to Fig. 8 To begin the trap conversion.

S Refer to Condensate Drain section for information how to install

the condensate drain.

Condensate Trap--Horizontal Orientation.

When the furnace is installed in the horizontal right position, the condensate trap will be initially located at the bottom left corner of the collector box, as received from the factory. See the top image in Fig. 9. When the furnace is installed in the horizontal left position, the condensate trap will be initially located at the top of the collector box, as received from the factory. See the top image in Fig. 10. In both cases, the trap must be repositioned on the collector box for proper condensate drainage. See the bottom images in Fig. 9 and 10.

A field--supplied, accessory Horizontal Installation kit (trap grommet) is required for all direct--vent horizontal installations (only). The kit contains a rubber casing grommet designed to seal between the furnace casing and the condensate trap. See Fig. 17.

NOTICE

The field--supplied, accessory horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. It it NOT required for applications using single--pipe or ventilated combustion air venting.

NOTICE

The condensate trap extends below the side of the casing in the horizontal position. A minimum of 2--in. (51 mm) of clearance is required between the casing side and the furnace platform for the trap to extend out of the casing in the horizontal position. Allow at least 1/4--in. per foot (20 mm per meter) of slope down.

To Relocate the Condensate Trap:

S Remove the knockout in the casing for the condensate trap. S Install the grommet in the casing when required for direct--vent

horizontal applications.

S Orient the furnace in the desired position. S Allow for 2 in. (51 mm) of clearance underneath the furnacefor

the condensate trap and drain line.

S Fig. 9 shows the condensate trap and tubing before and after

relocation in the horizontal right position.

S Fig. 10 shows the condensate trap and tubing before and after

relocation in the horizontal left position.

S Refer to the appropriate figure to begin the trap conversion. S Refer to Condensate Drain section for information how to install

the condensate drain.

59MN7A

Collector Box

Plugs

Condensate Trap

Relief Port

Fig. 7 -- Upflow Trap Configuration

Vent Pipe Clamp

Pressure Switch

(Appearance May Vary)

Vent Elbow Clamp

Vent Elbow

Collector Box

Plug

Condensate Trap

Relief Port

Condensate Trap

Outlet

Port

A11306

Page 12

Remove relief tube from relief port on condensate trap.

Remove pressure switch tube from pressure switch port.

Remove trap from collector box.

Loosen clamp on inlet to vent elbow.

59MN7A

Remove middle and bottom plugs. DO NOT DISCARD.

Install plugs on open ports on collector box.

Connect relief tube to port on collector box.

Remove tube from relief port.

Trim excess tube. Connect pressure switch tube to port on collector box.

Attach condensate trap with screw to collector box.

Rotate elbow to desired position and

tighten clamp to 15 lb.-in.

Slide tube in stand-offs to adjust length.

Connect relief tube to relief port on condensate trap.

Align condensate trap over middle and bottom ports of collector box.

A11585

Fig. 8 -- Downflow Trap Configuration

(Appearance May Vary)

Page 13

Remove plug from collector box. DO NOT DISCARD.

Unconverted Factory Trap Configuration

As Viewed in the Horizontal Right Orientation

If alternate vent position is required, loosen clamp on inlet of vent elbow.

Remove trap from collector box.

59MN7A

Attach condensate trap to collector box with screw.

Install plug in open port on collector box.

Horizontal Right Trap Configuration

Slide relief tube in stand-offs to adjust length.

Vent elbow shown in alternate orientation. Tighten clamp on inlet to vent elbow 15 lb.-in.

Align trap over middle and right-hand port on collector box.

A11278

Fig. 9 -- Horizontal Right Trap Configuration

(Appearance May Vary)

Page 14

If alternate vent position is required, loosen clamp on vent elbow inlet.

Remove trap from collector box.

Remove relief tube from relief port on condensate trap.

Remove pressure switch tube from port on collector box.

59MN7A

Remove relief tube from port on collector box.

Remove middle and right plug from collector box. DO NOT DISCARD

Unconverted Factory Trap Configuration

As Viewed in the Horizontal Left Orientation

Install plugs in open

Rotate elbow to desired position and torque clamp on inlet 15 lb.-in.

Slide relief tube in stand-offs to adjust length.

ports on collector box.

Connect relief tube to port on collector box.

Attach condensate trap to collector box with screw.

Align trap over middle and right-hand port on collector box.

Horizontal Left Trap Configuration

Trim excess tube. Route pressure switch tube underneath relief tube and connect to port on collector box.

Connect relief tube to relief port on condensate trap.

A11586

Fig. 10 -- Horizontal Left Configuration

(Appearance May Vary)

Page 15

CONDENSATE DRAIN CONNECTION

CAUTION

FROZEN AND BURST WATER PIPE HAZARD

Failure to protect against the risk of freezing may result in property damage.

Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper operation or damage to equipment. If furnace environment has the potential of freezing, the drain trap and drain line must be protected. The use of accessory drain trap heaters, electric heat tape and/or RV antifreeze is recommended for these installations.

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in burst water pipes and/or property damage.

If a condensate pump is installed, a plugged condensate drain or a failed pump may cause the furnace to shut down. Do not leave the home unattended during freezing weather without turning off water supply and draining water pipes or otherwise protecting against the risk of frozen pipes.

DO NOT trap the drain line in any other location than at the condensate drain trap supplied with the furnace. If possible, DO NOT route the drain line where it may freeze. The drain line must terminate at an inside drain to prevent freezing of the condensate and possible property damage.

Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper operation or damage to the equipment. If the furnace environment has the potential of freezing, the drain trap and drain line must be protected. A self--regulating, shielded and waterproof heat tape rated at 3 to 6 watt per foot (10 to 20 watt per meter) at 115 volt, 40_F(4_C) may be used to help provide freeze protection. Wrap the drain trap and drain line with the heat tape and secure with appropriate plastic ties. Follow the heat tape manufacturer’s recommendations. Prime the trap before furnace operation.

Upflow/Downflow Orientation

In the Upflow or Downflow orientation, the condensate trap is inside the furnace casing. The condensate drain must be routed from the trap through the furnace casing. The condensate drain can be routed through the left or right side of the casing. (The left or right side is as you are viewing/facing the furnace from the front.) The furnace condensate drain can be connected to the indoor coil condensate drain, humidifier or auxiliary drain traps as shown in Fig. 12.

NOTE: On narrower casings, it may be easier to remove the condensate trap, connect the drain line components and re-install the condensate trap. Read the steps thoroughly to familiarize yourself with the required steps.

For Right Side Condensate Drain:

1. Remove the 7/8--in. knock--out from the right side of the casing. See Fig. 11 for suggested knockout removal technique.

2. Remove the pre--formed rubber drain elbow and two spring clamps from the loose parts bag.

3. Slide a spring clamp 1--in. (25 mm) down the plain end (the end without the formed grommet) of the drain elbow.

4. From inside the casing, insert the formed grommet end of the elbow through the 7/8--in. knockout in the casing.

5. Pull the grommet through the casing from the outside until it is seated in the knockout

6. Attach the plain end of the drain elbow to the outlet stub on the drain trap. Secure the drain elbow to the trap with the spring clamp.

The remaining drain line can be constructed from field supplied 1/2--in. CPVC or 3/4--in. PVC pipe, in compliance with local building codes. A factory--supplied 1/2--in. CPVC to 3/4--in. PVC adapter is supplied in the loose parts bag for use as required.

7. Install the adapter or connect the 1/2--in. CPVC pipe by sliding a spring clamp over the open end of the grommet on the outside the furnace casing.

8. Open the spring clamp and insert the long end of the adapter or the 1/2--in. CPVC pipe into the outlet stub on the drain tube.

9. Connect additional condensate piping to a code--approved drain, or to a condensate pump approved for use with acidic furnace condensate and compatible with mineral and vegetable oils, such as canola oil.

Allow at least 1/4-in. per foot (20 mm per meter) of slope down and away from the furnace in horizontal sections of drain line.

TIP FROM CONTRACTORS: Contractors have found that temporarily removing the inducer assembly in upflow applications while performing the steps, below, makes upflow left--side drain connections easier.

For Left Side Condensate Drain Connection:

1. For left side condensate drainage, the drain line is routed from the condensate trap, behind the inducer (upflow) or gas valve (downflow) and out through the left side of the furnace casing. A pre-formed 1/2--in. CPVC “Z-pipe” is provided with the furnace. The Z-pipe is long enough to extend across the casing for drain connections.

2. Locate the Z-pipe. Remove the pre-formed drain elbow and four spring clamps from the loose parts bag.

3. The Z-pipe is connected to the condensate trap and the outside of the furnace by modifying the formed rubber drain elbow as shown in Fig. 14.

4. Remove the formed grommet from the rubber drain elbow by cutting the elbow along the vertical line located about 1--3/8 in. (35 mm) away from the formed grommet. See Fig.

14. DO NOT DISCARD THE FORMED GROMMET OR THE RUBBER ELBOW. Both of these pieces will be used.

Assemble and route the drain line to the opposite side of the furnace as detailed below:

5. Remove the knock-out from the left side of the casing. See Fig. 11 for suggested knockout removal technique.

6. From the outside of the casing, insert the angled end of the Z-pipe through drain hole in the left side of the casing and behind the inducer or gas valve. Allow the Z-pipe to temporarily rest on the blower shelf (upflow) or burner box (downflow). (NOTE: When the inducer housing has been removed to ease installation in upflow applications, this step is not needed.)

7. After inserting the Z--pipe through the casing, slide a spring clamp over each end of the Z--pipe.

8. From inside the casing, insert the short end of the formed grommet cut from the rubber drain elbow through the 7/8-in. drain knockout in the casing.

9. Pull the grommet through the casing from the outside until it is seated in the knockout.

10. Align the Z-pipe with the long end of the grommet inside the furnace and insert slightly. The angled end of the tube at

59MN7A

Page 16

the other side of the casing should be facing the front of the furnace.

11. Slide a spring clamp over the end of the remaining rubber drain elbow.

12. Attach the drain elbow to the angled end of Z-pipe and the drain trap outlet stub. Adjust the length of Z-pipe inserted into the grommet at the opposite side of the furnace as necessary for proper fit and positioning. In both upflow and downflow orientations, the Z-pipe should NOT be resting on any sheet metal parts.

13. Secure the rubber elbow to the drain trap and the Z-pipe with spring clamps.

14. Secure the grommet to the Z-pipe with the spring clamp.

The remaining drain line can be constructed from field supplied 1/2--in. CPVC or 3/4--in. PVC pipe, in compliance with local building codes. A factory-supplied 1/2--in. CPVC to 3/4--in. PVC adapter is supplied in the loose parts bag for use as required.

15. Install the adapter or connect the 1/2--in. CPVC pipe by sliding a spring clamp over the open end of the grommet on the outside the furnace casing.

16. Open the spring clamp and insert the long end of the

59MN7A

adapter or the 1/2--in. CPVC pipe into the outlet stub on the drain tube.

17. Connect additional condensate piping to a code-approved drain, or to a condensate pump approved for use with acidic furnace condensate and compatible with mineral and vegetable oils, such as canola oil.

Allow at least 1/4-in. per foot (20 mm per meter) of slope down and away from the furnace in horizontal sections of drain line.

7. The remaining drain line can be constructed from field-supplied 1/2--in. CPVC or 3/4--in. PVC pipe, in compliance with local building codes. A factory--supplied 1/2--in. CPVC to 3/4--in. PVC adapter is supplied in the loose parts bag for use as required.

8. Install the adapter or connect the 1/2--in. CPVC pipe by sliding a spring clamp over the open end of the elbow or grommet on the outside the furnace casing.

9. Open the spring clamp and insert the long end of the adapter or the 1/2--in. CPVC pipe into the outlet stub on the drain tube.

10. Connect additional condensate piping to a code--approved drain, or to a condensate pump approved for use with acidic furnace condensate and compatible with mineral and vegetable oils, such as canola oil.

Allow at least 1/4-in. per foot (20 mm per meter) of slope down and away from the furnace in horizontal sections of drain line.

NOTICE

The field--supplied, accessory horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. It is NOT required for applications using single--pipe or ventilated combustion air venting.

TIP FROM CONTRACTORS: When installing the furnace horizontally, use the entire drain elbow (that is, do NOT cut as shown in Fig. 14 to connect the trap to the drain line. This helps to prevent bumps and shocks to the drain line from damaging the furnace drain trap. Avoid misalignment of the drain pipe which may cause kinks in the elbow.

Horizontal Orientation

1. The condensate trap outlet extends 2--in. (51 mm) below the furnace casing. Leave enough clearance between the furnace and the furnace platform for the trap.

2. To allow for servicing the trap, the condensate drain elbow in the loose parts bag can be used to make a coupler to allow for future service of the condensate trap and drain line.

3. Remove the knock-out for the condensate trap in the side of the casing.

4. Install the drain trap grommet in the casing if required for direct--vent applications. If necessary, remove the trap, install the grommet and re-install the trap.

5. Remove the pre-formed rubber drain elbow, and two spring clamps from the loose parts bag.

6. Connect the full or modified elbow and/or grommet to the outlet of the condensate trap with one spring clamp. Avoid misalignment of the drain pipe which may cause kinks in the elbow or grommet.

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.

L12F019B

Fig. 11 -- Knockout Removal

OPEN STAND PIPE FOR A/C OR HUMIDIFIER DRAIN

TEE

TO OPEN DRAIN

Fig. 12 -- Example of Field Drain Attachment

A11276

Page 17

INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAP

PULL DRAIN STUB THROUGH CASING

OPEN SPRING CLAMP

INSERT FACTORYïSUPPLIED 1/2ïIN. CPVC TO 3/4ïIN. PVC ADAPTER OR 1/2ïIN. CPVC PIPE

*CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN TUBE

NOTE: Trap grommet is required only for direct-vent applications.

Remove knockout. Install grommet before relocating condensate trap.

59MN7A

Fig. 13 -- Formed Rubber Drain Grommet

A11342A

Fig. 15 -- Horizontal Drain Trap Grommet

Attach elbow to condensate trap

Cut formed end off

Formed end of grommet

Factory supplied 1/2ïin. CPVC to 3/4ïin. PVC adapter

TRAP, DRAIN ELBOW WITH DISCHARGE PIPE

Formed end of grommet Open spring clamp. Insert 1/2ïin. to 3/4ïin. CPVC to PVC adapter or 1/2ïin. CPVC pipe

condensate drain elbow

Connect short end of “Z” pipe to modified drain elbow

A11582

Modified drain elbow connect to condensate trap and “Z” pipe

Fig. 14 -- Modify Rubber Drain Elbow

A11581

NOTE: Remove Inducer Housing for easier access, if desired.

LEFT SIDE DRAIN ROUTED BEHIND INDUCER

L12F015

Fig. 16 -- Drain Trap Connection and Routing

(Appearance may vary)

Page 18

INSTALLATION

NOTICE

This furnace is certified to leak 2% or less of nominal air conditioning CFM delivered when pressurized to 1--in. water column with all present air inlets, including bottom closure in upflow and horizontal applications, air outlets, and plumbing and electrical ports sealed.

Upflow Installation

NOTE: The furnace must be pitched as shown in Fig. 22 for

proper condensate drainage.

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 for sampling the air stream. The cover attachment shall prevent leaks.

59MN7A

Connect supply--air duct to flanges on furnace supply--air outlet. Bend flange upward to 90_ with wide duct pliers. See Fig. 19. 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 supply--side accessories MUST be connected to duct external to furnace main casing.

Return Air Connections

WARNING

FIRE HAZARD

A 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.

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. Bypass humidifier may be attached into unused return air side of the furnace casing. See Fig. 23, 24, 25.

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove this panel when bottom return air is used. This panel may be used as the bottom closure of an accessory bottom return air box, or discarded. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 4 screws holding bottom plate. See Fig. 21.

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate 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.

NOTE: Side return--air openings can be used in UPFLOW and some HORIZONTAL configurations. Do not use side return--air openings in DOWNFLOW configuration. See Fig. 23, 24, and

25.

Leveling Legs (If Desired)

In upflow position with side return inlet(s), leveling legs may be used. See Fig. 20. 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 in Step 1 above.

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace.

2. For each leg, install nut on bolt and then install bolt with 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: The furnace must be pitched as shown in Fig. 22 for

proper condensate drainage.

Supply Air Connections

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 Box Part No. KCAKC

1. Determine application being installed from Table 8.

2. Construct hole in floor per Table 8 and Fig. 18.

3. Construct plenum to dimensions specified in Table 8 and Fig. 18.

4. Install special base coil assembly or coil box as shown in in Fig. 18.

NOTE: It is recommended that the perforated supply--air duct flanges be completely 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. 19.

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.

Connect supply--air duct to supply--air outlet on furnace. Bend flange inward past 90_ with wide duct pliers. See Fig. 19. 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 factory--approved accessory subbase, 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 supply--side accessories MUST be connected to duct external to furnace casing.

Page 19

Return Air Connections

WARNING

FIRE HAZARD

A 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.

The return--air duct must be connected to return--air opening (bottom inlet). DO NOT cut into casing sides (left or right). Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. See Fig. 24.

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 in downflow applications. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 4 screws holding bottom plate. See Fig. 21.

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate and screws.

Horizontal Installation

NOTE: The furnace must be pitched forward as shown in Fig. 22

for proper condensate drainage.

WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

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

CAUTION

MINOR PROPERTY HAZARD

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

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

The furnace can be installed horizontally in an attic or crawlspace 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.

Platform Furnace Support

Construct working platform at location where all required furnace clearances are met. See Table 2 and Fig. 26.) For furnaces with 1--in. (25 mm) clearance requirement on side, set furnace on non--combustible blocks, bricks or angle iron. For crawlspace 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.

Suspended Furnace Support

The furnace must be supported under the entire length of the furnace with threaded rod and angle iron. See Fig. 27. Secure angle iron to bottom of furnace as shown.

Roll--Out Protection

Provide a minimum 12--in. x 22--in. (305 x 559 mm) piece of sheet metal for flame roll--out protection in front of burner area for furnaces closer than 12--in. (305 mm) above the combustible deck or suspended furnaces closer than 12--in. (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. 26 for proper orientation of roll--out shield.

Supply Air Connections

Connect supply--air duct to flanges on furnace supply--air outlet. Bend flange upward to 90_ with wide duct pliers. See Fig. 19. 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.

Return Air Connections

The return--air duct may be connected to bottom of the furnace. The side of casing that faces downward may also be used for return air connection. A combination of the bottom and downward facing side may also be used. The upward facing side of the casing cannot be used as a return air connection. See Fig. 25.

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove this panel when bottom return air is used. This panel may be used as a roll--out shield or discard. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 4 screws holding bottom plate. See Fig. 21.

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate 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) are used without a bottom return air inlet.

Not all horizontal furnaces are approved for side return air connections. See Fig. 25.

Filter Arrangement

WARNING

FIRE, CARBON MONOXIDE AND POISONING HAZARD

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

Never operate a furnace without a filter or filtration device installed. Never operate a furnace with filter or filtration device access doors removed.

59MN7A

Page 20

There are no provisions for an internal filter rack in these furnaces. An external filter is required.

The furnace is shipped with a factory-supplied Media Filter Cabinet. The Media Filter Cabinet uses either a standard 1--in. (25 mm) filter or 4--in. (102 mm) wide Media Filter which can be purchased separately. A field supplied accessory air cleaner may also be used in place of the media cabinet.

The Media Cabinet is sized for bottom return applications for use in upflow, downflow and horizontal applications. A 16--inch (406 mm) Media Cabinet is shipped with the 14--3/16-in. (360 mm) furnace and includes block-off plates.

For upflow side return applications, the Media Cabinet (or field supplied accessory air cleaner) can be installed on the side of the furnace or side and bottom when a bottom plenum is used. See Fig. 17 and 23.

For downflow applications, the Media Cabinet (or field supplied accessory air cleaner) must only be connected to the bottom opening on the furnace. See Fig. 17 and 24.

For horizontal applications, the Media Cabinet (or field supplied accessory air cleaner) for all models can be connected to the bottom opening on the furnace. For side return use in the horizontal position, refer to Fig. 25. If both side and bottom

59MN7A

openings are used in Fig. 25, each opening used will require a filter.

The media cabinet (or field supplied accessory air cleaner) can also be installed in the common return duct prior to entering the return air opening in any orientation.

Refer to the instructions supplied with Media Cabinet or accessory air filter for assembly and other details. See Table 7 for filter size details.

Filter and Return Duct Sizing

Pressure drop must be taken into account when sizing filters, filter racks, IAQ devices, and associated system ductwork. See Table 5 for a comparison of Pressure Drop (initial/clean resistance to airflow) versus Airflow for a variety of filter media types and sizes. These are representative numbers. Consult the filter or IAQ device manufacturers’ specification sheet for performance data for a particular filter media or IAQ device.

Design the filter and associated ductwork for the best match of pressure drop versus filter size. Best practice usually chooses filter systems with pressure drops under 0.2 in. W.C. (50 Pa), with the best blower electrical efficiency and system airflow performance occurring with filter pressure drops under 0.1 in. W.C. (25 Pa).

NOTICE

Design the duct system FIRST to determine how much pressure drop may be allowed in the filter system. See the Air Ducts section. Excessive filter pressure drop often compromises system airflow and duct performance, causes inadequate airflow to the furthest ends of the duct system, as well as causes excess noise and higher than anticipated electrical consumption.

Provide duct transitions, as required, to smoothly transition airflow from the return duct system to the filter (or IAQ device) to the furnace when the dimensions of the ductwork or furnace return air opening do not match the required filter or IAQ device dimensions. See the instructions supplied with factory--accessory duct adapters.

Page 21

Table 5 – Filter Media Pressure Drop (Clean) Versus Airflow -- In. W.C. (Pa)

14 x 25 Filter

(356 x 635 mm)

CFM L/s (1-in. / 2.5 cm) (4-in. / 10 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

600 (283) 0.04 (12) 0.05 (12) 0.07 (17) 0.10 (26) 0.24 (60) 0.16 (40)

800 (378) 0.06 (15) 0.07 (19) 0.10 (25) 0.15 (39) 0.34 (85) 0.23 (59) 1000 (472) 0.07 (18) 0.10 (27) 0.13 (34) 0.21 (52) - - 0.32 (81) 1200 (566) 0.08 (20) 0.14 (36) 0.17 (43) 0.27 (68) - - - -

Factory-Accessory

Washable

Factory-Accessory

Media*

Representative After-Market Filter Media*

Fiberglass* Pleated*

16 x 25 Filter

(406 x 635 mm)

CFM L/s (1-in. / 2.5 cm) (4-in. / 10 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

600 (283) 0.04 (10) 0.05 (13) 0.06 (15) 0.09 (22) 0.20 (51) 0.13 (34)

800 (378) 0.05 (13) 0.07 (18) 0.08 (21) 0.13 (32) 0.29 (72) 0.20 (49) 1000 (472) 0.06 (16) 0.11 (28) 0.11 (28) 0.17 (43) - - 0.27 (67) 1200 (566) 0.07 (18) 0.15 (37) 0.14 (36) 0.22 (56) - - - 1400 (661) 0.08 (21) 0.19 (48) 0.18 (45) 0.28 (70) - - - 1600 (755) 0.09 (23) 0.24 (60) 0.21 (54) - - - - - 1800 (850) 0.10 (25) - - 0.26 (64) - - - - - -

20 x 25 Filter

(508 x 635 mm)

CFM (L/s) (1-in. / 2.5 cm) (4-in. / 10 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

800 (378) 0.04 (11) 0.05 (12) 0.06 (16) 0.09 (24) 0.22 (55) 0.15 (37) 1000 (472) 0.05 (13) 0.07 (18) 0.08 (21) 0.13 (32) 0.29 (72) 0.20 (49) 1200 (566) 0.06 (15) 0.09 (22) 0.11 (27) 0.16 (41) - - 0.25 (63) 1400 (661) 0.07 (17) 0.12 (31) 0.13 (33) 0.20 (51) - - 0.31 (79) 1600 (755) 0.08 (19) 0.15 (38) 0.16 (40) 0.24 (61) - - - 1800 (850) 0.08 (21) 0.18 (47) 0.18 (47) 0.29 (73) - - - 2000 (944) 0.09 (23) 0.22 (56) 0.21 (54) - - - - - 2200 (1038) 0.09 (24) 0.26 (66) 0.25 (62) - - - - - -

25 x 25 Filter

(635 x 635 mm)

CFM L/s (1-in. / 2.5 cm) (4-in. / 10 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

800 (378) 0.03 (9) 0.03 (8) 0.05 (12) 0.07 (18) 0.17 (43) 0.11 (28) 1000 (472) 0.04 (11) 0.05 (12) 0.06 (16) 0.09 (24) 0.22 (55) 0.15 (37) 1200 (566) 0.05 (13) 0.07 (17) 0.08 (20) 0.12 (31) 0.27 (68) 0.18 (47) 1400 (661) 0.06 (15) 0.09 (23) 0.10 (24) 0.15 (38) - - 0.23 (58) 1600 (755) 0.06 (16) 0.12 (31) 0.11 (29) 0.18 (45) - - 0.28 (69) 1800 (850) 0.07 (18) 0.14 (35) 0.13 (34) 0.21 (53) - - - 2000 (944) 0.08 (19) 0.16 (41) 0.16 (39) 0.24 (61) - - - 2200 (1038) 0.08 (21) 0.19 (49) 0.18 (45) 0.28 (70) - - - -

Factory-Accessory

Washable

Factory-Accessory

Washable

Factory-Accessory

Washable

Factory-Accessory

Media*

Factory-Accessory

Media*

Factory-Accessory

Media*

Representative After-Market Filter Media*

Fiberglass* Pleated*

Representative After-Market Filter Media*

Fiberglass* Pleated*

Representative After-Market Filter Media*

Fiberglass* Pleated*

59MN7A

If the filter size that you are looking for is not contained in Table 5, refer to Table 6 for a comparison of Pressure Drop (initial/clean resistance to airflow) versus Face Velocity for a variety of filter media types.

The following equations relate Face Velocity (FPM), Filter Area and Airflow (CFM):

Filter Face Velocity = Airflow / Filter Area Minimum Filter Area = Rated System Airflow / Maximum Filter Face Velocity

Table 6 – Filter Media Pressure Drop (Clean) Versus Face Velocity-- In. W.C. (Pa)

Face Velocity

FPM (m/s) (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm)

200 (1) 0.04 (10) 0.05 (13) 0.08 (20) 0.18 (47) 0.12 (31) 300 (1.5) 0.05 (14) 0.09 (22) 0.13 (34) 0.30 (75) 0.21 (52) 400 (2) 0.07 (17) 0.13 (32) 0.20 (50) - - 0.31 (78) 500 (2.5) 0.08 (21) 0.18 (44) 0.27 (69) - - - 600 (3) 0.09 (23) 0.23 - - - - - - 700 (3.6) 0.10 (26) 0.29 - - - - - - -

Factory-Accessory

Washable

Representative After-Market Filter Media*

Fiberglass* Pleated*

Page 22

Table 7 – AirFilter Selection and Duct Sizing -- In. (mm)

FURNACE CASING WIDTH

17 --- 1/2 (445)

21 (533)

24 --- 1/2 (622)

* Recommended to maintain air filter face velocity. See Product Data for part number.

SIDE RETURN BOTTOM RETURN

16 x 25 x 3/4

(406 x 635 x 19)

16 x 25 x 3/4

(406 x 635 x 19)

16 x 25 x 3/4

(406 x 635 x 19)

FILTER SIZE

Air Filter Located in Filter Cabinet

FILTER CABINET HEIGHT --- IN (MM) F I L T E R S I Z E --- I N ( M M ) FILTER TYPE

(1) 16 x 25 x 3/4*

16 (406)

20 (508)

59MN7A

24 (610)

* Filters with a side return---air may have a different filter size. Measure the filter to obtain the correct size. * Recommended to maintain air filter face velocity. See Product Data for part number.

(406 x 635 x 19) or

(1) 16 x 25 x 4--- 5/16

(406 x 635 x 110)

(1) 20 x 25 x 3/4*

(508 x 635 x 19) or

(1) 20 x 25 x 4--- 5/16

(508 x 635 x 110)

(1) 24 x 25 x 3/4*or

(610 x 635 x 19) or

(1) 24 x 25 x 4--- 5/16

(610 x 635 x 110)

16 x 25 x 3/4

(406 x 635 x 19)

20 x 25 x 3/4

(508 x 635 x 19)

24 x 25 x 3/4

(610 x 635 x 19)

FILTER TYPE

Washable*

Washable or Media*

Page 23

14-3/16 and 17-1/2-in.

Furnace

21-in. Furnace

4-Ton or less, AC

capacity airflow

4-in. Block Off Plate

Screws

1/2-in.

16-in. Media Cabinet

Media Cabinet Installation

Side Return

21- or 24-1/2-in.

Furnace

Up to 5-Ton AC

capacity airflow

20- or 24-in. Media

Cabinet

Bottom Return Plenum

20- or -24-in. Media Cabinet Installation

for Combination Side and Bottom Return

20-in. Media Cabinet

Media Cabinet Installation Option for

4-Ton or Less A/C Capacity

59MN7A

21-in. Furnace up to 5-Ton AC Capacity

24-1/2-in. Furnace up to 4-Ton AC Capacity

45°

Transition

20- or 24-in. Media Cabinet

20- or -24-in. Media Cabinet Installation

with Angled Transition

14-3/16-in. Furnace

Screw

Filler plates

14--3/16-in. Furnace with Filler Plates, Centered

14-3/16-in. Furnace

Screws

Screw

Filler plate

14--3/16-in. Furnace with Filler Plates, Off-- Set to Right

A11437

Fig. 17 -- Media Filter

Page 24

FURNACE

(OR COIL CASING

WHEN USED)

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

PLENUM

OPENING

FLOOR

OPENING

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A10491

Fig. 18 -- Installation on Combustible Flooring

59MN7A

Table 8 – Opening Dimensions -- In. (mm)

FURNACE

CASING

WIDTH

IN. (mm)

17–1/2

(445)

(533)

24 --- 1/2

(622)

APPLICATION

Upflow Applications on Combustible or Noncombustible Floor-

Downflow Applications on Noncombustible Flooring (KGASB

Downflow applications on combustible flooring (KGASB sub-

Downflow Applications on Combustible Flooring with CNPV,

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

ing (KGASB subbase not required)

subbase not required)

base required)

subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

Downflow Applications on Noncombustible Flooring (KGASB

Downflow applications on combustible flooring (KGASB sub-

Downflow Applications on Combustible Flooring with CNPV,

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

ing (KGASB subbase not required)

subbase not required)

base required)

subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

Downflow Applications on Noncombustible Flooring (KGASB

Downflow applications on Combustible flooring (KGASB sub-

Downflow Applications on Combustible Flooring with CNPV,

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

ing (KGASB subbase not required)

subbase not required)

base required)

subbase not required)

PLENUM OPENING FLOOR OPENING

A B C D

(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--- 1/8

(537)

(483)

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)

Page 25

PERFORATED DISCHARGE DUCT FLANGE

UPFLOW DOWNFLOW HORIZONTAL

90°

(8mm)

(44mm)

″

1 3 / 4 ″

(8mm)

″

/ 4 ″

1 (44mm)

120°

MIN

YES

Fig. 19 -- Duct Flanges

120°

MIN

YES

120°

MIN

YES

A10493

59MN7A

(8mm)

″

(44mm)

4 ″

(44mm)

Fig. 20 -- Leveling Legs

LEVEL 0-IN. (0 MM) TO 1/2-IN. (13 MM) MAX

(8mm)

″

UPFLOW OR DOWNFLOW

A89014

Fig. 21 -- Removing Bottom Closure Panel

MIN 1/4-IN. (6 MM) TO 1/2-IN. (13 MM) MAX

HORIZONTAL

Fig. 22 -- Furnace Pitch Requirements

BOTTOM CLOSURE PAN EL

BOTTOM PLA TE

A11092

A11237

Page 26

ANY COMBINATION OF 1, 2, OR 3 PERMITTED.

Fig. 23 -- Upflow Return Air Configurations and Restrictions

59MN7A

Fig. 25 -- Horizontal Return Air Configurations

A11036

HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL

and Restrictions

A11037

Fig. 24 -- Downflow Return Air Configurations

and Restrictions

A11038

Page 27

COMBUSTION - AIR PIPE (SEE VENTING SECTION)

2-IN.

(51 mm)

30 IN. (762 mm)

MIN. WORK AREA

ROLLOUT PROTECTION REQUIRED

Install 12” x 22” (305 x 559 mm) sheet metal in front of burner compartment area.

A11154

Fig. 26 -- Working Platform for Attic Installation

NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.

COMBUSTION-AIR PIPE (SEE VENTING SECTION)

2-IN.

(51 mm)

59MN7A

NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.

A11155

Fig. 27 -- Suspended Furnace Installation

Page 28

AIR DUCTS

NOTICE

Many states, provinces and localities are considering or have

implemented standards and/or restrictions on duct sizing

practices, ductwork leakage, and/or ductwork thermal, airflow

and electrical efficiencies. CONSULT LOCAL CODE

OFFICIALS for ductwork design and performance

requirements in your area.

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 Manual D) , 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.

59MN7A

The furnace airflow rates are provided in Table 9--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.

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

Ductwork passing through unconditioned space should be insulated 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.

Return Duct Sizing

Refer to the Filter Selection and Duct Sizing section for information on the proper selection of filter sizes and the associated ductwork and duct transitions. Improperly designed filtering systems and return ductwork are the most common causes of airflow and/or noise complaints in HVAC systems.

Ductwork Acoustical Treatment

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.

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

Page 29

Table9–Cooling

and Heating Air Delivery -- CFM (Bottom Return5With Filter)

(SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2)

Unit Size

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

060-14

Clg Default: OFF OFF OFF 1060 1070 1080 1080 1075 1065 1050 1035 1025 1010

CF Default: OFF OFF OFF 545 530 520 525 510 Seenote4

OFF OFF ON 545 530 520 525 510 Seenote4

OFF ON OFF 710 710 710 695 690 Seenote4

OFF ON ON 875 880 890 895 895 890 885 880 870 855

Cooling (SW2)

ON OFF OFF 1060 1070 1080 1080 1075 1065 1050 1035 1025 1010

Cont Fan (SW3)

ON OFF ON 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115

ON ON OFF 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115

ON ON ON 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

Unit Size

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1425 1425 1405 1370 1335 1300 1260 1225 1190 1155

1075 1085 1095 1095 1090 1080 1065 1050 1035 1020

535 515 505 515 495 Seenote4

420 410 415 400 380 Seenote4

060 --- 20

Clg Default: OFF OFF OFF 1735 1735 1725 1715 1700 1685 1665 1650 1625 1605

CF Default: OFF OFF OFF 545 530 520 525 510 Seenote4

OFF OFF ON 540 525 525 520 540 Seenote4

OFF ON OFF 680 725 725 720 720 Seenote4

OFF ON ON 925 915 910 895 900 890 875 865 860 855

Cooling (SW2)

ON OFF OFF 1070 1075 1080 1070 1080 1075 1055 1045 1030 1020

Cont Fan (SW3)

ON OFF ON 1215 1245 1235 1220 1220 1210 1200 1195 1185 1175

ON ON OFF 1380 1385 1395 1390 1395 1390 1380 1365 1355 1340

59MN7A

ON ON ON 1735 1735 1725 1715 1700 1685 1665 1650 1625 1605

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

NOTE: See notes at end of table.

1955 1950 1940 1925 1905 1885 1855 1815 1745 1685

1080 1085 1095 1090 1095 1085 1070 1055 1045 1030

685 725 730 725 730 Seenote4

560 555 555 550 565 Seenote4

Page 30

and Heating Air Delivery -- CFM (Bottom Return5With Filter) (Continued)

Unit Size

Table 9 -- Cooling

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

080-14

Clg Default: OFF OFF OFF 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005

CF Default: OFF OFF OFF 520 505 505 495 490 Seenote4

OFF OFF ON 520 505 505 495 490 Seenote4

OFF ON OFF 665 685 680 660 665 Seenote4

OFF ON ON 885 895 905 900 900 895 885 875 860 845

Cooling (SW2)

ON OFF OFF 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005

Cont Fan (SW3)

ON OFF ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

ON ON OFF 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

ON ON ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185

59MN7A

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

Unit Size

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1520 1485 1450 1415 1375 1335 1300 1265 1225 1190

755 745 755 755 765 Seenote4

620 625 630 620 610 Seenote4

080 --- 20

Clg Default: OFF OFF OFF 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685

CF Default: OFF OFF OFF 700 710 750 725 750 Seenote4

OFF OFF ON 700 710 750 725 750 Seenote4

OFF ON OFF 830 860 870 890 960 Seenote4

OFF ON ON 1045 1045 1060 1070 1070 1070 1095 1090 1080 1070

Cooling (SW2)

ON OFF OFF 1215 1220 1245 1240 1235 1235 1225 1220 1235 1235

Cont Fan (SW3)

ON OFF ON 1370 1370 1390 1390 1400 1395 1400 1390 1390 1385

ON ON OFF 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685

ON ON ON 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

NOTE: See notes at end of table.

1920 1920 1945 1945 1945 1960 1950 1940 1915 1900

1340 1355 1370 1385 1380 1385 1400 1400 1385 1380

780 810 835 840 845 Seenote4

595 595 600 595 605 Seenote4

Page 31

and Heating Air Delivery -- CFM (Bottom Return5With Filter) (Continued)

Unit Size

Table 9 -- Cooling

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

100-22

Clg Default: OFF OFF OFF 1820 1825 1840 1845 1840 1835 1825 1805 1780 1770

CF Default: OFF OFF OFF 750 740 745 730 715 Seenote4

OFF OFF ON 750 740 745 730 715 Seenote4

OFF ON OFF 900 900 915 910 905 Seenote4

Cooling (SW2)

Cont Fan (SW3)

OFF ON ON 1070 1075 1095 1095 1090 1085 1095 1080 1065 1070

ON OFF OFF 1280 1285 1305 1305 1310 1305 1295 1300 1290 1285

ON OFF ON 1440 1445 1465 1465 1470 1485 1480 1485 1475 1460

ON ON OFF 1820 1825 1840 1845 1840 1835 1825 1805 1780 1770

ON ON ON 2135 2140 2140 2135 2140 2130 2115 2100 2070 2015

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

Unit Size

Clg/CF Switch Settings External Static Pressure (ESP)

SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

2160 2165 2175 2170 2160 2150 2135 2120 2065 2020

1570 1575 1595 1595 1600 1605 1600 1600 1590 1575

950 955 965 975 970 Seenote4

755 745 750 735 720 Seenote4

120-22

Clg Default: OFF OFF OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730

CF Default: OFF OFF OFF 930 925 915 900 885 Seenote4

OFF OFF ON 765 745 740 705 680 Seenote4

OFF ON OFF 930 925 915 900 885 Seenote4

59MN7A

OFF ON ON 1095 1100 1110 1105 1085 Seenote4

Cooling (SW2)

ON OFF OFF 1265 1255 1265 1280 1275 1285 1270 1260 1250 1230

Cont Fan (SW3)

ON OFF ON 1465 1455 1470 1465 1465 1470 1455 1450 1435 1415

ON ON OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730

ON ON ON 2200 2200 2200 2190 2185 2170 2145 2085 1990 1890

Clg SW2: Maximum Clg Airflow

Maximum Heat Airflow

Heating

(SW1)

Intermediate Heat Airflow

Minimum Heat Airflow

1. Nominal 350 CFM/ton cooling airflow is delivered with SW1--5 and SW4--3 set to OFF.

2. Maximum cooling airflow is achieved when switches SW2--1, SW2--2, SW2--3 and SW1--5 are set to ON, and SW4--3 is set to OFF.

3. All heating CFM’s are when low/medium heat rise adjustment switch (SW1--3) and comfort/efficiency adjustment switch (SW1--4) are both

set to OFF.

4. Ductwork must be sized for high--heating CFM within the operational range of ESP. Operation within the blank areas of the chart is not recommended because high--heat operation will be above 1.0 ESP.

5. All airflows on 21” casing size furnaces are 5% less on side return only installations.

6. Return air above 1800 CFM on 24.5” casing sizes requires two sides, one side and bottom or bottom only , to allow sufficient airflow to the furnace.

Set SW1--5 to ON for nominal 400 CFM/ton (+15% airflow). Set SW4--3 to ON for nominal 325 CFM/ton (--7% airflow). Set both SW1--5 and SW4--3 to ON for nominal 370 CFM/ton (+7% airflow). The above adjustments in airflow are subject to motor horsepower range/capacity.

2200 2200 2200 2190 2185 2170 2145 2085 1990 1890

1815 1820 1825 1820 1815 1795 1775 1745 1720 1700

1095 1100 1110 1105 1085 Seenote4

905 900 890 875 855 Seenote4

Page 32

GAS PIPING

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/orproperty 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. A fire or explosion may result causing property damage, personal injury or loss of life.

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

59MN7A

injury, death, and/orproperty damage. Use proper length of pipe to avoid stress on gas control

manifold and gas valve.

WARNING

FIRE OR EXPLOSION HAZARD

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

Gas valve inlet and/or inlet pipe must remain capped until gas supply line is permanently installed to protect the valve from moisture and debris. Also, install a sediment trap in the gas supply piping at the inlet to the gasvalve.

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S.A. Refer to current edition of NSCNGPIC 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: Use a back--up wrench on the inlet of the gas valve when connecting the gas line to the gas valve.

NOTICE

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 in. (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 10 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 one 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.

WARNING

FIRE OR EXPLOSION HAZARD

A failure to follow this warning could result in personal injury, death, and/orproperty 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.

CAUTION

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace damage. Connect gas pipe to furnace using a backup wrench to

avoid damaging gas controls and burner misalignment.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. (2 M) of furnace.

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

29. 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.

Piping should be pressure and leak tested in accordance with the current addition of the NFGC in the United States, local, and national plumbing and gas codes before the furnace has been connected. Refer to current edition of NSCNGPIC in Canada. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

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. W.C.) stated on gas control valve. See Fig. 52.

If pressure exceeds 0.5 psig (14--In. W.C.), gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than 0.5 psig (14--In. W.C.), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF.

Some installations require gas entry on right side of furnace (as viewed in upflow). See Fig. 28.

Gas Pipe Grommet

For direct vent (2-pipe) applications, the knockout for the gas pipe must be sealed to prevent air leakage. Remove the knockout, install the grommet in the knockout, then insert the gas pipe. The grommet is included in the loose parts bag. See Fig. 28.

Page 33

Table 10 – Maximum Capacity of Pipe

NOMINAL

IRON PIPE

SIZE

IN. (MM)

1/2 (13) 175 120 97 82 73 3/4 (19) 360 250 200 170 151

1 ( 25) 680 465 375 320 285 1-1/4 (32) 1400 950 770 660 580 1-1/2 (39) 2100 1460 1180 990 900

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14 --- In. W.C.) or less and a pressure drop of 0.5--- In. W.C. (based on a 0.60 specific gravity gas). Ref: Table 10 above and 6.2 of NFPA54/ANSI Z223.1 --- 2009.

Left Side Gas Entry. Gas Pipe Grommet Required For Direct Vent Applications.

(3.0)20(6.0)30(9.1)40(12.1)50(15.2)

LENGTH OF PIPE --- FT (M)

Gas Pipe Grommet Required For Direct Vent Applications

Field--supplied wiring shall conform with the limitations of 63_F (33_C) rise.

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

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

The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70--2011 or local codes to minimize personal injury if an electrical fault should occur. In Canada, refer to Canadian Electrical Code CSA C22.1. This may consist of electrical wire, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer’s ratings for proper wire gauge. Do not use gas piping as an electrical ground.

GAS

SUPPLY

MANUAL SHUT OFF VALV E (REQUIRED)

SEDIMENT TRAP

Fig. 28 -- Gas Entry

FRONT

UNION

Fig. 29 -- Typical Gas Pipe Arrangement

NOTE: Union may be inside the vestibule where permitted by local codes.

ELECTRICAL CONNECTIONS

A11338

A11035

CAUTION

FURNACE MAY NOT OPERATE HAZARD

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

Furnace control must be grounded for proper operation or else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw.

115-- V Wiring

Furnace must have a 115-v power supply properly connected and grounded.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 11 for equipment electrical specifications.

U.S.A. Installations: Make all electrical connections in accordance with the current edition of the National Electrical Code (NEC) ANSI/NFPA 70 and any local codes or ordinances that might apply.

Canada Installations: Make all electrical connections in accordance with the current edition of the Canadian Electrical Code CSA C22.1 and any local codes or ordinances that might apply.

59MN7A

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Blower door switch opens 115--v power to control. No

component operation can occur. Do not bypass or close

switch with blower door removed.

See Fig. 33 for field wiring diagram showing typical field 115--v wiring. Check all factory and field electrical connections for tightness.

WARNING

FIRE HAZARD

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

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. See Fig. 31.

Use a separate, fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 11 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

Page 34

J--Box Installation

WARNING

FIRE OR ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury, death, or property damage.

If field--supplied manual disconnect switch is to be mounted

on furnace casing side, select a location where a drill or

fastener cannot damage electrical or gas components.

The J-Box is used when field line voltage electrical connections are made to the furnace wiring harness inside the furnace casing. The J-Box is not required if a field-supplied electrical box is attached to the outside of the furnace casing and the box is grounded to the green ground wire of the main wiring harness and the earth ground of the field electrical supply.

The J--Box cover, mounting bracket and screws are shipped in the loose parts bag included with the furnace. The J--Box can be mounted on the left or right side of the casing, as viewed from the upflow position. See Fig. 30.

59MN7A

Remove the J--Box cover and mounting bracket from the loose parts bag. Select a 7/8--in. (22 mm) knock-out on the desired side of the casing. Remove the knock-out from the casing. Drill two (2) 1/8--in. (3 mm) pilot holes in the casing dimples by the desired 7/8--in. (22 mm) knock-out.

Align the J--box mounting bracket against the inside of the casing and secure the mounting bracket with the screws. See Fig. 30.

Electrical Box on Furnace Casing Side

NOTE: Check that duct on side of furnace will not interfere with

installed electrical box.

1. Fasten a field-supplied external electrical box to the outside of the casing by driving two field-supplied screws from inside electrical box into casing. See Fig. 31.

2. Route field power wiring into external electrical box.

3. Pull furnace power wires through 1/2-in. (12 mm) diameter hole in J-Box. If necessary, loosen power wires from strain-relief wire-tie on furnace wiring harness.

4. Connect any code required external disconnect(s) to field power wiring.

5. Route external field power wires through holes in electrical box and casing.

6. Connect field ground wire and factory ground wire to green ground screw on J--Box mounting bracket as shown in Fig.

30.

7. Connect field power and neutral leads to furnace power leads as shown in Fig. 33.

8. Attach furnace J-Box cover to mounting bracket with screws supplied in loose parts bag. Do not pinch wires between cover and bracket.

9. Complete external disconnect wiring and installation. Connect line voltage leads as shown in Fig. 31. Use best practices (NEC in U.S.A. for wire bushings, strain relief, etc., CANADA: Canadian Electrical Code CSA C22.1)

Power Cord Installation in Furnace J--Box

NOTE: Power cords must be able to handle the electrical

requirements listed in Table 11. Refer to power cord manufacturer’s listings.

1. Install J--Box mounting bracket to inside of furnace casing. See Fig. 30.

2. Route listed power cord through 7/8--in. (22 mm) diameter hole in casing and J--Box bracket.

3. Secure power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used.

4. Pull furnace power wires through 1/2--in. (12 mm) diameter hole in J--Box. If necessary, loosen power wires from strain—relief wire--tie on furnace wiring harness.

5. Connect field ground wire and factory ground wire to green ground screw on J--Box mounting bracket as shown in Fig.

30.

6. Connect power cord power and neutral leads to furnace power leads as shown in Fig. 33.

7. Attach furnace J--Box cover to mounting bracket with screws supplied in loose parts bag. Do not pinch wires between cover and bracket. See Fig. 30.

BX Cable Installation in Furnace J--Box

1. Install J--Box mounting bracket to inside of furnace casing. See Fig. 30.

2. Route BX connector through 7/8--in. (22 mm) diameter hole in casing and J--Box bracket.

3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.

4. Connect field ground wire and factory ground wire to green ground screw on J--Box mounting bracket as shown in Fig.

30.

5. Connect field power and neutral leads to furnace power leads. as shown in Fig. 33.

6. Attach furnace J--Box cover to mounting bracket with screws supplied in loose parts bag. Do not pinch wires between cover and bracket.

24--V Wiring

Make field 24--v connections at the 24--v terminal strip. See Fig.

34. Connect terminal Y/Y2 as shown in Fig. 33 for proper cooling operation. Use only AWG No. 18, color--coded, copper thermostat wire.

NOTE: Use AWG No. 18 color-coded copper thermostat wire for lengths up to 100 ft. (31 M). For wire lengths over 100 ft., use AWG No. 16 wire.

The 24--v circuit contains an automotive--type, 3--amp. fuse located on the control. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3--amp. fuse of identical size. See Fig. 34.

Thermostats

For best results, use a communicating wall control to control this modulating furnace. A single stage or two--stage heating and cooling thermostat can be used with the furnace. The furnace control board CPU will control the furnace and outdoor unit staging. A two stage heating and cooling thermostat can also be used to control the staging. However, full modulating capability will not be available when the furnace staging is controlled by the thermostat. Furnace staging will be limited to Minimum and Maximum inputs or Intermediate and Maximum inputs depending on the configuration of set-up switches SW1-2 and SW4-2. For two stage thermostat control of a 2-stage outdoor unit, remove the ACRDJ jumper from the furnace control board. Refer to typical thermostat wiring diagrams and the Sequence of Operation section for additional details. Consult the thermostat installation instructions for specific information about configuring the thermostat. See Fig. 34 and 35.

Accessories (See Fig. 32 and 34.)

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using 1/4--in. female quick connect terminals to the two male 1/4--in. quick--connect terminals on the control board marked EAC--1 and EAC--2. The terminals are rated for 115VAC, 1.0 amps maximum and are energized during blower motor operation.

Page 35

2. Humidifier (HUM)

The HUM terminal is a 24 VAC output, energized when the blower is operating during a call for heat.

Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the ¼--in. male quick--connect HUM terminal and COM--24V screw terminal on the control board thermostat strip.

NOTE: If the humidifier has its own 24 VAC power supply, an isolation relay may be required. Connect the 24 VAC coil of the isolation relay to the HUM and COM/24V screw terminal on the control board thermostat strip. See Fig. 32.

3. Communication Connector (communication connection) This connection is used when the furnace is controlled by an optional communicating User Interface instead of a standard thermostat. The communication plug is supplied with the User Interface. Refer to the instructions supplied with the User Interface for complete details. See Fig. 34.

4. Outside Air Thermistor (OAT) The OAT connection is used in conjunction with commu-

nicating User Interface. It is not required when the furnace is controlled by a standard type thermostat. Refer to the instructions supplied with the User Interface for complete details.

Alternate Power Supplies

This furnace is designed to operate on utility generated power which has a smooth sinusoidal waveform. If the furnace is to be operated on a generator or other alternate power supply, the alternate power supply must produce a smooth sinusoidal waveform for compatibility with the furnace electronics. The alternate power supply must generate the same voltage, phase, and frequency (Hz) as shown in Table 11 or the furnace rating plate.

Power from an alternate power supply that is non-sinusoidal may damage the furnace electronics or cause erratic operation.

Contact the alternate power supply manufacturer for specifications and details.

Table 11 – Electrical Data

MODULATING

UNIT SIZE V O LT S ---

060 --- 14 1 1 5 --- 6 0 --- 1 127 104 9.7 12.7 14 29 (8.8) 15 060 --- 20 1 1 5 --- 6 0 --- 1 127 104 14.8 19.1 12 30 (9.1) 20 080 --- 14 1 1 5 --- 6 0 --- 1 127 104 9.7 12.7 14 29 (8.8) 15 080 --- 20 1 1 5 --- 6 0 --- 1 127 104 14.8 19.1 12 30 (9.1) 20 100 --- 22 1 1 5 --- 6 0 --- 1 127 104 14.8 19.1 12 30 (9.1) 20 120 --- 22 1 1 5 --- 6 0 --- 1 127 104 14.8 19.1 12 30 (9.1) 20

* Permissible limits of the vol tage range at which the un it operates satisfactorily. # Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier,

etc.) full load amps.

{Time---delay type is recommended. }Length shown is as measured one way along wire path between furnace and service panel for maximum 2 percent voltage drop.

H E R T Z ---

PHASE

OPERATING VOLTAGE

RANGE*

Maximum* Minimum*

MAXIMUM

UNIT

AMPS

UNIT

AMPACITY#

MINIMUM

WIRE

SIZE

AWG

MAXIMUM

WIRE

LENGTH

FT (M)}

MAXIMUM

FUSE OR CKT

BKR

AMPS{

59MN7A

Page 36

GROUND

NEUTRAL

LINE VOLTAGE

59MN7A

ELECTRIC

DISCONNECT

SWITCH

COPPER

WIRE ONLY

Fig. 30 -- Installing J--Box (When Used)

Appearance May Vary

A12226

ALUMINUM

WIRE

A11146

Fig. 31 -- Field--Supplied Electrical Box on Furnace Casing

Page 37

To Humidifier Leads

To HUM Terminal On

Furnace Control Board

24 V

Coil

To Humidifier Leads

To Com/24V Screw Terminal

on Thermostat Strip

Fig. 32 -- Field--supplied Isolation Relay for Humidifiers with Internal Power Supply

COM

W/W1

Y/Y2

A11157

59MN7A

Fig. 33 -- Typical Field Wiring Diagram

A11401

Page 38

24-V THERMOSTAT

TERMINALS

PL2 – HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

115-VAC (L2) NEUTRAL

CONNECTIONS

115-VAC (L1) LINE

VOLTAGE CONNECTIONS

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

PL1 – LOW VOLTAGE MAIN

HARNESS CONNECTOR

PL3 – ECM BLOWER

HARNESS

CONNECTOR

TRANSFORMER 24-VAC

CONNECTIONS

3-AMP FUSE

STATUS AND COMM

LED LIGHTS

SW1 SETUP

SWITCHES AND

BLOWER OFF-

DELAY

MODEL PLUG CONNECTOR

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

COMMUNICATION

CONNECTOR

CONTINUOUS FAN

(CF) AIRFLOW

SETUP SWITCHES

OUTDOOR

AIR TEMP

CONNECTOR

HUMIDIFIER

TERMINAL (24-VAC

0.5 AMP MAX.

ACRDJ – AIR

CONDITIONING

RELAY DISABLE

JUMPER

FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

SW4 SETUP

SWITCHES

SOFTWARE

VERSION

PART NUMBER AND

DATE CODE WWYY

PL8 - MODULATING

GAS VALVE

CONNECTOR

59MN7A

A11616

Fig. 34 -- Example of Modulating Furnace Control

Page 39

THERMOSTAT

59MN7A

See notes 2, 5, 7, 10, 11, 16, and 17 See notes 1, 2, 4, 6, 7, 9, 10, 11, 15, 16, and 17

Modulating and 2-Stage Furnace with Single-Speed Air Conditioner

THERMOSTAT

Modulating and 2-Stage Furnace with Single-Speed Heat Pump

THERMOSTAT

See notes 2, 5, 8, 10, 11, 12, 16, and 17

Modulating and 2-Stage Furnace with Two-Speed Air Conditioner

See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13, 15, 16, and 17

Modulating and 2-Stage Furnace with Two-Speed Heat Pump

A12222

Fig. 35 -- Thermostat Wiring Diagrams

Page 40

NOTES FOR THERMOSTAT WIRING DIAGRAMS

1. Heat pump MUST have a high pressure switch for dual fuel applications.

2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

3. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two speed heat pump control. Heat pumps with date code 1601E and later do not have or require a “ZONE” selection.

4. Outdoor Air Temperature - sensor must be attached in all dual fuel applications.

5. Configure the thermostat for air conditioner installations. Refer to thermostat instructions.

6. Configure thermostat for heat pump installations. Refer to thermostat instructions.

7. Configure thermostat for single-stage compressor operation. Refer to thermostat instructions.

8. Configure thermostat for two-stage compressor operation. Refer to thermostat instructions.

9. Configure thermostat for Dual Fuel Operation. Refer to thermostat instructions.

10. NO connection should be made to the furnace HUM terminal when using a thermostat with a 24 volt humidifier output.

11. Optional connection - If wire is connected to W2 on furnace control board, either dip switch SW1-2 or SW4-2 on furnace control should be set in ON position to allow thermostat to control furnace at 2 stages Min/Max or Intermediate/Max.

12. Optional connection - If wire is connected, ACRDJ jumper on furnace control should be removed to allow thermostat to control outdoor unit staging.

13. Furnace must control its own staging operation via furnace control algorithm. This is factory default.

14. The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.

15. If thermostat has internal control of heat pump balance point, DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two-speed heat pump control board. Refer to thermostat instructions

59MN7A

16. Configure Dehumidify function to remove 24 VAC from Dehum terminal on a demand to dehumidify.

17. Thermostat signals may vary. Consult thermostat installation instructions for more information.

VENTING

NOTE: Planning for the venting system should be done in

conjunction with planning for the ductwork, drainage, and furnace accessories, such as air cleaners and humidifiers. Begin assembling the venting system AFTER the furnace is set in place in the required orientation.

Venting for this furnace shall follow all Local codes for Category IV venting systems. This furnace is CSA approved for venting with PVC/ABS DWV venting systems. This furnace is also CSA approved for venting with M&G DuraVentR PolyProR polypropylene venting systems.

NOTE: THESE INSTRUCTIONS DO NOT CONTAIN DETAILED INSTALLATION INSTRUCTIONS FOR POLYPROPYLENE VENTING SYSTEMS. Refer to the polypropylene venting system manufacturer’s installation instructions for the polypropylene venting system installation.

NOTE: When using polypropylene venting systems, all venting materials used, including the vent terminations, must be from the same manufacturer.

Special Venting Requirements for Installations in Canada

Installation in Canada must conform to the requirements of CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC S636. The special vent fittings, accessory concentric vent termination kits and accessory external drain trap available from the furnace manufacturer have been certified to ULC S636 for use with those Royal Pipe and IPEX PVC vent components which have been certified to this standard. In Canada, the primer and cement must be of the same manufacturer as the vent system – GVS-65 Primer (Purple) for Royal Pipe or IPEX System 636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and GVS-65 PVC Solvent Cement for Royal Pipe or IPEX System 636 Venting, rated Class IIA, 65 deg C. must be used with this venting system - do not mix primers and cements from one manufacturer with a vent system from a different manufacturer. Follow the manufacturer’s instructions in the use of primer and cement and never use primer or cement beyond its expiration date.

The safe operation, as defined by ULC S636, of the vent system is based on following these installation instructions, the vent system manufacturer’s installation instructions, and proper use of primer and cement. All fire stop and roof flashing used with this system

t, PVC Cement for Flue Gas

(1)

must be UL listed material. Acceptability under Canadian standard CAN/CSA B149 is dependent upon full compliance with all installation instructions. Under this standard, it is recommended that the vent system be checked once a year by qualified service personnel.

The authority having jurisdiction (gas inspection authority, municipal building department, fire department, etc.) should be consulted before installation to determine the need to obtain a permit.

*IPEX System 636™ is a trademark of IPEX Inc.

Consignes spéciales pour l’installation de ventilation au Canada

L’installation faite au Canada doit se conformer aux exigences du code CSA B149--2010. Ce systême de ventillation doit se composer de tuyaux, raccords, ciments et apprêts conformes au ULC S636. La tuyauterie de ventilation des gaz, ses accessoires, le terminal concentrique mural ainsi que l’ensemble du drain de condensation extérieur fourni par le fabricant de cette fournaise ont été certifiés ULCS 636 pour l’application des composantes Royal Pipe, IPEX PVC qui sont certifiées à ce standard. Au Canada, l’apprêt et le ciment doivent être du même fabricant que le système d’évacuation. L’apprêt GVS-65 (Purple) et le ciment-solvant GVS-65 doivent être utilisé avec les Royal Pipe. Système IPEX 636, apprêt PVC/CPVC, Purple pour évacuation des gaz de combustion et système IPEX 636(1)t, ciment PVC pour évacuation des gaz de combustion, coté classe IIA, 65 deg C. doivent être utilisés avec le système d’évacuation IPEX 636 – Ne pas combiner l ’apprêt et le ciment d’un manufacturier avec un système d’évacuation d’un manufacturier différent.

Bien suivre les indications du manufacturier lors de l’utilisation de l’apprêt et du ciment et ne pas utiliser ceux-ci si la date d’expiration est atteinte.

L’opération sécuritaire, tel que définit par ULC S636, du système de ventilation est basé sur les instructions d’installation suivantes, ainsi que l’usage approprié de l’apprêt et ciment. Tout arrët feu et solin de toit utilisés avec ce système doivent être des matériaux listés UL. L’acceptation du standard Canadien CAN/CSA B149 est directement relié à l’installation conforme aux instructions cihaut mentionnées. Le standard Canadien recommande l’ inspection par un personel qualifié et ce, une fois par année.

Les autoritées ayant juridiction (inspecteurs de gas, inspecteurs en bâtiments, département des incendies, etc) devraient être consultées avant l’installation afin de déterminer si un permis est requis.

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WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1 Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1 Natural Gas and Propane Installation Code.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas--fired burning appliance to their previous conditions of use.

General

If this furnace replaces a furnace that was connected to a vent system or chimney, the vent or vent connectors of other remaining appliances may need to be re--sized. Vent systems or vent connectors of other appliances must be sized to the minimum size as determined using appropriate table found in the current edition of National Fuel Gas Code NFPA 54/ANSI Z--223.1. In Canada, refer to CAN/CSA--B149.1.

An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion--air (when applicable) and vent pipes. Each furnace must have its own set of combustion--air and vent pipes and be terminated individually, as shown in Fig. 46 for Direct Vent (2--Pipe) system or Fig. 47 for ventilated combustion air option.

A furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.

Other gas appliances with their own venting system may also use the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code and the vent or liner manufacturer’s installation instructions. Care must be taken to prevent the exhaust gases from one appliance from contaminating the combustion air of other gas appliances.

Do not take combustion air from inside the chimney when using ventilated combustion air or single pipe vent option.

These furnaces can be vented as either direct vent (two--pipe) or as ventilated combustion air system. Each type of venting system is described below. Common venting between these furnaces or other appliances is prohibited.

Materials

U.S.A.

Combustion air and vent pipe, fittings, primers, and solvents must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards. See Table 13 for approved materials for use in the U.S.A. This furnace is also CSA approved for venting with M&G DuraVentR PolyProR polypropylene venting systems.

Canada

Special Venting Requirements for Installations in Canada Installation in Canada must conform to the requirements of CAN/CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC S636. M&G DuraVent PolyPro polypropylene venting systems are ULC S636 listed.

NOTE: When using polypropylene venting systems, all venting materials used, including the vent terminations must be from the same manufacturer.

Ventin g Systems

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the instructions outlined below for each appliance being placed into operation could result in carbon monoxide poisoning or death.

For all venting configurations for this appliance and other gas appliances placed into operation for this structure, provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with: U.S.A. Installations: Section 9.3 NFPA 54/ANSI Z223.1

--2009, Air for Combustion and Ventilation and applicable provisions of the local building codes.

Canadian Installations: Part 8 of CAN/CSA--B149.1--10. Venting Systems and Air Supply for Appliances and all authorities having jurisdiction.

NOTICE

RECOMMENDED SUPPORT FOR VENT TERMINATION

It is recommended that sidewall vent terminations of over 24 inches (0.6 M) in length or rooftop vent terminations of over 36 inches (1 M) in length be supported by EITHER the factory accessory vent termination kit or field--supplied brackets or supports attached to the structure. A factory accessory vent termination kit may be used for direct vent terminations. Termination kits are available for 2--in. or 3--in. pipe. See Table 12 for available options.

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Table 12 – Vent Termination Kit for Direct Vent (2--pipe)

Systems

DIRECT VENT

(2 --- PIPE)

TERMINATION KIT

2 --- in . ( 5 1 mm)

Concentric Vent Kit

3 --- in . ( 7 6 mm)

Concentric Vent Kit

TERMINATION

SYSTEM

Single Penetration of

Wall or Roof

Single Penetration of

wall or Roof

DIAM. OF COMBUSTION AIR AND VENT

PIPES --- IN. (mm)

1, 1---1/2, 2, or 2---1/2

(24, 36, 51, 64 mm)

2---1/2, 3 or 4

(64, 76, 102 mm)

Direct Vent / 2-Pipe System

In a direct-vent (2-pipe) system, all air for combustion is taken directly from outdoor atmosphere, and all flue products are discharged to outdoor atmosphere. Combustion-air and vent pipes must terminate together in the same atmospheric pressure zone, either through the roof (preferred) or a sidewall. See Fig. 44 for references to clearances required by National code authorities.

NOTICE

OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

In applications where there is a risk of excessive moisture entering the combustion air inlet pipe, a moisture trap may be

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added to the inlet pipe to help prevent moisture from entering the furnace from the combustion air inlet pipe. See Fig. 51.

When sizing venting systems, the equivalent length of the optional inlet pipe moisture trap must be taken into account.

Ventilated Combustion Air Systems

In a ventilated combustion air option, the vent terminates and discharges the flue products directly to the outdoors similar to a direct vent system. See Fig. 45 for references to clearances required by National code authorities.

All air for combustion is piped directly to the furnace from a space that is well ventilated with outdoor air (such as an attic or crawl space) and the space is well isolated from the living space or garage. Combustion air requirements for this option are the same as the requirements for providing outside air for combustion for a single pipe vent system. Refer to the “Air For Combustion and Ventilation” Section.

NOTICE

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the instructions outlined below for each appliance being placed into operation could result in carbon monoxide poisoning or death.

The instructions included with this furnace DO NOT APPLY to vent systems that are located below the furnace.

CAREFULLY FOLLOW THE INSTRUCTIONS PROVIDED WITH THE EXTERNAL VENT TRAP KIT FOR LAYING OUT THE VENTING SYSTEM AND THE DRAIN SYSTEM when all or part of the venting

system is placed below the furnace. Proper configuration of the venting and drain system is critical

when placing all or part of the venting system below the level of the furnace. VENT GASSES COULD BE RELEASED FROM THE DRAINAGE SYSTEM if the instructions provided with the External Vent Trap Kit are not followed.

Locating the Vent Termination

General

NOTE: Termination Requirements for the Provinces of Alberta and Saskatchewan are located at the end of this section.

Combustion--air inlet pipe (direct vent/2--pipe system only) and vent pipe must terminate outside structure, either through sidewall or roof.

For vent termination clearance, references to National codes are shown in Fig. 44 for Direct Vent/2--Pipe system and Fig. 45 for Ventilated Combustion Air system. For exterior termination arrangements, refer to Fig. 46 for Direct Vent/2--Pipe system and Fig. 47 for Ventilated Combustion Air system. Contact Local code authorities for other requirements to and/or exemptions from the National codes shown in the figures.

Roof termination is often preferred since it is less susceptible to damage or contamination, is usually located away from adjacent structures, is less prone to icing conditions, and it often has less visible vent vapors. Sidewall terminations may require sealing or shielding of building surfaces with a corrosive resistance material due to the corrosive properties of combustion products from the vent system, as well as protection of adjacent structures.

OPTIONAL VENTING BELOW THE FURNACE

The venting system may be positioned below the furnace ONLY IF the factory accessory External Vent Trap Kit is used. The External Vent Trap Kit is only approved for PVC/ABS DWV venting systems.

CAREFULLY FOLLOW THE INSTRUCTIONS PROVIDED WITH THE EXTERNAL VENT TRAP KIT FOR LAYING OUT THE VENTING SYSTEM AND THE DRAIN SYSTEM. The instructions included with this

furnace DO NOT APPLY to vent systems that are located below the furnace.

NOTICE

RECOMMENDED SUPPORT FOR VENT TERMINATIONS

It is recommended that sidewall vent terminations in excess of 24 inches (0.6 M) or rooftop terminations in excess of 36 inches (1 M) in vertical length be supported by EITHER the Direct Vent Termination Kit shown in Table 12 or by field--supplied brackets or supports fastened to the structure.

When determining appropriate location for termination, consider the following guidelines:

1. Comply with all clearance requirements stated in Fig. 44 or Fig. 45 per application.

2. Termination or termination kit should be positioned where vent vapors will not damage plants/shrubs or air conditioning equipment.

3. Termination or termination kit should be positioned so that it will not be affected by wind eddy, such as inside building corners, nor by recirculation of flue gases, airborne leaves, or light snow.

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4. Termination or termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones, balls, etc.

5. Termination or termination kit should be positioned where vent vapors are not objectionable.

Direct Vent / 2-Pipe System

Direct vent (2--pipe) vent and combustion air pipes must terminate outside the structure. See Fig. 44 For references to vent clearances re. Allowable vent and combustion air terminations are shown in Fig. 46.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the instructions outlined below for each appliance being placed into operation could result in carbon monoxide poisoning or death.

--2009, Air for Combustion and Ventilation and applicable provisions of the local building codes.

Canadian Installations: Part 8 of CAN/CSA--B149.1--10. Venting Systems and Air Supply for Appliances and all authorities having jurisdiction.

Ventilated Combustion Air

The vent pipe for a Ventilated Combustion Air System must terminate outdoors. See Fig. 45 For references to vent clearances required by National code authorities. Allowable vent terminations are shown in Fig. 47. The combustion air pipe terminates in a well--ventilated attic or crawl space. Follow the clearances as shown in Fig. 49.

The combustion air pipe cannot terminate in attics or crawl spaces that use ventilation fans designed to operate in the heating season. If ventilation fans are present in these areas, the combustion air pipe must terminate outdoors as a Direct Vent System.

Termination Requirements for the Provinces of Alberta and Saskatchewan

The Provinces of Alberta and Saskatchewan require a minimum unobstructed distance of 4 ft. (1.2 M) from the foundation to the property line of the adjacent lot for vent termination of any appliance with an input over 35,000 btuh. If there is less than 4 ft. (1.2 M) of unobstructed distance to the property line of the adjacent lot, no type of vent termination is permitted for appliances with inputs greater than 35,000 btuh.

There are no additional restrictions on unobstructed distances greater than 8 ft. (2.4 M). All single, two-pipe and concentric vents may be used, providing all other Code and manufacturer’s requirements in these instructions are adhered to. Refer to the appropriate Vent Termination section above for locating the vent termination

If the unobstructed distance from the foundation to the property line of the adjacent lot is no less than 4 ft. (1.2 M) and no greater than 8 ft. (2.4 M), it will be necessary to re-direct the flue gas plume. In this situation, a concentric vent kit cannot be used. A 2-pipe termination (or single pipe termination when permitted with ventilated combustion air applications) that re-directs the flue gas

away by use of an elbow or tee, certified to ULC S636 from the adjacent property line must be used. See Fig. 48.

The concentric vent kit currently cannot be modified to attach an elbow to the vent portion of the rain cap. A tee attached to the rain cap could potentially direct the flue gas plume toward the intake air stream and contaminate the incoming combustion air for the furnace.

Refer to Fig. 48 for terminations approved for use in Alberta and Saskatchewan.

Size the Vent and Combustion Air Pipes

General

Furnace combustion air and vent pipe connections are sized for 2-in. (50 mm ND) PVC/ABS DWV pipe. The combustion air and vent pipe connections also accommodate 60 mm polypropylene venting systems with outside diameters of approximately 60 mm (2--3/8 inches). Any pipe diameter change should be made outside furnace casing in vertical pipe. Any change is diameter to the pipe must be made as close to the furnace as reasonably possible.

The Maximum Vent Length for the vent and combustion air pipe (when used) is determined from the Maximum Equivalent Vent Length in Table 15 or 17, minus the number of fittings multiplied by the deduction for each type of fitting used from Table 16.

NOTICE

OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE

In applications where there is a risk of excessive moisture entering the combustion air inlet pipe, a moisture trap may be added to the inlet pipe to help prevent moisture from entering the furnace from the combustion air inlet pipe. See Fig. 51.

When sizing venting systems, the equivalent length of the optional moisture trap (15 feet/5 M) must be taken into account.

Optional Combustion Air Inlet Moisture Trap

As an option to prevent moisture from trickling into the furnace vestibule, a trap can be installed in the intake air pipe near the furnace. Connecting a drain line to the trap is optional as trace amounts of moisture will evaporate into the intake air stream. If the combustion air inlet is located near a moisture exhaust duct, or there are other concerns of excessive moisture being drawn into the combustion air inlet, it is encouraged to connect a drain line to the trap.

The trap can be constructed from a running tee of the same diameter of the intake air pipe with EITHER a removable cap attached to a 6-inch long pipe connected to the tee or the External Vent Trap Kit to help prevent contaminants from entering the furnace. See Fig. 51.

The External Vent Trap Kit accessory may be used as a trap for the combustion air inlet pipe if a large amount of moisture must be removed. The drain line may be connected to the same drain as the furnace condensate and the evaporator coil condensate line ONLY if the inlet air trap drain and the evaporator coil drain empty into an open segment of pipe above the drain. See Fig.12. When using the External Vent Trap Kit, refer to those instructions for proper drain connections.

The tee may also be connected to the intake air pipe on the side of the casing. See Fig. 51.

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In any configuration, it will be necessary to add the equivalent length of the tee (15 feet/5 M) to the Total Equivalent Vent Length of the venting system.

NOTICE

ADDITIONAL INFORMATION FOR POLYPROPYLENE VENTING SYSTEMS

Polypropylene venting systems include flexible vent pipe. These flexible vent pipes have a different equivalent vent length than straight sections of PVC/ABS DWV vent pipe. Be sure to make the appropriate deductions from the Maximum Equivalent Vent Length (MEVL), or additions to the Total Equivalent Vent Length (TEVL), when applying flexible vent pipes in polypropylene venting systems. See the polypropylene vent system manufacturer’s installation instructions for details.

When using metric-sized venting systems, use these equivalencies for obtaining the proper MEVL from the Tables: Use 2” Vent Tables for 60 mm (o.d.) vent systems Use 3” Vent Tables for 80 mm (o.d.) vent systems

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Use 4” Vent Tables for 100 mm (o.d.) vent systems

The measured length of pipe used in a single or 2--pipe termination is included in the total vent length. Include deductions from the Maximum Equivalent Vent Length (MEVL) contained in the Venting Tables for elbows and flexible vent pipe. Factory accessory concentric vent terminations or pipe lengths and elbows used for “standard” vent terminations do not require a deduction from the Maximum Equivalent Vent Length. See vent termination figures associated with Table 15. Include a deduction for a Tee when used for Alberta and Saskatchewan terminations.

NOTE: Polypropylene venting systems MAY require additional deductions from the MEVL, or additions to the TEVL, for vent terminations and flexible pipe sections. See the polypropylene venting system manufacturer’s instructions for details on equivalent lengths of vent terminations and flexible vent pipes, and for calculating total vent lengths.

To calculate the Total Equivalent Vent Length (TEVL) of the venting system:

1. Measure the individual distance from the furnace to the termination for each pipe.

2. Count the number of elbows for each pipe.

3. For each pipe, multiply the number of elbows by the equivalent length for the type of elbow used. Record the equivalent length of all the elbows for each pipe.

4. If a Tee is used on the termination (Alberta and Saskatchewan, when required) record the equivalent length of the Tee u sed .

5. Calculate Total Equivalent Vent Length by adding the equivalent lengths of the fittings to the lengths of the individual vent and combustion air pipes.

6. When using polypropylene venting systems with flexible vent pipes, perform adjustments for the equivalent length of the flexible vent pipe to the calculated total equivalent venting system length. See the polypropylene vent system manufacturer’s instructions for details.

7. Select a diameter of vent pipe from Tables 15 and 17 and note the Maximum Equivalent Vent Length (MEVL) shown for that application for that specific furnace input size. Compare the Total Equivalent Vent Length (TEVL) to the MEVL:

8. If the Total Equivalent Vent Length is shorter than the Maximum Equivalent Vent Length for the diameter of pipe chosen, then that diameter of pipe selected may be used.

9. If the Total Vent Length is longer than the Maximum

Equivalent Vent Length for the diameter of pipe chosen, that diameter pipe MAY NOT be used for venting the furnace. Try the next larger diameter pipe

NOTE: If the calculated Total Equivalent Vent Lengths results in different diameter pipes for the vent and combustion air, select the larger diameter for both pipes.

NOTE: If the Maximum Vent Length for diameter of the pipe selected is longer than the measured length and the equivalent length of all the fittings and terminations (TEVL), recalculate Total Equivalent Vent Length using the next smaller diameter. If the Maximum Equivalent Vent Length is still longer than the longer TEVL of the vent pipe or combustion air pipe, then that diameter of pipe selected may be used.

When installing vent systems pipe lengths of 10 ft. (3 M) or less, use the smallest allowable pipe diameter. Using a pipe size greater than required for short venting systems may result in loss of efficiency, incomplete combustion, flame disturbance, or flame sense lockout.

For vent systems longer than 10 ft. (3 M), any larger diameter vent pipe shown in Table 15 or 17 FOR THAT SIZE FURNACE may be used.

Combustion Air and Vent Piping Insulation Guidelines

NOTE: Use closed cell, neoprene insulation or equivalent.

The vent pipe may pass through unconditioned areas. The amount of exposed pipe allowed is shown in Table 14.

1. Using winter design temperature (used in load calculations), find appropriate temperature for your application and furnace model.

2. Determine the amount of total and exposed vent pipe.

3. Determine required insulation thickness for exposed pipe length(s).

4. When combustion air inlet piping is installed above a suspended ceiling, the pipe MUST be insulated with moisture resistant insulation such as Armaflex or other equivalent type of insulation.

5. Insulate combustion air inlet piping when run in warm, humid spaces.

6. Install the insulation per the insulation manufacturer’s installation instructions.

NOTE: Pipe length (ft. / M) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as calculated from Table 15 or 17.

Configure the Furnace

WARNING

CARBON MONOXIDE POISONING HAZARD

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

To route the vent pipe and combustion air pipe through the furnace, the manufacturer supplied kit must be used. Failure to properly seal the blower compartment from the furnace vestibule could result in the circulation of carbon monoxide throughout the structure. The vent pipe and combustion air pipe must be a continuous pipe while passing through the blower compartment. Seals supplied in this kit must be installed per the instructions provided. Follow all procedures outlined in these instructions.

Page 45

Install the Vent and Combustion Air Pipes

With the furnace installed in the required position, remove the desired knockouts from the casing. It will be necessary to remove one knockout for the vent pipe and the other knockout for the combustion air connection. See Fig. 11.

Use a flat blade screwdriver and tap on the knockout on opposite sides, where the knockout meets the casing. Fold the knockout down with duct pliers and work the knockout back and forth until it is removed. Trim any excess metal from the knockout with tin snips.

The vent elbow can be rotated to the required location on the casing if necessary. See Fig. 37. To rotate the vent elbow:

1. Loosen the clamp on the inlet of the vent elbow attached to the inducer.

2. Rotate the vent elbow to the required position. There are rounded notches in the vent elbow to align it with the inducer housing for each orientation.

3. Tighten the clamp around the vent elbow. Torque the clamp to 15 lb--in. See Fig. 38--41.

Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter

WARNING

CARBON MONOXIDE POISONING HAZARD

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

WARNING

CARBON MONOXIDE POISONING HAZARD

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

DO NOT use cement to join polypropylene venting systems. Follow the polypropylene venting system manufacturer’s instructions for installing polypropylene venting systems.

NOTE: The rubber coupling that attaches to the vent pipe adapter must be used. The adapter seals the vent pipe to the casing and reduces the strain on the vent elbow attached to the inducer.

1. Apply the gaskets to the vent pipe and combustion air pipe adapters. If supplied, remove and discard round center “slug” from interior of gasket. See Fig. 36.

NOTE: The vent pipe adapter can be distinguished from the inlet pipe adapter by the absence of an internal pipe--stopping ring. The vent pipe can pass through the vent pipe adapter; it cannot pass through the inlet pipe adapter.

2. Align the screw holes in the plastic vent pipe adapter with the dimples in the casing.

3. Pilot drill the screw holes for the adapter in the casing and attach the vent pipe adapter to the furnace with sheet metal screws

4. Slide the end of the rubber vent coupling with notches in it over the standoffs on the vent pipe adapter.

5. Insert a length of vent pipe through the coupling into the outlet of the vent elbow.

6. Tighten the clamp around the outlet of the vent elbow. Torque the clamp to 15 lb--in.

NOTICE

The following instructions are for PVC/ABS DWV vent piping only. DO NOT USE THESE TECHNIQUES FOR POLYPROPYLENE VENT PIPING SYSTEMS. See the polypropylene vent system manufacturer’s instructions for installing polypropylene venting systems.

Install the remaining vent and combustion air pipes as shown below. It is recommended that all pipes be cut, prepared, and preassembled before permanently cementing any joint.

1. Working from furnace to outside, cut pipe to required length(s).

2. De--burr inside and outside of pipe.

3. Chamfer outside edge of pipe for better distribution of primer and cement.

4. Clean and dry all surfaces to be joined.

5. Check dry fit of pipe and mark insertion depth on pipe.

6. Insert the vent pipe into the vent elbow.

7. Torque clamp on vent elbow 15 lb--in.

8. Torque clamp on vent coupling 15 lb--in.

9. Insert the combustion air pipe into the adapter.

10. Pilot drill a screw hole through the adapter into the combustion air pipe and secure the pipe to the adapter with sheet metal screws. DO NOT DRILL INTO POLYPROPYLENE VENT PIPES. Use an optional accessory vent coupling, if needed.

11. Seal around the combustion air pipe with silicone or foil tape. SILICONE SEALERS MAY NOT BE APPROPRIATE FOR POLYPROPYLENE VENT SYSTEMS. SEE POLYPROPYLENE VENT SYSTEM MANUFACTURER’S INSTRUCTIONS.

12. After pipes havebeen cut and preassembled, apply generous layer of cement primer to pipe fitting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat. DO NOT CEMENT POLYPROPYLENE FITTINGS.

13. While cement is still wet, twist pipe into socket with 1/4--in. turn. Be sure pipe is fully inserted into fitting socket.

14. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint.

15. Handle pipe joints carefully until cement sets.

16. Horizontal portions of the venting system shall be supported to prevent sagging. Support combustion air piping and vent piping a minimum of every 5 ft. (1.5M)[3 ft. (.91M) for SDR--21 or --26 PVC] using perforated metal hanging strap or commercially available hangars designed to support plastic pipe.

17. Prevent condensate from accumulating in the pipes by sloping the combustion air piping and vent piping downward towards furnace a minimum of 1/4-in. per linear ft. with no sags between hangers.

18. Complete the vent and combustion air pipe installation by connecting the concentric vent or by installing the required

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termination elbows as shown in Fig. 46, 47 and 48. For Ventilated Combustion Air Termination, See Fig. 49.

19. Use appropriate methods to seal openings where combustion air pipe and vent pipe pass through roof or sidewall.

WARNING

CARBON MONOXIDE POISONING HAZARD

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

DO NOT use cement to join polypropylene venting systems. Follow the polypropylene venting system manufacturer’s instructions for installing polypropylene venting systems.

Optional Installation of the Vent Pipe

NOTE: DO NOT USE THIS TECHNIQUE FOR

POLYPROPYLENE VENTING SYSTEMS. This option provides a disconnect point for the vent pipe. The vent

pipe must be cemented to the plastic vent pipe adapter to maintain a sealed vestibule. See Fig. 42.

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1. Insert a length of vent pipe through the casing into the outlet of the vent elbow.

2. Slide the plastic vent pipe adapter over the length of the vent pipe down to the furnace casing. Mark the pipe where it is flush with the outlet of the adapter.

3. Remove the pipe from the furnace and the adapter and cut off any excess pipe.

4. Clean and prime the end of the pipe that is flush with the vent adapter with a primer that is appropriate for the type of pipe being used.

5. Re--insert the pipe through the casing into the vent elbow.

6. Tighten the clamp around the outlet of the vent elbow. Torque the clamp to 15 lb--in.

7. Apply cement to the end of the pipe and to the inside of the plastic vent adapter.

8. Slide the adapter over the vent pipe and align the screw holes in the adapter with the dimples in the furnace casing.

9. Pilot drill 1/8--in. screw holes for the adapter in the casing and secure the adapter to the furnace with sheet metal screws.

10. Loosen the clamps on the rubber vent coupling.

11. Slide the end of the coupling with notches in it over the standoffs in the vent pipe adapter.

12. Tighten the clamp of the coupling over the vent pipe adapter. Torque the lower clamp around the vent pipe adapter to 15 lb--in.

13. Pilot drill a 1/8--in. hole in the combustion air pipe adapter.

14. Complete the vent and combustion air pipe as shown in “Install the Vent and Combustion Air Pipe.”

NOTICE

FOR POLYPROPYLENE VENTING SYSTEMS

When using polypropylene venting systems, all venting materials used, including the vent terminations, must be from the same manufacturer.

Installing the Vent Termination

Roof Terminations

A roof termination of any type will require a 4-in. (102 mm) flashing for a 2 inch (50 mm ND) concentric vent or a 5--in.

diameter (127 mm) flashing for a 3-inch (80 mm ND) concentric vent kit. For two-pipe or single pipe vent systems, a flashing for each pipe of the required diameter will be necessary.

It is recommended that the flashing be installed by a roofer or competent professional prior to installing the concentric vent. The terminations can be installed on a flat or pitched roof.

Concentric Vent

Single or multiple concentric vent must be installed as shown in Fig. 46. Maintain the required separation distance between vents or pairs of vents as shown in Fig. 46 and all clearance shown in Fig. 44.

NOTE: Follow the instructions of the vent terminal manufacturer. These instructions are provided as a reference, only.

Cut one 4--in. (102 mm) diameter hole for 2--in. (50 mm ND) kit, or one 5--in. (127 mm) diameter hole for 3--in. (80 mm ND) kit in the desired location.

Loosely assemble concentric vent/combustion air termination components together using instructions in kit.

Slide assembled kit with rain shield REMOVED through hole in wall or roof flashing.

NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.

Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. DO NOT CEMENT POLYPROPYLENE FITTINGS.

Two--Pipe (Direct Vent) and Single--Pipe (Ventilated Combustion Air) Terminations

Single and two pipe vent terminals must be installed as shown in Fig. 46 and 47. Maintain the required separation distance between vents or pairs of vents as shown in Fig. 46 and 47. and all clearance shown in Fig. 44 and 45.

NOTICE

RECOMMENDED SUPPORT FOR VENT TERMINATIONS

It is recommended that rooftop vent terminations in excess of 36 inches (1 M) in vertical length be supported by EITHER the Direct Vent Termination Kit shown in Table 12 or by field--supplied brackets or supports fastened to the structure.

Cut the required number of holes in the roof or sidewall for vent and (when used) combustion air pipes. Sidewall holes for two-pipe vent terminations should be side-by-side, allowing space between the pipes for the elbows to fit on the pipes.

Holes in the roof for direct--vent (two pipe) terminations should be spaced no more than 18 in. (457 mm) apart to help avoid vent gas recirculation into combustion air intake.

Termination elbows will be installed after the vent and (if used) combustion air pipe is installed.

Sidewall Terminations Concentric Vent Termination

NOTE: Follow the instructions of the vent terminal manufacturer.

These instructions are provided as a reference only. Determine an appropriate location for termination kit using the guidelines provided in section “Locating The Vent Termination” in this instruction.

1. Cut one 4--in. diameter hole for 2--in. kit, or one 5--in. diameter hole for 3--in. kit.

2. Loosely assemble concentric vent/combustion air termination components together using instructions in kit.

3. Slide assembled kit with rain shield REMOVED through hole.

Page 47

NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.

4. Locate assembly through sidewall with rain shield positioned no more than 1--in. (25 mm) from wall as shown in Fig. 46.

5. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. DO NOT CEMENT POLYPROPYLENE FITTINGS.

2--Pipe (Direct Vent) and 1--Pipe (Ventilated Combustion Air) Vent Termination

NOTE: Follow the instructions of the vent terminal manufacturer.

These instructions are provided as a reference, only.

NOTICE

RECOMMENDED SUPPORT FOR VENT TERMINATIONS

It is recommended that sidewall vent terminations in excess of 24 inches (0.6 M) in vertical length be supported by EITHER the Direct Vent Termination Kit shown in Table 12 or by field--supplied brackets or supports fastened to the structure.

Determine an appropriate location for termination kit using the guidelines provided in section “Locating The Vent Termination” in

this instruction.

1. Cut two holes, one for each pipe, of appropriate size for pipe size being used.

2. Loosely install elbow in bracket (if used) and place assembly on combustion--air pipe.

3. Install bracket as shown in Fig. 46 and 48.

NOTE: For applications using vent pipe option indicated by dashed lines in Fig. 46 and 47, rotate vent elbow 90_ from position.

4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping. DO NOT CEMENT POLYPROPYLENE FITTINGS.

For ventilated Combustion Air Terminations, terminate as shown in Fig. 47.

(Direct Vent / 2-Pipe System ONLY)

When two or more furnaces are vented near each other, two vent terminations may be installed as shown in Fig. 46, but next vent termination, or pair of vent terminations, must be at least 36 in. (914 mm) away from the first two terminations. It is important that vent terminations be made as shown in Fig. 46 to avoid recirculation of vent gases.

Inducer Outlet Restrictor

The loose parts bag may contain an inducer outlet restrictor. The outlet restrictor is NOT used on these furnaces. Discard restrictor.

59MN7A

Table 13 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A. Installations)

ASTM SPECIFICATION

(MARKED ON MATERIAL)

D1527 ABS Pipe — — S c h e d u le --- 4 0 D1785 PVC Pipe — — S c h e d u le --- 4 0 D2235 For ABS — — Solvent Cement For ABS D2241 PVC Pipe — — SD R --- 2 1 & S D R --- 2 6 D2466 PVC — Fittings — S c h ed u l e --- 4 0 D2468 ABS — Fittings — S c he d u l e --- 4 0 D2564 For PVC — — Solvent Cement For PVC D2661 ABS Pipe Fittings — DWV at Schedule--- 40 IPS sizes D2665 PVC Pipe Fittings — DWV

F438 CPVC — Fittings — S c h e d u le --- 4 0 F441 CPVC Pipe — — S c h e d u l e --- 4 0 F442 CPVC Pipe — — SDR F493 For C PVC — — Solvent Cement For CPVC

F628 ABS Pipe — —

F656 For PVC — — Primer For PVC F891 PVC Pipe — — Cellular Core Schedule --- 40 & DWV

MATERIAL PIPE FITTINGS

SOLVENT CEMENT

AND PRIMERS

DESCRIPTION

Cellular Core DWV at Schedule --- 40

IPS sizes

Page 48

Modulating

Furnace High

Heat Input

60000

Winter Design

Te m p ° F ( ° C )

20 (-10)

0 (-20)

-20 (-30)

-40 (-40)

Table 14 – Maximum Allowable Exposed Vent Lengths Insulation Table -- Ft. / M

Maximum Length of Uninsulated and Insulated Vent Pipe-Ft (M)

Pipe

Length in

Ft. & M

Ft. 34.0 29.0 28.0 23.0 N/A 55.0 88.0 79.0 69.0 N/A 55.0 104.0 93.0 81.0 N/A

M 10.4 8.8 8.5 7.0 N/A 16.8 26.8 24.1 21.0 N/A 16.8 31.7 28.3 24.7 N/A

Ft. 14.0 9.0 7.0 0.0 N/A 55.0 49.0 43.0 34.0 N/A 55.0 60.0 52.0 42.0 N/A

M 4.3 2.7 2.1 0.0 N/A 16.8 14.9 13.1 10.4 N/A 16.8 18.3 15.8 12.8 N/A

Ft. 5.0 0.0 0.0 0.0 N/A 41.0 32.0 26.0 18.0 N/A 50.0 40.0 33.0 24.0 N/A

M 1.5 0.0 0.0 0.0 N/A 12.5 9.8 7.9 5.5 N/ A 15.2 12.2 10.1 7.3 N/A

Ft. 0.0 0.0 0.0 0.0 N/A 30.0 21.0 16.0 8.0 N/A 37.0 28.0 22.0 13.0 N/A

M 0.0 0.0 0.0 0.0 N/A 9.1 6.4 4.9 2.4 N/A 11.3 8.5 6.7 4.0 N/A

No Insulatio n 3/8-in. (9.5 mm) 1/2-in. (12.7 mm)

Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Diameter-inches (mm)

1.5 2.0 2.5 3.0 4.0 1.5 2.0 2.5 3.0 4.0 1.5 2.0 2.5 3.0 4.0

(38) (51) (64) (76) (102) (38) (51) (64) (76) (102) (38) (51) (64) (76) (102)

20 (-10)

0 (-20)

60600

59MN7A

80000

100000

-20 (-30)

-40 (-40)

20 (-10)

0 (-20)

-20 (-30)

-40 (-40)

20 (-10)

0 (-20)

-20 (-30) Ft. N/A 8.0 6.0 0.0 0.0 N/A 50.0 49.0 38.0 23.0 N/A 50.0 60.0 48.0 32.0

-40 (-40) Ft. N/A 1.0 0.0 0.0 0.0 N/A 42.0 34.0 24.0 10.0 N/A 50.0 43.0 32.0 18.0