Carrier 59TN6A User Manual

Installation, Start-up, Operating and

Service and Maintenance Instructions

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

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

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

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ... 4

ACCESSORIES ..................................... 5

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

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

CONDENSATE TRAP ............................... 12

Upflow ........................................ 12

Downflow ..................................... 12

Horizontal ...................................... 12

CONDENSATE DRAIN ............................. 16

INSTALLATION ................................... 19

Upflow ........................................ 19

Downflow ..................................... 19

Horizontal ...................................... 20

Filter Arrangement ............................... 20

AIR DUCTS ....................................... 27

Ductwork Acoustical Treatment ..................... 27

GAS PIPING ...................................... 31

ELECTRICAL CONNECTIONS ....................... 32

115-V Wiring ................................... 32

J-Box Installation ................................ 33

24-V Wiring .................................... 33

Accessories ..................................... 33

Alternate Power Supplies .......................... 34

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

Special Venting Requirements for Installations in Canada . 40

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

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

Locating Vent Termination ......................... 41

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

Combustion Air and Vent Piping Insulation Guidelines ... 42

Configure the Furnace ............................ 43

Installing the Vent Termination ...................... 44

Venting System Length Calculations ................. 48

START-UP, ADJUSTMENT, AND SAFETY CHECK ...... 61

Select Setup Switch Positions ........................ 61

Prime Condensate Trap ............................. 61

Purge Gas Lines ................................... 61

Adjustments ...................................... 62

Check Safety Controls .............................. 64

Checklist ........................................ 64

SERVICE AND MAINTENANCE PROCEDURES ........ 72

Cleaning Heat Exchangers ........................... 77

SEQUENCE OF OPERATION ........................ 81

PARTS REPLACEMENT GUIDE ...................... 88

TABLE

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

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

Minimum Free Area Required ......................... 11

Minimum Space Volumes ............................. 11

Filter Size Information ............................... 21

Opening Dimensions ................................ 23

Air Delivery CFM ................................... 28

Maximum Capacity of Pipe ........................... 32

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

Vent Termination Kit for Direct Vent (2-Pipe) Systems ...... 41

Combustion-Air Vent Pipe, Fitting 8: Cement Material ....... 45

Maximum Allowable Exposed Vent Lengths Insulation ...... 46

Maximum Equivalent Vent Length ...................... 47

Deductions from Maximum Equivalent Vent Length ........ 47

Altitude Derate Multiplier for U.S.A ..................... 69

Blower Off Delay Setup Switch ........................ 69

Gas Rate .......................................... 69

Orifice Size and Manifold Pressure ..................... 70

Always Ask For

Use of the AHRI Cellified rMMark indicates a
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
Z223.1-2009©, 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.

ISO9001

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.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall

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) in. 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.

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous
operation, personal iniury, 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 iniury or property damage. Consult a
qualified service agency, local gas supplier, or your

distributor or branch for information or assistance. The
qualified service agency nmst use only factory-authorized

and listed kits or accessories when modifying this product.

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 nmst 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.

CUT HAZARD

Failure to follow this caution may result in personal iniury.
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 A'x When you see this symbol on
the furnace and in instructions or manuals, be alert to the potential

for personal iniury.
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 iniury or death. WARNING signifies a hazard

which could result in personal iniury or death. CAUTION is used
to identify hazards which may result in nfinor personal iniury or

product and property damage. NOTE is 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 spe-
cified in the "Location" section of these instructions.

3. Provide adequate combustion and ventilation air to the fur-
nace space as specified in "Air for Combustion and Ventila-

tion" section.

4. Combustion products must be discharged outdoors. Con-
nect this furnace to an approved vent system only, as spe-

cified in the "Venting" section of these instructions.

5. Never test for gas leaks with an open flame. Use a commer-
cially available soap solution made specifically for the de-

tection of leaks to check all connections, as specified in the
"Gas Piping" section.

6. Always install furnace to operate within the furnace's inten-
ded temperature-rise range with a duct system which has an

external static pressure within the allowable range, as spe-
cified 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 contain-

ing the furnace, the return air shall also be handled by
duct(s) sealed to the furnace casing and ternfinating outside

the space containing the furnace. See "Air Ducts" section.

8. A gas-fired furnace for installation in a residential garage
nmst 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 instruc-
tions.

10. These Multipoise Gas-Fired Furnaces are CSA design-cer-
tified for use with natural and propane gases (see furnace
rating plate) and for installation in alcoves, attics, base-

ments, 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 con-
struction.

12. Maintain a 1-in. (25 ram) clearance from combustible ma-
terials to supply air ductwork for a distance of 36 in. (914

ram) horizontally from the furnace. See NFPA 90B or local
code for further requirements.

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

flooring. In downflow installations, factory accessory floor

base MUST be used when installed on combustible materi-

als 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 com-

bustible construction information.

il

H

INTRODUCTION

This 4-way multipoise Category IV condensing furnace is CSA
design-certified as a direct (2-pipe) or non-direct vent (1-pipe)

furnace. (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

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

• US: National Fuel (;as Code (NFGC) NFPA 54-2009/ANSI
Z223.1-2009 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B

• CANADA: National Standard of Canada, Natural Gas and
Propane Installation Code (NSCNGPIC CAN/CSA

B149.1-2010

General Installation

• US: NFGC and the NFPA 90B. For copies, contact the National
Fire Protection Association Inc., Batterymarch Park, Quincy,

MA 02269; or for only the NFGC contact the American Gas
Association, 400 N. Capitol, N.W., Washington DC 20001

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke

(Toronto), Ontario, Mgw IR3, Canada

Combustion and Ventilation Air

• US: Section 9.3 of the NFPA54/ANSI Z223.1-2009 Air for
Combustion and Ventilation

• CANADA: Part 8 of the CAN/CSA B149.1-2010, Venting
Systems and Air Supply for Appliances

Duct Systems

• US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors
National Association (SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers (ASHRAE) 2005

Fundamentals Handbook Chapter 35

Acoustical Lining and Fibrous Glass Duct

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

Gas Piping and Gas Pipe Pressure Testing

• 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:

• This product must be installed by a licensed plumber or gas fitter.

• When flexible connectors are used, the maximum length shall
not exceed 36 in. (914 mm).

• When lever type gas shutoffs are used they shall be T-handle type.

• The use of copper tubing for gas piping is not @proved by the
state of Massachusetts.

Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70-2011

• CANADA: Canadian Electrical Code CSA C22.1

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

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 fur-
nace chassis which is close to the control. Tools held in a

person's hand during grounding will be satisfactorily dis-
charged.

3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to

recharge your body with static electricity (for example; DO
NOT move or shuffle your feet, do not touch ungrounded

objects, etc.).

4. If you touch ungrounded objects (and recharge your body

with static electricity), firmly touch a clean, unpainted metal

surface of the furnace again before touching control or

wires.

5. Use this procedure for installed and uninstalled (ungroun-
ded) 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 con-

trol or yourself in contact with the furnace. Put all used and
new controls into containers before touching ungrounded

objects.

7.AnESDservicekit(availablefromcommercialsources)
mayalsobeusedtopreventESDdamage.

ACCESSORIES

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

LOCATION

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.

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:

• be installed so the electrical components are protected from
water.

• not be installed directly on any combustible material other than

wood flooring (refer to SAFETY CONSIDERATIONS).

• be located close to the chimney or vent and attached to an air
distribution system. Refer to Air Ducts section,

• be provided ample space for servicing and cleaning. Always
comply with minimum fire protection clearances shown in

Table 2 or on the furnace clearance to combustible construction
label.

CARBON MONOXIDE POISONING / COMPONENT
DAMAGE HAZARD

Failure to follow this warning could result in personal iniury
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:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms

• 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:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative

pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return-air duct to

prevent pulling air from the burner area.

ii

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 nmst be located at least 18 in.
(457 ram) above the floor. The furnace must be located or
protected to avoid damage by vehicles. When the furnace is

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.)
installed in a public garage, airplane hangar, or other
building having a hazardous atmosphere, the furnace nmst

be installed in accordance with the NFPA 54/ANSI
Z223.1-2009 or CAN/CSA B149.2-2010. (See Fig. 5.)

Location Relative to Cooling Equipment

The cooling coil nmst be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat

exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the

furnace. If the dampers are manually operated, they nmst be

ii

equipped with means to prevent operation of either unit unless the
damper is in the full-heat or full-cool position.

Table 1 - Factory-Supplied Installation Parts

DESCRIPTION

Outlet Choke Plate (provided with 40K BTUH furnaces only; see Note)

Air Intake Pipe Flange

Vent Pipe Flange

Pipe Flange Gaskets

Sharp Tip Screws (Vent and Inlet Flanges)

Vent Pipe Coupling

Vent Pipe Coupling Clamps

Pressure Switch Tube

Rubber Drain Elbow

Drain Tube Clamps

1/2-in. CPVC to 3/4-in. PVC Pipe Adapter

Gas Line Grommet

Junction Box Cover

Junction Box Base

Green Ground Screw

Blunt Tip Screws (Junction Box)

Thermostat Wire Grommet

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

QUANTITY

1
1
1

2

10

1

2

1
1

4

1
1
1

1
1

3

1
1

NOTE: Only used for 40K BTUH furnaces from 0-2000 ft. (0 to 610 M) above sea level for total equivalent vent lengths under 10 ft. (3 M)

Table 2 - Minimum Clearances to Combustible Materials for All Units

POSITION CLEARANCE

Rear 0 (0 mm)

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

Required for service *24 in. (610 mm)

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

Sides 0 (0 mm)

Vent 0 (0 mm)

Top of Furnace 1 in. (25 mm)

Recommended

6 15/1_

[176.1]

611116
[17o.1]

26 11/16

_ 26 3/8

_ 23 5/16

- 20 5/8 _

k.i

I

.=.

=

-.J

=

=_

CONDENSATE DRAIN TRAP _\

=.

_r_

LOCAT,ON[1o1.__

THERMOSTAT ENTRY

[670.0]

[592,91

[522.7]

19 1/8

14s5.61_

AIR FLOW

[678.1 ]

25 1/8

[63s.7]

_ 7/8 ...........

[22.a 2 1/2 _-_

_ 3/lO

[76.21

VENT

AIR INTAKE

F_3

/ [76.2]

AIR INTAKE

[44.61

[88,4]

[76.21 1

13/4

FURNACE SIZE

(MODELS)

(59TN6)

060-14

080=14

D

08_20

100-22
120-22

A S C SHIPPING

(CABINET WIDTH) (OUTLET WIDTH) (BOTTOM INLET WIDTH) D WEIGHT

Inches mm Inches mm inches mm mm LBS KG

171/2 445

21 533

241/2 622

15 7/8 403 16 406

193/8 492 191/2 495

22 7/8 581 23 584

_A_

_B_

OUTLET WIDTH

AIR FLOW

inches

8 3/4

101/2

12 114

140.0 63.0

222

150.0 67.5

154.5 70.2

267

164.5 74.0

311 188.5 84.8

[76.2[

AIR INTAKE

Ill1 =,

NOTE: ALL DIMENSIONS IN INCH [MM]

29 1/2

[749.3]

283/4

173o,51

26 11/16

1678.1 ]

26 3/8

[669.01

227116

[569.8]

1/16

[838.8]

AIR FLOW

_ _ 13/4

[_-61
GAS CONN

.... _/_7/8

[22.2]

.... _7/8

, [22.2]

_ THERMOSTAT ENTRY

4

[101.61

........ _7/8

[ [22.2] POWER CONN

_ 7/8SIDE INLET

_ 7/8122"21 I

L

[25.4]

22

[588,31

21

1834.o1

26 5/16

[SSS.8]

I I 1518.8 181/.166 2_';'!

[17.5] BOTTOM RETURN [17.5[ 1 5/16

WIDTH [33.3]

[22.2]

23 3/8

[6_.oI

26 3/16

1668.81

SD_02,1 ,':

I

[26.41

H

AIRFLOW

THE BLOWER IS LOCATED

TOTHE RIGHT OFTHE

BURNER SECTION, AND

AIR CONDiTiONED AiR iS

DISCHARGED TO THE LEFT.

THE BLOWER iS

LOCATED ABOVE TH E

BURNER SECTION, AND

CONDiTiONED AIR IS

DISCHARGED DOWNWARD AIRFLOW

Fig. 2 - Multipoise Orientations

THE BLOWER iS

LOCATED BELOW THE

BURNER SECTION, AND

CONDiTiONED AiR iS

DISCHARGED UPWARD.

AIRFLOW

THE BLOWER iS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDiTiONED AiR IS

DISCHARGED TO THE RIGHT.

A02097

SUPPLYAIR

32° F/0 ° C MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED

Fig. 3 - Freeze Protection and Return Air Temperature

FRONT

RETURN

AIR

MAX80 °F / 27°C

MIN60°F / 16°O

A10490

BACK FRONT

Fig. 4 - Prohibited Installations

A10494

18-IN. (457.2 mm)
MINIMUM TO BURNERS

A93044

Fig. 5 - Installation in a Garage

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 airfor combustion. Follow the guidelines below to
insure thatother gas appliances have sufficient air for combustion.

Non-Direct Vent (1-pipe) Applications

When the furnace is installed as a non-direct vent (l-pipe) furnace,
it will be necessary to insure there is adequate air for combustion.
Other gas appliances installed with the furnace may also require air

for combustion and ventilation in addition to the amount of
combustion air and ventilation air required for the furnace. Follow

the guidelines below to insure that the furnace and 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 nmst 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

nmst 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 or crawl
space) 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:

• U.S.A. Installations: Section 9.3 of the NFPA 54/ANSI
Z223.1-2009, Air for Combustion and Ventilation and

applicable provisions of the local building codes.

• Canada: Part 8 of the CAN/CSA-B149.1-2010, Venting
Systems and Air Supply for Appliances.

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.
Air for combustion nmst not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and

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

fresheners, and other household products.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal
iniury 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 of make-up air is availaMe.

The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume of

at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.

• Spaces having less than 50 cubic feet per 1,000 Btuh (4.8 cubic
meters per kW) require the Outdoor Combustion Air Method,

• Spaces having at least 50 cubic feet per 1,000 Btuh (4.8 cubic
meters per kW) may use the Indoor Combustion Air,

Standard or Known Air Infiltration Method.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion,

ventilation, and dilution of flue gases using permanent hori-

zontal or vertical duct(s) or opening(s) directly communicat-
ing with the outdoors or spaces that freely communicate

with the outdoors.

2. Fig. 6 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and vent-

ilation air opening, to the outdoors.

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

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

b. Size openings and ducts per Fig. 6 and TaMe 3.

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

ram) of free area per 2,000 Btuh (1,100 mm2/kW) of com-
bined input for all gas appliances in the space per Fig. 6and

Table 3.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

sq. in. (645 sq. ram) of free area per 4,000 Btuh (550
mm2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.

3. ONE OUTDOOR OPENING requires:

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

mm2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.

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

the space.

The opening shall commence within 12 in. (300 ram) of the
ceiling. Appliances in the space shall have clearances of at least 1

in. (25 ram) from the sides and back and 6 in. (150 ram) from the
front. The opening shall directly communicate with the outdoors or

shall conmmnicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely communicate with the

outdoors.

ii

ii

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

Indoor air is pernfitted for combustion, ventilation, and dilution, if

the Standard or Known-Air-Infiltration Method is used.

CARBON MONOXIDE POISONING HAZARD

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

Many homes require air to be supplied from outdoors
for furnace combustion, ventilation, and dilution of flue
gases.

The furnace combustion air supply must be provided in

accordance with this instruction manual.

Standard Method

1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances

installed in the space and

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

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

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

ACH and shall be deternfined per Table 4 or Equations 1 and 2.
Deternfine the minimum required volume for each appliance in the

space and add the volumes together to get the total minimum
required volume I\_r the space.

Table 4 - Minimum Space Volumes were deternfined by using the
following equations from the current edition of the National Fuel

Gas Code ANSI Z223.1/NFPA 54, 9.3.2.2:

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

Volume _ 21ft3 ("- !other __

Other ACH _000 Btu/hrJ

A04002

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

of the floor. The minimum dimension of air openings shall
be at least 3 in. (80 ram). (See Fig. 7.)

c. Combining space on different floor levels. The volumes of

spaces on different floor levels shall be considered as com-
municating spaces if connected by one or more permanent

openings in doors or floors having free area of at least 2
in.2/1,000 Btuh (4,400 mm2/kW) of total input rating of

all gas appliances.

2. An attic or crawlspace may be considered a space that freely
communicates with the outdoors provided there are ad-

equate permanent ventilation openings directly to outdoors
having free area of at least 1-in.2/4,000 Btuh of total input

rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, in-
filtration should be adequate to provide air for combustion,

permanent ventilation and dilution of flue gases. However,
in buildings with unusually tight construction, additional air

MUST be provided using the methods described in the
Outdoor Combustion Air Method section.

4. Unusually tight construction is defined as Construction

with:

a. Walls and ceilings exposed to the outdoors have a continu-

ous, sealed vapor barrier. Openings are gasketed or sealed

and

b. Doors and openable windows are weatherstripped and

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

around window and door frames, between sole plates and

floors, between wall-ceiling joints, between wall panels,

at penetrations for plumbing, electrical and gas lines, etc.

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combus-

tion Air Method below and,

2. Outdoor openings shall be located as required in the Out-
door Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows:

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

required volume for Indoor Combustion Air Method be-
low.

b. Outdoor opening size reduction Factor is I nfinus the Ra-

tio in a. above.

c. Minimum size of Outdoor openings shall be the size re-

quired in Outdoor Combustion Air Method above multi-
plied by reduction Factor in b. above. The minimum di-
mension of air openings shall be not less than 3 in. (80 ram).

Volume _ 15ft 3 ("_ I _ _'_

Fan ACH _000" Btu/hr/

If: Iother = combined input of all other than fan-assisted appliances
in Btuh/hr

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

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

1. Adjoining rooms can be considered part of a space if:
a. There are no closeable doors between rooms.

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

have free area of at least I in.2/1,000 Btuh (2,000 mm2/kW)
of the total input rating of all gas appliances in the space,
but not less than 100 in. 2 (0.06 m2). One opening shall

commence within 12 in. (300 ram) of the ceiling and the
second opening shall commence within 12 in. (300 ram)

J

A04003

10

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

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR

FURNACE (1,100 SQ. MM/KW) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH)

INPUT (550 SQ. MM/KW)
(BTUH) Free Area of Round Duct Free Area of Round Duct Free Area of Open- Round Duct

40,000* 20 (12904) 5 (127) 14 (8696) 5 (127) 10 (6452) 4 (102)

60,000 30 (19355) 6 (152) 20 (13043) 5 (127) 15 (9678) 5 (127)
80,000 40 (25807) 7 (178) 27 (17391) 6 (152) 20 (12904) 5 (127)

100,000 50 (32258) 8 (203) 34 (21739) 7 (178) 25 (16130) 6 (152)
120,000 60 (38709) 9 (229) 40 (26087) 7 (178) 30 (19355) 6 (152)

140,000" 70 (45161) 10 (254) 47 (30435) 8 (203) 35 (22581) 7 (178)

*Not all families have these models.

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 FAN-ASSISTED TOTAL

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

30 40 50 40 60 80 100 120 140

ACH Space Volume Ft3 (M3)

0,60 (29.7) (39.6) (49.5) (39.6) (42.5) (56.6) (70.8) (84.9) (99.1)

0,50 (35.6) (47.5) (59.4) (47.5) (51.0) (67.9) (84.9) (101.9) (118.9)

0,40 (44.5) (59.4) (74.3) (59.4) (63.7) (84.9) (106.1 ) (127.3) (148.6)

0,30 (59.4) (79.2) (99.1) (79.2) (84.9) (113.2) (141.5) (169.8) (198.1 )

0.20 (89.1) (118.9) (148.6) (118.9) (127.3) (169.8) (212.2) (254.6) (297.1)

0.10 (178.0) (237.8) (297.3) (237.8) (254.6) (339.5) (424.4) (509.2) (594.1)
0,00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

1,050 1,400 1,750 1,400 1,500 2,000 2,500 3,000 3,500

1,260 1,680 2,100 1,680 1,800 2,400 3,000 3,600 4,200

1,575 2,100 2,625 2,100 2,250 3,000 3,750 4,500 5,250

2,100 2,800 3,500 2,800 3,000 4,000 5,000 6,000 7,000

3,150 4,200 5,250 4,200 4,500 6,000 7,500 9,000 10,500

6,300 8,400 10,500 8,400 9,000 12,000 15,000 18,000 21,000

OUTDOORSI "._,_._

_ I I ! JJ }i

(305mm) 12"MAX] ]1 I D II 1-_

1sa,a &/ I _o IVENT k-l_

PER2000 "/ ;IBI _ _ ITHROUGH FI:_

BTUFF !i I <;5 I ROOF F_ql S._

,' //I II I1£'"

DUOTS// II 8

, _:

.uT;°ORS// II

..........NN N ',

// II,so

// I II 40(

1SQN /J I _ _ = _M ,

PER 2000 ,_/'IAI _ _ 7- _:_--
BTUFF T :0

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

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

! J I i i BTL

i .......... _ L L_P=-I

A l i i 12"MAX/

OROULAT,.GA,RDUCTS J\

A&BC&DD&EF&G

(1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) VERTICAL DUCTS

Opening and Duct Opening and Duct ing and Duct

Sq, In (Sq, mm) In. (mm) Dia Sq, In (Sq, mm) In. (mm) Dia Sq, In (mm) In. (mm) Dia.

EXAMPLES: Determining Free Area

-- 1 SQIN.

Duss-h / °TU.

PER 4000

o

12

(305mm)

(305mm)

CIRCULATING AiR

I I

1 1

I I

INTERIOR

HEATED

SPACE

DUCTS

VENT THROUGH ROOF

I I

I I

_: 12" AX(S05mm)

o

-_- 1 SQ IN.
PER 1000

BTUH* IN DOOR
OR WALL

UNCONFINED
SPACE

6" MIN (152mm)
(FRONT)0

1 SQ IN.
PER 1000

BTUH* IN DOOR

-- OR WALL

12" MAX (305mm)

r(305mm)"

:_8TX_ 1so,..

I TO PER 4000

OUTDOORS BTUH*

Outdoors

A03174

CIRCULATING AIR DUCTS

l'

* Minimum opening size is 100 sq. in. (64516 sq. mm) with minimum dimensions

of 3 in. (76 mm)

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

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

Indoors

A03175

11

ii

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. 8 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
factory-installed trap will be located at the upper left corner of the

collector box. When the furnace is installed in the downflow
orientation, the factory-installed trap must be relocated for proper

condensate drainage,
To Relocate the Condensate Trap:

• Orient the fllmace in the downflow position.

• Fig. 9 shows the condensate trap and tubing before and after
relocation, Refer to Fig. 9 to begin the trap conversion,

• Refer to Condensate Drain section for infomaation how to install the
condensate drain,

Condensate Trap - Horizontal Orientation.

When the fl_mace is installed in the horizontal right position, the
factory-installed trap will be located at the bottom of the collector box.

When the fl_mace is installed in the horizontal left position, the
factory-installed trap will be located at the top of the collector box.

The trap must be repositioned on the collector box for proper
condensate drainage.

When the furnace is installed as a direct-vent furnace, 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. 16.)

NOTE: The Horizontal Installation Kit (trap grommet) is NOT
required for single-pipe, ventilated combustion air, or other
non-direct vent applications.

NOTE: 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. (6 mm) per foot of slope away from

the furnace in horizontal sections of drain line.
To Relocate the Condensate Trap:

• Remove the knockout in the casing for the condensate trap.

• Install the grommet in the casing when required.

• Orient the fl_mace in the desired position.

• Allow for 2 in. (51 mm) of clearance underneath the fllmace for the
condensate trap and drain line.

• Fig. 10 shows the condensate trap and tubing before and after
relocation in the horizontal right position.

• Fig. 11 shows the condensate trap and tubing before and after
relocation in the horizontal left position.

• Refer to the appropriate figure to begin the trap conversion,

• Refer to Condensate Drain section for infom_ation how to install the
condensate drain,

Collector Box

Plugs

Condensate Trap

Relief Port

Fig. 8 - Upllow Trap Configuration

Vent Pipe Clamp

Pressure Switch

UPFLOW TRAP CONFIGURATION

1 & 2 Stage Units

(Appearance may vary)

Clamp

Vent Elbow

Collector Box

Plug

Condensate Trap

Relief Port

Trap

Outlet

Port

Al1307

12

Remove relief tube from relief
port on condensate trap.

._ Remove pressure switch tube from

front pressure switch and discard. A
new tube is shipped in the loose parts bag.

,'}_) Remove tube from relief port.

(_ emove the screw

(_) nstall the two plugs

previously removed
on the open ports

of the collector box.

that secures the trap
to the collector box and

remove trap.

to vent elbow.

(_ Loosen clamp on inlet

(1 and 2 Stage Units)

Remove middle and bottom
plugs. DO NOT DISCARD.

Unconverted Factory Configuration as

Viewed in the Downflow Orientation

Connect the new pressure switch
tube from Loose Parts bag to /f_ Route tube through inducer
port on front pressure switch. _ stand-offs to adjust position

/ _ of the tube.

/ / .| N J Trim excess tube.

/ / Sk"J Connect Pressure switch

/ / / tube to port on collector

_,_ _=_ _ ' / 1 box.

(_ Connect relief tube

to port on collector
box.

desired position and

(_ otate elbow to

tighten clamp to

15 lb.-in.

(_ Slide tube in stand-offs

to adjust length.

_ _/(_)_ _/_ f_ Attach condensate trap

_.\__ -_ IP===t II \ 'J J with screw to collector box.

__ _ Connect relief tube to

____------- relief port on condensate

" J,,O I "-I trap.

(1 and 2 Stage Units) /_

Downflow Trap Configuration

Fig. 9 - Downflow Trap Configuration

(Appearance may vary)

/

Align condensate trap

ports of collector box.

Al1587

13

collector box.

(_ emove plug from

DO NOT DISCARD.

If alternate vent position
is required, loosen clamp

on inlet of vent elbow.

ii

As Viewed in the Horizontal Right Orientation

NOTE: Remove knockout in
casing before re-installing the
condensate trap.

trap with screw to

(_ ttach condensate

collector box.

1_ Remove the screw that secures

(1 AND 2 STAGE UNITS)

Unconverted Factory Configuration

the trap to the collector box and

remove trap.

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.

open port of

(_) nstall plug on

collector box

(1 AND 2 STAGE UNITS)

Horizontal Right Trap Configuration

Fig. 10 - Horizontal Right Trap Configuration

(Appearance may vary)

14

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

Al1573

If alternate vent position
is required, loosen clamp

on vent elbow inlet.

from port on collector --

(_ emove relief tube

box.

(1 AND 2 STAGE UNITS)

Remove the screw that secures the
condensate trap to the collector box

and remove trap.

Remove relief tube from
relief port on condensate

trap.

Remove front pressure
switch tube and discard.

A new tube is shipped in
the Loose Parts bag.

H

Remove middle and right
plug from collector box.

DO NOT DISCARD.

NOTE: Remove knockout in
casing before re-installing the

condensate trap.

(_ Rotate elbow to

desired position
and torque clamp

on inlet 15 lb.-in.

(_ Slide relief tube instand-offs to adjust

length.

(_ ttach condensatetrap with screw to

collector box.

(_ Align trap over middleand right-hand port on

collector box.

Unconverted Factory Trap Configuration

As Viewed in the Horizontal Left Orientation

Install two plugs previously
removed in open ports on

collector box.
Connect relief tube to port

on collector box.

Connect the new pressure switch
tube from Loose Parts bag to port

on front pressure switch.

\

(1 AND 2 STAGE UNITS)

Route pressure switch tube
underneath relief tube and

connect to port on
collector box.

Connect relief tube to relief
port on condensate trap.

Horizontal Left Trap Configuration

Fig. ll - Horizontal Left Configuration

(Appearance may vary)

15

Al1574

H

CONDENSATE DRAIN CONNECTION

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 electric heat tape or RV antifreeze is

recommended for these installations.

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 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 the 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 Air
Conditioning condensate drain as shown in Fig. 13.

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. 12 .)

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

3. Slide a spring clamp 1 inch (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 tube to the trap with the

spring clamp.

The remaining drain line can be constructed from field supplied

l/2-in. CPVC or 3/4-in. PVC pipe, in compliance with local

building codes. A factory-supplied l/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 l/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 l/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 l/4-in. (6 mm) per foot of slope away from the
furnace in horizontal sections of drain line.

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 l/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. 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. 17.

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

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.

15. 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. 12.)

6. From the outside of the casing, insert the angled end of the
Z-pipe through drain hole in the side left 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).

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

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.

16

13.SecuretherubberelbowtothedraintrapandtheZ-pipe
withspringclamps.

14.SecurethegrommettotheZ-pipewiththespringclamp.

Theremainingdrainlinecanbeconstructedfromfieldsupplied
l/2-in.CPVCor3/4-in.PVCpipe,incompliancewithlocal

buildingcodes.Afactory-suppliedl/2-in.CPVCto3/4-in.PVC
adapterissuppliedintheloosepartsbagforuseasrequired.

15.Installtheadapterorconnectthel/2-in.CPVCpipeby
slidingaspringclampovertheopenendofthegrommeton

theoutsidethefurnacecasing.

16.Openthespringclampandinsertthelongendof the
adapterorthel/2-in.CPVCpipeintotheoutletstubonthe

draintube.

17.Connectadditionalcondensatepipingtoacode-approved
drain,ortoacondensatepumpapprovedforusewithacidic

furnacecondensateandcompatiblewithmineraland
vegetableoils,suchascanolaoil.

Allow at least l/4-in. (6 mm) per foot of slope away from the fur-
nace in horizontal sections of drain line.

Horizontal Orientation

1. In the Horizontal orientation, a field supplied accessory
drain trap grommet is required to seal the gap between the

casing and the condensate trap for direct vent applications,
only. The grommet is NOT required for single-pipe, or oth-

er non-direct-vent applications.

2. The condensate trap outlet extends 2 in. (51 ram) below the
furnace casing. To allow for servicing the trap, the
condensate drain tube in the loose parts bag can be modified

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. Remove the formed grommet on the elbow to create an
elbow or straight connector. (See Fig. 15.)

7. Connect the cut elbow or grommet to the outlet of the
condensate trap with 1 spring clamp.

The remaining drain line can be constructed from field-supplied
l/2-in. CPVC or 3/4-in. PVC pipe, in compliance with local build-

ing codes. A factory-supplied l/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 l/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. (6 ram) per foot of slope away from the
furnace in horizontal sections of drain line.

CUT HAZARD

Failure to follow this caution may result in personal iniury.
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.

Fig. 12 - Knockout Removal

OPENSTAND
PiPEFOR
A/COR

HUMIDIFIER
DRAIN

U

_T----TE E

TOOPEN

DRAIN

Fig. 13 - Example of Field Drain Attachment

H

Al1276

17

INSTALL CLAMPS ON DRAIN TUBE
ATTACH DRAIN TUBE TO CONDENSATE?

DRAIN TRAP

PULL DRAIN STUB /

THROUGH CASING / /

/' / "_\

' : / \

OPEN SPRING CLAMP

INSERT FACTORY-SUPPLIED 1/2-1N. CPVC
TO 3/4-1N. PVC ADAPTER OR 1/2-iN CPVC PtPE

*CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN
TUBE

RIGHT SiDE DRAIN iNSTALLATiON

/ \

/

/ _,

Fig. 14 - Formed Tube Grommet

/

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

J

/

Remove knockout,
Install grommet before

relocating condensate

trap.

Al1342A

Fig. 16 - Horizontal Drain Trap Grommet

Al1582

Cut line for left side condensate drain.

Do not disc

l !

Attach tube to condensate

Cut formed end off

Formed end of
grommet

of "Z" pipe to modified

condensate drain tube

Connect short end

ube

Factory supplied 1/2-in. CPVC to

3/4-in. PVC adapter

TRAP, DRAIN ELBOW WITH DISCHARGE PIPE

T

Formed end of grommet
Open spring clamp. Insert
1/2-in. to 3/4-in. CPVC to

PVC adapter or 1/2-in.

Modified drain tube connect to
condensate trap and "Z" pipe

CPVC pipe

1-3/8 in
(35 ram)

Fig. 15 - Modify Drain 1hbe

Al1581

LEFT SIDE DRAIN ROUTED BEHIND INDUCER

Al1583

Fig. 17 - Drain Trap Connection and Routing

(Appearance May Vary)

18

INSTALLATION

NOTE: This furnace is certified to leak 2% or less of nominal air
conditioning CFM delivered when pressurized to 1-inch water

column with all present air inlets, air outlets, and plumbing and
electrical ports sealed, including bottom closure in upflow and

horizontal applications.

Upflow Installation

NOTE: The furnace must be pitched as shown in Fig. 23 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.
Connect supply-air duct to flanges on furnace supply-air outlet.

Bend flange upward to 90 ° with wide duct pliers. (See Fig. 20.)
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

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.

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 in-
side nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

Downflow Installation

NOTE: The furnace must be pitched as shown in Fig. 23 for
proper condensate drainage.

Supply Air Connections

NOTE: For downflow @plications, this furnace is @proved for
use on combustible flooring when any one of the following 3

accessories are used:

• Special Base, KGASB

• Cased Coil Assembly Part No. CNPV, CNRV, CAP, or CAR

• Coil Box Part No. KCAKC

1. Determine application being installed from Table 6.

2. Construct hole in floor per Table 6 and Fig. 19.

3. Construct plenum to dimensions specified in Table 6 and
Fig. 19.

4. Install special base coil assembly or coil box as shown in in
Fig. 19.

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. 20.)

ii

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. 24, 25, 26.)
Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel, perform
the following:

1. Tilt or raise furnace and remove 4 screws holding bottom
plate. (See Fig. 22.)

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. 24, 25, 26.)
Leveling Legs (If Desired)

In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 21.) 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.

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. 20.) 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-@proved accessory subbase, or a
factory-@proved air conditioning coil casing. DO NOT cut main

furnace casing to attach supply side air duct, humidifier, or other

accessories. All accessories MUST be connected to duct external to
furnace casing.
Return Air Connections

FIRE HAZARD
A failure to follow this warning could cause personal iniury,

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).

19

Bypass humidifier connections should be made at ductwork or coil
casing sides exterior to furnace. (See Fig. 25.)
Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel, perform
the following:

Horizontal Installation

NOTE: The furnace must be pitched forward as shown in Fig. 23
for proper condensate drainage.

H

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. 270 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. 280 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. 27 for
proper orientation of roll-out shield.

1. Tilt or raise furnace and remove 4 screws holding bottom
plate. (See Fig. 22.)

2. Remove bottom plate.

3. Remove bottom closure panel.

4. Reinstall bottom plate and screws.

FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD

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

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.

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.

Connect supply-air duct to flanges on furnace supply-air outlet.

Bend flange upward to 90 ° with wide duct pliers. (See Fig. 20.)
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 must 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 side of the casing cannot be
used as a return air connection. Bypass humidifier may be attached

into unused return air side of the furnace casing. (See Fig. 26.)
Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when

bottom return air is used. To remove bottom closure panel, perform
the following:

1. Tilt or raise furnace and remove 4 screws holding bottom
plate. (See Fig. 22.)

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. 26.)

Filter Arrangement

FIRE, CARBON MONOXIDE AND POISONING
HAZARD

Failure to follow this warning could result in fre, personal
iniury 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.

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 I-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-in. (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. 18 and 24.)

20

Fordownflowapplications,the Media Cabinet (or field supplied

accessory air cleaner) nmst only be connected to the bottom
opening on the furnace. See Fig. 18 and 25.

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

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 5 for filter size details.

horizontal position, refer to Fig. 26. If both side and bottom
openings are used in Fig. 26, each opening used will require a

filter.

Table 5 - Filter Size Information - In. (mm)

FURNACE CASING WIDTH FILTER TYPE

14-3/161- (360) (406 x 635 x 19) (356 x 635 x 19)

17-1/2 (445) (406 x 635 x 19) (406 x 635 x 19)

21 (533) (406 x 635 x 19) (508 x 635 x 19)

24-1/2 (622) (406 x 635 x 19) (610 x 635 x 19)

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

1- Not all families have these models.

FILTER CABINET HEIGHT - IN (MM) FILTER SIZE - IN (MM) FILTER TYPE

16 (406) (1) 16 x 25 x 4-5/16

20 (508) (1) 20 x 25 x 4-5/16

24 (610) (1) 24 x 25 x 4-5/16

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.

SIDE RETURN BOTTOM RETURN

16 x 25 x 6/4 14 x 25 x 6/4 Washable*

16 x 25 x 3/4 16 x 25 x 3/4 Washable*

16 x 25 x 6/4 20 x 25 x 6/4 Washable*

16 x 25 x 6/4 24 x 25 x 6/4 Washable*

Air Filter Located in Filter Cabinet

FILTER SIZE

(1) 16 x 25 x 3/4"

(406 x 635 x 19) or Washable or Media*

(406 x 665 x 11 O)

(1) 20 x 25 x 6/4"

(508 x 665 x 19) or Washable or Media*

(508 x 665 x 11 O)

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

(610 x 665 x 19) or Washable or Media*

(610 x 635 x 11 O)

21

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

Furnace

21-in. Furnace

4:Ibn or less, AC

capaci b, airflow

m

4-in.
Block Off
Plate

16-in. Media Cabinet

Media Cabinet lnstallatig-n

Side Return

it ,4

21- or 24-1/2-in.

Furnace

Up to 5-rlbn AC

capacity airflow

m

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

it ,4

21-in, Furnace
up to 5-Ton AC

Capacity

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

Capacity

<_45 °

Transition j

20- or 24-in. Media Cabinet

20- or -24-in. Media Cabinet Installation

with Angled Transition

14 3/16 in. Furnace

H

Screw } ._1 I_. =:Screw

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

14 3/16 in. Furnace

Ncrews]l 5

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

A11437

Fig. 18 - Media Filter

22

(OR COIL CASING

WHEN USED)

FURNACE

APPROVED

COIL ASSEMBLY

OR

COIL BOX

_ COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL

PLENUM

-- FLOOR --
OPENING

SHEET METAL_

PLENUM

__ FLOOR __

OPENING

Fig. 19 - Installation on Combustible Flooring

FURNACE

Table 6 - Opening Dimensions

CASING

WIDTH

APPLICATION

IN.(mm)

Upflow Applications on Combustible or Noncombustible Floor- 12-11/16 21-5/8 13-5/16 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 12-9/16 19 13-3/16 19-5/8

14-3/16*

(360) Downflow applications on combustible flooring (KGASB sub- 11 - 13/16 19 13- 7/16 20- 5/8

Downflow Applications on Combustible Flooring with CNPV, 12-5/16 19 13-5/16 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB (619) (483) (338) (508)

Upflow Applications on Combustible or Noncombustible Floor- 16 21 - 5/8 16- 5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 15- 7/8 19 16-1/2 19- 5/8

17-1/2

(445) Downflow applications on combustible flooring (KGASB sub- 15-1/8 19 16-3/4 20-5/8

Downflow Applications on Combustible Flooring with ON PV, 15-1/2 19 16-1/2 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB (394) (483) (419) (508)

Upflow Applications on Combustible or Noncombustible Floor- 19-1/2 21-5/8 20-1/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 19-3/8 19 20 19-5/8

21

(533) Downflow applications on combustible flooring (KGASB sub- 18-5/8 19 20-1/4 20-5/8

Downflow Applications on Combustible Flooring with CNPV, 19 19 20 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB (483) (483) (508) (508)

Upflow Applications on Combustible or Noncombustible Floor- 26 21 - 1/8 26- 5/8 22-1/4

Downflow Applications on Noncombustible Flooring (KGASB 22- 7/8 19 26-1/2 19- 5/8

24-1/2

(622) Downflow applications on Combustible flooring (KGASB su b- 22-1/8 19 23- 3/4 20- 5/8

Downflow Applications on Combustible Flooring with ON PV, 22-1/2 19 26-1/2 20

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB (572) (483) (597) (508)

* Not all families h we these models.

ing (KGASB subbase not required) (322) (549) (338) (565)

subbase not required) (319) (483) (335) (498)

base required) (284) (483) (341) (600)

subbase not required)

ing (KGASB subbase not required) (406) (549) (422) (565)

subbase not required) (403) (483) (419) (498)

base required) (384) (483) (425) (600)

subbase not required)

ing (KGASB subbase not required) (495) (549) (511) (565)

subbase not required) (492) (483) (508) (498)

base required) (473) (483) (514) (600)

subbase not required)

ing (KGASB subbase not required) (584) (537) (600) (565)

subbase not required) (581) (483) (597) (498)

base required) (562) (483) (603) (600)

subbase not required)

In. (mm)

PLENUM OPENING FLOOR OPENING

A B C D

F

A10491

23

DISCHARGE DUCT
FLANGE

UPFLOW DOWNFLOW HORIZONTAL

[......

(8mm)

5/

1

(44mm)

120 °_

MIN

YES

\

YES

'\

120°_

YES

YES

YES

YES

MIN

NQ

NQ

NQ

A10493

Fig. 20 - Duct Flanges

(8mm)

(44mm) 13/4"

(44mm) 1

Fig. 21 - Leveling Legs

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

__ J

FRONT

UPFLOW OR
DOWNFLOW

Fig. 23 - Furnace Pitch Requirements

BOTTOM
CLOSURE
PANEL

BOTFOMPLATE

A89014

Al1092

Fig. 22 - Removing Bottom Closure Panel

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

/

HORIZONTAL

Al1237

24

NOT PERMITTED

l 0

d

dt

n_lunN

AI_

0

-- ANY COMBINATION OF 1,2, OR 3 PERMITTED

F/ET JRN

AIR

A11036

Fig. 24 - Upflow Return Air Configurations and Restrictions

HORIZONTAL

(

RETURN NOT
PERMITTED FOR

NOTE: RESTRIO11ON SAME FOR

14ORIZONAI I_T AIR

Fig. 25 - Downflow Return Air Configurations

and Restrictions

HORIZONAL
RETURN AIR

RESTRICTIONS

Al1037 /

Fig. 26 - Horizontal Return Air Configurations

and Restrictions

Al1038

25

COMBUSTION-AIRPIPE
(SEEVENTINGSECTION)-X

A 12-1N. (305 mm) MIN HORIZONTAL PIPE \

SECTION IS RECOMMENDED WITH A
SHORT (5 TO 8 FT / 1.5 TO 2.4 M) VENT

SYSTEM TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.

MANUAL
SHUTOFF _INDOOR

GAS VALVE / COIL

SEDIMENT_ CONDENSATE

TRAP TRAP

\

\

\

30 IN. (762 mm)

ROLLOUT PROTECTION REQUIRED
Install 12"x 22" (305 x 559 mm) sheet
metal in front of burner compartment

a rea.

NOTE: FURNACE SHOWN AS DIRECT VENT APPLICATION, REFER TO THE

VENTING SECTION FOR ALLOWABLE VENT CONFIGURATIONS

Fig. 27 - 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-AIRPIPE

_(SEEVENTINGSECTION)

_1/4-IN ROD

,/

NOTE: EXTEND ANf

IRON OUT FOR
COIL SUPPORT/ HEX NUT

& WASHER (4)

/

REQD. PER ROD

ROD LOCATION /
USING DIMPLE /

LOCATORS

NOTES: 1. A 1 In. (25mm) clearance minimum between

top of furnace and combustible material

Al1154

2. The entire length of furnace must be
supported when furnace is used in horizontal
position to ensure proper drainage,

3. Furnace shown is a direct vent application.
Refer to the Venting section for allowable vent

configurations.

Fig. 28 - Suspended Furnace Installation

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

2d

Al1155

AIR DUCTS

General Requirements

The duct system should be designed and sized according to
accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA) or

American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE) or consult The Air Systems Design

Guidelines reference tables available from your local distributor.
The duct system should be sized to handle the required system

design CFM at the design external static pressure. The furnace
airflow rates are provided in Table 7-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.

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.

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