Carrier DIRECT VENT 4 58HDV User Manual

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58HDV

Direct Vent 4---Way Multipoise

Condensing Gas Furnace

95% Downflow / Horizontal Orientations

93.5% Upflow Orientation

Installation Instructions

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 and accessory concentric vent termination kits and accessory external drain trap have been certified to ULC S636 for use with those 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 - IPEX System 636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and IPEX System 636, PVC Cement for Flue Gas 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 must be UL listed material. Acceptability under Canadian standard 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.

ama

CERTIFIED

Consignes spéciales pour l’installation de ventillation au Canada

L’installation faite au Canada doit se conformer aux exigences du code CSA B149. Ce systême de ventillation doit se composer de tuyaux, raccords, ciments et apprêts conformes au ULC S636. La tuyauterie de ventillation des gaz, ses accessoires, le terminal concentrique mural ainsi que l’ensemble du drain de condensat extérieur ont été certifiés ULCS 636 pour l’application des composantes IPEX PVC qui sont certifiées à ce standard. Au Canada l’apprêt et le ciment doivent être du même manufacturier que le systême de ventillation - IPEX Système 636, Apprêt PVC/CPVC. Mauve Violette pour conduit en évacuation des gaz et IPEX Système 636, ciment pour PVC pour conduit en évacuation des gaz, évalué CLASSE IIA, 65 deg. C. doit ëtre utilisé avec ce systèeme d’évacuation - ne pas mélanger l’apprêt et le ciment d’un manufacturier avec le systême de ventillation d’un autre manufacturier. 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 CSA B419 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.

TABLE OF CONTENTS

PAGE IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 2 SAFE INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . 3 COMBUSTION & VENTILATION AIR . . . . . . . . . . . . . . . . . . 8 CONCENTRIC TERMINATION . . . . . . . . . . . . . . . . . . . . . . . 31 GAS SUPPLY & PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

DUCTWORK & FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 CHECKS & ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 42 FURNACE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 44 SEQUENCE OF OPERATION & DIAGNOSTICS . . . . . . . . . 46

1

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

 

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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) 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.

2

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

NOTE: Please retain these instructions with the furnace after installation for future reference.

SAFETY CONSIDERATIONS

!CAUTION

FURNACE RELIABILITY HAZARD

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

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

!WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in 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 installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this product.

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 unit and other safety precautions that may apply.

These instructions cover the 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.

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

Recognize safety information. 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 unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight

suggestions which will result in enhanced installation, reliability, or operation.

!CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

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

SAFE INSTALLATION REQUIREMENTS

!WARNING

FIRE, EXPLOSION, AND ASPHYXIATION HAZARD

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

Improper adjustment, alteration, service, maintenance or installation could cause personal injury, death and/or property damage.

Installation or repairs made by unqualified persons could result in hazards to you and others. Installation MUST conform to local codes or, in the absence of local codes, with codes of all governmental authorities having jurisdiction.

The information contained in this manual is intended for use by a qualified service agency that is experienced in such work, is familiar with all precautions and safety procedures required in such work, and is equipped with the proper tools and test instruments.

NOTE: This furnace is design-certified by the CSA International (formerly AGA and CGA) for installation in the United States and Canada. Refer to the appropriate codes, along with this manual, for proper installation.

SUse only the type of gas approved for this furnace (see Rating Plate on unit). Overfiring will result in failure of heat exchanger and cause dangerous operation. (Furnaces can be converted to

Propane gas with approved kit.)

SInstall this furnace only in a location and position as specified in “Installation” of these instructions.

SProvide adequate combustion and ventilation air to the furnace as specified in “ Combustion and Ventilation Air” of these instructions.

SCombustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in “Vent and Combustion Air Piping” of these instructions.

S 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 “Gas Supply and Piping, Final Check” of these instructions.

SAlways 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 “Technical Support Manual” of these instructions. See furnace rating plate.

SWhen a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the

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58HDV

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

SA gas-fired furnace for installation in a residential garage must be installed as specified in “Installation” of these instructions.

SThis furnace is not to be used for temporary heating of buildings or structures under construction.

SThis furnace is NOT approved for installation in mobile homes, trailers or recreation vehicles.

S Seal around supply and return air ducts.

S Install correct filter type and size.

SUnit MUST be installed so electrical components are protected from direct contact with water.

Safety Rules

Your unit is built to provide many years of safe and dependable service providing it is properly installed and maintained. However, abuse and/or improper use can shorten the life of the unit and create hazards for you, the owner.

The U.S. Consumer Product Safety Commission encourages installation of carbon monoxide alarms. There can be various sources of carbon monoxide in a building or dwelling. The sources could be gas-fired clothes dryers, gas cooking stoves, water heaters, furnaces, gas-fired fireplaces, wood fireplaces.

Carbon monoxide can cause bodily injury and/or death. Carbon monoxide or “CO” is a colorless and odorless gas produced when fuel is not burned completely or when the flame does not receive sufficient oxygen.

Therefore, to help alert people of potentially dangerous carbon monoxide levels, you should have a commercially available carbon monoxide alarm that is listed by a nationally recognized testing agency in accordance with Underwriters Laboratories Inc. Standard for Single and Multiple Station Carbon Monoxide Alarms, ANSI/UL 2034 or the CSA 6.19-01 Residential Carbon Alarming Devices installed and maintained in the building or dwelling concurrently with the gas-fired furnace installation (see Note below). The alarm should be installed as recommended by the alarm manufacturer’s installation instructions.

There can be numerous sources of fire or smoke in a building or dwelling. Fire or smoke can cause bodily injury, death, and/or property damage. Therefore, in order to alert people of potentially dangerous fire or smoke, you should have fire extinguisher and smoke alarms listed by Underwriters Laboratories installed and maintained in the building or dwelling (see Note below).

NOTE: The manufacturer of your furnace does not test any alarms and makes no representations regarding any brand or type of alarms.

To ensure safe and efficient operation of your unit, you should do the following:

1.Thoroughly read this manual and labels on the unit. This will help you understand how your unit operates and the hazards involved with gas and electricity.

2.Do not use this unit if any part has been under water.

Immediately call a qualified service technician to inspect the unit and to replace any part of the control system and any gas control which has been under water.

3.Never obstruct the vent grilles, or any ducts that provide air to the unit. Air must be provided for proper combustion and ventilation of flue gases.

Frozen Water Pipe Hazard

!CAUTION

WATER DAMAGE TO PROPERTY HAZARD

Failure to follow this caution may result in property damage.

Do not leave your home unattended for long periods during freezing weather without turning off water supply and draining water pipes or otherwise protecting against the risk of frozen pipes and resultant damage.

Your furnace is designed solely to provide a safe and comfortable living environment. The furnace is NOT designed to ensure that water pipes will not freeze. It is equipped with several safety devices that are designed to turn the furnace off and prevent it from restarting in the event of various potentially unsafe conditions.

If your furnace remains off for an extended time, the pipes in your home could freeze and burst, resulting in water damage.

If the structure will be unattended during cold weather you should take these precautions.

1.Turn off the water supply to the structure and drain the water lines if possible and add an antifreeze for potable water to drain traps and toilet tanks. Open faucets in appropriate areas.

-or-

2.Have someone check the structure frequently during cold weather to make sure it is warm enough to prevent pipes from freezing. Instruct them on a service agency to call to provide service, if required.

-or-

3.Install a reliable remote sensing device that will notify somebody of freezing conditions within the home.

Winter Shutdown

If you go away during the winter months and do not leave the heat on in your home, the plastic transition box and the condensate trap on the furnace must be protected from freeze damage. (See Fig. 10 through Fig. 17)

1.Disconnect the 5/8OD rubber hose from the vent drain fitting that is located downstream of the combustion blower. Insert a funnel into the hose and pour four(4) ounces of san-

itary type (RV) antifreeze into the condensate trap. Reconnect the 5/8OD rubber hose to the stub on the vent drain fitting. Secure with the hose clamp.

2.Disconnect the 3/4OD rubber hose from the condensate trap. Insert a funnel into the hose and and pour four(4) ounces of sanitary type (RV) antifreeze into the plastic

Transition box. Squeeze the hose together near the end and

quickly reconnect the 3/4OD rubber hose to the stub on the condensate trap. Secure with the hose clamp.

When you return home, your furnace will be ready to start, as it is not necessary to drain the antifreeze from the furnace.

4

INSTALLATION

!WARNING

CARBON MONOXIDE POISONING HAZARD

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

This furnace can NOT be common vented or connected to any type B, BW or L vent or vent connector, nor to any portion of a factory-built or masonry chimney. If this furnace is replacing a previously common-vented furnace, it may be necessary to resize the existing vent and chimney to prevent oversizing problems for the other remaining appliance(s). See Venting and Combustion Air Check in Gas Vent Installation section. This furnace MUST be vented to the outside.

Installation Positions

This furnace can be installed in an upflow, horizontal (either left or right) or downflow airflow position. DO NOT install this furnace on its back. For the upflow position, the return air ductwork can be attached to either the left or right side panel and/or the bottom. For horizontal and downflow positions, the return air ductwork must be attached to the bottom. The return air ductwork must never be attached to the back of the furnace.

Location and Clearances

1.Refer to Fig. 1 for typical installation and basic connecting parts required. Refer to Fig. 4 for typical horizontal direct vent installation and basic connecting parts required. Supply and return air plenums and duct are also required.

2.If furnace is a replacement, it is usually best to install the furnace where the old one was. Choose the location or evaluate the existing location based upon the minimum clearance and furnace dimensions (Fig. 2).

!CAUTION

FROZEN AND BURST PIPE HAZARD

Failure to follow this caution may result in property damage.

Special precautions MUST be made is 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. (See “Condensate Trap Freeze Protection Section”)

 

Aluminum or non--rusting shield recommended.

*8″ (203.2mm) Min.

(See Vent Termination Shielding for dimensions).

 

Coupling on ends of

20′ (6.1m) Max.

 

 

exhaust pipe. Total

in same

 

Inlet Pipe

pipe & coupling out-

atmospheric

(not used on

side structure = 8″

zone

Single Pipe

(203.2mm)

 

 

model)

 

Vent Pipes MUST be

AIR

 

DISCHARGE

20′ (6.1m) Max.

Vertically

supported

 

*8″ (203.2mm) Min.

Horizontally and

 

 

 

in same atmospheric zone

* Increase minimum from 8″ (203.2mm) to 18(457.2mm) for cold climates (sustained temperatures 0° F (- 17° C) and below for 24 or more consecutive hours).

25--23--33

A07700

Fig. 1 - Typical Upflow Installation

 

See Vent Termination

Coupling on inside

 

Shielding in Vent Section.

 

and outside of wall to

 

 

 

*8″ Min. (203 mm)

restrain vent pipe

Inlet Pipe

 

20′ Max. in same (6 M)

8″ Min. (203 mm)

(not used on

atmospheric zone

Single Pipe

 

 

 

model)

 

 

Vent Pipes MUST

 

be supported Horizon-

*8″ Min. (203 mm)

tally and Vertically

20′ Max. (6.1 M)

 

in same

 

atmospheric zone

 

25--23--33a

* Increase minimum from 8to 18(203 to 457 mm) for cold climates (sustained temperatures

0°F ( - 1 8 °C ) and ) below for 24 or more consecutive hours).

 

A07762

Fig. 2 - Typical Downflow Installation

Installation Requirements

1.Install furnace level.

2.This furnace is NOT to be used for temporary heat of buildings or structures under construction.

3.Install furnace as centralized as practical with respect to the heat distribution system.

4.Install the vent pipes as short as practical, and in accordance to these instructions. (See Vent and Combustion Air Piping section).

5.Maintain clearance for fire safety and servicing. A front clearance of 24(609.6mm) required and 30(762mm) recommended for access to the burner, controls and filter. See clearance requirements in Fig. 4.

6.Use a raised base for upflow furnace if the floor is damp or wet at times.

7.For downflow installations, non combustible subbase must be used under the furnace unless installation is on a non combustible floor surface. This requirement applies even when a coil box or cabinet is used.

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5

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8.For horizontal installations, line contact is permissible only between lines formed by intersection of back and two sides of furnace jacket, and building joists, studs or framing.

9.Residential garage installations require:

SBurners and ignition sources installed at least 18(457.2mm) above the floor.

SLocated or physically protected from possible damage by a vehicle.

10.Local codes may require a drain pan under the entire furnace and condensate trap when the furnace is installed in attic application.

This furnace may be used for construction heat provided that all the following conditions are met:

SThe 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.

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

SClean 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.

S 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.

SThe air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the rating plate value.

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

SThe furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC

system components after construction is completed.

SAfter construction is complete, verify furnace operating conditions including ignition, input rate, temperature rise and venting according to these instructions.

!WARNING

CARBON MONOXIDE POISONING HAZARD

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

Do NOT operate furnace in a corrosive atmosphere containing chlorine, fluorine or any other damaging chemicals, which could shorten furnace life.

Refer to Combustion & Ventilation Air section, Contaminated Combustion Air for combustion air evaluation and remedy.

Furnace Installation Considerations

The installation of the furnace for a given application will dictate the position of the furnace, the airflow, ductwork connections, vent and combustion air piping. Consideration must be given to the following:

Condensate Trap and Drain Lines

The supplied condensate trap must be attached to the furnace side panel on either the left or right side. For horizontal installations, the drain trap is vertically attached to the side panel below the furnace. A minimum clearance of 6(152.4mm) below the furnace is required for the condensate trap. Downward slope of the condensate drain line from the condensate trap to the drain location must be provided. Adequate freeze protection of the drain trap and the drain line must be provided. See “Condensate Drain Trap” section for further details.

Leveling

Proper leveling of the furnace must be provided to insure proper drainage of the condensate from the furnace. The furnace must be level to within 1/4(6.4mm) from front to back and from side to side for upflow and downflow installations or top to bottom for horizontal installations.

Vent and Combustion Air Connections

For venting information literature, contact www.carrier.com with the complete model and serial number of the furnace.

On the Dual Certified furnace, the vent and combustion air pipes attach to the furnace through the top panel for the upflow and horizontal installations. For the downflow installation, the vent and combustion air pipes attach to the furnace through the alternate locations on the furnace side panels.

NOTE: On the Direct Vent furnace, the vent pipe attaches to the furnace through the side panels. The combustion air pipe attaches to the top panel or to the alternate location on the side panel.

On the Single Pipe furnace, the vent pipe attaches to the furnace through the furnace side panels.

NOTE: Repositioning of the combustion blower is required for the vent pipe connection to the furnace through the “right side” panel. See “Vent and Combustion Air Piping” section for further details.

Horizontal Furnace Installation

Inlet Pipe (not used on Single Pipe model)

Vent

Pipe

Condensate

Trap

NOTE: 6bottom clearance required for condensate trap.

A07703

Fig. 3 - Typical Horizontal Installation

This furnace can be installed horizontally in an attic, basement, crawl space, alcove, or suspended from a ceiling in a basement or utility room (See Fig. 3). Do not install furnace on its back as safety control operation will be adversely affected.

6

 

 

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

MINIMUM CLEARANCES TO COMBUSTIBLE

 

 

 

 

 

 

 

 

AIR INTAKE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

MATERIALS FOR ALL UNITS - in (mm)

 

 

 

 

 

 

 

 

VENT

 

 

 

 

 

REAR

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

TOP

 

 

 

 

 

 

 

 

 

 

 

 

FRONT (combustion air openings in

3″ (76.2)

 

 

 

 

 

 

 

 

 

 

H

 

 

 

 

 

 

furnace and in structure)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Required For Service

 

 

*24″ (609.6)

 

 

 

 

 

 

 

 

G

 

 

 

FRONT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ALL SIDES Of SUPPLY PLENUM

1″ (25.4)

 

 

 

 

 

 

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SIDES

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LEFT SIDE

 

 

611/16

ELECTRICAL

 

 

 

 

 

 

VENT

 

 

 

 

 

0

 

 

 

 

 

 

 

(177.5)

11/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

TOP OF FURNACE

 

 

 

1″ (25.4)

 

 

 

TRAP (KO) (COUNTERFLOW)

 

(318)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*30″

 

 

 

 

 

 

 

 

 

 

 

 

GAS

 

 

11/

(27)

 

 

 

 

 

 

(762mm) clearance recommended for furnace removal.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

Horizontal position: Line contact is permissible only between

 

 

 

 

VENT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1311/

 

 

 

 

lines formed by intersections of top and two sides of furnace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AIR INTAKE (KO)

 

 

 

 

 

 

16

 

 

 

 

jacket, and building joists, studs or framing.

 

 

 

 

 

 

 

 

 

 

(347.7)

 

 

 

 

 

 

 

 

(ALTERNATE)

413/

16

 

 

 

3111/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(34.9)

 

 

16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRAP (KO)

(122.2)

 

 

(804.9)

 

 

 

NOTE: Evaporator “A” coil drain pan dimensions may

 

 

 

 

3

 

(758.8)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

UPFLOW/HORIZONTAL

 

 

1 /8

 

297/

 

 

 

 

vary from furnace duct opening size. Always consult

 

 

 

 

 

 

 

 

 

 

8

 

 

 

 

evaporator specifications for duct size requirements.

21/

4

(57.2)

THERMOSTAT

 

 

7

 

 

283/4

 

 

 

 

 

 

 

 

 

 

(177.8)

241/

(730.3)

 

 

 

 

Furnace is designed for bottom return or side return.

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

 

 

 

 

(611.2)

1913/

 

 

 

Return air through back of furnace is NOT allowed.

 

131/

 

 

 

 

 

175/16

 

 

 

 

 

 

 

 

 

 

 

(439.7)

 

 

16

 

 

 

11/

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

(503.2)

 

 

 

 

 

 

 

 

 

 

 

 

(336.6)

 

 

 

 

 

111/16

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

(KO)

 

 

 

 

 

 

 

 

 

(31.7)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(42.9)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

215/

 

 

47/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

 

 

8

 

 

 

 

 

 

 

27/8

 

 

 

 

 

281/

 

 

 

 

 

7

 

(549.3)

 

 

(123.8)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 /8

 

24

 

 

 

 

 

 

 

 

 

 

(73)

 

 

 

45/16 (109.5)

(723.9)

1

 

3/ (19.1)

 

 

(47.6 )

 

(609.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

18

/

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

TYPE

 

 

 

 

 

 

 

 

 

Drawing is representative,

 

 

 

 

23/

(60.3 )

 

 

(469.9)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

but some models may vary

 

 

11/

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(27)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

 

D

 

BOTTOM

 

 

 

 

 

 

 

 

 

GAS (KO)

 

 

RIGHT SIDE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRAP (KO)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(COUNTERFLOW)

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRICAL (KO)

 

 

 

 

 

231/8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AIR INTAKE (KO)

 

 

 

 

 

 

 

37/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(587.4)

 

 

8

ALL DIMENSIONS: in (mm)

3

 

 

 

 

413/16

 

 

(ALTERNATE)

 

 

 

 

 

 

 

(98.4)

/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

(122.2)

 

 

 

 

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

(30.2)

 

 

 

 

 

VENT (KO)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(1016)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRAP (KO)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11/16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

297/8

 

 

 

 

UPFLOW/HORIZONTAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(27)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(758.8)

3

 

 

 

7

 

21/4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

27 /

 

 

(177.8)

 

(57.2)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(690.6)215/

 

THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

913/16

 

 

 

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(549.3)

 

 

 

131/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(249.2)

 

 

 

175/

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3311/

 

 

 

16

 

 

 

(336.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(439.7)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

111/

 

 

 

 

(KO)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(855.7)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(42.9)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

KO = KnockOut

47/

 

215/8

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

 

(549.3)

 

 

1 /8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(123.8)

 

24

 

 

(47.6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(609.6)

 

 

 

 

 

 

Unit

Cabinet

 

Bottom

 

 

 

Top

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Capacity

A

B

 

C

D

 

E

F

G

H

 

 

 

 

 

 

 

 

 

 

 

 

 

 

58HDV040---1--12/

191/8

175/8

21/8

143/4

 

43/8

41/2

21/2

91/2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

359BAV036040

(485.8)

(447.7)

(54)

(374.7)

(111.1)

(114.3)

(63.5)

(241.3)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

58HDV060---1--12/

191/8

175/8

21/8

143/4

 

43/8

41/2

21/2

91/2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

359BAV036060

(485.8)

(447.7)

(54)

(374.7)

(111.1)

(114.3)

(63.5)

(241.3)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

58HDV080---1--12/

223/4

211/4

115/16

183/4

 

43/8

41/2

25/8

113/8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

359BAV060080

(577.9)

(539.8)

(49.2)

(476.3)

(111.1)

(114.3)

(66.7)

(288.9)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

58HDV100---1--20/

241/2

23

 

7/16

23

 

43/8

41/2

21/4

121/4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

359BAV060100

(622.3)

(584.2)

(11.1)

(584.2)

(111.1)

(114.3)

(57.2)

(311.2)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

25--23--36b

58HDV

Specifications are subject to change without notice.

A09192

Fig. 4 - Dimensions and Clearances

7

58HDV

If the furnace is to be suspended from the floor joists in a crawl space or the rafters in an attic, it is necessary to use steel pipe straps or an angle iron frame to rigidly attach the furnace to prevent movement. These straps should be attached to the furnace bottom side with sheet metal screws and to the rafters or joists with bolts. The preferred method is to use an angle iron frame bolted to the rafters or joists.

If the furnace is to be installed in a crawl space, consult local codes. A suitable concrete pad or blocks are recommended for crawl space installation on the ground.

NOTE: 6(152.4mm) bottom clearance required for condensate trap.

24(609.6mm) inches between the front of the furnace and adjacent construction or other appliances MUST be maintained for service clearance. [30(762mm) inches is required to remove furnace].

Keep all insulating materials clear from louvered door. Insulating materials may be combustible.

The horizontal furnaces may be installed directly on combustible wood flooring or supports as long as all required furnace clearances are met. See Fig. 3.

This furnace MUST NOT be installed directly on carpeting or tile or other combustible material other than wood flooring or supports.

For horizontal installation over a finished living space. A field fabricated auxiliary drain pan with drain pipe is required to prevent damage by overflow due to blocked condensate drain.

Knock Outs

A07702

Fig. 5 - Hammer and Screwdriver used for Knockout

!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 clothing, safety glasses and gloves when handling parts and servicing furnaces.

Use a hammer and screwdriver to strike a sharp blow (See Fig. 5) directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout. Remove any burrs and sharp edges.

NOTE: If a knockout does not come out after two sharp blows, pull and snip as needed to remove the knockout.

COMBUSTION & VENTILATION

AIR

For Single Pipe Installation

!WARNING

CARBON MONOXIDE POISONING HAZARD

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

Use methods described here to provide combustion and ventilation air.

Furnaces require ventilation openings to provide sufficient air for proper combustion and ventilation of flue gases. All duct or openings for supplying combustion and ventilation air must comply with the gas codes, or in the absence of local codes, the applicable national codes.

Combustion and ventilation air must be supplied in accordance with one of the following:

NOTE: The Combustion & Ventilation Air Section in this document, uses tables and information from the ANSI Z223.1/NFPA 54. For use in Canada, use CSA B149.1 for this information.

1.Section 9.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, (NFGC), ANSI Z223.1-2006/NFPA 54-2006 in the U.S.,

2.Sections 8.2, 8.3, 8.5, 8.6, 8.7, and 8.8 of National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC), CSA B149.1-05 in Canada,

3.Applicable provisions of the local building code.

This furnace can NOT be common vented or connected to any type B, BW or L vent or vent connector, nor to any portion of a factory-built or masonry chimney. Multistory common venting is NOT permitted. If this furnace is replacing a previously common-vented furnace, it may be necessary to resize the existing vent and chimney to prevent oversizing problems for the other remaining appliance(s). See “Venting and Combustion Air Check” in this section. This furnace MUST be vented to the outside.

When the installation is complete, check that all appliances have adequate combustion air and are venting properly. See Venting And Combustion Air Check in “Gas Vent Installation” Section in this manual.

Outdoor Combustion Air Method

A space having less than 50 cubic feet per 1,000 BTUH input rating for all gas appliances installed in the space requires outdoor air for combustion and ventilation.

Air Openings and Connecting Ducts

1.Total input rating for all gas appliances in the space MUST be considered when determining free area of openings.

2.Connect ducts or openings directly to the outdoors.

3.When screens are used to cover openings, the openings MUST be no smaller than 1/4(6.35 mm) mesh.

4.The minimum dimension of air ducts MUST NOT be less than 3(76.2 mm).

5.When sizing a grille, louver, or screen use the free area of opening. If free area is NOT stamped or marked on grill or

louver, assume a 20% free area for wood and 60% for metal. Screens shall have a mesh size not smaller than 1/4(6.35

mm).

8

Confined Space Installation

a. One opening MUST commence within 12(304.8mm)

NOTE: A confined space is defined as an area with less than 50

of the floor and the second opening MUST commence

within 12(304.8mm) of the ceiling.

cubic feet (1.43M)per 1,000 BTUH (2.33 cm2/kW) input rating for

b. Size openings and ducts per Table 1.

all gas appliances installed in the area.

c. Horizontal duct openings require 1 square inch of free

Requirements

area per 2,000 BTUH (11 cm2/kW) of combined input

1. Provide the space with sufficient air for proper combustion

for all gas appliances in the space (see Table 1).

d. Vertical duct openings or openings directly

and ventilation of flue gases using horizontal or vertical

communicating with the outdoors require 1 square inch

ducts or openings.

of free area per 4,000 BTUH (5.5 cm2/kW) for

2. Fig. 6 illustrates how to provide combustion and ventilation

combined input of all gas appliances in the space (see

air. A minimum of two permanent openings, one inlet and

Table 1).

one outlet, are required.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

This installation NOT approved in Canada

Gas Vent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gable Vent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gas Vent

Ventilated Attic

 

 

 

 

 

 

58HDV

Top Above Insulation

 

Gable Vent

 

 

 

 

Alternate Inlet Air (1)

 

 

 

 

 

 

Gas Vent

 

Outlet

Outlet

 

 

 

 

Outlet Air (1)

Soffit Vent

Ventilated Attic

 

Air (1)

Air (2)

 

Top Above Insulation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OutletAir (1)

Soffit Vent

Inlet

Inlet

 

 

 

Air (1)

 

 

 

 

 

 

Air (2)

 

 

 

 

 

 

 

 

 

 

 

Inlet

 

Minimum One Inlet and One Outlet Air Supply is Required

 

 

 

 

 

May be in any Combination Shown

 

 

 

Inlet

 

Air (2)

 

Inlet Air Opening Must be Within12of floor

 

 

Ventilated Crawl Space

 

 

 

 

 

 

 

 

Outlet Air Opening Must be Within12of ceiling

 

 

alternate Inlet Air (1)

Air (1)

 

 

 

 

 

 

 

 

 

(1) 1 Square Inch per 4000 BTUH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(2) 1 Square Inch per 2000 BTUH

 

 

 

 

 

 

 

 

A07704

 

Fig. 6 - Outside Air

(This is ONLY a guide. Subject to codes of country having jurisdiction).

3.One opening MUST be within 12(304.8mm) of the floor and the second opening within 12(304.8mm) of the ceiling.

a.1 sq. in of free area per 3,000 BTUH (7 cm2/kW) for combined input of all gas appliances in the space (see

Table 1) and

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

The opening shall commence within 12(304.8mm) of the top of the enclosure. Appliances shall have clearances of at least 1(25.4mm) from the sides and back and 6(152.4mm) 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.

4.Size openings and ducts per Table 1.

a.Indoor openings that comply with the Indoor Combustion Air Method below and

b.Outdoor openings located as required in the Outdoor Combustion Air Method above and

c.Outdoor openings sized as follows.

(1.) Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method.

(2.) Outdoor opening size reduction Factor is 1 minus the Ratio in 1) above.

(3.) Minimum size of Outdoor openings shall be the size required in Outdoor Combustion Air Method above multiplied by reduction Factor.

5.Horizontal duct openings require 1 square inch of free area per 2,000 BTUH of combined input for all gas appliances in area (see Table 1).

6.Vertical duct openings or openings directly to outside

require 1 square inch of free area per 4,000 BTUH (5.5 cm2/kW) for combined input of all gas appliances in area

(see Table 1).

9

58HDV

Table 1

 

Free Area

 

 

 

 

 

 

 

 

 

 

Minimum Free Area Required for Each Opening or Duct to Outdoors

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BTUH (kW)

 

Two Horizontal Ducts

 

 

Single Opening

 

Two Vertical Ducts or

Round Duct

Input Rating

 

BTUH (kW)

 

 

BTUH (kW)

 

Openings

BTUH (kW)

 

 

sq. in./2,000(1 cm2/.09)

 

 

sq. in./3,000 (1 cm2/.135)

 

BTUH (kW)

sq.

 

 

 

 

 

sq. in./4,000(1 cm2/.18)

in./4,000(6.5cm2/.18)

 

 

 

 

 

 

 

40,000 (11.72)

 

20 sq. in. (129 cm2)

 

 

13.34 sq. in. (86 cm2)

 

10 sq. in. (65 cm2)

4(101.6mm)

50,000 (14.65)

 

25 sq. in. (161 cm2)

 

 

16.7 sq. in. (108 cm2)

 

12.5 sq. in. (81 cm2)

4(101.6mm)

60,000 (17.58)

 

30 sq. in. (194 cm2)

 

 

20 sq. in. (129 cm2)

 

15 sq. in. (97 cm2)

5(127mm)

75,000 (21.98)

 

37.5 sq. in. (242 cm2)

 

 

25 sq. in. (161 cm2)

 

18.75 sq. in. (121 cm2)

5(127mm)

80,000 (23.45)

 

40 sq. in. (258 cm2)

 

 

26.7 sq. in. (172 cm2)

 

20 sq. in. (129 cm2)

5(127mm)

100,000 (29.31)

 

50 sq. in. (322 cm2)

 

 

33.3 sq. in. (215 cm2)

 

25 sq. in. (161 cm2)

6(152.4mm)

125,000 (36.63)

 

62.50 sq. in. (403 cm2)

 

 

41.7 sq. in. (269 cm2)

 

31.25 sq. in. (202 cm2)

7(177.8mm)

EXAMPLE: Determining Free Area

 

 

 

 

 

 

Furnace

 

Water Heater

 

 

Total Input

 

 

 

100,000

+

30,000

=

(130,000 ÷ 4,000)

=

32.5 Sq. In. Vertical

 

29.31

 

8.8

 

(38.11 ÷ .18)

=

210 cm2 Vertical

 

Furnace

 

Water Heater

 

 

Total Input

 

 

 

100,000

+

30,000

=

(130,000 ÷ 2,000)

=

65 Sq. In. Horizontal

 

29.31

 

8.8

 

(38.11 ÷ .09)

=

423 cm2 Horizontal

 

Indoor Combustion Air (Unconfined Space)

!WARNING

CARBON MONOXIDE POISONING HAZARD

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

Most homes will require additional air from outdoors for combustion and ventilation. A space with at least 50 cubic feet (1.43M) per 1,000 (2.33 cm2/kW) Btuh Input rating or homes with tight construction may need outdoor air, supplied through ducts, to supplement air infiltration for proper combustion and ventilation of flue gasses.

Standard and KnownAir- Infiltration Rate Methods

© NFPA & AGA

Indoor air is permitted for combustion and ventilation, if the

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

The Standard Method may be used, if the space has no less volume than 50 cubic feet per 1,000 BTUH input rating for all gas

appliances installed in the space. The standard method permits indoor air to be used for combustion and ventilation air.

The Known Air Infiltration Rate Method shall be used if the infiltration rate is known to be less than 0.40 air changes per hour (ACH) and equal to or greater than 0.10 ACH. Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 2 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space, and add the volumes together to get the total minimum required volume for the space.

!WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to supply additional air by means of ventilation grilles or ducts could result in personal injury or death.

An unconfined space or homes with tight construction may not have adequate air infiltration for proper combustion and ventilation of flue gasses. Most homes will require additional air.

 

Table 2

 

MINIMUM SPACE VOLUME FOR 100% COMBUSTION AND VENTILATION AIR FROM INDOORS

 

 

 

Other Than FanAssisted Total

 

 

Fanassisted Total

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30,000 BTU

40,000 BTU

50,000 BTU

50,000 BTU

75,000

100,000 BTU

125,000 BTU

ACH

 

 

(8,790 kW)

(11,720 kW)

(14,650 kW)

(14,650 kW)

(21,975 kW)

(29,300 kW)

(36,625 kW)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ft3 (m3)

 

 

 

 

0.60

 

 

1,050 (29.7)

1,400 (39.2)

1,750

(49)

1,250 (35)

1,875 (52.5)

2,500

(70)

3,125 (87.5)

 

 

 

 

 

 

 

 

 

 

 

0.50

 

 

1,260 (35.3)

1,680 (47.04)

2,100 (58.8)

1,500 (42)

2,250 (63)

3,000

(84)

3,750 (105)

 

 

 

 

 

 

 

 

 

 

0.40

 

 

1,575 (44.1)

2,100 (58.8)

2,625 (73.5)

1,875 (52.5)

2,813 (78.8)

3,750 (105)

4,688 (131.3)

 

 

 

 

 

 

 

 

 

 

 

0.30

 

 

2,100 (58.8)

2,800 (78.4)

3,500

(98)

2,500 (70)

3,750 (105)

5,000 (140)

6,250 (175)

 

 

 

 

 

 

 

 

 

 

0.20

 

 

3,150 (88.2)

4,200 (117.6)

5,250 (147)

3,750 (105)

5,625 (157.5)

7,500 (210)

9,375 (262.5)

 

 

 

 

 

 

 

 

 

 

 

 

0.10

 

 

6,300 (176.4)

8,400 (235.2)

10,500

(294)

7,500 (210)

11,250 (315)

15,000

(420)

18,750 (525)

 

 

 

 

 

 

 

 

 

 

0.00

 

 

NP

NP

NP

NP

NP

NP

NP

 

 

 

 

 

 

 

 

 

 

 

 

 

ACH = Air Changes per Hour NP = Not Permitted

Table 2 Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223.1/NFPA 54---2006, 9.3.2.2:

1. For appliances other than fan-assisted appliances (such as

 

 

 

(

 

 

)

a draft hood-equipped water heater), calculate using the fol-

Required Volume other

 

21 ft3

I

other

lowing equation:

²

 

 

 

1000 Btu / hr

ACH

 

 

 

 

 

 

 

 

10

I fan

2.For fan-assisted appliances (such as this furnace), calculate using the following equation:

Required Volume fan ²

15 ft3

(

 

I fan

)

 

1000 Btu / hr

 

 

 

ACH

 

where:

I other = all appliances other than fan-assisted input in Btu per hour

= fan-assisted appliance input in Btu per hour

ACH =air change per hour (percent of volume of space exchanged per hour, expressed as a decimal)

3.For purposes of this calculation, an infiltration rate greater than 0.60 ACH shall not be used in the equations above.

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

SAdjoining rooms can be considered part of a space, if there are no closeable doors between rooms.

SCombining spaces on the same story. Each opening shall have a minimum free area of at least 1 in.2/1,000 BTUH (2,200 mm2/kW) of the total input rating of all appliances in the space

but not less than 100 in.2 (0.06 m2). One opening shall commence within 12 in. (304.8 mm) of the top, and one opening shall commence within 12 in. (304.8 mm) of the bottom, of the enclosure. The minimum dimension of air openings shall not be less than 3 in. (76.2 mm).

SCombining spaces in different stories. The volumes of spaces on different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in

doors or floors having a total minimum free area of 2 in.2/1,000 BTUH (4,400 mm2/kW) of total input rating of all appliances.

SAn attic or crawl space may be considered a space that freely communicates with the outdoors provided there are adequate ventilation openings directly to outdoors. Openings MUST remain open and NOT have any means of being closed off. Ventilation openings to outdoors MUST be at least 1 square inch

of free area per 4,000 BTUH (550 mm2/kW) of total input rating for all gas appliances in the space.

SIn spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be provided

using the methods described in section titled Outdoor Combustion Air Method:

SUnusually tight construction is defined as Construction with:

1.Walls and ceilings exposed to the outdoors have a continuous, sealed vapor barrier. Openings are gasketed or sealed and

2.Doors and openable windows are weather stripped and

3.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.

Ventilation Air

Some provincial codes and local municipalities require ventilation or make-up air be brought into the conditioned space as replacement air. Whichever method is used, the mixed return air temperature across the heat exchanger MUST not fall below 60° so that flue gases will not condense excessively in the heat exchanger. Excessive condensation will shorten the life of the heat exchanger and possibly void your warranty.

Venting and Combustion Air Check

NOTE: If this installation replaces an existing furnace from a commonly vented system, the original venting system may no longer be sized to properly vent the attached appliances. An improperly sized venting system may cause the formation of condensate in the vent and the leakage or spillage of vent gases. To make sure there is adequate combustion air for all appliances,

MAKE THE FOLLOWING CHECK.

Vent

Pipe

Draft Hood

Typical Gas

 

 

Water Heater

 

 

 

 

Match

A07688

Fig. 7 - Vent Check

The following information is supplied to allow the installer to make adjustments to the setup of existing appliances, IF REQUIRED, based on good trade practices, local codes, and good judgement of the installer. Manufacturer does NOT take responsibility for modifications made to existing equipment.

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58HDV

!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 the 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 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. (Fig. 6)

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.

For Two Pipe Installation (Direct Vent)

This furnace can NOT be common vented or connected to any type B, BW or L vent or vent connector, nor to any portion of a factory-built or masonry chimney. If this furnace is replacing a previously common-vented furnace, it may be necessary to resize the existing vent and chimney to prevent oversizing problems for the other remaining appliance(s). See “Venting and Combustion Air Check” in this section. This furnace MUST be vented to the outside.

VENT AND COMBUSTION AIR

PIPING

!WARNING

CARBON MONOXIDE POISONING HAZARD

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

Use methods described here to provide combustion and ventilation air.

Dual Certified

Direct or NonDirect Vent

This furnace is certified as a Category IV furnace. This furnace can be installed as a direct vent furnace using outside air for combustion or the furnace can use air from inside the structure for combustion. The INLET air pipe is optional. If combustion air comes from inside the structure, adequate make up air MUST be provided to compensate for oxygen burned. See Confined Space Installation in the Combustion and Ventilation Air chapter. If combustion air is drawn from outside the structure, it MUST be taken from the same atmospheric pressure zone as the vent pipe.

Contaminated Combustion Air

Installations in certain areas or types of structures will increase the exposure to chemicals or halogens that may harm the furnace.

The following areas or types of structures may contain or have exposure to the substances listed below. The installation must be evaluated carefully as it may be necessary to provide outside air for combustion.

S Commercial buildings.

S Buildings with indoor pools.

S Furnaces installed in laundry rooms.

S Furnaces installed in hobby or craft rooms.

S Furnaces installed near chemical storage areas. S Permanent wave solutions for hair.

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 Sulfuric Acid.

S Solvent cements and glues.

S Antistatic fabric softeners for clothes dryers. S Masonry acid washing materials.

Vent and Combustion Air Piping Guidelines

This furnace is approved for venting with Schedule 40 PVC, CPVC, ABS fittings, and Cellular Core and SDR-26 PVC pipe.

(1.) NOTE: In Canada, all pipe, fittings & cements must conform to applicable CSA standards or to local codes having jurisdiction.

12

 

Applicable ASTM Standards for Vent

Materials

 

 

 

 

 

 

 

 

 

 

Materi-

 

Sch. 40

SDR

Cell

 

 

 

Solv.

 

Core

Fittings

Primer

 

als

 

Pipe

Pipe

 

Cement

 

Pipe

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D2468

 

 

 

ABS

 

D1527

__

F628

&

----

 

D2235

 

 

 

 

 

D2661

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D2466

 

 

 

PVC

 

D1785

D2241

F891

&

F656

 

D2564

 

 

 

 

 

D2665

 

 

 

 

 

 

 

 

 

 

 

 

CPVC

 

F441

F442

----

F438

----

 

F493

 

 

 

 

 

 

 

 

 

ABS to

 

----

----

----

----

----

 

D3138

PVC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(2.) Only use solvent cements that are marked for use with the specific venting material.

(3.) ABS to PVC transition joints REQUIRE a special solvent cement that meets the requirements of ASTM D3138.

(4.) Refer to ASTM D2855 for general procedure to use for cementing plastic pipe and fittings.

NOTE: In order to create a seal that allows future removal of pipe,

RTV sealant MUST be used on the inlet pipe where it joins to the furnace.

NOTE: All vent piping MUST be installed in compliance with local codes or ordinances, these instructions, good trade practices, and codes of country having jurisdiction.

1.Determine the best routing and termination for the vent pipe and air inlet pipe by referring to all of the instructions and guidelines in this Section.

2.Determine the size required for the vent pipe and air inlet pipe.

3.Loosely assemble all venting parts without adhesive (pipe joint cement) for correct fit before final assembly.

4.Furnace shall be installed so as to prevent the accumulation of condensate.

5.Use of vertical piping is preferred because there will be some moisture in the flue gases that may condense as it leaves the vent pipe (See Instructions for Horizontal Vents).

6.The vertical vent pipe MUST be supported so that no weight is allowed to rest on the combustion blower.

7.Exhaust vent piping or air inlet piping diameter MUST NOT be reduced.

8.All exhaust vent piping from the furnace to termination

MUST slope upwards. A minimum of 1/4(6.4mm) per foot (304.8mm) of run is required to properly return condensate to the furnace drain system.

9.Use DWV type long radius elbows whenever possible, as they provide for the minimum slope on horizontal runs and they provide less resistance in the vent system. If DWV elbows cannot be used, use two, 45° elbows when possible. On horizontal runs the elbows can be slightly misaligned to provide the correct slope.

10.All horizontal pipe runs MUST be supported at least every five feet (1.5 M) with galvanized strap or other rust resistant material. NO sags or dips are permitted.

11.All vertical pipe runs MUST be supported every six feet (4.8 M) where accessible.

12.The maximum pipe length is 40(12.2m) total in the inlet or outlet side of the system. Up to five, 90° elbows can be used on the inlet or the outlet. With the Concentric Vent Termination Kits (KGAVT0701CVT or KGAVT0801CVT), the maximum pipe length is 35(10.7m) with four 90° elbows. If more elbows are required, reduce the length of

both the inlet and exhaust pipes 5(1.5m) for each additional elbow used. (See Table 3 or Table 4).

13.The minimum vent length is 5(1.5m) of PVC.

14.The piping can be run in the same chase or adjacent to supply or vent pipe for water supply or waste plumbing. It can also be run in the same chase with a vent from another 90+ furnace.

NOTE: In NO case can the piping be run in a chase where temperatures can exceed 140° F (60° C). or where radiated heat from adjacent surfaces would exceed 140° F(60° C).

15.The vent outlet MUST be installed to terminate in the same atmospheric pressure zone as the combustion air inlet.

16.The vent system can be installed in an existing unused chimney provided that:

SBoth the exhaust vent and air intake run the length of the chimney.

SNo other gas fired appliance or fireplace (solid fuel) is vented into the chimney.

SThe top of the chimney MUST be sealed flush or crowned up to seal against rain or melting snow so ONLY the piping protrudes.

SThe termination clearances shown in Fig. 8 are maintained.

17.Furnace applications with vertical vents requiring vent diameter increaser fittings must have increaser fittings installed in vertical portion of the vent. Condensate will be trapped in the vent if the vent diameter is increased prior to having an elbow turned upward. This could cause nuisance tripping of the pressure switch.

Combustion Air and Vent Piping Insulation Guidelines

NOTE: Use closed cell, neoprene insulation or equivalent. If Fiberglass or equivalent insulation is used it must have a vapor barrier. Use R values of 7 up to 10(3.1m), R-11 if exposure exceeds 10(3.1m). If Fiberglass insulation is used, exterior to the structure, the pipe MUST be boxed in and sealed against moisture.

1.When the vent or combustion air pipe height above the roof exceeds 30(76.2mm), or if an exterior vertical riser is used on a horizontal vent to get above snow levels, the exterior portion MUST be insulated.

2.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.

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

Sizing Combustion Air and Vent Pipe

Consult Table 3 or Table 4 to select the proper diameter exhaust and combustion air piping. Exhaust and combustion air piping is sized for each furnace Btuh size based on total lineal vent length (on inlet or outlet side), and number of 90° elbows required.

1.Double Pipe Installation-If installing as a direct-vent appliance, consult Table 4 to select the proper diameter exhaust and combustion air piping. Exhaust and combustion air piping is sized for each furnace Btuh size based on total lineal vent length (on inlet or outlet side), and number of 90° elbows required.

2.Single Pipe Installation-If installing as a non-direct vent appliance, (single outlet pipe and no inlet pipe) refer to Table 3. The table shows the maximum number of elbows allowed with any given pipe diameter and length of run.

3.Use of Elbows-Two 45° elbows can be substituted for one 90° elbow. The elbow or elbows used for vent termination outside the structure ARE counted, including elbows needed to bring termination above expected snow levels.

58HDV

13

58HDV

Table 3

Pipe Diameter Table

Single Piping ONLY

 

40,000, 50,000, 60,000 & 75,000 Btuh Furnaces

40′ (12.2m) & (5) 90° elbows with 2″ (50.8mm) PVC pipe

80,000 & 100,000 Btuh Furnace

40′ (12.2m) & (5) 90° elbows with 3″ (76.2mm) PVC pipe

125,000 Btuh Furnace

40′ (12.2m) & (5) 90° elbows with 3″ (76.2mm) PVC pipe

The minimum vent length is 5’ (1.5m) of PVC. Elbows are DWV Long Radius Type for 2” (50.8mm) and 3” (76.2mm) vents.

If more than five elbows are required, reduce the length of both the inlet and exhaust pipes 5(1.5m) for each additional elbow used. If less than five elbow are required, the length can be INCREASED by 5(1.5m) for each additional elbow NOT used.

NOTE: It is allowable to use larger diameter pipe and fitting than shown in the tables but not smaller diameters than shown.

Table 4

Pipe Diameter Table

Dual Piping ONLY

 

40,000, 50,000, 60,000 & 75,000 Btuh Furnaces

40′ (12.2m) & (5) 90° elbows with 2″ (50.8mm) PVC pipe

80,000 & 100,000 Btuh Furnace

40′ (12.2m) & (5) 90° elbows with 3″ (76.2mm) PVC pipe

125,000 Btuh Furnace

40′ (12.2m) & (5) 90° elbows with 3″ (76.2mm) PVC pipe

The minimum vent length is 5’ (1.5m) of PVC. Elbows are DWV Long Radius Type for 2” (50.8mm) and 3” (76.2mm) vents.

If more than five elbows are required, reduce the length of both the inlet and exhaust pipes 5(1.5m) for each additional elbow used. If less than five elbow are required, the length can be INCREASED by 5(1.5m) for each additional elbow NOT used.

* Feet (M) of pipe is whichever pipe run is the longest, either inlet or outlet side.

For venting table, see“Concentric Termination Kit” in this manual.

Vent Termination Clearances

!WARNING

CARBON MONOXIDE POISONING HAZARD

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

Inlet and outlet pipes may NOT be vented directly above each other.

1.Determine termination locations based on clearances specified in following steps and as shown in Fig. 8, 9, and 22 through 30.

For “Concentric Termination Kit” clearances, see Fig. 32, 33, 34, 35 and 36 in this manual.

2.This furnace is Dual Certified and can be installed as a single pipe appliance (all combustion from inside the structure) or as a direct vent appliance where all combustion air is taken from outside the structure.

3.For Direct Vent installation, refer to Fig. 8 for vent termination.

4.For Single Pipe installation refer to Fig. 9 for vent termination clearances.

14

V

V

58HDV

12 inches (30 cm) for applieances >10,000 Btuh(3 kW) and < 100,000 Btuh(30kW), 36 inches (91cm) for appliances > 100,000 Btuh(30kW)

A08600

Fig. 8 - Direct Vent Termination Clearance

15

Carrier DIRECT VENT 4 58HDV User Manual

58HDV

A08601

Fig. 9 - Other than Direct Vent Termination Clearance

16

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