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
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 ci-- haut
mentionnées. Le standard Canadien recommande l’ inspection par
un personel qualifié et ce, une fois par année.
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.
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
ama
CERTIFIED
1
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NOTE: Read the entire instruction manual before starting the
installation.
suggestions which will result in enhanced installation, reliability, or
operation.
NOTE: Please retain these instructions with the furnace after
installation for future reference.
!
CAUTION
CUT HAZARD
SAFETY CONSIDERATIONS
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.
!
CAUTION
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
SAFE INSTALLATION REQUIREMENTS
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, 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.
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
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.
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.
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.
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.
S Use 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.)
S Install this furnace only in a location and position as specified in
“Installation” of these instructions.
S Provide adequate combustion and ventilation air to the furnace as
specified in “ Combustion and Ventilation Air” of these
instructions.
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.
S Combustion 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.
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.
S Always install furnace to operate within the furnace’s intended
temperature--rise range with a duct system which has an external
static pressure within the allowable range, as specified in
“Technical Support Manual” of these instructions. See furnace
rating plate.
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
S When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the
3
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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.
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
S A gas--fired furnace for installation in a residential garage must
be installed as specified in “Installation” of these instructions.
S This furnace is not to be used for temporary heating of buildings
or structures under construction.
!
CAUTION
WATER DAMAGE TO PROPERTY HAZARD
S This furnace is NOT approved for installation in mobile
homes, trailers or recreation vehicles.
Failure to follow this caution may result in property damage.
S Seal around supply and return air ducts.
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.
S Install correct filter type and size.
S Unit MUST be installed so electrical components are protected
from direct contact with water.
Safety Rules
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.
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.
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.
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.
-- o r --
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.
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.
-- o r --
3. Install a reliable remote sensing device that will notify some-
body of freezing conditions within the home.
Winter Shutdown
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).
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)
5
1. Disconnect the / ″ OD rubber hose from the vent drain fit-
8
ting 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. Recon-
NOTE: The manufacturer of your furnace does not test any alarms
and makes no representations regarding any brand or type of
alarms.
5
nect the / ″ OD rubber hose to the stub on the vent drain
8
fitting. Secure with the hose clamp.
To ensure safe and efficient operation of your unit, you should do
the following:
3
2. Disconnect the / ″ OD rubber hose from the condensate
4
trap. Insert a funnel into the hose and and pour four(4)
ounces of sanitary type (RV) antifreeze into the plastic
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.
Transition box. Squeeze the hose together near the end and
3
quickly reconnect the / ″ OD rubber hose to the stub on the
4
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
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Aluminum or non--rusting shield recommended.
(See Vent Termination Shielding for dimensions).
INSTALLATION
*8″ (203.2mm) Min.
20′ (6.1m) Max.
in same
atmospheric
zone
Coupling on ends of
exhaust pipe. Total
pipe & coupling out-
side structure = 8″
(203.2mm)
!
WARNING
Inlet Pipe
(not used on
Single Pipe
model)
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
Vent Pipes MUST be
supported
Horizontally and
Vertically
*8″ (203.2mm) Min.
20′ (6.1m) Max.
insameatmospheric zone
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.
* Increase minimum from 8″ (203.2mm) to 18″ (457.2mm) for cold climates (sus-
tained temperatures 0° F (-17° C) and below for 24 or more consecutive hours).
2 5 -- 2 3 -- 3 3
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.
A07700
Fig. 1 -- Typical Upflow Installation
See Vent Termination
Shielding in Vent Section.
Coupling on inside
and outside of wall to
restrain vent pipe
*8″ Min. (203 mm)
Inlet Pipe
(not used on
Single Pipe
model)
20′ Max. in same (6 M)
atmosphericzone
8″ Min. (203 mm)
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.
Vent Pipes MUST
be supported Horizon-
tally and Vertically
*8″ Min. (203 mm)
20′ Max. (6.1 M)
in same
2. If furnace is a replacement, it is usually best to install the fur-
nace where the old one was. Choose the location or evaluate
the existing location based upon the minimum clearance and
furnace dimensions (Fig. 2).
atmospheric zone
!
CAUTION
25--23--33a
FROZEN AND BURST PIPE HAZARD
*
Increase minimum from 8″ to 18″ (203 to 457 mm) for cold climates (sustained temperatures
0°F ( - 1 8 °C ) and ) below for 24 or more consecutive hours).
Failure to follow this caution may result in property damage.
A07762
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”)
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.
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.
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:
9. Residential garage installations require:
S Burners and ignition sources installed at least 18″ (457.2mm)
above the floor.
Condensate Trap and Drain Lines
S Located or physically protected from possible damage by a
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.
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:
S 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.
S The furnace is controlled by a thermostat. It may not be “hot
wired” to provide heat continuously to the structure without
thermostatic control.
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 / ″ (6.4mm) from front to back and from side to
side for upflow and downflow installations or top to bottom for
horizontal installations.
1
4
Vent and Combustion Air Connections
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.
S 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.
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.
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.
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.
S The 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.
Horizontal Furnace Installation
Inlet Pipe (not used on Single Pipe model)
S The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
Vent
Pipe
S 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.
S After construction is complete, verify furnace operating
conditions including ignition, input rate, temperature rise and
venting according to these instructions.
Condensate
Trap
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
NOTE: 6″ bottom clearance required for condensate trap.
A07703
Do NOT operate furnace in a corrosive atmosphere containing
chlorine, fluorine or any other damaging chemicals, which
could shorten furnace life.
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.
Refer to Combustion & Ventilation Air section, Contaminated
Combustion Air for combustion air evaluation and remedy.
6
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F
MINIMUM CLEARANCES TO COMBUSTIBLE
MATERIALS FOR ALL UNITS -- in (mm)
AIR INTAKE
VENT
A
B
REAR
0
TOP
FRONT (combustion air openings in 3″ (76.2)
furnace and in structure)
H
Required For Service
ALL SIDES Of SUPPLY PLENUM
SIDES
*
24″ (609.6)
G
FRONT
1″ (25.4)
E
0
11
(177.5)
ELECTRICAL
1
(318)
VENT
0
LEFT SIDE
6
/
16
1 /
4
TOP OF FURNACE
1″ (25.4)
TRAP (KO) (COUNTERFLOW)
*
30″ (762mm) clearance recommended for furnace removal.
GAS
VENT
1
(27)
16
1 /
Horizontal position: Line contact is permissible only between
lines formed by intersections of top and two sides of furnace
jacket, and building joists, studs or framing.
11
(347.7)
13
/
16
AIR INTAKE (KO)
11
(804.9)
13
(ALTERNATE)
31
/
4
/
16
16
(34.9)
(122.2)
TRAP (KO)
NOTE: Evaporator “A” coil drain pan dimensions may
vary from furnace duct opening size. Always consult
evaporator specifications for duct size requirements.
(758.8)
3
1 /
8
UPFLOW/HORIZONTAL
7
29 /
8
3
28 /
7
4
1
THERMOSTAT
(57.2)
2 /
(730.3)
4
(177.8)
1
Furnace is designed for bottom return or side return.
24 /
16
(611.2)
5
13
Return air through back of furnace is NOT allowed.
17 /
19
/
16
16
1
13 /
(439.7)
4
1
(503.2)
1 /
4
(336.6)
11
1
/
(31.7)
16
(42.9)
(KO)
5
21 /
8
7
4 /
8
7
2 /
8
1
28 /
(549.3)
2
(123.8)
7
1 /
5
(109.5)
8
(73)
(723.9)
4 /
3
24
(19.1)
16
1
/
4
(47.6 )
18 /
2
(609.6)
(469.9)
TYPE
Drawing is representative,
but some models may vary
3
(60.3 )
(27)
2 /
8
1
1 /
16
RIGHT SIDE
TRAP (KO)
(COUNTERFLOW)
GAS (KO)
BOTTOM
D
ELECTRICAL (KO)
AIR INTAKE (KO)
(ALTERNATE)
C
1
23 /
7
8
3 /
8
ALL DIMENSIONS: in (mm)
13
(587.4)
(98.4)
4
/
16
3
1 /
16
(122.2)
40
(30.2)
VENT (KO)
(1016)
TRAP (KO)
1
(27)
1 /
UPFLOW/HORIZONTAL
16
7
29 /
8
(758.8)
1
2 /
4
7
3
27 /
16
(57.2)
(177.8)
(690.6)
5
THERMOSTAT
21 /
8
13
(249.2)
9
/
16
(549.3)
1
13 /
5
4
17 /
16
(336.6)
(KO)
11
(855.7)
(439.7)
33
/
16
11
1
/
16
(42.9)
5
21 /
7
8
4 /
7
8
1 /
KO = KnockOut
8
(549.3)
(123.8)
(47.6)
24
(609.6)
Cabinet
Bottom
Top
Unit
Capacity
C
2 /
A
B
D
E
4 /
(111.1)
3
4 /
8
(111.1)
3
4 /
8
(111.1)
3
4 /
8
F
4 /
(114.3)
1
4 /
2
(114.3)
1
4 /
2
(114.3)
1
4 /
2
G
2 /
H
1
5
1
3
3
1
1
1
19 /
8
17 /
14 /
9 /
8
8
4
8
2
2
2
58HDV040---1--12/
359BAV036040
58HDV060---1--12/
359BAV036060
(485.8)
(447.7)
(54)
(374.7)
(63.5)
(241.3)
1
9 /
2
(241.3)
3
11 /
8
(288.9)
1
12 /
4
1
19 /
8
5
17 /
8
1
3
14 /
4
1
2 /
2
2 /
8
(485.8)
(447.7)
(54)
15
(374.7)
3
18 /
4
(63.5)
3
22 /
4
1
21 /
4
5
2 /
8
1
/
58HDV080---1--12/
359BAV060080
58HDV100---1--20/
359BAV060100
16
(577.9)
(539.8)
(49.2)
(476.3)
(66.7)
1
24 /
2
7
1
2 /
4
23
/
23
16
(622.3)
(584.2)
(11.1)
(584.2)
(111.1)
(114.3)
(57.2)
(311.2)
2 5 -- 2 3 -- 3 6 b
Specifications are subject to change without notice.
A09192
Fig. 4 -- Dimensions and Clearances
7
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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.
COMBUSTION & VENTILATION
AIR
For Single Pipe Installation
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
NOTE: 6″ (152.4mm) bottom clearance required for condensate
trap.
Use methods described here to provide combustion and
ventilation air.
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.
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:
This furnace MUST NOT be installed directly on carpeting or tile
or other combustible material other than wood flooring or supports.
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.
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.
1. Section 9.3, Air for Combustion and Ventilation, of the Na-
tional Fuel Gas Code, (NFGC), ANSI Z223.1--2006/NFPA
54--2006 in the U.S.,
Knock Outs
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.
A07702
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.
Fig. 5 -- Hammer and Screwdriver used for Knockout
!
CAUTION
Outdoor Combustion Air Method
CUT HAZARD
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.
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.
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.
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.
3. When screens are used to cover openings, the openings
1
MUST be no smaller than / ″ (6.35 mm) mesh.
4
4. The minimum dimension of air ducts MUST NOT be less
than 3″ (76.2 mm).
NOTE: If a knockout does not come out after two sharp blows,
pull and snip as needed to remove the knockout.
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.
1
Screens shall have a mesh size not smaller than / ″ (6.35
4
mm) .
8
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a. One opening MUST commence within 12″ (304.8mm)
of the floor and the second opening MUST commence
within 12″ (304.8mm) of the ceiling.
Confined Space Installation
NOTE: A confined space is defined as an area with less than 50
3
2
cubic feet (1.4 M)per 1,000 BTUH (2.33 cm /kW) input rating for
all gas appliances installed in the area.
b. Size openings and ducts per Table 1.
c. Horizontal duct openings require 1 square inch of free
2
area per 2,000 BTUH (11 cm /kW) of combined input
Requirements
for all gas appliances in the space (see Table 1).
1. Provide the space with sufficient air for proper combustion
and ventilation of flue gases using horizontal or vertical
ducts or openings.
d. Vertical duct openings or openings directly
communicating with the outdoors require 1 square inch
2
of free area per 4,000 BTUH (5.5 cm /kW) for
2. Fig. 6 illustrates how to provide combustion and ventilation
air. A minimum of two permanent openings, one inlet and
one outlet, are required.
combined input of all gas appliances in the space (see
Table 1).
This installation NOT approved in Canada
Gas Vent
Gable Vent
Gas Vent
Ventilated Attic
Top Above Insulation
Gable Vent
Alternate Inlet Air (1)
Gas Vent
Outlet
Air (1)
Outlet
Air (2)
Ventilated Attic
Soffit Vent
Outlet Air (1)
Top Above Insulation
Inlet
Air (1)
OutletAir (1)
Soffit Vent
Inlet
Air (2)
Minimum One Inlet and One Outlet Air Supply is Required
May be in any Combination Shown
Inlet
Air (2)
Inlet Air Opening Must be Within12″ of floor
Outlet Air Opening Must be Within12″ of ceiling
(1) 1 Square Inch per 4000 BTUH
Inlet
Air (1)
Ventilated Crawl Space
alternate Inlet Air (1)
(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 b. Outdoor openings located as required in the Outdoor
and the second opening within 12″ (304.8mm) of the
Combustion Air Method above and
ceiling.
c. Outdoor openings sized as follows.
2
a. 1 sq. in of free area per 3,000 BTUH (7 cm /kW) for
combined input of all gas appliances in the space (see
Table 1) and
(1.) Calculate the Ratio of all Indoor Space volume
divided by required volume for Indoor
Combustion Air Method.
b. not less than the sum of the areas of all vent connectors
in the space.
(2.) Outdoor opening size reduction Factor is 1 minus
the Ratio in 1) above.
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.
(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
4. Size openings and ducts per Table 1.
a. Indoor openings that comply with the Indoor
Combustion Air Method below and
2
cm /kW) for combined input of all gas appliances in area
(see Table 1).
9
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Table 1
Free Area
Minimum Free Area Required for Each Opening or Duct to Outdoors
Two Vertical Ducts or
Round Duct
BTUH (kW)
sq.
BTUH (kW)
Input Rating
Two Horizontal Ducts
BTUH (kW)
Single Opening
Openings
BTUH (kW)
BTUH (kW)
2
2
sq. in./2,000(1 cm /.09)
sq. in./3,000 (1 cm /.135)
2
2
sq. in./4,000(1 cm /.18)
in./4,000(6.5cm /.18)
2
2
2
40,000 (11.72)
50,000 (14.65)
60,000 (17.58)
75,000 (21.98)
80,000 (23.45)
100,000 (29.31)
125,000 (36.63)
20 sq. in. (129 cm )
13.34 sq. in. (86 cm )
10 sq. in. (65 cm )
4″ (101.6mm)
4″ (101.6mm)
5″ (127mm)
5″ (127mm)
5″ (127mm)
6″ (152.4mm)
7″ (177.8mm)
2
2
2
25 sq. in. (161 cm )
16.7 sq. in. (108 cm )
12.5 sq. in. (81 cm )
2
2
2
30 sq. in. (194 cm )
20 sq. in. (129 cm )
15 sq. in. (97 cm )
2
2
2
37.5 sq. in. (242 cm )
25 sq. in. (161 cm )
18.75 sq. in. (121 cm )
2
2
2
40 sq. in. (258 cm )
26.7 sq. in. (172 cm )
20 sq. in. (129 cm )
2
2
2
50 sq. in. (322 cm )
33.3 sq. in. (215 cm )
25 sq. in. (161 cm )
2
2
2
62.50 sq. in. (403 cm )
41.7 sq. in. (269 cm )
31.25 sq. in. (202 cm )
EXAMPLE: Determining Free Area
Furnace
Water Heater
Total Input
100,000
29.31
Furnace
100,000
29.31
+
+
30,000
8.8
Water Heater
=
=
(130,000 ÷ 4,000)
(38.11 ÷ .18)
Total Input
(130,000 ÷ 2,000)
(38.11 ÷ .09)
=
=
32.5 Sq. In. Vertical
210 cm Vertical
2
30,000
8.8
=
=
65 Sq. In. Horizontal
2
423 cm Horizontal
appliances installed in the space. The standard method permits
indoor air to be used for combustion and ventilation air.
Indoor Combustion Air (Unconfined Space)
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 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
(1.4 M) per 1,000 (2.33 cm /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.
3
2
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to supply additional air by means of ventilation grilles
or ducts could result in personal injury or death.
Standard and Known- Air- Infiltration Rate Methods
© NFPA & AGA
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.
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
MINIMUM SPACE VOLUME FOR 100% COMBUSTION AND VENTILATION AIR FROM INDOORS
Table 2
Other Than Fan- Assisted Total
Fan- assisted Total
30,000 BTU
(8,790 kW)
40,000 BTU
(11,720 kW)
50,000 BTU
(14,650 kW)
50,000 BTU
(14,650 kW)
75,000
(21,975 kW)
100,000 BTU
(29,300 kW)
125,000 BTU
(36,625 kW)
ACH
3
ft3 (m )
0.60
0.50
0.40
0.30
0.20
0.10
0.00
1,050 (29.7)
1,260 (35.3)
1,575 (44.1)
2,100 (58.8)
3,150 (88.2)
6,300 (176.4)
NP
1,400 (39.2)
1,680 (47.04)
2,100 (58.8)
2,800 (78.4)
4,200 (117.6)
8,400 (235.2)
NP
1,750 (49)
2,100 (58.8)
2,625 (73.5)
3,500 (98)
5,250 (147)
10,500 (294)
NP
1,250 (35)
1,500 (42)
1,875 (52.5)
2,500 (70)
3,750 (105)
7,500 (210)
NP
1,875 (52.5)
2,250 (63)
2,813 (78.8)
3,750 (105)
5,625 (157.5)
11,250 (315)
NP
2,500 (70)
3,000 (84)
3,750 (105)
5,000 (140)
7,500 (210)
15,000 (420)
NP
3,125 (87.5)
3,750 (105)
4,688 (131.3)
6,250 (175)
9,375 (262.5)
18,750 (525)
NP
ACH = Air Changes per Hour
NP = Not Permitted
Tab le 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-
lowing equation:
I other
21 ft3
(
Required Volume
)
²
other
1000 Btu / hr
ACH
10
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2. For fan--assisted appliances (such as this furnace), calcu-
using the methods described in section titled Outdoor
Combustion Air Method:
late using the following equation:
S Unusually tight construction is defined as Construction with:
I fan
15 ft3
ACH
1. Walls and ceilings exposed to the outdoors have a continu-
ous, sealed vapor barrier. Openings are gasketed or sealed
and
(
)
Required Volume
²
fan
1000 Btu / hr
where:
2. Doors and openable windows are weather stripped and
I
= all appliances other than fan--assisted input in Btu
other
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.
per hour
I
=
fan--assisted appliance input in Btu per hour
fan
ACH =air change per hour (percent of volume of space exchanged
per hour, expressed as a decimal)
Ventilation Air
3. For purposes of this calculation, an infiltration rate greater
than 0.60 ACH shall not be used in the equations above.
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.
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
S Adjoining rooms can be considered part of a space, if there are
no closeable doors between rooms.
S Combining spaces on the same story. Each opening shall have a
2
minimum free area of at least 1 in. /1,000 BTUH (2,200
Venting and Combustion Air Check
2
mm /kW) of the total input rating of all appliances in the space
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.
2
2
but not less than 100 in. (0.06 m ). 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).
S Combining 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
2
Vent Pipe
Draft Hood
doors or floors having a total minimum free area of 2 in. /1,000
2
BTUH (4,400 mm /kW) of total input rating of all appliances.
Typical Gas
Water Heater
S An 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
Match
A07688
Fig. 7 -- Vent Check
2
of free area per 4,000 BTUH (550 mm /kW) of total input rating
for all gas appliances in the space.
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.
S In 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
11
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VENT AND COMBUSTION AIR
PIPING
!
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:
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
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:
Use methods described here to provide combustion and
ventilation air.
1. Seal any unused openings in the venting system.
Dual Certified
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.
Direct or Non-Direct 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.
4. Close fireplace dampers.
Contaminated Combustion Air
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.
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.
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.
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.
For Two Pipe Installation (Direct Vent)
S Solvent cements and glues.
S Antistatic fabric softeners for clothes dryers.
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.
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
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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.
Applicable ASTM Standards for Vent Materials
Cell
Core
Pipe
Materi-
als
Sch. 40
Pipe
SDR
Pipe
Solv.
Fittings
Primer
-- --
Cement
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.
D2468
&
D2661
ABS
D1527
__
F628
F891
D2235
D2564
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).
D2466
&
D2665
PVC
D1785 D2241
F656
CPVC
F441
-- --
F442
-- --
-- --
-- --
F438
-- --
-- --
-- --
F493
15. The vent outlet MUST be installed to terminate in the same
atmospheric pressure zone as the combustion air inlet.
ABS to
PVC
D3138
16. The vent system can be installed in an existing unused
chimney provided that:
S Both the exhaust vent and air intake run the length of the
(2.) Only use solvent cements that are marked for use
with the specific venting material.
chimney.
(3.) ABS to PVC transition joints REQUIRE a special
solvent cement that meets the requirements of
ASTM D3138.
S No other gas fired appliance or fireplace (solid fuel) is vented
into the chimney.
S The top of the chimney MUST be sealed flush or crowned up to
seal against rain or melting snow so ONLY the piping protrudes.
S The termination clearances shown in Fig. 8 are maintained.
(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.
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.
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.
Combustion Air and Vent Piping Insulation
Guidelines
2. Determine the size required for the vent pipe and air inlet
pipe.
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.
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).
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.
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
3. Insulate combustion air inlet piping when run in warm,
humid spaces.
1
MUST slope upwards. A minimum of / ″ (6.4mm) per foot
4
(304.8mm) of run is required to properly return condensate
to the furnace drain system.
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.
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.
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.
11. All vertical pipe runs MUST be supported every six feet
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.
(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
13
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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.
Pipe Diameter Table
Single Piping ONLY
40,000, 50,000, 60,000 & 75,000 Btuh Furnaces
Table 3
40′ (12.2m) & (5) 90° elbows with 2″ (50.8mm) PVC pipe
* Feet (M) of pipe is whichever pipe run is the longest, either
inlet or outlet side.
80,000 & 100,000 Btuh Furnace
40′ (12.2m) & (5) 90° elbows with 3″ (76.2mm) PVC pipe
For venting table, see“Concentric Termination Kit” in
this manual.
125,000 Btuh Furnace
40′ (12.2m) & (5) 90° elbows with 3″ (76.2mm) PVC pipe
Vent Termination Clearances
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.
!
WARNING
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.
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.
NOTE: It is allowable to use larger diameter pipe and fitting than
shown in the tables but not smaller diameters than shown.
1. Determine termination locations based on clearances
specified in following steps and as shown in Fig. 8, 9, and
22 through 30.
Pipe Diameter Table
Table 4
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
For “Concentric Termination Kit” clearances, see Fig. 32, 33, 34,
35 and 36 in this manual.
80,000 & 100,000 Btuh Furnace
40′ (12.2m) & (5) 90° elbows with 3″ (76.2mm) PVC pipe
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.
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.
4. For Single Pipe installation refer to Fig. 9 for vent
termination clearances.
14
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V
V
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
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A08601
Fig. 9 -- Other than Direct Vent Termination Clearance
16
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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.
Condensate Drain Trap
This furnace removes both sensible and latent heat from the
products of combustion. Removal of the latent heat results in
condensation of the water vapor. The condensate is removed from
the furnace through the drains in the plastic transition and the vent
fitting. The drains connect to the factory installed internally
mounted condensate drain trap on the left or right side of the
furnace.
1. A condensate sump pump MUST be used if required by
local codes, or if no indoor floor drain is available. The
condensate pump must be approved for use with acidic
condensate.
The startup of a new furnace will involve a cycle or two of the
furnace to properly prime the condensate trap with water. Until the
trap is fully primed, some condensate will be pulled into the
combustion blower. The furnace may cycle on the pressure switch
connected to the plastic transition box due to condensate buildup.
After the trap is primed, the condensate will start draining from the
furnace. The combustion blower will clear out any remaining
condensate in the blower housing through the vent fitting
2. A plugged condensate drain line or a failed condensate
pump will allow condensate to spill. If the furnace is
installed where a condensate spill could cause damage, it is
recommended that an auxiliary safety switch be installed to
prevent operation of the equipment in the event of pump
failure or plugged drain line. If used, an auxiliary safety
switch should be installed in the R circuit (low voltage)
ONLY.
3. If the auxiliary switch in the condensate pump is used, the
furnace may shut down due to a blocked condensate line or
failed pump. To prevent frozen water pipes see the “Frozen
Water Pipe Hazard” section of this manual.
downstream of the blower. Note that the condensate trap can also be
1
primed by pouring water into the / ″ (12.7mm) drain hose.
2
1
Remove the / ″ (12.7mm) ID drain hose from either the gutter or
2
the white PVC tee trap. Using a funnel pour eight (8) ounces (30
1
ml) of water into / ″ (12.7mm) ID drain hose. Water will flow
2
through the drain hose and into the condensate drain trap. This will
prime both the vent and the transition sides of the trap. Reconnect
!
CAUTION
1
the / ″ (12.7mm) ID drain hose to the original component, either
2
the gutter or the PVC tee trap.
FROZEN AND BURST WATER PIPE HAZARD
The condensate drain trap supplied with the furnace MUST be
used. The drain connection on the condensate drain trap is sized for
Failure to follow this caution may result in property damage.
3
1
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.
/ ″ (19.1mm) PVC or CPVC pipe, however alternate / ″
4
2
5
(12.7mm) CPVC [nominal / ″ (15.9mm) O.D.] or vinyl tubing
with a minimum inner diameter (I.D.) of / ″ (15.9mm) may also be
8
5
8
used, as allowed by local codes. Alternate drain pipes and hoses
may be used as allowed by local codes.
1
The drain line must maintain a / ″ (6.4mm) per foot (304.8mm)
4
1
downward slope toward the drain. / ″ (6.4mm) per foot
4
Condensate Drain Trap Freeze Protection
(304.8mm) is recommended. Installation of an overflow line is
1
recommended when the / ″ (6.4mm) per foot (304.8mm) slope to
4
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 the furnace environment has the
potential of freezing, the drain trap and drain line must be protected.
Use 3 to 6 watt per foot at 115 volt, 40° F (4°C) self--regulating
shielded and waterproof heat tape. 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.
the condensate drain cannot be maintained. A drain tube clip is
included in the furnace to prevent kinking/buckling of the drain
tube. The clip should remain in the furnace (between the door
switch plate and the blower shelf, Fig. 10) during operation. See
Fig. 20 for proper routing and installation of the overflow.
Drain Tube
Clip
Blower
Door
Shelf
Switch
Representative drawing only, some models may vary in appearance.
A07705
Fig. 10 -- Drain Tube Clip Location
17
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On Some Models
ONLY
Plastic Caps (2)
Yellow or black
Coupling & Clamps
(Optional)
Vent Drain
& Clamps
V
E
N
T
Single Pressure Switch
Relief Tube
ON
OFF
Dual Pressure Switch Detail
3
Black Rubber /
(4.8mm) ID
″
16
Drain Tee
Drain Tube
Black Rubber
1
/ ″ (12.7mm) ID &
2
Clamps
Drain Tube
Street Elbow
1
Corrugated
/ ″ (12.7mm) CPVC
2
5
/ ″ (15.9mm) ID &
8
(Loose parts bag)
Clamps
Drain Connector Black PVC
3
1
/ ″ (18.1mm) PVC X / ″
4
2
(12.7mm) CPVC (Loose
parts bag)
Casing Grommet
Black Rubber
″ (15.9mm) ID
(Loose parts bag)
3
Drain Line Vent Tee / ″
4
5
Drain Tube Black Rubber / ″ (15.9mm) ID &
8
1
(18.1mm) PVC or / ″ (12.7mm)
CPVC (Field supplied)
2
Clamps, Cut length to fit (Loose parts bag)
2 5 -- 2 4 -- 6 7
Representative drawing only, some models may vary in appearance.
A07706
Fig. 11 -- Upflow Installations Top Vent
Upflow Installations Top Vent (See Fig. 11)
Remove knockout from the side of the furnace casing where drain
Glue the CPVC street elbow to the trap using appropriate cleaner
and solvent cement.
tube will exit.
5
3
1
Install casing grommet [black rubber / ″ (15.9mm) ID grommet --
The field supplied / ″ (18.1mm) PVC or / ″ (12.7mm) CPVC
8
4
2
in loose parts bag].
drain line vent tee must vent outside the furnace cabinet (see
exploded view above).
1
Install the / ″ (12.7mm) CPVC street elbow on discharge of trap
2
3
1
Note: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Trap
must be primed before operation. Verify all condensate drain
connections are securely clamped. A coupling and clamps (in loose
part bag) may be installed as shown for future servicing of the vent
system.
Install the black PVC tube connector [ / ″ (18.1mm) PVC x / ″
(12.7mm) CPVC from loose parts bag] as shown in the illustration
above.
4
2
5
Cut the black drain tube [ / ″ (15.9mm) ID -- in loose parts bag] to
length to fit between trap and tube connector through grommet.
Clamp both ends of the drain tube using clamps provided.
8
NOTE: “PVC” is used as a generic term. Pipe and fitting materials used must be acceptable to the local code officials hav-
ing jurisdiction.
18
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Plastic Cap
Yellow or black
On Some Models
ONLY
2″ (50.8mm) PVC
Coupling
Coupling & Clamps
(Optional)
Vent Drain
& Clamps
Either: The PVC
Drain Tee or a field
supplied 2″
V
E
N
T
Single Pressure Switch
ON
(50.8mm) PVC Tee
OFF
Dual Pressure Switch Detail
Relief Tube
Black Rubber /
(4.8mm) ID
3
″
16
Tee Trap White PVC
(loose parts bag)
Drain Tube
Black Rubber
1
/ ″ (12.7mm) ID
2
Drain Tube
& Clamps
Corrugated
5
/ ″ (15.9mm) ID
8
& Clamps
Drain Connector Black PVC
/ ″ (19.1mm) PVC X / ″
3
1
4
2
SIDE VIEW
(12.7mm) CPVC
(Loose parts bag)
Rotate downward
5° to 10°
Casing Grommet
Black Rubber
5
/ ″ (15.9mm) ID
8
(Loose parts bag)
NOTE: Built--in channel will
be angled 5° to 10° also.
3
1
Drain Line Vent Tee / ″ (18.1mm) PVC or / ″
4
2
(12.7mm) CPVC (Field supplied)
2 5 -- 2 4 -- 6 7 a
Representative drawing only, some models may vary in appearance.
A07707
Fig. 12 -- Upflow Installations Vent through Left Side
Upflow Installations Vent through Left--Side (See Fig. 12)
5
Remove drain tee from inducer discharge and remove black drain
Cut the black drain tube [ / ″ (15.9mm) ID -- in loose parts bag] to
8
1
tube / ″ (12.7mm) ID from bottom of drain tee.
length to fit between trap and tube connector through grommet.
2
Install Vent Pipe grommet in side of casing.
Clamp both ends of the drain tube using clamps provided.
Cut an appropriate length of 2″ (50.8mm) PVC pipe long enough
to exit the cabinet and connect the vent drain to either:
Glue the CPVC street elbow to the trap using appropriate cleaner
and solvent cement.
S A 2″ (50.8mm) PVC coupling fastened onto the drain tee
Connect the tee trap and the main drain line exiting the casing as
shown in Fig. 12
Install tee trap into bottom of tee.
Note: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the internal trap and the external tee trap must be primed
before operation. Verify all condensate drain connections are
securely clamped. A coupling and clamps (in loose part bag) may
be installed as shown for future servicing of the vent system.
Remove knockout from the side of the furnace casing where drain
tube will exit.
1
Install the / ″ (12.7mm) CPVC street elbow on discharge of trap
2
3
1
Install the black PVC drain connector [ / ″ (19.1mm) PVC x / ″
4
2
CPVC from loose parts bag] as shown in the illustration above.
19
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Plastic Cap
Yellow or black
On Some Models
ONLY
Dual Pressure Switch
Either: The PVC Drain
Tee or a field supplied
2″ (50.8mm) PVC Tee
Vent Drain
& Clamps
Relief Tube
Black Rubber
3
/ ″ ⟨4.8mm) ID
16
V
E
N
T
Single Pressure Switch Details
ON
OFF
2″ (50.8mm)
PVC
Coupling
Drain Tube
Corrugated
5
/ ″ (15.9mm) ID &
8
Tee Trap White PVC
(loose parts bag)
Clamps
Elbow Tubes (2) Black Rubber
1
/ ″ (12.7mm) ID & Clamps
2
(loose parts bag)
1
3
Barbed Coupling, / ″ (12.7mm) OD
2
Drain Line Vent Tee / ″
4
1
(loose parts bag)
(18.1mm) PVC or / ″
2
(12.7mm) CPVC (Field sup-
plied)
SIDE VIEW
Rotate
downward
5° to 10°
Drain Connector Black PVC
3
1
/ ″ (19.1mm) PVC X / ″
4
2
(12.7mm) CPVC
(Loose parts bag)
Casing Grommet
NOTE: Built--in channel will
be angled 5° to 10° also.
5
Black Rubber / ″ (15.9mm) CPVC
8
2 5 -- 2 4 -- 6 8
(Loose parts bag)
A07708
Fig. 13 -- All Models Vent Through Right Side
All Models Vent through Right--Side (See Fig. 13)
Disconnect the black drain tube between the drain vent and the trap.
1
Install the / ″ (12.7mm) CPVC street elbow on discharge of trap.
2
3
1
Rotate the inducer 180° for a right side vent after loosening the four
(4) inducer attachment screws. Reinstall and retighten the inducer
screws to 20 in. lb. (2.3Nm) torque.
Install the black PVC tube connector [ / ″ (19.1mm) PVC x / ″
4
2
(12.7mm) CPVC from loose parts bag] as shown in the illustration
above.
1
5
Using the / ″ (12.7mm) OD barbed coupling in the loose parts bag
Cut the black drain tube [ / ″ (15.9mm) ID -- in loose parts bag] to
length to fit between trap and tube connector through grommet.
2
8
1
connect together with the two short / ″ (12.7mm) ID elbow tubes
2
and connect the lower discharge port of the vent drain to the trap.
Secure all connections with clamps.
Clamp both ends of the drain tube using clamps provided.
Glue the CPVC street elbow to the trap using appropriate cleaner
and solvent cement.
Install the vent pipe grommet into the casing
Cut an appropriate length of 2″ (50.8mm) PVC pipe long enough
to exit the cabinet and connect the vent drain to either:
S A 2″ (50.8mm) PVC coupling fastened onto the drain tee
Connect the tee trap and the main drain line exiting the casing as
shown in Fig. 13
NOTE: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the internal trap and the external tee trap must be primed
before operation. Verify all condensate drain connections are
securely clamped. A coupling and clamps (in loose part bag) may
be installed as shown for future servicing of the vent system.
Install tee trap into bottom section of tee.
Remove knockout from the side of the furnace casing where drain
tube will exit.
5
Install casing grommet black rubber [ / ″ (15.9mm) ID grommet --
8
in loose parts bag]
20
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SIDE VIEW
Plastic Cap
Yellow or black
Rotate downward
5° to 10°
Coupling & Clamps
(Optional)
2″ (51 mm) PVC Coupling
NOTE: Built--in channel will
be angled 5° to 10° also.
Vent Drain
& Clamps
Either: The PVC
Drain Tee or a field
supplied 2″ (51 mm)
PVC Tee
Relief Tube
3
Dual Pressure Switch
Black Rubber / ″ (5 mm) ID
16
Single Pressure Switch Detail
On Some Models
ONLY
INLET
Drain Tube
Flexible Tubing Connector,
3
Tee Trap White PVC
(loose parts bag)
Black Rubber
/
16
″ (5 mm) OD (loose parts bag)
1
/ ″ ID (13 mm) & Clamps
2
Elbow Tube Black Rubber
Relief Tube,
1
/ ″ ID (13 mm) & Clamps
2
Extension Black Rubber,
(Loose Parts Bag)
3
/ ″ (5 mm) ID Cut to fit
16
F
O F
(loose parts bag)
WARNING
O N
Move Caps to
top of trap
Trap Connection
“Clamp ears”
Pointed OUT
5
Drain Tube Black, / ″ (16 mm) ID Corrugated
8
Cut at straight section
1
Barbed Coupling / ″ (13 mm) OD
2
(loose parts bag)
Preassemble &
insert into furnace
Cut Here
Leave room for clamp
25--24--69
A07767
Fig. 14 -- Downflow Left--Side Vent and Trap
Downflow Left--Side Vent and Trap (See Fig. 14).
Remove the inducer mounting screws, rotate the inducer 180° and
retighten the inducer screws to 20″ pounds torque.
Disconnect the hoses from the trap assembly, and remove trap and
trap mounting bracket from the blower compartment. Using cover
plate and gasket provided in the loose parts bag, cover the hole
from the burner compartment to the blower compartment and
secure with screws.
some cases, additional hose length will be needed. Use the clear
3
plastic / ″ (4.8mm) OD flexible tubing connector and a suitable
16
3
length of extra / ″ (4.8mm) ID hose to make this connection.
16
Install the vent pipe grommet into the casing
Cut an appropriate length of 2″ (50.8mm) PVC pipe long , enough
to exit the cabinet and connect the vent drain to either:
S A 2″ (50.8mm) PVC coupling fastened onto the drain tee
Move the caps to the top of the trap and mount the trap externally
to the left side of the unit using the two(2) screws provided.
Install tee trap into bottom section of tee and glue pipe.
Remove knockout from the side of the furnace casing where drain
tube will exit.
Connect the tee trap and the main drain line exiting the casing as
shown in Fig. 14.
5
Cut the / ″ (15.9mm) ID corrugated hose as shown above and
8
fasten the 90° bend end to the trap and fasten the straight end to the
transition drain. Secure both connections with clamps.
1
Reconnect the / ″ (12.7mm) ID drain hose from the vent drain to
2
NOTE: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the external trap and the external tee trap must be primed
before operation. Verify all condensate drain connections are
securely clamped. A coupling and clamps (in loose part bag) may
be installed as shown for future servicing of the vent system.
the trap and secure with a clamp. In some cases, additional length
1
will be required for this hose. Use the Black plastic / ″ (12.7mm)
2
1
OD barbed coupling and a suitable section of / ″ (12.7mm) ID
2
hose to make the connection. Secure all connections with clamps
3
Connect the / ″ (4.8mm) ID relief tube from the small port on the
16
trap to the top port of the transition as shown in the picture. In
21
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Plastic Cap
Yellow or black
Trap Connection
“Clamp ears”
Pointed OUT
Elbow Tube Black Rubber
Vent Drain
& Clamps
1
/ ″ (13 mm) ID & Clamps
Relief Tube
2
Preassemble &
insert into furnace
(Loose Parts Bag)
Black Rubber
3
SIDE VIEW
/ ″ (5 mm) ID
16
Coupling & Clamps
(Optional)
Barbed Coupling
1
Rotate downward
5° to 10°
/ ″ (13 mm) OD
2
(Loose Parts Bag)
Drain Hose
Black Rubber
1
/ ″ (13 mm) ID Cut to
2
Dual Pressure Switch
Fit & Clamps
NOTE: Built--in channel will
be angled 5° to 10° also.
On Some
Models
ONLY
2″ (51 mm) PVC Coupling
Either: The PVC
Single Pressure Switch Detail
Drain Tee or a field
supplied 2″ (51 mm) PVC Tee
Tee Trap White PVC
(loose parts bag)
Drain Tube Corrugated
5
Black, / ″ (16 mm)
Drain Connector Black
3
8
F
O F
ID & Clamps
PVC / ″
(19 mm)
4
WARNING
Move Caps to
top of trap
1
O N
PVC X / ″
(13 mm)″
2
CPVC (Loose parts bag)
Drain Tube Black Rubber,
5
/ ″ ID (16 mm) Cut to fit & Clamps
8
(loose parts bag)
A07768
Fig. 15 -- Downflow Right--Side Vent and Trap
Downflow Right--Side Vent and Trap (See Fig. 15)
Remove the drain tee if installed.
Install the vent pipe grommet into the casing
Disconnect the hoses from the trap assembly, and remove trap and
trap mounting bracket from the blower compartment. Using cover
plate and gasket provided in the loose parts bag, cover the hole
from the burner compartment to the blower compartment and
secure with screws.
Cut an appropriate length of 2″ (50.8mm) PVC pipe long , enough
to exit the cabinet and connect the vent drain to either:
S A 2″ (50.8mm) PVC coupling fastened onto the drain tee
Install tee trap into bottom section of tee and glue pipe.
Remove knockout from the side of the furnace casing where drain
tube will exit.
Move the caps to the top of the trap and mount the trap externally
to the right side of the unit using the two(2) screws provided.
Connect the tee trap and the main drain line exiting the casing as
shown in Fig. 15.
Connect the corrugated drain tube from the transition box to the
trap as shown. If an extension is required, use the black PVC tube
NOTE: Note: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the external trap and the external tee trap must be primed
before operation. Verify all condensate drain connections are
securely clamped. A coupling and clamps (in loose part bag) may
be installed as shown for future servicing of the vent system.
5
connector and the black / ″ (15.9mm) ID drain tube in the loose
8
parts bag. Cut tube to length. Secure all connections with clamps.
Connect the drain hose from the Vent Drain to the trap. If an
1
extension is required, use the black / ″ (12.7mm) OD barbed
2
1
coupling, connect a black / ″ (12.7mm) ID elbow tube and a
2
1
suitable section of a / ″ (12.7mm) ID drain tube to make
2
connection from the vent drain to the trap. Secure all connections
with clamps.
22
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Single Pressure Switch Detail
Vent Drain
& Clamps
Plastic Caps
Yellow or black
Trap Connection
“Clamp ears”
Pointed OUT
W
O
L F
A I R
Preassemble &
insert into furnace
Alternate Orientation
Relief Tube Black Rubber
3
/ ″ (4.8mm) ID
16
Dual Pressure Switch
Flexible tubing connector
3
/
″ (4.8mm) OD (Loose
16
Parts Bag)
Relief Tube Extension
3
Black Rubber
/
″ (4.8mm) ID
16
W O F L R A I
Cut to Fit (Loose Parts Bag)
Drain Tube Corrugated
5
/ ″ (15.9mm) ID & Clamps
8
Remove KO before
mounting Trap
Cut at straight section
Drain Tube
Field
Supplied Tee
Black Rubber
Coupling & Clamps
(Optional)
1
/ ″ (12.7mm) ID
2
& Clamps
Tee Trap White PVC
(loose parts bag)
Cap and Clamp
Open End
Leave room for clamp
Cut Here
2 5 -- 2 4 -- 7 0
Representative drawing only, some models may vary in appearance.
A07709
Fig. 16 -- Horizontal Left through Top
Horizontal Left through Top (See Fig. 16)
Disconnect the hoses from the trap assembly, and remove trap and
trap mounting bracket from the blower compartment. Using cover
plate and gasket provided in the loose parts bag, cover the hole
from the burner compartment to the blower compartment and
secure with screws.
3
Connect the / ″ (4.8mm) ID relief tube to the middle port on the
16
3
trap. If an extension is required, use the / ″ (4.8mm) OD flexible
tubing connector and the black / ″ (4.8mm) ID relief tube in the
loose parts bag. Cut tube to length. Secure all connections with
clamps.
16
3
16
Remove knockout from the side of the furnace casing where drain
tube will exit.
Cut an appropriate length of 2″ (50.8mm) PVC pipe, long enough
to exit the cabinet and connect the vent drain to either:
S A 2″ (50.8mm) PVC coupling fastened onto the drain tee
Mount the trap externally to the bottom side of the unit using the
two screws provided in the location shown.
Install tee trap into bottom section of tee and glue pipe.
Cut the corrugated tube as shown in the illustration above. Connect
the corrugated hose from the transition to the trap. Secure
connections with clamps.
Connect the tee trap and the main drain line exiting the casing as
shown in Fig. 16.
NOTE: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the external trap and the external tee trap must be primed
before operation. Verify all condensate drain connections are
securely clamped. A coupling and clamps (in loose part bag) may
be installed as shown for future servicing of the vent system.
1
Remove the black / ″ (12.7mm) ID drain tube from the drain tee.
2
Install a yellow cap and clamp over the open drain port of the drain
tee.
1
Connect the black / ″ (12.7mm) ID drain tube from the Vent Drain
2
to the trap. Secure connections with clamps.
23
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Single Pressure Switch Detail
Alternate Orientation
Yellow or black
Plastic Cap
Field
Supplied Tee
Level or Sloped towards Tee
Dual Pressure Switch
Vent Drain
& Clamps
Relief Tube Black Rub-
3
ber
/
16
″ (4.8mm) ID
1
Elbow Tube Black Rubber / ″ (12.7mm)
2
AIR FLOW
ID & Clamps (Loose Parts Bag)
1
Barbed Coupling / ″ (12.7mm) OD
2
(Loose Parts Bag)
Tee Trap White PVC
(loose parts bag)
Drain Tube Black Rubber
1
/ ″ (12.7mm) ID & Clamps
2
On Some
Models ONLY
Drain Tube Corrugated
5
/ ″ (15.9mm) ID & Clamps
8
3
Flexible Tube Connector
/
16
″
(4.8mm) OD (Loose Parts Bag)
Cut at straight section
Relief Tubing Extension
3
Black Rubber
/
16
″ (4.8mm) ID
WARNING
Move Caps to
top of trap
Cut to Fit (Loose Parts Bag)
Leave room for clamp
Cut Here
25--24--70a
Representative drawing only, some models may vary in appearance.
A07710
Fig. 17 -- Horizontal Left--Side Vent
Horizontal Left--Side Vent (See Fig. 17)
3
Remove the drain tee from the Vent Drain if installed.
Connect the / ″ (4.8mm) ID relief tube to the middle port on the
16
3
trap. If an extension is required, use the / ″ (4.8mm) OD flexible
tubing connector and the black / ″ (4.8mm) ID relief tube in the
loose parts bag. Cut tube to length.
16
Rotate the inducer 180° for a side vent after loosening the 4 inducer
attachment screws. Reinstall and retighten the inducer screws to 20
in. lbs. (2.3 Nm) torque.
3
16
Cut an appropriate length of 2″ (50.8mm) PVC pipe, fittings and
extension pipe long enough to exit the cabinet and connect the vent
drain to either:
Disconnect the hoses from the trap assembly, and remove trap and
trap mounting bracket from the blower compartment. Using cover
plate and gasket provided in the loose parts bag, cover the hole
from the burner compartment to the blower compartment and
secure with screws.
S A 2″ (50.8mm) PVC coupling fastened onto the drain tee
Install tee trap into bottom section of tee and glue pipe.
Remove knockout from the side of the furnace casing where drain
tube will exit.
Important: The pipe to the tee trap must be level or sloping towards
the tee trap
Mount the trap externally to the bottom side of the unit using the
two screws provided in the location shown.
Connect the tee trap and the main drain line exiting the casing as
shown in Fig. 17.
Cut the corrugated tube as shown in the illustration above. Connect
the corrugated hose from the transition to the trap. Secure
connections with clamps.
NOTE: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the external trap and the external tee trap must be primed before
operation. Verify all condensate drain connections are securely
clamped. A coupling and clamps (in loose part bag) may be
installed as shown for future servicing of the vent system.
1
Connect the black / ″ (12.7mm) ID drain tube from the Vent Drain
2
1
to the trap. If an extension is required, use the black / ″ (12.7mm)
OD flexible tubing connector and the black / ″ (12.7mm) ID drain
2
1
2
tube in the loose parts bag. Cut tube to length. Secure connections
with clamps.
24
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Alternate Orientation
Single Pressure Switch Detail
Trap Connection
“Clamp ears”
Pointed OUT
3
/
″ (4.8mm) ID Rub-
16
ber Tube
Plastic Cap
Yellow or black
AIRFLOW
Coupling & Clamps
(Optional)
Preassemble &
insert into furnace
Drain Tube Black
1
Vent Drain
& Clamps
Rubber / ″ (12.7mm)
2
ID & Clamps
Field
Supplied Tee
WARNING
Add Cap and Clamp
Relief Tube Black Rub-
3
ber / ″ (4.8mm) ID
16
Flexible Tubing Connector
3
/
″ (4.8mm) OD (Loose
16
Parts Bag)
Tee Trap White PVC
(loose parts bag)
Relief Tube Extension
3
Black Rubber / ″ (4.8mm) ID
16
INLET
Cut to Fit (Loose Parts Bag)
On Some Models
ONLY
Dual Pressure Switch
1
Barbed Coupling / ″ (12.7mm)
2
OD (Loose Parts Bag)
5
Drain Tube Corrugated / ″ (15.9mm) ID &
Clamps Cut at straight section
8
Drain Tube Black Rubber
1
/ ″ (12.7mm) ID & Clamps
2
Remove KO before
mounting Trap
Cut Here
Leave room for clamp
2 5 -- 2 4 -- 7 0 b
Representative drawing only, some models may vary in appearance.
A07711
Fig. 18 -- Horizontal Right through Top
Horizontal Right through Top (See Fig. 18)
3
Disconnect the hoses from the trap assembly, and remove trap and
trap mounting bracket from the blower compartment. Using cover
plate and gasket provided in the loose parts bag, cover the hole
from the burner compartment to the blower compartment and
secure with screws.
Connect the / ″ (4.8mm) ID relief tube to the middle port on the
16
3
trap. If an extension is required, use the clear
flexible tubing connector and the black / ″ (4.8mm) ID relief tube
in the loose parts bag. Cut tube to length.
Cut an appropriate length of 2″ (50.8mm) PVC pipe, fittings and
extension pipe long enough to exit the cabinet and connect the vent
drain to a standard field supplied 2″ (50.8mm) PVC tee
/
16
″ (4.8mm) OD
3
16
Remove knockout from the side of the furnace casing where drain
tube will exit.
S A 2″ (50.8mm) PVC coupling fastened onto the drain tee
Mount the trap externally to the bottom side of the unit using the
two(2) screws provided in the location shown.
Install tee trap into bottom section of tee and glue pipe.
Cut the corrugated tube as shown in the illustration above. Connect
the corrugated hose from the transition to the trap. Secure
connections with clamps.
Connect the tee trap and the main drain line exiting the casing as
shown in Fig. 18.
NOTE: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the external trap and the external tee trap must be primed
before operation. Verify all condensate drain connections are
securely clamped. A coupling and clamps (in loose part bag) may
be installed as shown for future servicing of the vent system.
1
Connect the black / ″ (12.7mm) ID drain tube from the Vent Drain
2
1
to the trap. If an extension is required, use the black / ″ (12.7mm)
2
1
OD barbed coupling and the black / ″ (12.7mm) ID drain tube in
2
the loose parts bag. Cut tube to length. Secure connections with
clamps.
25
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Plastic Cap
Yellow or black
Coupling & Clamps
(Optional)
Single Pressure Switch Detail
AIR FLOW
Field
Supplied Tee
Vent Drain
& Clamps
Level or Sloped
towards Tee
Tee Trap
White PVC
(loose parts bag)
Elbow Tube Black Rubber
Relief Tube
Black Rubber
(4.8mm) ID
1
/ ″ (12.7mm) ID & Clamps
3
2
/ ″
16
(Loose Parts Bag)
On Some Models
ONLY
3
Flexible Tubing Connector /
″
16
INLET
(4.8mm) OD (Loose Parts Bag)
Relief Tube Extension
3
Alternate Orientation
Black Rubber / ″ (4.8mm) ID
16
Cut to Fit (Loose Parts Bag)
Remove KO before
mounting Trap
Dual Pressure Switch
5
Drain Tube Black, / ″ (15.9mm) ID & Clamps
8
Drain Tube
1
Corrugated Cut at straight section
Barbed Coupling / ″ (12.7mm)
2
Black Rubber
OD (Loose Parts Bag)
1
/ ″ (12.7mm) ID
2
& Clamps
Leave room for clamp
2 5 -- 2 4 -- 7 0 c
Cut Here
Representative drawing only, some models may vary in appearance.
A07712
Fig. 19 -- Horizontal Right Side Vent
Horizontal Right -Side Vent (See Fig. 19)
Disconnect drain tee if installed
Cut an appropriate length of 2″ (50.8mm) PVC pipe, fittings and
extension pipe long enough to exit the cabinet and connect the vent
drain to either:
Disconnect the hoses from the trap assembly, and remove trap and
trap mounting bracket from the blower compartment. Using cover
plate and gasket provided in the loose parts bag, cover the hole
from the burner compartment to the blower compartment and
secure with screws.
S A 2″ (50.8mm) PVC coupling fastened onto the drain tee
Install tee trap into bottom section of tee and glue pipe.
Important: The pipe to the tee trap must be level or sloping towards
the tee trap
Remove knockout from the side of the furnace casing where drain
tube will exit.
Connect the tee trap and the main drain line exiting the casing as
shown in Fig. 19.
Mount the trap externally to the bottom side of the unit using the
two(2) screws provided in the location shown.
Cut the corrugated tube as shown in the illustration above. Connect
the corrugated hose from the transition to the trap. Secure
connections with clamps.
NOTE: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the external trap and the external tee trap must be primed
before operation. Verify all condensate drain connections are
securely clamped. A coupling and clamps (in loose part bag) may
be installed as shown for future servicing of the vent system.
1
Connect the black / ″ (12.7mm) ID drain tube from the Vent Drain
2
1
to the trap. If an extension is required, use the / ″ (12.7mm) OD
2
1
barbed coupling and the black / ″ (12.7mm) ID drain tube in the
2
loose parts bag. Cut tube to length. Secure connections with
clamps.
3
Connect the / ″ (4.8mm) ID relief tube to the middle port on the
trap. If an extension is required, use the clear
splice connector and the black / ″ (4.8mm) ID relief tube in the
16
3
/
16
″ (4.8mm) OD
3
16
loose parts bag. Cut tube to length.
26
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Connecting Vent and Combustion Air Piping
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
V
E
N
T
ON
Cement or mechanically seal all joints, fittings, etc. to prevent
leakage of flue gasses.
Open Tee
OFF
Refer to Fig. 11 through Fig. 19 that corresponds to the installation
position of the furnace for the application.
Preassemble the vent and combustion air piping from the furnace to
the vent termination. Do not cement the pipe joints until the pipe
preassembly process is complete.
Tee Trap
Combustion Air Pipe Connection (Direct Vent)
Install the air intake coupling and gasket to the furnace with the
four(4) screws.
Evaporator
Coil
Drain Line
(Optional)
Note: The air intake coupling and gasket can be installed to the top
panel to the alternate air intake locations on either the left or right
side panels of the furnace.
For downflow installation, the air intake coupling and gasket must
be installed to the alternate air intake location on either the left or
right side panels. Remove the 3″ (76.2mm) hole plug from the
furnace accessory bag and relocate to the open hole in the furnace
Main
Drain
Line
panel. Use four screws to seal the four mounting holes in the top
7
panel next to the hole plug. Drill four / ″ (2.8mm) diameter holes
64
Condensate
Trap
in the casing using the air intake coupling as the template.
The air intake coupling is sized for 2″ (50.8mm) PVC pipe.
Representative drawing only, some models may vary in appearance.
Install the combustion air pipe to the air intake coupling using RTV
sealant to provide for future serviceability.
A07713
Fig. 20 -- Connecting Tee Trap to Condensate Trap and Main
Drain Line
Vent Pipe Connection
Install the vent pipe grommet to the furnace panel. Locate the
grommet in the furnace panel at a location directly away from the
vent fitting on the combustion blower. The grommet snaps into the
3″ (76.2mm) hole from the furnace panel. NOTE: Depending on
the installation position, the vent pipe grommet will be installed to
the top panel or to the alternate location on the side panels. If
needed, remove the 3″ (76.2mm) hole plug from the loose parts bag
and install it in the open hole in the furnace panel. (See Fig. 11 or
Fig. 20)
The tee trap must be connected to the main condensate drain line as
conceptually shown above. Different installations may require
slightly different orientations. The following steps apply to all
installations.
1. The tee trap should be installed as close to the side or top of
the furnace as practical. Minimize the distance between the
inducer and the tee trap as much as possible.
2. An open tee is to be used at the tee trap discharge. The top
end of the tee should be open to the atmosphere to eliminate
potential air lock problems.
3. The drain line from the tee trap is to be connected to the
furnace condensate trap drain line as shown above.
Install the vent pipe to the rubber coupling, the vent fitting or the
PVC vent extension pipe. Securely attach using the clamp or PVC
cement as required.
NOTE: The vent fitting MUST be installed with the air flow
marking arrow pointed toward the vent pipe. (See Fig. 21).
Some installations require the vent fitting to be installed with a
5° to 10° downward slope. (See Fig. 11 thru Fig. 20)
4. Condensate drain lines from a cooling coil may be
connected downstream of the connection point of the tee
trap and furnace condensate trap.
Important: Prime both traps with water before operation.
Failure to prime the traps may result in discharge of flue gases from
the condensate drain line and open tee for a period of time, and may
result in temporary lockout of the furnace upon start up. Main drain
line construction is left to the discretion of the installer. It may be
made of either ridged pipe or flexible tube. Tube ID should NOT
1
be less than / (12.7mm).
2
″
27
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Connecting Vent Pipes and Termination
Vent Pipe
(Top Panel Exit)
Rubber Coupling
& Clamps
NOTE: Combustion air intake and vent MUST terminate in the
same atmospheric pressure zone. If installation is in a cold climate
(sustained temperatures 0°F (--17°C) and below for 24 or more
consecutive hours), increase the minimum distance between vent
pipe and air intake from 8″ (203.2mm) to 18″(457.2mm).
NOTE: The 90° elbow is approved
for use inside the furnace ONLY.
Vent Pipe
Vent Fitting
& Clamps
90° Elbow
!
WARNING
Combustion
Blower
CARBON MONOXIDE POISONING HAZARD
Failure to properly vent this furnace could result in personal
injury or death.
Maintain a minimum of 36″ (914.4mm) between
combustion air inlet and clothes dryer vent. Terminate
the combustion air intake as far as possible from any
air conditioner, heat pump, swimming pool,
swimming pool pumping, chlorinator or filtration unit.
Vent Extension
Pipe (Side Panel
Exit)
SIDE VIEW
Rotate downward
5° to 10°
Tee
1. Install all couplings, nipples and elbows using proper
procedures for Joining Pipe and Fittings and maintain
spacing between vent and combustion air piping as indicated
in Fig. 22through 30.
NOTE: Built--in channel will be angled 5° to 10° also.
A07714
Fig. 21 -- Proper Sealing Procedure for Combustion Blower
8” (203.2mm)* MIN.
20’ (6.1m) MAX
*18″ (457.2mm) Minimum for
cold climates [sustained 0_F
(-17_C) and below for 24 or
more consecutive hours]
Joining Pipe and Fittings
SEE VENT AND COMBUSTION AIR PIPING, Vent and
Combustion Air Piping Guidelines in this manual for applicable
ASTM Standards for vent materials.
8” (203.2mm) MIN.
!
WARNING
12 ” (304.8mm) MIN.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
GRADE LEVEL
OR
SNOW LEVEL
25--00--05F
Do NOT use solvent cement that has become curdled, lumpy
or thickened and do NOT thin. Observe precautions printed
on containers. For applications below 32_F (0_C), use only
low temperature type solvent cement. Poor joints may lead to
disconnected or leaking vent pipe joints allowing carbon
monoxide to enter the living space.
A07715
Fig. 22 -- Sidewall Termination 12” (304.8 mm) or More Above
Snow Level or Grade Level
Horizontal Termination
1
1. Cut two holes. 2 / ″ (63.5mm) for 2″ (50.mm) pipe, 3″
2
1. Cut pipe end square, remove ragged edges and burrs.
Chamfer end of pipe, then clean fitting, socket and pipe joint
of all dirt, grease, or moisture.
1
1
(76.2mm) for 2 / ″ (63.5mm) pipe, or 3 / ″ (88.9mm) for 3″
2
2
(76.2mm) pipe. Do NOT make the holes oversized, or it will
be necessary to add a sheet metal or plywood plate on the
outside with the correct size hole in it.
NOTE: Stir the solvent cement frequently while using. Use a
natural bristle brush or the dauber supplied with the cement. The
proper brush size is one inch.
2. Check hole sizes by making sure it is smaller than the
couplings or elbows that will be installed on the outside. The
couplings or elbows MUST prevent the pipe from being
pushed back through the wall.
2. After checking pipe and socket for proper fit, wipe socket
and pipe with cleaner-primer. Apply a liberal coat of primer
to inside surface of socket and outside of pipe. Do NOT
allow primer to dry before applying cement.
3. Apply a thin coat of cement evenly in the socket. Quickly
apply a heavy coat of cement to the pipe end and insert pipe
into fittings with a slight twisting movement until it bottoms
out.
3. Extend vent pipe and combustion air pipe through the wall
3
/ ″ (19.1mm) to 1″ (25.4mm) and seal area between pipe
4
and wall.
4. Install the couplings, nipple and termination elbows as
shown and maintain spacing between vent and combustion
air piping as indicated in Fig. 22 and Fig. 23.
NOTE: Cement MUST be fluid while inserting pipe. If NOT,
recoat pipe.
A metal shield is recommended 18″ x 18″ (457.2mm x 457.2mm)
min. or 18″ (457.2mm) min. diameter around the vent termination
at the exterior wall to protect the house exterior materials from flue
product or condensation (freezing) damage.
4. Hold the pipe in the fitting for 30 seconds to prevent the
tapered socket from pushing the pipe out of the fitting.
5. Wipe all excess cement from the joint with a rag. Allow 15
minutes before handling. Cure time varies according to fit,
temperature and humidity.
28
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Using Exterior Risers
OVERHANG
12″ (304.8mm) MIN.
1. Install elbows and pipe to form riser as shown in Fig. 23
EXHAUST
2. Secure vent pipe to wall with galvanized strap or other rust
resistant material to restrain pipe from moving.
3. Insulate pipe with Armaflex or equivalent moisture resistant
closed cell foam insulation or Fiberglass insulation if boxed
in and sealed against moisture.
90°
INLET
Vertical Termination
12″ (304.8mm) MIN. Ground
1. Fig. 25 shows the proper installation and clearances for
vertical vent termination. The vertical roof termination
should be sealed with a plumbing roof boot or equivalent
flashing. The inlet of the intake pipe and end of the exhaust
vent must be terminated no less than 12″ (307.8mm) above
the roof or snow accumulation level, and 12″ (307.8mm)
away from a vertical wall or other protrusion.
Level OR Snow Level
25-23-73
SIDE VIEW
FRONT VIEW
2. If the vent system is installed in an existing chimney make
sure clearances shown in Fig. 25 are maintained. Horizontal
section before the termination elbow can be extended on the
inlet air to provide necessary clearance.
12″ (304.8mm) MIN.
Vent Termination Shielding
Same Joist
Space
Under certain wind conditions some building materials may be
affected by flue products expelled in close proximity to unprotected
surfaces. Sealing or shielding of the exposed surfaces with a
corrosion resistant material (such as aluminum sheeting) may be
required to prevent staining or deterioration. The protective material
should be attached and sealed (if necessary) to the building before
attaching the vent terminal.
A07699
Fig. 24 -- Recommended Alternate Installation
for Sustained Cold Weather
(0_F (--17_C) & below for 24 or more consecutive hours)
Multi Vent Termination Clearances
When two (2) or more furnaces are vented near each other, each
furnace must be individually vented.
B
Two (2) vent terminations may be installed as shown in Fig. 26, 27,
28, 29, and 30 but the next vent termination must be at least 36″
(914.4mm) away from first two terminations. It is important that
vent terminations be made as shown to avoid recirculation of flue
gases.
A
*18″ (457.2mm) Minimum for
cold climates [sustained 0_F
(-17_C) and below for 24 or
more consecutive hours]
8” (203.2mm)* MIN.
20’ (6.1m) MAX
A
8” (203.2mm)
MIN.
2 5 -- 0 0 -- 0 6
A = 12″ (304.8mm) Above roof or snow accumulation level
B = 8″ (203.2mm) Min., 20′ (6.1m) Maximum, except in areas
with extreme cold temperatures [sustained 0°F(--17°C) and
below for 24 or more consecutive hours], the 18″ (457.2mm)
Min.
12 ” (304.8mm)
MIN.
A07717
Fig. 25 -- Rooftop Termination
GRADE LEVEL
OR
SNOW LEVEL
25--00--04F
A07716
Fig. 23 -- Sidewall Termination with Exterior Risers to Get
Above Snow Level or Grade Level
29
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2” (50.8mm) Max
36” Min
(914.4mm)
Exhaust
“A”
8″ Min.
Exhaust
“A”
Inlet
OR
36”Min
(914.4mm)
12″ (304.8mm)
Min. Grade or
Snow Level
8″ (457.2mm) Min.
20′ (6.1m) Max.
Combustion
Air
12″ (304.8mm) Min.
Grade or Snow Level
18″ (457.2mm) Min. for Cold Climates
[Sustained 0°F(-17°C) and below for
24 hours or more consecutive hours]
Dimension “A” is touching or 2″ (50.8mm) maximum separation.
A07718
A07696
Fig. 26 -- Concentric Vent and Combustion--Air
Roof Termination
Fig. 28 -- Sidewall Inlet Vent and Exhaust--Air Termination
8″ (203.2mm) Min.
8″ (203.2mm) Min.
20′ (6.1m) Max.
1″ (25.4mm)
Maximum
Combustion Air
Exhaust
12″ (457.2mm)
Min. Grade or
Snow Level
Vent
Inlet
“A”
“A”
18″ (457.2mm) Min. for Cold Climates
[Sustained 0°F(-17°C) and below for
24 hours or more consecutive hours]
Exhaust
Vent
2 5 -- 2 2 -- 0 2 d
“A”
Dimension “A” is touching or 2″ (50.8mm) maximum separation.
Dimension “A” is touching or 2″ (50.8mm) maximum separation.
A07695
A07697
Fig. 27 -- Concentric Vent and Combustion Air
Sidewall Termination
Fig. 29 -- Sidewall Inlet Vent and Exhaust--Air Termination
with Exterior Risers
8″ (203.2mm) Min.
20′ (6.1m) Max.
Inlet
12″ (304.8mm)
Min. Grade or
Snow Level
Exhaust
18″ (457.2mm) Min. for Cold Climates
[Sustained 0°F(-17°C) and below for
24 hours or more consecutive hours]
25--22--43
A07698
Fig. 30 -- Rooftop Inlet Vent and Exhaust--Air Termination
30
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2. Determine the best location for the termination kit. See Fig.
32 for vertical termination or Fig. 35 and 36 for horizontal
termination. Roof termination is preferred since it is less
susceptible to damage, has reduced intake contaminants and
less visible vent vapor. For side wall termination,
consideration should be given to: 1) possible damage from
the vapors to plants/shrubs, other equipment and building
materials, 2) possible damage to the terminal from foreign
objects, 3) wind effects that may cause recirculation of flue
products, debris or light snow and 4) visible vent vapor.
CONCENTRIC VENT
TERMINATION
Vent Termination Clearances
!
WARNING
CARBON MONOXIDE POISONING, FIRE AND
EXPLOSION HAZARD
Kit Contents:
Failure to follow this warning could result in personal injury,
death, or property damage.
3″ (76.2) Rain Cap or 2″ (50.8) Rain Cap
1
3″ (76.2) Diameter SDR--26 Pipe, 19 / ″ (495.3) Long or
2
4″ (101.6) Diameter SDR--26 Pipe, 24″ (609.6) Long,
Inlet and outlet pipes may NOT be vented directly above each
other (standard vent terminals).
5
2″ (50.8) Diameter SDR--26 Pipe, 31 / ″ (803.3) Long or
8
1
1
2 / ″ (63.5) Diameter SDR--26 Pipe, 37 / ″ (973) Long,
2
8
2″ (50.8) or 3″
(76.2) Dia.
Rain Cap
3″ (76.2) Y Concentric Fitting or 2″ (50.8) Y Concentric Fitting
Nominal 3″ (76.2) or 4″
(101.6) Dia. SDR--26 Pipe
1. Determine termination locations based on clearances
specified in following steps and as shown in Fig. 8, 31
through 36
2. The vent termination must be located at least 12″ (304.8mm)
above ground or normally expected snow accumulation
levels.
3. Do NOT terminate over public walkways. Avoid areas
where condensate may cause problems such as above
planters, patios, or adjacent to windows where steam may
cause fogging.
2″ (50.8) or 3″ (76.2) Dia.
1
2 (50.8) or 2 / ″ (63.5)
2
Y Concentric Fitting
Dia. SDR--26 Pipe
2 5 -- 2 2 -- 0 3
A07719
Fig. 31 -- Kit Components
Maintain 12″ (304.8mm)
min. clearance above high-
est anticipated snow level.
Max. of 24″ (609.6mm)
above roof.
Vent
4. The vent termination shall be located at least 4′ (1.2m)
horizontally from any electric meter, gas meter, gas
regulator, and any relief equipment. These distances apply
ONLY to U.S. installations.
5. The vent termination is to be located at least 3′ (.91m) above
any forced air inlet located within 10′ (3m); and at least 10′
(3m) from a combustion air intake of another appliance,
except another direct vent furnace intake.
Combustion
Air
Roof Boot/
Flashing
(Field Supplied)
6. In Canada, the Canadian Fuel Gas Code takes precedence
Support
(Field Supplied)
over the preceding termination instructions.
Concentric Vent Termination
Kit # KGAVT0701CVT & KGAVT0801CVT
45° Elbow
(Field Supplied)
These kits are for vertical or horizontal termination of the
combustion air inlet and the exhaust vent pipes on Category IV
gas--fired condensing furnaces. The KGAVT0701CVT kit can be
used for 2″ (50.8mm) diameter pipe systems. The
KGAVT0801CVT kit can be used for 3″ (76.2mm)diameter pipe
system. Refer to Table 5 for the correct pipe size for the furnace.
Both the combustion air inlet and the exhaust vent pipes must
attach to the termination kit. The termination kit must terminate
outside the structure and must be installed per the instructions
outlined below for vertical or horizontal termination. Vertical
termination is preferred. Field supplied pipe and fittings are
required to complete the installation.
Vent
Combustion
Air
25--22--02
Note:
Support must be field installed to secure termination kit to structure.
A07720
Fig. 32 -- Concentric Vent Roof Installation
3. Cut one 5″ (127mm)diameter hole through the structure for
the KGAVT0701CVT Kit or one 4″ (101.6mm)diameter
hole for the KGAVT0801CVT Kit .
4. Dimension D may be lengthened to 60″ (1524mm)max. or
shortened by cutting the pipes to 12″ (304.8mm) min.
Dimension A will change according to D dimension. (See
Fig. 33.)
Vertical & Horizontal Termination
1. Determine the pipe diameters required for the installation
from Table 5 and Fig. 33
31
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Drill clearance hole in rain
cap and pilot hole in vent pipe.
B PVC
Vent/Exhaust
C
D
Stainless steel screw
(Field supplied)
1
1 / ″
2
(38 mm)
A07722
B
PVC Intake/Combustion Air
Fig. 34 -- Rain Cap to Vent Pipe Assembly
A
Model
A*
B
C
D**
!
WARNING
7
1
1
KGAVT0801CVT
KGAVT0701CVT
38 /
3
2
4 /
21 /
8
8
2
2
8
3
1
5
33 /
3 /
16 /
8
CARBON MONOXIDE POISONING HAZARD
* = Dimension will change accordingly as dimension D is lengthened
or shortened.
**= Dimension D may be lengthened to 60″ may also be shortened by
cutting the pipes provided in the kit to 12″ minimum.
Failure to follow this warning could result in personal injury
or death.
When using the alternate screw assembly method, drill a
clearance hole in the rain cap and a pilot hole in the vent pipe
for the screw size being used. Failure to drill adequate holes
may cause cracking of the PVC components, allowing flue
gasses to be recirculated.
A09195
Fig. 33 -- Concentric Vent Dimensional Drawing
Concentric Termination Kit
KGAVT0701CVT & KGAVT0801CVT
Venting Table Dual Piping ONLY
Table 5
6. Install the Y concentric fitting and the pipe assembly
through the structure’s hole. For vertical termination, install
the parts through the field supplied roof boot/flashing.
NOTE: Do not allow insulation or other materials to
accumulate inside the pipe assembly when installing through
the structure’s hole.
40,000, 50,000, 60,000, & 75,000 Btuh Furnaces
KGAVT0701CVT - 35′ (10.7m) & (4) 90° elbows
with 2″ (50.8mm) PVC pipe
80,000, 100,000 & 125,000 Btuh Furnaces
KGAVT0801CVT - 35′ (10.7m) & (4) 90° elbows
with 3″ (76.2mm) PVC pipe
!
WARNING
1. Do not include the field supplied 45° elbow in the
total elbow count.
2. If more than four elbows are required, reduce the
length of both the inlet and the exhaust pipes five feet
for each additional elbow used.
3. Elbows are DWV long radius type for 2″ (50.8mm)
and 3″ (76.2mm) vents.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
Do not operate the furnace with the rain cap removed as
recirculating of the flue gasses may occur. Water may also
collect inside the larger combustion air pipe and flow to the
burner enclosure.
If more than four elbows are required, reduce the length of both
the inlet and exhaust pipes 5′ (1.5m)for each additional elbow
used.
* Feet of pipe is whichever pipe run is the longest, either inlet or
outlet side.
7. Secure the assembly to the structure as shown in Fig. 32 or
Fig. 36 using field supplied metal strapping or equivalent
material.
If assembly needs to be extended to meet height or side wall
thickness requirement, the two pipes supplied in the kit may be
replaced by using the same diameter solid, single (no coupling
connections) field supplied SDR--26 PVC (ASTM D2241) pipes.
Do not extend dimension D more than 60″(1524mm). (See Fig.
33.)
Do not use field supplied couplings to extend the pipes. Airflow
restriction will occur and the furnace pressure switch may cause
intermittent operation.
NOTE: Ensure the termination height is above the roof surface or
anticipated snow level as shown in Fig. 32 for vertical termination.
Ensure the termination location clearance dimensions are as shown
in Fig. 35 and Fig. 36 for horizontal termination.
8. Install the rain cap and the small diameter pipe assembly in
the Y concentric fitting and the large pipe assembly. Ensure
that the small diameter pipe is bottomed out and securely
cemented in the Y concentric fitting.
9. Cement the furnace combustion air and vent pipes to the
concentric vent termination assembly. See Fig. 32 or Fig. 36
for proper pipe attachment.
10. Operate the furnace through one heat cycle to ensure
combustion air and vent pipes are properly connected to the
concentric termination connections.
5. Partially assemble the concentric vent termination kit. Clean
and cement the parts using the procedures for Joining Pipe
and Fittings section of the manual.
a. Cement the Y Concentric fitting to the longest of the
two straight kit pipes. See Fig. 34.
b. Cement the rain cap to the shortest of the straight kit
parts. (See Fig. 34.)
NOTE: A field supplied stainless steel screw may be used to
secure the rain cap to the pipe instead of cementing when field
disassembly is desired for cleaning (See Fig. 34.)
32
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(See Propane Gas Conversion Kit instruction manual for furnaces
converted to Propane gas)
Roof Overhang
S Use only the Type of gas approved for this furnace. See rating
plate for approved gas type.
1
S A / ″ NPT plugged tapping, accessible for a test gauge
8
12″ (304.8mm) min.
connection,must be installed immediately upstream of the gas
supply connection to furnace.
1″ (25.4mm) max.
Combustion
S Gas supply pressure should be within minimum and maximum
values listed on rating plate. Pressures are usually set by gas
suppliers.
Air
Vent
S Gas input must not exceed the rated input shown on the rating
plate. Overfiring will result in failure of heat exchanger and cause
dangerous operation.
Maintain 12″ (304.8mm) clearance
above highest anticipated snow level
or grade whichever is greater.
25--22--02
S Do not allow minimum supply pressure to vary downward.
Doing so will decrease input to furnace. Refer to Table 6 for Gas
supply. Refer to Tables 7 through 10 for manifold pressures.
A07736
Fig. 35 -- Concentric Vent and Combustion--Air
Side Termination
Table 6
Gas Pressures
Strap
(Field Supplied)
Supply Pressure
Combustion
Air
Gas Type
Natural
Recommended
Max.
Min.
7 in wc
(1744 Pa)
14 in wc
(3487 Pa)
4.5 in wc
(1121 Pa)
Vent
11 in wc
(2740 Pa)
14 in wc
(3487 Pa)
11 in wc
(2740 Pa)
Vent
Propane
Flush to
1″ (25.4mm)
Combustion
Air
Gas Piping Requirements
max.
45° Elbow
(Field Supplied)
NOTE: The gas supply line must be installed by a qualified service
25--22--02
technician in accordance with all building codes.
Note:
NOTE: In the state of Massachusetts.
Securing strap must be field installed to prevent movement of termina-
tion kit in side wall.
a. Gas supply connections MUST be performed by a
licensed plumber or gas fitter.
A07723
Fig. 36 -- Concentric Vent Sidewall Attachment
b. When flexible connectors are used, the maximum length
shall not exceed 36″ (915 mm).
c. When lever handle type manual equipment shutoff
valves are used, they shall be T--handle valves.
GAS SUPPLY AND PIPING
d. The use of copper tubing for gas piping is NOT
approved by the state of Massachusetts.
!
WARNING
1. Install gas piping in accordance with local codes, or in the
absence of local codes, the applicable national codes. Refer
to NFPA 54/ANSI Z223.1 for proper gas pipe size.
2. It is recommended that a manual equipment shutoff valve be
installed in the gas supply line outside the furnace. Locate
valve as close to the furnace as possible where it is readily
accessible. Refer to Fig. 37.
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Models designated for Natural Gas are to be used with Natural
Gas ONLY, unless properly converted to use with Propane gas.
3. Use black iron or steel pipe and fittings or other pipe
approved by local code.
NOTE: The rating plate is stamped with the model number, gas
type and gas input rating. In addition, models manufactured for sale
in Canada have orifice size information stamped on the rating plate.
4. Use pipe thread compound which is resistant to natural and
Propane gases.
5. Use ground joint unions and install a drip leg no less than 3″
(76.2mm) long to trap dirt and moisture before it can enter
gas controlvalve inside furnace.
Gas Supply Requirements
!
WARNING
6. Use two pipe wrenches when making connections to prevent
gas valve from turning.
7. Install a manual shut--off valve external to furnace casing
and tighten all joints securely.
8. If local codes allow the use of flexible gas appliance
connectors, always use a new listed connector.
Do not use a connector which has previously serviced
another gas appliance.
FIRE HAZARD
Failure to follow this warning could result in personal injury
or death.
Do NOT set input rating above that shown on rating plate.
Gas supply pressure should be within minimum and maximum
values listed on rating plate. Pressures are usually set by gas
suppliers.
9. Flexible corrugated metal gas connector may NOT be used
inside the furnace or be secured or supported by the furnace
or ductwork.
33
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10. Properly size gas pipe to handle combined appliance load or
run gas pipe directly from gas meter or Propane gas
regulator.
!
WARNING
NOTE: Refer to Fig. 37 or Fig. 38 for the general layout at the
furnace. The rules listed apply to natural and Propane gas pipe
installations.
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury
or death.
NOTE: On the Dual Certified or Direct Vent models, install the
gas pipe grommet to the furnace side panel with the gas pipe entry.
If needed, remove the 2″ (50.8mm) hole plug from the plastic
accessory bag and relocate to the open hole in the furnace side
panel.
Failure to properly install metal gas connector could
result in personal injury, death, and/or property
damage.
A flexible corrugated metal gas connector must be
properly installed, shall not extend through the side of
the furnace,and shall not be used inside the furnace.
11. Install correct pipe size for run length and furnace rating.
12. Measure pipe length from gas meter or Propane second stage
regulator to determine gas pipe size.
Black iron pipe shall be installed at the furnace gas
control valve and extend a minimum of 2″ (50.8mm)
outside furnace casing.
Vent Pipe Grommet
(Single Pipe)
Manual shut-off
valve
Drip Leg and Union, Union* should be outside the
cabinet. Manual shut--off valve MUST be upstream of
dripleg, union, and furnace.
3″ (76.2mm)
pipe nipple
Use elbows and 3″ (76.2mm) pipe nipple
to connect valve to piping when using
right side gas pipe entry.
Propane low pressure switch.
Alternative
installation
* Union may be installed inside the cabinet when necessary because of clearances.
Representative drawing only, some models may vary in appearance.
2 5 -- 2 5 -- 4 5
A09196
Fig. 37 -- Typical Gas Piping for Upflow
34
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Use elbows and 3″ (76 mm) pipe nipple to connect valve to
piping when using left side gas pipe entry.
Propane low pressure
switch.
Manual shut- off
valve
Alternative
installation
Drip Leg and Union, Union* should be outside the cabinet.
Manual shut--off valve MUST be upstream of dripleg, union,
and furnace.
Gas Pipe Grommet
(Single Pipe)
*Union may be installed inside the cabinet when necessary
because of clearances.
A09206
Fig. 38 -- Typical Gas Piping for Downflow
3. For operation with Propane gas, gas orifices MUST be
changed and manifold pressure MUST be maintained as
Additional Propane Connection Requirements
1. Have a licensed Propane gas dealer make all connections at
storage tank and check all connections from tank to furnace.
per
Table 8. Orifices can be ordered through your
distributor. See Fig. 39.
2. If copper tubing is used, it MUST comply with limitation
4. In cases where Table 7 is not applicable, eg. alternate input
rate application, refer to above table for required high
altitude input rate.
set in National Fuel Gas Code or CGA codes.
3. Two--stage regulation of Propane gas is recommended.
High Altitude Input Rate =
Propane Conversion
Nameplate Sea Level Input Rate x (Multiplier)*{
An accessory kit shall be used to convert to propane gas use, see the
furnace rating plate for the Propane conversion accessory kit part
number.
High Altitude Multiplier
Natural Gas Propane Gas
Elevation
ft (m)
2001′ - 3000′
(609.9 -- 914.4){
0.95
0.90
!
WARNING
3001′ - 4000′
0.93
0.91
0.89
0.87
0.85
0.86
0.82
0.78
0.74
0.70
(914.7 -- 1219.2)
FIRE, EXPLOSION HAZARD
4001′ - 5000′
(1219.5 -- 1524)
Failure to follow this warning could result in personal injury
or death.
5001′ - 6000′
(1524.3 -- 1828.8)
A
Propane conversion accessory kit is required when
operating the furnace with Propane gas.
6001′ - 7000′
(1829.1 -- 2133.6)
7001′ - 8000′
(2133.9 -- 2438.4)
General Derating Rules
1. These furnaces may be used at full input rating when
installed at altitudes up to 2,000′ (609.6m). When installed
above 2,000′ (609.6m), the input must be decreased 2%
(Natural) or 4% (Propane) for each 1000′ above sea level in
the USA. In Canada, the input rating must be derated 5%
(Natural Gas) and 10% (Propane Gas) for altitudes 2000′ to
4500′ (609.6 to 1371.6m) above sea level.
High Altitude Air Pressure Switch
Altitudes over 4,000′ (1219.2m) may require a different air pressure
switch than the one installed at the factory. Check parts list for
pressure switch and consult your distributor for part number and
availability. In Canada, provincial codes may govern installation of
switch. Check with governing authorities.
2. For operation with natural gas at altitudes above 2,000′
(609.6m), orifice change and/or manifold pressure
adjustments may be required for the gas supplied. First
consult your local gas supplier, then refer to or Table 7 for
required pressure change and/or orifice change for high
altitudes.
* In the USA, derating of these furnaces at 2% (Natural Gas) and
4% (Propane Gas) has been tested and design--certified by CSA.
{In Canada, the input rating must be derated 5% (Natural Gas)
and 10% (Propane Gas) for altitudes of 2,000 to 4,500 (609.6 to
1371.6m) above sea level. Use the 2001 to 3000 (609.9 to 914.4
m) column in Table 7 and Table 8.
* Based on mid --- r an ge of el evation .
35
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NATURAL GAS MANIFOLD PRESSURE (in wc) 20,000 BTU per burner
Table 7
MEAN ELEVATION ABOVE SEA LEVEL ft(m)
0 to 2000
(0 to 609.6)
3001 to 4000
(914.7 to 1219.2)
4001 to 5000
(1219.5 to 1524)
5001 to 6000
(1524.3 to 1828.8)
6001 to 7000
(1829.1 to 2133.6)
7001 to 8000
(2133.9 to 2438.4)
2001 to 3000{
(609.9 to 914.4){
HEATING
VALUE at
ALTITUDE
BTU/CU.
FT.
Orifice
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
Orifice
No.
Manifold
Pressure
No.
HI
-- --
-- --
-- --
-- --
-- --
-- --
-- --
LO
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
HI
-- --
-- --
-- --
-- --
-- --
-- --
-- --
3.5
3.3
3.2
3.6
3.6
3.4
3.5
3.7
LO
-- --
-- --
-- --
-- --
-- --
-- --
-- --
1.7
1.6
1.5
1.8
1.8
1.7
1.7
1.8
HI
-- --
-- --
-- --
-- --
LO
-- --
-- --
-- --
-- --
-- --
1.8
1.7
1.6
1.8
1.8
1.7
1.9
1.8
1.8
1.7
HI
-- --
LO
-- --
HI
-- --
LO
-- --
HI
-- --
LO
-- --
HI
LO
1.8
1.7
1.6
1.9
1.7
1.9
1.7
1.9
1.8
1.7
1.9
1.8
1.7
-- --
700
725
750
775
800
825
850
875
900
925
950
975
1000
1050
1100
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
44
44
44
44
46
47
-- --
-- --
-- --
-- --
-- --
-- --
-- --
44
44
44
45
46
46
47
48
-- --
-- --
-- --
-- --
-- --
44
44
44
45
46
46
47
47
48
48
-- --
-- --
-- --
-- --
44
44
44
46
46
46
47
47
48
48
49
-- --
-- --
-- --
44
44
45
46
46
47
47
47
48
48
49
-- --
-- --
44
44
44
45
46
46
47
47
48
48
48
49
-- --
-- --
44
44
44
46
46
47
47
48
48
48
49
49
49
-- --
-- --
3.7
3.4
3.2
3.8
3.6
3.8
3.6
3.8
3.6
3.4
3.8
3.6
3.4
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
3.7
3.5
3.2
3.7
3.6
3.4
3.7
3.5
3.7
3.5
3.4
3.8
-- --
1.8
1.7
1.6
1.8
1.8
1.7
1.8
1.7
1.8
1.7
1.6
1.8
-- --
3.5
3.3
3.8
3.7
3.5
3.8
3.6
3.4
3.7
3.5
3.7
-- --
1.7
1.6
1.8
1.8
1.7
1.8
1.8
1.7
1.8
1.7
1.8
-- --
-- --
3.6
3.4
3.2
3.8
3.6
3.4
3.7
3.5
3.8
3.4
3.7
1.8
1.7
1.6
1.9
1.8
1.7
1.8
1.7
1.8
1.7
1.8
3.7
3.5
3.3
3.7
3.7
3.5
3.8
3.6
3.7
3.4
-- --
-- --
-- --
3.7
3.5
3.3
3.2
3.6
3.8
1.8
1.7
1.6
1.6
1.8
1.8
-- --
-- --
-- --
-- --
Conversion: 1 in wc = 249 Pa
Bold- indicates factory orifice size.
NOTE: Propane data is based on 1.53 specific gravity. For fuels with different specific gravity consult the National Fuel Gas Code ANSI
Z223.1--2006/NFPA 54--2006 or National Standard of Canada, Natural Gas and Propane Installation Code CSA B149.1--05.
In the USA, derating of these furnaces at 2% (Natural Gas) and 4% (Propane Gas) has been tested and design--certified by CSA.
{
In Canada, the input rating must be derated 5% (Natural Gas) and 10% (Propane Gas) for altitudes of 2,000 to 4,500 (609.6 to 1371.6m)
above sea level. Use the 2001 to 3000 (609.9 to 914.4m) column in Table 7 and Table 8.
Table 8
PROPANE GAS MANIFOLD PRESSURE (in wc) 20,000 BTU per burner
MEAN ELEVATION FEET ABOVE SEA LEVEL ft(m)
HEATING VALUE
at ALTITUDE
BTU/CU. FT.
0 to 2000
(0 to 609.6)
3001 to 3999
(914.7 to
1219.2)
4001 to 5000
(1219.5 to 1524)
5001 to 6000
(1524.3 to
1828.8)
6001 to 7000
(1829.1 to
2133.6)
7001 to 8000
(2133.9 to
2438.4)
2001 to 3000{
(609.9 to
914.4){
Hi
Lo
Hi
Lo
Hi
Lo
Hi
Lo
Hi
Lo
Hi
Lo
Hi
Lo
2500
10.0
4.9
8.9
4.4
8.4
4.1
10.0
4.9
10.0
4.9
10.0
4.9
10.0
4.9
Orifice Size
#55
#55
#55
#56
#56
#56
#56
Conversion: 1 in wc = 249 Pa
NOTE: Propane data is based on 1.53 specific gravity. For fuels with different specific gravity consult the National Fuel Gas Code ANSI
Z223.1 -2006/NFPA 54 -2006 or National Standard of Canada, Natural Gas and Propane Installation Code CSA B149.1 -05.
In the USA, derating of these furnaces at 2% (Natural Gas) and 4% (Propane Gas) has been tested and design--certified by CSA.
{
In Canada, the input rating must be derated 5% (Natural Gas) and 10% (Propane Gas) for altitudes of 2,000 to 4,500 (609.6 to 1371.6m)
above sea level. Use the 2001 to 3000 (609.9 to 914.4m) column in Table 7 and Table 8.
The burner orifice part numbers are as follows:
Changing Orifices for High Altitude
Orifice
41
Part #
Orifice
42
Part #
!
WARNING
333730--701
333730--703
333730--705
333730--710
333730--712
333730--707
333730--702
333730--704
333730--709
333730--711
333730--706
333730--708
43
44
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
45
46
Failure to follow this warning could result in personal injury,
death, and/or property damage.
47
48
49
54
Turn OFF electric power (at disconnect) and gas supply (at
manual valve in gas line) when installing orifices. Installation
of orifices requires a qualified service technician.
55
56
NOTE: Main burner orifices can be changed for high altitudes.
1. Disconnect gas line from gas valve.
2. Remove manifold from furnace.
3. Remove the orifices from the manifold and replace them
with properly sized orifices.
4. Tighten orifices so it is seated and gas tight. (See Fig. 39.)
36
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Measure from face of ori-
fice to the back side of the
manifold.
ELECTRICAL WIRING
1.11″ (28.2mm)
1.21″ (30.8mm)
!
WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury
or death.
Turn OFF electrical power at fuse box or service panel
before making any electrical connections and ensure a
proper ground connection is made before connecting
line voltage.
A07725
Fig. 39 -- Changing Orifices
5. Reinstall manifold. Ensure burners do NOT bind on new
Power Supply Wiring
orifices.
The furnace MUST be electrically wired and grounded in
accordance with local codes, or in the absence of local codes with
the latest edition of The National Electric Code, ANSI NFPA 70
and/or The Canadian Electric Code CSA C22.1.
Final Gas Piping Check
1. The furnace and the equipment shut off valve must be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess of
Field wiring connections must be made inside the furnace
connection box. A suitable strain relief should be used at the point
the wires exit the furnace casing.
1
/2″ PSIG. Close the manual shut--off valve before testing at
such pressures.
2. The furnace must be isolated from the gas supply system by
closing the equipment shut off valve during any pressure
testing of the gas supply system at test pressure equal to or
NOTE: Furnace will not have normal operation is line polarity is
reversed. Check ALL field and control connections prior to
operation.
1
less than /2″ PSI.
Copper conductors shall be used. Line voltage wires should
conform to temperature limitation of 35° C rise and be sized for the
unit maximum amps stated on the rating plate. Add the full load
amps for potential field--installed accessories such as electronic air
cleaners and humidifiers that would receive power from the furnace
control board. The furnace control board is rated for a maximum of
1.0 amps combined for EAC and HUM. Consult NEC or local
codes for proper wire and circuit sizing.
3. When installation is complete, test all pipe connections for
1
leaks with the gas pressure less than /2″ PSIG to the gas
valve.
4. Apply a commercial soap solution to all joints to test for
leaks. Correct any leaks indicated by bubbles.
5. Correct even the smallest leak at once.
6. Check for leaks at gas valve and orifice connections to the
burner manifold along with the pilot tube connections to the
valve and pilot assembly while the furnace is operating.
Junction Box (J-Box) Relocation
The J--Box is installed on left side of casing. An alternate J--Box
location on right side can be used.
!
WARNING
1. Remove bag containing two hole plugs and two self tapping
screws from loose parts bag in blower compartment.
2. Remove two screws holding J--Box to casing.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death, and/or property damage.
3. Install large hole plug from loose furnace accessory bag into
the left J--Box location.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the
detection of leaks to check all connections. A fire or explosion
could result causing property damage, personal injury and/or
loss of life.
4. Clip wire tie holding J--Box wires.
5. Move J--Box to alternate location and attach using two self
tapping screws from bag.
6. Apply two hole plugs from bag at left J--Box location.
Thermostat
!
Heating
AVERTISSEMENT
The two--stage furnace control board will operate with either a
single stage or a two--stage heating thermostat and will provide
two--stage heating operation.
RISQUE D‘INDENDIE OU D‘EXPLOSION
Le non--respect des avertissements de sécurité pourrait
d‘entrainer des blessures graves, la mort ou des dommages
matériels.
For single--stage thermostat installations, the R and W wires from
the thermostat connect to the R and W1 connections on the furnace
control board. (See Fig. 40and wiring diagram)
NOTE: The TT (Thermostat Type) SW1 DIP switch #3 should be
in the OFF position for the furnace to operate properly with a
single--stage thermostat. Failure to change DIP switch with
single--stage thermostat will result in Low Heat operation ONLY.
Ne jamais utiliser une flamme nue por vérifier la présence des
fuites de gaz. Pour la vérification de tous les joints, utiliser
plutôt une solution savonneuse commerciale fabriquée
spécifiquement pur la détection des fuites de gaz. Un incendie
ou une explosion peut entrainer des dommages matériels, des
blessures ou la mort.
During operation, the furnace will operate on Low Heat for up to12
minutes. If the heat request exists for more than 12 minutes, the
furnace will automatically shift to the High Heat mode for the
remaining duration of the heating cycle.
37
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For two--stage thermostat installations, the R, W1 and W2 wires
from the thermostat connect to the R, W1 and W2 connections on
the furnace control board. Set TT SW1 DIP switch #3 to ON
position. During operation, the furnace will shift from Low Heat to
High Heat as requested by the thermostat. (See Fig. 40 and wiring
diagram)
Dehumidification
The furnace control board has a dehumidification feature which
reduces cooling airflow by 20% when the DEHUM terminal ( / ”
male quick connect) is energized by 24VAC and there is a cooling
call. DEHUM may be operated by a thermostat dehumidify
(24VAC for dehumidify) command or a dehumidistat (switch closes
on call for dehumidification) with one terminal connected to (Y1
for two--stage cooling or Y/Y2 for single--speed cooling
applications) and the other terminal connected to DEHUM.
1
4
Heat anticipator setting will need to be measured if 24VAC
humidifier is installed. Measure current in series from R to W1 at
the thermostat. Be sure 24VAC humidifier is operating during this
check. Allow furnace to operate for 2 minutes before recording the
AC amperage reading. Set anticipator on thermostat to recorded
value.
Furnace Control Fuse
The 24V circuit contains a 5--amp, automotive--type fuse located on
furnace control board. (See Fig. 41) Any electrical shorts of 24V
wiring during installation, service, or maintenance may cause fuse
to blow. If fuse replacement is required, use only a fuse of identical
size (5 amp.)
Thermostat location has an important effect on the operation of the
furnace. Follow instructions included with thermostat for correct
mounting and wiring.
Low voltage connections to furnace must be made on terminal
board to furnace control board. (See Fig. 41)
Cooling
If single--speed cooling is used, the Y and G from the thermostat
must be connected to the control board Y/Y2 and G to energize
cooling blower speed.
If two--stage cooling is used, the Y1, Y2, G of the thermostat must
be connected to Y1 of tap select interface board for low cooling,
Y/Y2 of the furnace control board for high cooling and G of the
furnace control board for continuous fan speed.
115V. 60 Hz.
W
BK
G
Connection
Box
Ground
Optional Equipment
R
All wiring from furnace to optional equipment MUST conform to
local codes or, in the absence of local codes with the latest edition
of The National Electric Code, ANSI NFPA 70 and/or The
Canadian Electric Code CSA C22.1. Install wiring in accordance
with manufacturer’s instructions. The wiring MUST have a
minimum temperature rating of 105° C.
LowVoltage
C
TerminalBoard
W2
W1
Y/Y2
G
W
G
R
SingleStage
Thermostat
Humidifier/Electronic Air Cleaner
The furnace is wired for humidifier and/or electronic air cleaner
connection.
R
C
LowVoltage
TerminalBoard
W2
W1
Y/Y2
G
HUMIDIFIER -- The HUM (24V) terminal is energized when the
low pressure switch closes on a call for heat. The HUM (115V) is
energized when the inducer is energized.
ELECTRONIC AIR CLEANER -- EAC terminal is energized
when there is a blower speed call, except it is NOT energized when
blower operates in the hard--wired continuous fan mode.
W2
W1
G
TwoStage
Thermostat
R
NOTE:115VAC/60Hz/single----phase
Operatingvoltagerange*:127VACmax,104VACmin.
!
CAUTION
* Permissible limits of voltage at which unit will operate satisfactorily
A07779
REDUCED FURNACE LIFE HAZARD
Fig. 40 -- Electrical Connections
Failure to follow this caution may result in reduced furnace
life.
Do NOT exceed 115V/1.0 amp. maximum current load for
both the EAC terminal and the HUM terminal combined.
Tap Select Interface Board
The Tap Select Interface Board is used with the Variable Speed
motor. There are DIP switches (SW2) for continuous blower adjust,
heating blower adjust, cooling blower adjust and cooling on/off
delay profiles. There is a jumper (J1) for slight blower adjustment,
increase (+)/no change (NOM)/decrease (--). There is a jumper (J2)
for airflow selection of Heat Pump EFFICIENCY or COMFORT.
(EFFICIENCY provides no airflow reduction in airflow whether
O is energized or not. COMFORT provides a 10% reduction in
airflow when O is not energized with a cooling call).
Furnace Control Board
The furnace control board has a fixed blower ON delay of 30
seconds for High Heat calls and 45 seconds for Low Heat calls. The
blower OFF timing is factory preset at 140 seconds. If desired, the
fan OFF delay can be reset to obtain the longest delay times while
still maintaining comfort levels. See “Furnace Wiring Diagram”.
The O terminal is available for use for Heat Pump applications, if
desired.
The Y1 terminal (if a two--stage Air Conditioner or two--stage Heat
Pump is used) will provide low cooling blower speed when
energized. (Only Y/Y2 on the furnace control board is used if a
single--stage Air Conditioner or Heat Pump is installed)
38
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!
WARNING
Diagnostic Light
CARBON MONOXIDE POISONING HAZARD
Dip Switch
Failure to follow this warning could result in personal injury
or death.
See “Wiring
Diagram”
for switch settings
Cool air passing over heat exchanger can cause condensate to
form resulting in heat exchanger failure.
24 VAC
HUM
115
VAC
HUM
Connections
NOTE: Return air can enter through either side, both sides, the
bottom or a side and the bottom. Return air can not enter through
rear of the furnace. When the furnace is located in an area near or
adjacent to the living area, the system should be carefully designed
with returns to minimize noise transmission through the return
grille. Any blower moving a high volume of air will produce
audible noise which could be objectionable to when the unit is
located very close to living areas. It is advisable to route the return
air ducts under the floor or through the attic.
EAC
FUSE
DEHUM
A07780
Fig. 41 -- Control Connections
1. For side connections using a 16″ x 25″ (406.4 x 635mm)
filter, cut out the embossed area shown in Fig. 42. This will
1
1
DUCTWORK AND FILTER
provide a 14 / ″ x 22 / ″ (368.3 x 571.5mm) approximate
2
2
opening.
!
A = 14 / ″ (368.3mm) Height of Cutout for 16″ x 25″ (406.4 x 635mm) Filter
2
WARNING
1
B = 22 / ″ (571.5mm) Width of Cutout for 16″ x 25″ (406.4 x 635mm) Filter
2
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
B
Do NOT draw return air from inside a closet or utility room
where furnace is located. Return air duct MUST be sealed to
furnace casing.
Embossed Area
on Side of Furnace
A
Furnace
Installation
Bottom
NOTE: Design and install the air distribution system to comply
with Air Conditioning Contractors of America manuals and/or
NFPA pamphlets 90A and 90B or other approved methods that
conform to local codes and good trade practices.
A07728
Fig. 42 -- Side Return Air Cutout
1. When furnace supply ducts carry air outside furnace area,
seal return air duct to furnace casing and terminate duct
outside furnace space.
NOTE: Furnaces with 5 TONS cooling capacity may require
two(2) side returns or one side return with bottom return.
2. Bottom returns can be made by removing the knockout
panel in the furnace base. Do NOT remove knock-out
except for a bottom return.
2. Install air conditioning cooling coil (evaporator) on outlet
side of furnace.
3. For furnaces installed without
a
cooling coil, it is
3. Installation of locking-type dampers are recommended in all
branches, or in individual ducts to balance system’s air flow.
recommended that the outlet duct be provided with a
removable access panel. This panel should be accessible
when the furnace is installed so the exterior of the heat
exchanger can be viewed for inspections. The access panel
MUST be sealed to prevent leaks.
4. Non-combustible,
flexible
duct
connectors
are
recommended for return and supply connections to furnace.
5. If air return grille is located close to the fan inlet, install at
least one, 90° air turn between fan and inlet grille to reduce
noise.
4. If separate evaporator and blower units are used, install good
sealing dampers for air flow control. Chilled air going
through the furnace could cause condensation and shorten
the furnace life.
NOTE: To further reduce noise, install acoustical air turning vanes
and/or line the inside of duct with acoustical material.
NOTE: Dampers (field supplied) can be either automatic or
manual. Manually operated dampers MUST be equipped with a
means to prevent furnace or air conditioning operation unless
damper is in the full heat or cool position.
Sizing
Existing or new ductwork MUST be sized to handle the correct
amount of airflow for either heating only or heating and air
conditioning.
Insulation
1. Insulate ductwork installed in attics or other areas exposed to
outside temperatures with a minimum of 2″ (50.8mm)
insulation and vapor barrier.
39
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2. Insulate ductwork in indoor unconditioned areas with a
minimum of 1″ (25.4mm) insulation with indoor type vapor
barrier.
1
1 / ″
2
(38.1)
3″
(76.2)
Filters
A filter must be used:
Filters are supplied with these furnaces, and additional filters may
be purchased from your distributor.
1
(31.8)
1 / ″
4
Use either filter type:
S
S
S
Washable, high velocity filters are based on a maximum
air flow rating of 600 FPM.
26 Ga. Galvanized Steel
11
/
FAST part number 1008482
″
16
(27)
Disposable, low velocity filters are based on a maximum
air flow of 300 FPM when used with filter grille.
A07730
Fig. 45 -- Filter Clip Construction
See Service & Maintenance Manual, Circulation Air
Blower Data for additional data.
Refer to Fig. 46 and for guidelines to install filters. Furnaces which
require larger filter media and have limited clearances on one side
of furnace, require a standoff filter rack, see Fig. 46, available from
your distributor.
NOTE: If filters are only suitable for heating application,
advise homeowner that filter size may need to be increased if
air conditioning is added.
NOTE: Disposable, low velocity filters may be replaced with
washable, high velocity filter providing they meet the minimum
size areas. Washable, high velocity filters can be replaced ONLY
with same type and size.
Using Optional
Standoff Filter
Rack
A07729
Fig. 43 -- Side Mounted Filter Rack
Filter Installation using Filter Rack
When installing or removing a bottom mounted filter, slide the two
side filter clips to the back of the furnace BEFORE installing or
removing. This will allow the filter to clear the front raised edge of
the furnace. Insert filter into side clips first and push filter back until
it is fully engaged into back clip. When filter is in place, slide clips
back into place midway on filter as shown in Fig. 44 or Fig. 45
A07731
Fig. 46 -- Standoff Filter Rack
Center Clip
s i d e -- t o -- s i d e
Addition Of Air Conditioning
When a refrigeration coil is used in conjunction with this unit, it
must be installed parallel with or on the discharge side of the unit to
avoid condensation on the heat exchanger. All furnaces are
designed with a break--away duct flange on the supply air side of
the furnace. This allows for installation in the horizontal right or
downflow applications. The coil installation instructions must be
consulted for proper coil location and installation procedures. With
a parallel flow arrangement, dampers must be installed to prevent
chilled air from entering the furnace. If manually operated dampers
are used, they must be equipped with a means to prevent operation
of either unit unless the damper is in full heat or full cool position.
A 3″ clearance is required on the right side of the furnace in order to
run the condensate drain line. Copper or plastic tubing may be used
for the condensate drain line.
9″ (152.4mm)
25--24--18--1
Slide filter clips towards back before removing
A07691
Downflow Furnace Installation
Fig. 44 -- Bottom Mounted Filter Rack
Non-Combustible Floor Installation
Fabricate a plenum to the dimensions given in Fig. 47, for the
3
furnace outlet. Plenum should be flanged, approximately / ″
4
(19.1mm) for support.
40
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Note: The three(3) screws in the top panel of the furnace next to the
duct flange MUST be removed to provide serviceability of the
primary heat exchangers in the downflow installation
Note: When using the subbase for combustible floors, the discharge
air duct flanges on the furnace MUST be broken down to provide
proper fit up to the subbase. Use duct pliers to bend the duct flanges
flat onto the furnace casing. DO NOT bend the duct flanges inward
(toward the heat exchangers) as air flow restrictions may occur.
The Subbase for Combustible Floors MUST be used when a
downflow furnace is set on a combustible floor, even when the
furnace is installed on a coil box.
1. Position plenum through the floor and set the furnace over
the opening in the floor. If necessary, grout around the base
to seal air leaks between the base and the floor.
Combustible Floor Installation
1. Cut the opening in the floor according to Table 9. The hole
in the floor must be cut to the dimensions listed in Table 9
since the base is equipped with locating tabs that center the
base over the opening.
!
WARNING
FIRE HAZARD
1
1
The opening in the base is 1 / ″ (31.8mm) shorter and 1 / ″
4
8
Failure to install unit on noncombustible subbase could
result in personal injury, death, and/or property
damage.
(28.6mm) narrower than the recommended size of the opening in
the floor. This is done to maintain clearance between the floor and
the plenum.
Place furnace on noncombustible subbase on
downflow applications, unless installing on non-
combustible flooring. The noncombustible subbase
also must be used on downflow applications in
addition to a coil box installation.
2. Fabricate the plenum to the dimensions given in Table 9.
Note that the dimensions given are outside dimensions.
3. Set the base over the opening in the floor, centering it over
the opening. Fasten the base to the floor with screws or nails.
See Fig. 47, 48, and 49.
4. Drop the plenum through the opening in the base. The
flange of the plenum should rest on top of the subbase.
Subbase for Combustible Floor
NOTE: The three(3) screws in the top panel of the furnace next to
the duct flange MUST be removed to provide serviceability of the
primary heat exchangers in the downflow installation
Table 9
Subbases for Combustible Floors Dimensions -- in(mm)
Sub -base for Combustible
Floor Dimensions
Opening In
Typical Plenum
Dimensions
Sub -base for
Combustible Floors
Part Number
Opening In Floor
Base For Plenum
*
H
J*
K**
L
M
N
P
R
S
T
Furnace Only
5
3
3
1
1
1
1
19 /
28 /
18 /
16 /
18 /
17 /
17 /
16
4
16
4
4
8
8
KGASB0301P01
16(406.4)
16(406.4)
16(406.4)
15 (381)
15 (381)
15 (381)
15 (381)
15 (381)
15 (381)
(490.5)
15
(730.3)
(462)
(412.8)
(463.6)
(435.6)
(435.6)
3
13
1
7
3
3
22
/
28 /
21 /
16 /
21 /
19 /
19 /
4
16
4
16
4
8
4
KGASB0401P02
(582.6)
11
(730.3)
3
(554)
9
(412.8)
1
(555.6)
5
(501.7)
1
(501.7)
1
24 /
28 /
23 /
16 /
23 /
22 /
22 /
2
16
4
16
4
8
2
KGASB0801P06
Subbase for Coil Box
KGASB0501P03
(627.1)
(730.3)
(598.5)
(412.8)
(600.1)
(571.5)
(571.5)
3
9
3
1
1
1
1
1
19 /
20 /
18 /
16 /
16 /
18 /
17 /
17 /
8
16
16
16
4
4
8
8
15 (381)
15 (381)
15 (381)
15 (381)
15 (381)
15 (381)
(181.1)
(522.3)
9
(462)
13
(408)
1
(412.8)
1
(463.6)
7
(435.6)
3
(435.6)
3
20 /
21 /
16 /
16 /
21 /
19 /
19 /
4
16
16
16
4
8
4
KGASB0601P04
KGASB0701P05
23 (284.2)
3
(522.3)
9
(554)
9
(408)
1
(412.8)
1
(555.6)
5
(501.7)
1
(501.7)
1
24 /
20 /
23 /
16 /
(408)
16 /
23 /
22 /
22 /
2
4
16
16
16
4
8
2
(628.7)
(522.3)
(598.5)
(412.8)
(600.1)
(571.5)
(571.5)
*
Outside Dimension
Base Spacer Side To Side
**
Conversion: 1 in = 25.4 mm
41
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S
A = 4 1/4” (108mm) Minimum
clearance from back of hole
to wall or other obstruction.
T
Plenum
H
J
2″ (50.8mm)
1″ (25.4mm)
K
R
P
2″
L
(50.8mm)
M
N
Hole in
Floor
A07784
25--20--46
A
Fig. 50 -- Condensate Line Raised by Base
A07781
CHECKS AND ADJUSTMENTS
Fig. 47 -- Exploded View of Subbase for Furnace Only
NOTE: Verify the input rate of the furnace.
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death and /or property damage.
1
Turn OFF gas at shut off before connecting manometer.
2 /2″ (63.5mm)
1
1 /2″ (38.1mm)
Startup
NOTE: Refer to the start--up procedures in the “User’s Information
Manual” or to the “Operating Instructions Label” on the furnace.
!
WARNING
ELECTRICAL OPERATION HAZARD
A09182
Failure to follow this warning could result in personal injury,
death, and/or property damage.
Fig. 48 -- Exploded View of Base for Downflow Cased Coil
If any sparks, odors or unusual noises occur, immediately shut
OFF power to the furnace. Check for wiring errors or
obstruction to blower.
5. Position furnace or coil cabinet and furnace on subbase so it
aligns between the locating tabs.
Furnace
Installation of
Combustible
Floor Base
Gas Supply Pressure
Gas supply pressure should be within minimum and maximum
values listed on rating plate. Pressures are usually set by gas
suppliers.
Manifold Gas Pressure Adjustments
Wood Floor
Plenum
(High and Low Heat)
NOTE: Make adjustment to manifold pressure with burners
operating.
A07783
Fig. 49 -- Setting the Subbase
!
WARNING
This subbase for combustible floors has been designed so that the
height of the subbase raises the downflow coil off the floor to allow
easy installation of the condensate drain. See Fig. 50
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death and /or property damage.
Turn OFF gas at shut off before connecting manometer.
42
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1. With gas OFF, connect manometer to manifold pressure tap
on the outlet of gas control valve. See Fig. 51Use a
manometer with a 0 to 12 inches of water column range.
Example (BTUH)
Natural Gas
BTU Content
per cu. foot
No. of
Seconds
Per Hour
Time Per
Cubic Foot in
Seconds
BTU Per
Hour
2. Turn gas ON. Operate the furnace on High Heat by using a
jumper wire on the R to W1 & W2 thermostat connections
on the furnace control board.
1,000
3,600
48
75,000
1,000 x 3,600 ÷ 48 = 75,000 BTUH
3. Remove manifold pressure adjustment screw cover on
3
To Determine the appliance kW input rate from a .05m test dial
that has been clocked at 80 seconds for one complete revolution.
furnace gas control valve.
Turn adjusting screw
counterclockwise to decrease the manifold pressure and
clockwise to increase pressure. See Fig. 51
Example (kW)
NOTE: Adjustment screw cover MUST be replaced on gas control
valve before reading manifold pressure and operating furnace.
Number of
Number of
seconds per
hour
Size of test
dial
(.05m )
seconds per
complete
rotation
3
kW m /h
3
Regulator
Adjustment
Under Cap
3,600
80
.05
2.25
3
3,600 ÷ 80 x .05 = 7.2 m /h
HONEYWELL
HI
3
3
2.25m /h x 10.35 kWh/m = 23.28 kW
23.28 x 3.412 = 79,431 BTU
LO
4. Remove jumper wire from R to W1 and W2.
5. Relight all appliances and ensure all pilots are operating.
ON
Main Burner Flame Check
Allow the furnace to run approximately 10 minutes then inspect the
main burner and pilot flames. See Fig. 52.
INLET
OFF
Pressure
OUTLET
Pressure
1
Tap --
/
25--24--98a8
1
Tap --
/
Check for the following (Fig. 52:
8
• Stable and blue flames. Dust may cause orange tips
or wisps of yellow, but flames MUST NOT have solid,
yellow tips.
A07792
Fig. 51 -- Typical Gas Control Valve (Honeywell)
• Flames extending directly from burner into heat ex-
4. Set manifold pressure to value shown in Table 7,or Table 8.
changer.
5. Operate the furnace on Low Heat by using a jumper wire on
the R to W1 thermostat connections on the furnace control
board.
• Flames do NOT touch sides of heat exchanger.
If any problems with main burner flames are noted, it may be
necessary to adjust gas pressures, or check for drafts.
NOTE: The SW1 DIP switch #3 should be in the ON position to
set the Low Heat manifold pressure. (See wiring diagram.)
Burner Face
6. Repeat steps 3 and 4 for Low Heat operation.
7. When the manifold pressures are properly set, replace the
adjustment screw covers on the gas control valve.
8. Remove the jumper wires from the thermostat connections
on the furnace control board. Remove manometer
connection from manifold pressure tap, and replace plug in
gas valve.
9. Return SW1 DIP switch #3 to previous setting.
10. Check for leaks at plug.
A07734
Fig. 52 -- Main Burner
Natural Gas Input Rating Check
NOTE: The gas meter can be used to measure input to furnace.
Rating is based on a natural gas BTU content of 1,000 BTU’s per
cubic foot. Check with gas supplier for actual BTU content.
NOTE: For Igniter location see Fig. 53.
1/
2
(52.4)
16
5
1
/
16
(8)
/ (6.4)
4
1. Turn OFF gas supply to all appliances and start furnace. Use
jumper wire on R to W1 and W2 for High Heat.
2. Time how many seconds it takes the smallest dial on the gas
meter to make one complete revolution. Refer to Example.
3. Repeat steps 1 and 2 with jumper wire on R to W1 for Low
Heat.
NOTE: If meter uses a 2 cubic foot dial, divide results (seconds)
A07735
by two.
Fig. 53 -- Igniter Location
NOTE: SW1 DIP switch #3 must be in ON position. (See Furnace
Wiring Diagram). Return SW1 DIP switch #3 to previous setting
after check.
Temperature Rise Check
The blower speed MUST be set to give the correct air temperature
rise through the furnace as marked on the rating plate for both High
Heat and Low Heat operation. Temperature rise is the difference
between supply and return air temperatures.
43
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To check temperature rise,use the following procedure:
Switches #7 and #8 adjust the cooling speed on/off delay
profiles. See the “Technical Support Manual” for the
switch settings for the desired airflow rates for the
installation.
The jumper J1 is used to slightly increase (+) or decrease
(--) or not change (NOM) the blower speed selected from
SW2. J1 effects BOTH cooling and heating airflow.
Continuous blower selection DIP 10 and 11 will cause
the blower to run in high cooling speed for all low
cooling (Y1) calls. Continuous blower DIP settings of 00
and 01 will allow low cooling (Y1) calls to operate
normally.
1. Place thermometers in supply and return air registers as close
to furnace as possible, avoiding direct radiant heat from heat
exchangers.
2. Operate furnace on High Heat for 10 minutes with all the
registers and duct dampers open by using a jumper wire on
R to W1 and W2 thermostat connections on the furnace
control board.
S
Note: The SW1 DIP switch #3 should be in the on position.
(See furnace wiring diagram)
3. Take readings and compare with range specified on rating
plate.
4. If the temperature rise is not in the correct range, the blower
speed must be changed. A higher blower speed will lower
the temperature rise. A lower blower speed will increase the
temperature rise.
Continuous-Fan using “G”
Energizing the ”G” terminal on the furnace control board provides
continuous fan operation. This is done by connecting the G
terminal of the thermostat to the G terminal on the furnace control
board. When the FAN switch is turned from auto to ON the fan
will operate continuously at airflow selected by DIP SW2 switch #1
and DIP SW2 switch #2. EAC will be energized in this mode.
5. Repeat steps 2 thru 4 with the furnace operating on Low
Heat for 10 minutes by using a jumper wire on the R to W1
thermostat connections on the furnace control board.
6. Remove the jumper wire after the adjustments are complete.
Return SW1 DIP switch #3 to previous setting.
NOTE: In heating, the fan will not turn off during furnace ignition
and warm up.
Blower Adjustments
Hard Wired Continuous Fan Operation
Not available for variable speed models.
Changing Blower Speed
FURNACE MAINTENANCE
!
WARNING
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
FIRE, EXPLOSION, OR CARBON MONOXIDE
HAZARDS
Turn OFF power to furnace before changing blower speed.
Failure to follow this warning could result in personal injury,
death and/or property damage.
It is recommended that the furnace be inspected and serviced
on an annual basis (before the heating season) by a qualified
service technician.
NOTE: The blower speeds that the manufacturer sets from the
factory for this product are based on a nominal 400 CFM (189 L/s)
per ton cooling and the mid range on the temperature rise for
heating.
Since the manufacturer cannot predict the static pressure that
will be applied to the furnace, it is the responsibility of the
installing dealer/contractor to select the proper speeds for the
application when the furnace is installed.
!
WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
If it is necessary to change speeds, refer to steps below.
Failure to follow this warning could result in personal injury,
death, and/or property damage.
1. The 115 VAC power supply to the furnace must be turned
OFF before making adjustments to the motor.
Before servicing, disconnect all electrical power to furnace.
NOTE: Allow at least 1 minute before restoring power to
the furnace after making Blower Control changes.
When servicing controls, label all wires prior to disconnecting.
Reconnect wires correctly.
2. The heating, cooling and continuous blower speeds can be
adjusted by changing the SW2 DIP switch settings that are
located on the Tap Select Interface Board (See Fig. 54).
Verify proper operation after servicing.
S
Switches #1 and #2 adjust the continuous blower speeds.
Switches #3 and #4 adjust the heating speed.
Switches #5 and #6 adjust the cooling speed.
See “User’s Information Manual” and the “Service
Manual”.
44
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ON
=
=
1
0
1
8
OFF
A09197
Fig. 54 -- Variable Speed Tap Select Interface Board
Diagnostic Light
DIP Switch
See “Wiring
Diagram”
for switch settings
24 VAC
HUM
115
VAC
HUM
EAC
FUSE
DEHUM
A09198
Fig. 55 -- Control Board
45
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SEQUENCE OF OPERATION & DIAGNOSTICS
The following is the normal operating sequence at factory default settings (SW1 OFF/ON/OFF, SW2 all OFF)
NOTE: SW1 DIP switches (G, Y/Y2, W1, W2 thermostat terminals) and DEHUM (1/4” male quick connect terminal) are located on the
FCB.
SW2 DIP switches and Y1 and O thermostat terminals are located on the TSIB.
Low Cooling (Y1) Request:
24VAC signals applied to Y1 & G terminals of TSIB (Tap Select Interface Board) and FCB (Furnace Control Board), respectively.
S Low Cooling motor speed is energized after 5 second Cool Fan On Delay time.
Y1 & G signals removed from TSIB and FCB
S Low Cooling motor speed is de--energized after 90 second Cool Fan Off Delay time. Cooling (Y1) and dehumidification (DEHUM)
requests:
S 24 VAC signals applied to Y1, DEHUM & G terminals of TSIB and FCB.
S Same operation as the cooling (Y1) request, except the cooling airflow is reduced 20% to compensate for high humidity conditions during
cooling operation. The low cooling airflow returns to the normal setting after the DEHUM signal is removed.
High Cooling (Y1 & Y/Y2) or (Y/Y2) Request:
24VAC signals applied to Y1 & Y/Y2 & G or Y/Y2 & G terminals of FCB (Furnace Control Board).
S High Cooling motor speed is energized after 5 second Cool Fan On Delay time.
Y1 & Y/Y2 & G or Y/Y2 & G signals removed from TSIB and FCB
S High Cooling motor speed is de--energized after 90 second Cool Fan Off Delay time.
High Cooling (Y1 & Y/Y2 or Y/Y2) and dehumidification (DEHUM) requests:
S 24 VAC signals applied to Y1 & Y/Y2 or Y/Y2, DEHUM, & G terminals of TSIB and FCB.
S Same operation as the high cooling (Y1 & Y/Y2 or Y/Y2) request, except the cooling airflow is reduced 20% to compensate for high
humidity conditions during cooling operation. The high cooling airflow returns to the normal setting after the DEHUM signal is removed.
Low or high cooling and O terminal (Heat Pump mode):
S If the J2 jumper is in the AC/HP EFFICIENCY position, there will be no change in blower airflow regardless of the O terminal being
energized or de--energized.
S If the J2 jumper is in the HP COMFORT position, then there will be a 10% reduction in airflow when the O terminal is de--energized (HP
heating) and no airflow reduction when O is energized (HP cooling).
NOTE 1) The motor has been set up to recognize the O terminal as energized during cooling calls (reversing valve energized for cooling).
Continuous Circulating Fan (G) Request:
24VAC signal applied to G terminal of FCB.
S Continuous fan speed is energized without delay.
G signal removed from FCB.
S Continuous fan speed is de--energized after 5 second delay.
NOTE 2) Heat or Cooling requests received during a Fan request, cause the fan speed to change to the appropriate heat or cool speed after the
Fan On Delay time expires. The fan returns to continuous circulating speed after the selected Fan Off Delay time expires following loss of the
Heating or Cooling request.
NOTE 3) Hard--wire option not available for variable speed models.
NOTE 4) Continuous blower selection DIP 10 and 11 will cause the blower to run in high cooling speed for all low cooling (Y1) calls.
Continuous blower DIP settings of 00 and 01 will allow low cooling (Y1) calls to operate normally.
Heating (W1) Request (single stage thermostat operation, SW1 DIP switch #3 on the FCB
must be in OFF position) (see furnace wiring diagram):
24VAC signal applied to W1 terminal of FCB.
S Inducer motor turns on at high speed.
S Following a 15 second prepurge delay after the low pressure switch closes, the igniter begins a 17 second warm up.
S The gas valve is energized, the main burners light at Low Heat rate.
S The igniter is de--energized, and the inducer drops to low speed after the main burners ignite.
S The FCB will delay Low Heat blower operation for the 45--second Low Heat Fan On Delay time timed from the opening of the gas valve.
S If the W1 request is still present after 12 minutes, timed from the opening of the gas valve, the inducer switches to high speed, closing the
high pressure switch, then the High Heat solenoid energizes, and the fan switches to High Heat speed.
W1 signal removed from FCB.
S The gas valve de--energizes and the main burners go out.
S The inducer runs at its present speed for a 15 second postpurge period.
S The fan runs at its present speed.
S The blower de--energizes after the selected Heat Fan Off Delay time expires timed from the gas valve de--energizing.
46
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NOTE 5) If a new Heating request arrives while the control is waiting for the Heat Fan Off Delay time to expire, the FCB will wait for the
selected Heat Fan Off Delay, and then start a new heating cycle.
Heating (W1 & W2) Request (two-stage thermostat operation, SW1 DIP switch #3 must be in
ON position) (see furnace wiring diagram):
24VAC signals applied to W1 terminal of FCB.
S Same response as single stage thermostat operation described above except the burners, inducer, and blower will not go to high heat rate,
and High Heat Fan speed unless a W2 signal is applied.
24VAC signal applied to W1 and W2 terminals of FCB.
S Same light--off routine as described for the signal stage thermostat operation except burners light at High Heat rate, the inducer remains on
high speed after ignition, and the FCB will delay High Heat blower operation for the 30--second High Heat Fan On Delay.
NOTE 6) The FCB responds without delay to the presence or loss of W2 (with W1 constant). W1 & W2 result in high inducer, High Heat
rate, and High Heat Fan speed. W1 only results in low speed inducer, Low Heat rate, and Low Heat Fan speed.
Heating Request with Gas Shut Off:
24 VAC signals applied to W1 terminal of FCB.
The FCB will attempt 4 cycles for ignition then go to soft lockout for 3 hours, and then try for ignition again as long as the heat call remains.
Power reset will clear lockout.
S Inducer motor turns on at high speed.
S Following a 15 second prepurge delay after the low pressure switch closes, the igniter begins warm up.
S The igniter glows red--hot for 22 seconds, then turns off. The FCB flashes error code 6.
S The igniter stays off for 17 seconds, then begins to warm up again.
S The igniter glows red hot for 22 seconds then turns off. The FCB continues flashing error code 6.
S The igniter stays off for 17 seconds, then begins to warm up again.
S The igniter glows red hot for 22 seconds then turns off. The FCB continues flashing error code 6.
S The igniter stays off for 17 seconds, then begins to warm up again.
S The igniter glows red hot for 22 seconds then turns off. The FCB proceeds to soft lockout. Stops flashing error code 6, and begins flashing
error code 6 + 1.
S The inducer motor de--energizes 15 seconds after error code 6 + 1 starts flashing.
Furnace Control Board Diagnostic Codes (See Fig. 55):
OFF
=
=
=
24VAC or 115VAC is off, fuse is open
Heartbeat
ON SOLID
Normal operation or no previous Diagnostic Code
Soft Lockout - Furnace Control Error (1 hr delay) If code repeats immediately following
power reset then replace control
1 Flash
=
=
=
=
=
=
=
=
Not used
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
6 + 1 Flashes
7 Flashes
Pressure switch(es) closed when should be open
Low pressure switch open when should be closed
Limit or flame roll-out switch open (less than 2 minutes)
Flame sensed out of sequence
Failure to ignite or flame sense lost while running
Soft Lockout - Max of four trials for ignition reached (3 hr delay)
Limit or flame roll-out switch open longer than 2 minutes (1 hr delay) (roll-out switch
requires manual reset)
8 Flashes
=
Permanent Lockout - Gas valve relay contact stuck closed or miswired gas valve (power
reset only)
9 Flashes
=
=
High pressure switch open when should be closed
10 Flashes
Improper transformer phasing on twinned applications or improper line voltage polarity.
* If status code recall is needed, briefly (2--3 seconds) remove then reconnect one limit switch wire (main or rollout) to display last stored
status code. Do not remove power or blower door before initiating status code recall or code will be lost. Code is automatically cleared after
72 hours or upon power reset.
* Proper flame sense microamps: 0.7 microamps D.C. minimum, 2.0 -- 4.0 microamps nominal
NOTE 7) Continuous blower selection DIP 10 and 11 will cause the blower to run in high cooling speed for all low cooling (Y1) calls.
Continuous blower DIP settings of 00 and 01 will allow low cooling (Y1) calls to operate normally.
S
HUMIDIFIER -- The 24VAC HUM is energized when the low pressure switch closes on a call for heat. The 115V HUM (called
HUM on Control) is energized when the inducer is energized.
S
ELECTRONIC AIR CLEANER -- EAC is energized when there is a blower speed call. It is NOT energized when blower operates
in the hard--wired continuous fan mode.
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WIRING DIAGRAM
48
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8. 24V HUM terminal on furnace control is used to
power a humidifier (on call for heat and pressure
switch closed) if no HUM thermostat option is
available.
9. DEHUM provides a 20% reduction in airflow (when
Y1 or Y1 + Y2 is energized) when the furnace
control DEHUM terminal is energized with 24V.
10. If no DEHUM thermostat option is available, a
dehumidistat that has closed contacts on a call for
dehumidify may be used
11. O provides a 10% reduction in airflow when Y1 or
Y1 + Y2 is energized and O is NOT energized. (J2
jumper on TSIB must be in HP COMFORT position
to get this function. AC/HP EFFICIENCY position
results in no reduction of airflow for Y1 or Y1 + Y2
calls regardless of O being energized or not.)
Thermostat Wiring Guide
1. These diagrams are for reference. See thermostat
wiring
instructions
for
specific
terminal
assignments, connections or operation.
2. Humidifier/humidistat is optional and not included
with the furnace.
3. Dehumidify feature requires thermostat with
DEHUM feature or a separate dehumidistat to get
the dehumidification operation. Dehumidistat is
optional and not included with the furnace.
4. Underlined terminal indicates intended use for
multiple function terminals.
5. TSIB terminals only available on 58HDV/359BAV
models.
6. Two-stage Air Conditioning or two-stage Heat
Pump compatible.
7. W2 furnace operation is from furnace control
algorithm SW1 DIP switch #3 (TT) set to OFF.
Furnace runs in Low Heat for 12 minutes then
switches to High Heat if heating call still exists.
12. For Heat Pump/Furnace systems, refer to Fossil Fuel
Kit or Dual Fuel Thermostat Installation Instructions
for wiring.
TSIB NOTE 5
NO CONNECTION
NO CONNECTION
Y1
O
NOTE 11
TWO-STAGE or VS
FURNACE
CONTROL
SINGLE-STAGE
THERMOSTAT
W2
NOTE 7
SINGLE-STAGE
W
Y
W1
Y/Y2
G
AIR CONDITIONER
Y
G
R
R
DEHUM
DEHUM
NOTE 3, 9, 10
C
COM
C
24V HUM
HUM
OPTIONAL
HUMIDIFIER
24V in
COM
NOTE 2
A07787
Fig. 56 -- HUM and DEHUM Terminal available from Thermostat. Humidifier Wiring Models and Dehumidify Wiring
49
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TSIB NOTE 5
Y1
NO CONNECTION
NO CONNECTION
O
NOTE 11
TWO-STAGE or VS
FURNACE
CONTROL
SINGLE-STAGE
THERMOSTAT
W2
NOTE 7
SINGLE-STAGE
OPTIONAL
DEHUMIDISTAT
W
Y
W1
Y/Y2
G
AIR CONDITIONER
Y
1
2
G
R
R
Connect 1 to Y/Y2 for
1-stage AC/ HP
applications
NOTE 3
DEHUM
C
COM
C
24V HUM
OPTIONAL
HUMIDIFIER
OPTIONAL
HUMIDISTAT
H-STAT
24V in
COM
NOTE 2
A09202
Fig. 57 -- No HUM and/or DEHUM Terminal available from Thermostat. HuNmOiTdEif2ier Wiring Models
and Dehumidify Wiring
TSIB NOTE 5
Y1
NO CONNECTION
O
NOTE 11
NO CONNECTION
(HP may use O)
TWO-STAGE or VS
FURNACE
CONTROL
SINGLE-STAGE
THERMOSTAT
W2
NOTE 7
SINGLE-STAGE
OPTIONAL
W
Y
W1
Y/Y2
G
AIR CONDITIONER
DEHUMIDISTAT
Y
1
2
G
R
R
Connect 1 to Y/Y2 for
1-stage AC/ HP
applications
NOTE 3
DEHUM
C
COM
C
24V HUM
OPTIONAL
HUMIDIFIER
OPTIONAL
HUMIDISTAT
H-STAT
24V in
COM
NOTE 2
NOTE 2
A09203
Fig. 58 -- Single--Stage Thermostat with Variable Speed Furnace Models
and Single--Stage Air Conditioner
50
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TWO-STAGE
TSIB NOTE 5
Y1
THERMOSTAT
Y1
O
NOTE 11
SINGLE STAGE
AIR CONDITIONER
VS FURNACE
CONTROL
OPTIONAL
DEHUMIDISTAT
If no DEHUM from
thermostat available
W2
W2
W1
Y2
G
NOTE 7
W1
Y/Y2
G
1
2
Y
Connect 1 to Y1 for 2-
stage AC-HP
applications.
R
R
NOTE 3, 9, 10
DEHUM
DEHUM
OR
Connect 1 to Y/Y2 for
1-stage AC- HP
applications
C
COM
C
24V HUM
OPTIONAL
HUMIDIFIER
HUM
24V in
COM
NOTE 2
A09204
Fig. 59 -- Two--Stage Thermostat with Variable Speed Furnace Models
and Single--Stage Air Conditioner
TSIBNOTE 5
Y1
THERMOSTAT
Y1
O
NOTE 11
TWO-STAGE
AIR CONDITIONER
OPTIONAL
DEHUMIDISTAT
VS FURNACE
CONTROL
If no DEHUM from
thermostat available
Y1
Y2
W2
W1
Y2
G
W2
W1
Y/Y2
G
1
2
Connect 1 to Y1 for 2-
stage AC-HP
applications.
R
R
NOTE 3, 9, 10
DEHUM
DEHUM
OR
Connect 1 to Y/Y2 for
1-stage AC- HP
applications
C
COM
C
24V HUM
OPTIONAL
HUMIDIFIER
HUM
24V in
COM
NOTE 2
A09205
Fig. 60 -- Two--Stage Thermostat with Variable Speed Furnace and Two--Stage Air Conditioner
and Single--Stage Air Conditioner
51
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Catalog No: 58HDV---01SI
Copyright 2009 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 04/09
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
Replaces: NEW
52
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