Bryant 120/C Series Guide

1
Installation Start--up, Operating, and
Service and Maintenance,
Instructions Series 120/C
315A
Variable Speed
Induced---Combustion Deluxe
4---Way Multipoise Furnace
SAFETY CONSIDERATIONS 2........................
INTRODUCTION 4..................................
CODES AND STANDARDS 4..........................
Safety 4...........................................
General Installation 4................................
Combustion and Ventilation Air 4......................
Duct Systems 4.....................................
Acoustical Lining and Fibrous Glass Duct 4...............
Gas Piping and Gas Pipe Pressure Testing 4...............
Electrical Connections 4..............................
Venting 4.........................................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE 4.....................................
LOCATION 5.......................................
AIR FOR COMBUSTION AND VENTILATION 8.........
Outdoor Combustion Air Method 8....................
The Standard Method: 9............................
Combination of Indoor and Outdoor Air 10.............
INSTALLATION 10..................................
Bottom Return Air Inlet 10..........................
Side Return Air Inlet 10.............................
Leveling Legs (If Desired) 10........................
Bottom Return Air Inlet 11..........................
Suspended Furnace Support 11.......................
Platform Furnace Support 11.........................
Roll--Out Protection 11.............................
Bottom Return Air Inlet 11..........................
Side Return Air Inlet 12.............................
General Requirements 12............................
Ductwork Acoustical Treatment 13....................
Supply Air Connections 13..........................
Upflow and Horizontal Furnaces 13...................
Downflow Furnaces 15.............................
Return Air Connections 19..........................
Downflow Furnaces 19.............................
Upflow and Horizontal Furnaces 19...................
START--UP, ADJUSTMENT, AND SAFETY CHECK 36.....
General 36........................................
Start--Up Procedures 38..............................
Adjustments 39.....................................
Check Safety Controls 47.............................
Checklist 48.......................................
SERVICE AND MAINTENANCE PROCEDURES 48.......
Introduction 50.....................................
Care and Maintenance 52.............................
Sequence of Operation 55.............................
Wiring Diagram 59..................................
Troubleshooting 59..................................
ama
REGISTERED
ISO 9001:2000
CERTIFIED
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1--2006E, with permission of National Fire Protection
Association, Quincy, MA 02269 and American Gas Association,
Washington DC 20001. This reprinted material is not the
complete and official position of the NFPA or ANSI on the
referenced subject, which is represented only by the standard in
its entirety.

2
SAFETY CONSIDERATIONS
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, personal injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified service agency, local gas supplier, or your
distributor or branch for information or assistance. The
qualified service agency must use only factory--authorized
and listed kits or accessories when modifying this product.
!WARNING
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.
CAUTION
!
Installing and servicing heating equipment can be hazardous due
to gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with furnace and other safety
precautions that may apply.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as
a minimum for a safe installation.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts, and servicing furnaces.
CAUTION
!
Wear safety glasses and work gloves. Have fire extinguisher
available during start--up and adjustment procedures and service
calls.
This is the safety--alert symbol . When you see this symbol on
the furnace and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify hazards which may result in minor personal injury or
product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
1. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
2. Install this furnace only in a location and position as
specified in the “Location” section of these instructions.
3. Provide adequate combustion and ventilation air to the
furnace space as specified in “Air for Combustion and
Ventilation” section.
4. Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system only, as
specified in the “Venting” section of these instructions.
5. Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections, as specified
in the “Gas Piping” section.
6. Always install furnace to operate within the furnace’s
intended temperature--rise range with a duct system which
has an external static pressure within the allowable range,
as specified in the “Start--Up, Adjustments, and Safety
Check” section. See furnace rating plate.
7. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space
containing the furnace, the return air shall also be handled
by duct(s) sealed to the furnace casing and terminating
outside the space containing the furnace. See “Air Ducts”
section.
8. A gas--fired furnace for installation in a residential garage
must be installed as specified in the warning box in the
“Location” section.
9. The furnace may be used for construction heat provided
that the furnace installation and operation complies with
the first CAUTION in the LOCATION section of these
instructions.
10. These Multipoise Gas--Fired Furnaces are CSA (formerly
A.G.A. and C.G.A.) design--certified for use with natural
and propane gases (see furnace rating plate) and for
installation in alcoves, attics, basements, closets, utility
rooms, crawlspaces, and garages. The furnace is
factory--shipped for use with natural gas. A CSA (A.G.A.
and C.G.A.) listed accessory gas conversion kit is required
to convert furnace for use with propane gas.
11. See Fig. 1 for required clearances to combustible
construction.
12. Maintain a 1--in. clearance from combustible materials to
supply air ductwork for a distance of 36 inches
horizontally from the furnace. See NFPA 90B or local
code for further requirements.
13. These furnaces SHALL NOT be installed directly on
carpeting, tile, or any other combustible material other
than wood flooring. In downflow installations, factory
accessory floor base MUST be used when installed on
combustible materials and wood flooring. Special base is
not required when this furnace is installed on
manufacturer’s Coil Assembly Part No. CAPVP, CAPMP,
or CNPVP, or when Coil Box Part No. KCAKC is used.
See Fig. 1 for clearance to combustible construction
information.
315A

3
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES
INSTALLATION
327590-101 REV. C
Ø
*
Clearance arrows
do not change with
furnace orientation.
BOTTOM
DESSOUS
0"
3"
0"
0"
1"
0"
24"
MIN
SIDE
CÔTÉ
FRONT
AVANT
BCK
ARRIÈ
A
E
R
SERVIE
C
ENTRT
E
N
E
I
V
AN
AT
FRONT
SIE
CÔTÈ
FOU
U
FRNAC
S
E
E
I
A
RN
Ø
TOP / PLENUM
DESSUS / CHAMBRED'AIR
D
*
*
†
MIN
Ø
*
†
This forced air furnace is equipped for use with
natural gas at altitudes 0-10,000 ft (0-3,050m).
An accessory kit, supplied by the
manufacturer, shall be used to convert to propane
gas use or may be required for some natural gas
applications.
This furnace is for indoor installation in a
building constructed on site.
This furnace may be installed on combustible
flooring in alcove or closet at minimum clearance
as indicated by the diagram from combusitble
material.
This furnace may be used with a Type B-1 Vent
and may be vented in common with other gas
fired appliances.
Cette fournaise à air pulsé est équipée
pour utilisation avec gaz naturel et altitudes
comprises entre 0-3,050m (0-10,000 pi).
Utiliser une trousse de conversion, fournie par
le fabricant, pour passer au gaz propane ou pour
certaines installations au gaz naturel.
Cette fournaise est prévue pour être
installée dans un bâtiment construit sur place.
Cette fournaise peut être installée sur
un plancher combustible dans une alcôve ou
dans un garde-robe en respectant le minimum
d'espace libre des matériaux combustibles, tel
qu
´ indiqué sur le diagramme.
Cette fournaise peut être utilisée avec un
conduit d
´ évacuation de Type B-1 ou connectée
au conduit ommun d 'autres appareils à gaz.
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
Installation on non-combusibible floors only.
For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,
Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.
18 inches front clearance required for alcove.
Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible
between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists,
studs or framing.
DOWNFLOW POSITIONS:
DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS
DE CONSTRUCTION COMBUSTIBLES
Pour l ´ installation sur plancher non combustible seulement.
Pour l
´ installation sur un plancher combustible seulement quand on utilise la base spéciale, pièce
nº KGASB0201ALL, l
´ ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de serpentin, pièce
nº KCAKC.
Dans une alcôve, on doit maintenir un dégagement à l
´ avant de 18 po (450mm).
La poistion indiquée concerne le côté d
´ entrée ou de retour quand la fournaise est dans la
position horizontale.
Le contact n
´ est permis qu ´ entre les lignes formées par les intersections du dessus et des
deux côtés de la cherrise de la fournaise et les solives, montant sous cadre de charpente.
POUR LA POSITION COURANT DESCENDANT:
Cette fournaise est approuvée pour l 'installation HORIZONTALE
et la circulation d 'air VERS LE HAUT et VERS LE BAS.
This furnace is approved for UPFLOW, DOWNFLOW, and
HORIZONTAL installations.
Clearance in inches
Dégagement (po).
Les fléches de dégagement
ne change pas avec
l 'orientation de la fournaise.
Vent Clearance to combustibles:
For Single Wall vents 6 inches (6 po).
For Type B-1 vent type 1 inch (1 po).
Dégagement de l ´ évent avec combustibles:
Pour conduit d ´ évacuation à paroi simple 6 po (6 inches).
Pour conduit d
´ évacuation de Type B-1 1 po (1 inch).
†
A04123
Fig. 1 -- Clearances to Combustibles
315A

4
INTRODUCTION
The Series 120/C 4.way multipoise Category I fan--assisted
furnace is CSA (formerly A.G.A. and C.G.A.) design--certified. A
Category I fan--assisted furnace is an appliance equipped with an
integral mechanical means to either draw or force products of
combustion through the combustion chamber and/or heat
exchanger. The furnace is factory--shipped for use with natural
gas. This furnace is not approved for installation in mobile
homes, recreational vehicles, or outdoors.
60
80 / 27 C
/ 16 C
A06745
Fig. 2 -- Return Air Temperature
This furnace is designed for minimum continuous return--air
temperature of 60_F db or intermittent operation down to 55_F
db such as when used with a night setback thermostat. Return--air
temperature must not exceed 80_F db. Failure to follow these
return--air temperature limits may affect reliability of heat
exchangers, motors, and controls. (See Fig. 2.)
For accessory installation details, refer to the applicable
instruction literature.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
CODES AND STANDARDS
Follow all national and local codes and standards in addition
to these instructions. The installation must comply with
regulations of the serving gas supplier, local building, heating,
plumbing, and other codes. In absence of local codes, the
installation must comply with the national codes listed below and
all authorities having jurisdiction.
In the United States and Canada, follow all codes and standards
for the following:
Safety
SUS: National Fuel Gas Code (NFGC) NFPA
54.2006/ANSI Z223.1.2006 and the Installation
Standards, Warm Air Heating and Air Conditioning
Systems ANSI/NFPA 90B .
SCANADA: CSA B149.1--00 National Standard of
Canada Natural Gas and Propane Installation Code
(CAN/CSA--B149.1--05)
General Installation
SUS: Current edition of the NFGC and the NFPA 90B.
For copies, contact the National Fire Protection
Association Inc., Batterymarch Park, Quincy, MA
02269; (www.NFPA.org) or for only the NFGC,
contact the American Gas Association, 400 N. Capitol
Street, N.W., Washington, DC 20001 (www.AGA.org.)
.
SCANADA: CAN/CSA--B149.1--05. For a copy,
contact Standard Sales, CSA International, 178
Rexdale Boulevard, Etobicoke (Toronto), Ontario,
M9W 1R3 Canada
Combustion and Ventilation Air
SUS: Section 9.3 of the NFGC, Air for Combustion and
Ventilation .
SCANADA: Part 7 of CAN/CSA--B149.1--05, Venting
Systems and Air Supply for Appliances
Duct Systems
SUS and CANADA: Air Conditioning Contractors
Association (ACCA) Manual D, Sheet Metal and Air
Conditioning Contractors National Association
(SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers
(ASHRAE) 2001 Fundamentals Handbook Chapter 34
or 2000 HVAC Systems and Equipment Handbook
Chapters 9 and 16.
Acoustical Lining and Fibrous Glass Duct
SUS and CANADA: current edition of SMACNA and
NFPA 90B as tested by UL Standard 181 for Class I
Rigid Air Ducts
Gas Piping and Gas Pipe Pressure Testing
SUS: NFGC; chapters 5, 6, and 7 and National
Plumbing Codes .
SCANADA: CAN/CSA--B149.1--05 Parts 4, 5, 6, and 9
and Appendices A, B, E and H.
Electrical Connections
SUS: National Electrical Code (NEC) ANSI/NFPA
70.2006 .
SCANADA: Canadian Electrical Code CSA C22.1
Venting
US: NFGC; chapters 12 and 13 .
CANADA: CAN/CSA--B149.1--05 Part 8 and Appendix C
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing
to protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
CAUTION
!
1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY’S ELECTRO-
STATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
315A

5
a person’s hand during grounding will be satisfactorily
discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example;
DO NOT move or shuffle your feet, do not touch
ungrounded objects, etc.).
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch a clean, unpainted
metal surface of the furnace again before touching control
or wires.
2-7/16"
1-1/8"
28-7/8"
25-1/4"
22-9/16"
JUNCTION BOX
LOCATION
7/8" DIA
ACCESSORY 1/2" DIA THERMOSTAT
WIRE ENTRY
3-15/16"
LEFT HAND GAS
ENTRY
33-5/16" 24-7/8"
5-1/2"
7/8" DIA. ACCESSORY
11/16"
21-5/8"
BOTTOM INLET 1-11/16"
13/16"
11/16"
4-13/16"
AIRFLOW
19"
OUTLET
13/16"
11/16"
8-9/16"
VENT OUTLET
5 PLACES (TYP)
3-3/4"
1-3/4" DIA.RIGHT HAND
GAS ENTRY
7/8" DIA. K.O. WIRE ENTRY
SIDE INLET
14-7/8"
7/8" DIA. ACCESSORY
1-1/4"
1"
22-1/16"
A
D
F
E
(FLUE COLLAR)
5-15/16"
24"
CASING
1-5/16"
1/2" DIA. K.O.THERMOSTAT
WIRE ENTRY
ALTERNATE
JUNCTION BOX
LOCATIONS (TYP)
26-1/8"
1-1/2"
7-3/4" 9-5/8"
11-1/2"
5-1/2"
NOTES:
1. Two additional 7/8-in. diameter holes are located in the top plate.
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.
a. For 800 CFM-16-in. round or 14 1/2 x 12-in. rectangle.
b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle.
c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets
a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
A04037
NOTES: 1. Two additional 7/8---in. diameter holes are located in the top plate. 2. Minimum return---air openings at furnace, based on metal duct. If flex duct is
used, see flex duct manufacturer’s recommendations for equivalent diameters. a. For 800 CFM---16---in. round or 14 1/2 x 12---in. rectangle. b. For 1200
CFM---20---in. round or 14 1/2 x 19 1/2---in. rectangle. c. For 1600 CFM---22 ---in. round or 14 1/2 x 22 1/16 ---in. rectangle. d. For airflow requirements above 1800
CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or
the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
Fig. 3 -- Dimensional Drawing
Table 1 – Dimensions (IN.)
FURNACE
SIZE
A
CABINET
WIDTH (IN.)
D
SUPPLY ---
AIR WIDTH
(IN.)
E
RETURN---
AIR WIDTH
(IN.)
F
CENTER LINE TOP AND
BOTTOM FLUE COL-
LAR (IN.)
FLUE
COLLAR* (IN.)
SHIP WT.
(LB)
FILTER ME-
DIA CABINET
SIZE (IN.)
070---12/03607
0
14---3/16 12---9/16 12---11/16 9---5/16 4127 16
090---16/04809
0
17---1/2 15---7/8 16 11---9/16 4151 16
110---20/06011
0
21 19---3/8 19---1/2 13---5/16 4163 20
135---22/06613
5
24---1/2 22---7/8 23 15---1/16 4† 177 24
155---22/06615
5
24---1/2 22---7/8 23 15---1/16 4† 183 24
*5” or 6” vent connector may be required in some cases.
{5” or larger vent is required. Use a 4---5 or 4 ---6 inch vent adapter be-
tween furnace and vent connector.
5. Use this procedure for installed and uninstalled
(ungrounded) furnaces.
6. Before removing a new control from its container,
discharge your body’s electrostatic charge to ground to
protect the control from damage. If the control is to be
installed in a furnace, follow items 1 through 4 before
bringing the control or yourself in contact with the
furnace. Put all used and new controls into containers
before touching ungrounded objects.
7. An ESD service kit (available from commercial sources)
mayalsobeusedtopreventESDdamage.
LOCATION
GENERAL
This multipoise furnace is shipped in packaged configuration.
Some assembly and modifications are required when used in any
of the four applications shown in Fig. 4.
NOTE: For high--altitude installations, the high--altitude
conversion kit MUST be installed at or above 5500 ft. above sea
315A

6
level. Obtain high--altitude conversion kit from your area
authorized distributor.
This furnace must:
Sbe installed so the electrical components are protected
from water.
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
A02097
Fig. 4 -- Multipoise Orientations
Snot be installed directly on any combustible material
other than wood flooring (refer to SAFETY
CONSIDERATIONS).
Sbe located close to the chimney or vent and attached to
an air distribution system. Refer to Air Ducts section.
Sbe provided ample space for servicing and cleaning.
Always comply with minimum fire protection
clearances shown on the furnace clearance to
combustible construction label.
CARBON MONOXIDE POISONING / COMPONENT
DAMAGE HAZARD
Failure to follow this warning could result in personal injury
or death and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
!WARNING
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
SCommercial buildings
SBuildings with indoor pools
SLaundry rooms
SHobby or craft rooms, and
SChemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
SPermanent wave solutions
SChlorinated waxes and cleaners
SChlorine based swimming pool chemicals
SWater softening chemicals
SDe--icing salts or chemicals
SCarbon tetrachloride
SHalogen type refrigerants
SCleaning solvents (such as perchloroethylene)
SPrinting inks, paint removers, varnishes, etc.
SHydrochloric acid
SCements and glues
SAntistatic fabric softeners for clothes dryers
SMasonry acid washing materials
All fuel--burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return--air duct to
prevent pulling air from the burner area and from draft safeguard
opening.
315A

7
FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 in.
above the floor. The furnace must be located or protected to
avoid damage by vehicles. When the furnace is installed in a
public garage, airplane hangar, or other building having a
hazardous atmosphere, the furnace must be installed in
accordance with the NFGC or CAN/CSA--B149.1--05. (See
Fig. 5.)
!WARNING
18-IN. MINIMUM
TO BURNERS
A93044
Fig. 5 -- Installation in a Garage
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace. (See Fig. 6.)
!WARNING
LOCATION RELATIVE TO COOLING EQUIPMENT
The cooling coil must be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the
furnace. If the dampers are manually operated, they must be
equipped with means to prevent operation of either unit unless
the damper is in the full--heat or full--cool position.
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Improper use or installation of this furnace may result in
premature furnace component failure. This gas furnace may
be used for heating buildings under construction provided
that:
--The furnace is permanently installed with all electrical
wiring, piping, venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the
space containing the furnace. This prevents a negative
pressure condition as created by the circulating air blower,
causing a flame rollout and/or drawing combustion
products into the structure.
--The furnace is controlled by a thermostat. It may not be
“hot wired” to provide heat continuously to the structure
without thermostatic control.
--Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the
entrainment of drywall dust into combustion air, which can
cause fouling and plugging of furnace components.
--The temperature of the return air to the furnace is
maintained between 55_F(13_C) and 80_F(27_C), with
no evening setback or shutdown. The use of the furnace
while the structure is under construction is deemed to be
intermittent operation per our installation instructions.
--The air temperature rise is within the rated rise range on
the furnace rating plate, and the gas input rate has been set
to the nameplate value. --The filters used to clean the
circulating air during the construction process must be
either changed or thoroughly cleaned prior to occupancy.
--The furnace, ductwork and filters are cleaned as necessary
to remove drywall dust and construction debris from all
HVAC system components after construction is completed.
--Verify proper furnace operating conditions including
ignition, gas input rate, air temperature rise, and venting
according to these installation instructions.
CAUTION
!
A02054
Fig. 6 -- Prohibit Installation on Back
315A

8
Table 2 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors
FUR-
NACE
INPUT
(BTUH)
TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS
(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)
Free Area of Opening
and Duct (Sq.. In.)
Round Duct (in.
Dia)
Free Area of Opening
and Duct (sq. In.)
Round Duct (in.
Dia)
Free Area of Opening
and Duct (Sq. In.)
Round Duct (In.
Dia)
44,000 22 614.7 511 4
66,000 33 722 616.5 5
88,000 44 829.3 722 6
110,000 55 936.7 727.5 6
132,000 66 10 44 833 7
154,000 77 10 51.3 938.5 8
EXAMPLES: Determining Free Area
FURNACE WATER HEATER TOTAL INPUT
110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq.. In. for each two Vertical Ducts or Open-
ings
66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq.. In. for a Single Duct or Opening
88,000 +30,000 =(118,000 divided by 2,000) =59.0 Sq.. In. for each of two Horizontal Ducts
Table 3 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors
ACH
OTHER THAN FAN---ASSISTED TOTAL
(1,000s BTUH GAS INPUT RATE)
FAN---ASSISTED TOTAL
(1,000s BTUH GAS INPUT RATE)
30 40 50 44 66 88 110 132 154
SpaceVolume(ft.3)
0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850
0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620
0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775
0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700
0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550
0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100
0.00 NP NP NP NP NP NP NP NP NP
NP = Not Permitted
AIR FOR COMBUSTION AND
VENTILATION
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
SU.S. Installations: Section 9.3 of the NFGC, Air for
Combustion and Ventilation and applicable provisions
of the local building codes.
SCanadian Installations: Part 8 of the
CAN/CSA--B149.1--05, Venting Systems and Air
Supply for Appliances and all authorities having
jurisdiction.
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
CAUTION
!
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make--up air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to the
Carbon Monoxide Poisoning Hazard warning in the venting
section of these instructions to determine if an adequate
amount of make--up air is available.
!WARNING
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume
of at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
SSpaces having less than 50 cubic feet per 1,000 Btuh
require the OUTDOOR COMBUSTION AIR
METHOD.
315A

9
1 SQ IN.
PER
4000
BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
CIRCULATING
AIR DUCTS
VENT
THROUGH
ROOF
D
B
A
C
E
1 SQ IN.
PER 4000
BTUH*
DUCT
TO
OUTDOORS
CIRCULATING AIR DUCTS
1 SQ IN.
PER 2000
BTUH*
1 SQ IN.
PER 2000
BTUH*
DUCTS
TO
OUTDOORS
12″MAX
12″MAX
12″MAX
Use any of the following
combinations of openings:
A & B C & D D & E F & G
NOTE:
*
Minimum dimensions of 3 in.
12″
MAX
12″
MAX
OUTDOORS
1 SQ IN.
PER
4000
BTUH*
F
G
CLEARANCE IN FRONT
OF COMBUSTION AIR
OPENINGS SHALL BE
AT LEAST 3 IN.
A03174
Fig. 7 -- Air for Combustion, Ventilation, and Dilution for
Outdoors
SSpaces having at least 50 cubic feet per 1,000 Btuh
may use the INDOOR COMBUSTION AIR,
STANDARD or KNOWN AIR INFILTRATION
METHOD.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper
combustion, ventilation, and dilution of flue gases using
permanent horizontal or vertical duct(s) or opening(s)
directly communicating with the outdoors or spaces that
freely communicate with the outdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air opening, to the outdoors.
a. One opening MUST commence within 12 in. (300
mm) of the ceiling and the second opening MUST
commence within 12 in. (300 mm) of the floor.
b. Size openings and ducts per Fig. 7 and Table 2.
c. TWO HORIZONTAL DUCTS require 1 square inch
of free area per 2,000 Btuh (1,100 mm2/kW) of
combined input for all gas appliances in the space per
Fig. 7 and Table 2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
square inch of free area per 4,000 Btuh (550
mm2/kW) for combined input of all gas appliances in
the space per Fig. 7 and Table 2.
3. ONE OUTDOOR OPENING requires:
CIRCULATING AIR
DUCTS
6" MIN
(FRONT)
†
CIRCULATING AIR DUCTS
VENT THROUGH ROOF
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12" MAX
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12" MAX
* Minimum opening size is 100 sq in. with
minimum dimensions of 3 in.
†
Minimum of 3 in.. when t
yp
e-B1 vent is used.
UNCONFINED
SPACE
INTERIOR
HEATED
SPACE
CLEARANCE IN FRONT OF COMBUSTION AIR
OPENINGS SHALL BE AT LEAST 3 IN.
A03175
Fig. 8 -- Air for Combustion, Ventilation, and Dilution from
Indoors
a. 1 square inch of free area per 3,000 Btuh (734
mm2/kW) for combined input of all gas appliances in
the space per Table 2 and
b. Not less than the sum of the areas of all vent
connectors in the space.
The opening shall commence within 12 in. (300 mm) of the
ceiling. Appliances in the space shall have clearances of at least 1
in. (25 mm) from the sides and back and 6 in. (150 mm) from the
front. The opening shall directly communicate with the outdoors
or shall communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely communicate with
the outdoors.
Indoor Combustion AirENFPA & AGA
Standard and Known--Air--Infiltration Rate Methods
Indoor air is permitted for combustion, ventilation, and dilution,
if the Standard or Known--Air--Infiltration Method is used.
315A

10
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Many homes require air to be supplied from outdoors
for furnace combustion, ventilation, and dilution of flue
gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
!WARNING
The Standard Method:
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40
air changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 3 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.
Table 3--Minimum Space Volumes were determined by using
the following equations from the National Fuel Gas Code ANSI
Z223.1--2006/NFPA 54--2006, 9.3.2.2:
1. For other than fan--assisted appliances, such as a draft
hood--equipped water heater:
Volume
Other
=21ft
3
ACH
I
other
1000 Btu/hr
A04002
2. For fan--assisted appliances such as this furnace:
Volume
Fan
=15ft
3
ACH
I
fan
1000 Btu/hr
A04003
If: Iother = combined input of all other than fan--assisted
appliances in Btuh/hr
Ifan = combined input of all fan--assisted appliances in Btuh/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and
to the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closable doors between rooms.
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1 in.2/1,000 Btuh (2,000
mm2/kW) of the total input rating of all gas appliances
in the space, but not less than 100 in.2 (0.06 m2). One
opening shall commence within 12 in. (300 mm) of
the ceiling and the second opening shall commence
within 12 in. (300 mm) of the floor. The minimum
dimension of air openings shall be at least 3 in. (80
mm).(SeeFig.8.)
c. Combining space on different floor levels. The
volumes of spaces on different floor levels shall be
considered as communicating spaces if connected by
one or more permanent openings in doors or floors
having free area of at least 2 in.2/1,000 Btuh (4,400
mm2/kW) of total input rating of all gas appliances.
2. An attic or crawlspace may be considered a space that
freely communicates with the outdoors provided there are
adequate permanent ventilation openings directly to
outdoors having free area of at least 1--in.2/4,000 Btuh of
total input rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for
combustion, permanent ventilation and dilution of flue
gases. However, in buildings with unusually tight
construction, additional air MUST be provided using the
methods described in the Outdoor Combustion Air
Method section.
4. Unusually tight construction is defined as Construction
with:
a. Walls and ceilings exposed to the outdoors have a
continuous, sealed vapor barrier. Openings are
gasketed or sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include
joints around window and door frames, between sole
plates and floors, between wall--ceiling joints, between
wall panels, at penetrations for plumbing, electrical
and gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor
Combustion Air Method below and,
2. Outdoor openings shall be located as required in the
Outdoor Combustion Air Method mentioned previously
and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air
Method below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The
minimum dimension of air openings shall be not less
than3in.(80mm).
INSTALLATION
UPFLOW INSTALLATION
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
only side return air is used.
315A

11
A02098
Fig. 9 -- Removing Bottom Closure Panel
NOTE: Side return--air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return--air
openings in DOWNFLOW configuration.
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 10.) Install field--supplied, 5/16 X 1--1/2 in. (max)
corrosion--resistant machine bolts, washers and nuts.
NOTE: Bottom closure must be used when leveling legs are
used. It may be necessary to remove and reinstall bottom closure
panel to install leveling legs. To remove bottom closure panel, see
Item 1 in Bottom Return Air Inlet section in Step 1 above.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in
each bottom corner of furnace. (See Fig. 10.)
2. For each leg, install nut on bolt and then install bolt with
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install
flat washer if desired.)
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
DOWNFLOW INSTALLATION
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 3
accessories are used:
SSpecial Base, KGASB
SCased Coil Assembly Part No. CPVP, CAPMP or
CNPVP
SCoil Box Part No. KCAKC
1. Determine application being installed from Table 4.
2. Construct hole in floor per Table 4 and Fig. 11.
3. Construct plenum to dimensions specified in Table 4 and
Fig. 11.
4. If downflow subbase, KGASB is used, install as shown in
Fig. 12. If Coil Assembly Part No. CPVP, CAPMP or
CNPVP Coil Box Part No. KCAKC is used, install as
shown in Fig. 13.
NOTE: It is recommended that the perforated supply--air duct
flanges be completely folded over or removed from furnace when
installing the furnace on a factory--supplied cased coil or coil box.
To remove the supply--air duct flange, use wide duct pliers or
hand seamers to bend flange back and forth until it breaks off. Be
careful of sharp edges. (See Fig. 14.)
1
3
⁄ 4 ″
1
3
⁄ 4 ″
1
3
⁄ 4 ″
1
3
⁄ 4 ″
5
⁄ 16 ″
5
⁄ 16 ″
5
⁄ 16 ″
5
⁄ 16 ″
A02071
Fig. 10 -- Leveling Legs
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
HORIZONTAL INSTALLATION
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace.
!WARNING
The furnace can be installed horizontally in an attic or crawlspace
on either the left--hand (LH) or right--hand (RH) side. The furnace
can be hung from floor joists, rafters or trusses or installed on a
non--combustible platform, blocks, bricks or pad.
Suspended Furnace Support
The furnace may be supported under each end with threaded rod,
angle iron or metal plumber’s strap as shown. (See Fig. 15 and
16.) Secure angle iron to bottom of furnace as shown.
Heavy--gauge sheet metal straps (plumber’s straps) may be used
to suspend the furnace from each bottom corner. To prevent
screws from pulling out, use 2 #8 x .--in. screws into the side and
2 #8 x .--in. screws in the bottom of the furnace casing for each
strap. (See Fig. 15 and 16.)
If the screws are attached to ONLY the furnace sides and not the
bottom, the straps must be vertical against the furnace sides and
315A

12
not pull away from the furnace sides, so that the strap attachment
screws are not in tension (are loaded in shear) for reliable support.
Platform Furnace Support
Construct working platform at location where all required furnace
clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in.
clearance requirement on side, set furnace on non--combustible
blocks, bricks or angle iron. For crawlspace installations, if the
furnace is not suspended from the floor joists, the ground
underneath furnace must be level and the furnace set on blocks or
bricks.
Roll--Out Protection
Provide a minimum 17--3/4 in. X 22 in. piece of sheet metal for
flame roll--out protection in front of burner area for furnaces
closer than 12 inches above the combustible deck or suspended
furnaces closer than 12 inches to joists. The sheet metal MUST
extend underneath the furnace casing by 1 in. with the door
removed.
The bottom closure panel on furnaces of widths 17--1/2 in. and
larger may be used for flame roll--out protection when bottom of
furnace is used for return air connection. See Fig. 17 for proper
orientation of roll--out shield.
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove two screws holding
bottom filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
side return air inlet(s) are used without a bottom return air inlet.
PLENUM
OPENING
C
A
BD
FLOOR
OPENING
A96283
Fig. 11 -- Floor and Plenum Opening Dimensions
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
FLOOR
OPENING
FURNACE
(OR COIL CASING
WHEN USED)
COMBUSTIBLE
FLOORING
A96285
Fig. 12 -- Furnace, Plenum, and Subbase Installed on a Com-
bustible Floor
A04140
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
FURNACE
SHEET METAL
PLENUM
FLOOR
OPENING
COMBUSTIBLE
FLOORING
A04140
Fig. 13 -- Furnace, Plenum, and Coil Assembly or Coil Box
Installed on a Combustible Floor
Not all horizontal furnaces are approved for side return air
connections (See Fig. 20.)
315A

13
Table 4 – Opening Dimensions (In.)
FURNACE
CASING
WIDTH
APPLICATION PLENUM OPENING FLOOR OPENING
A B C D
14–3/16
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required) 12--- 11/16 21--- 5/8 13--- 5/16 22---1/4
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required) 12--- 9/16 19 13--- 3/16 19---5/8
Downflow applications on combustible flooring (KGASB sub-
base required) 11--- 13/16 19 13--- 7/16 20---5/8
Downflow Applications on Combustible Flooring with CAPVP,
CAPMP, or CNPVP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
12--- 5/16 19 13---5/16 20
17–1/2
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required) 16 21 ---5/8 16--- 5/8 22---1/4
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required) 15--- 7/8 19 16--- 1/2 19---5/8
Downflow applications on combustible flooring (KGASB sub-
base required) 15--- 1/8 19 16--- 3/4 20---5/8
Downflow Applications on Combustible Flooring with CAPVP,
CAPMP, or CNPVP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
15--- 1/2 19 16--- 1/2 20
21
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required) 19--- 1/2 21--- 5/8 20--- 1/8 22--- 1/4
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required) 19--- 3/8 19 20 19---5/8
Downflow applications on combustible flooring (KGASB sub-
base required) 18--- 5/8 19 20--- 1/4 20---5/8
Downflow Applications on Combustible Flooring with CAPVP,
CAPMP, or CNPVP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
19 19 20 20
24--- 1/2
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required) 23 21 ---1/8 23--- 5/8 22---1/4
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required) 22--- 7/8 19 23--- 1/2 19---5/8
Downflow applications on Combustible flooring (KGASB sub-
base required) 22--- 1/8 19 23--- 3/4 20---5/8
Downflow Applications on Combustible Flooring with CAPVP,
CAPMP, or CNPVP Coil Assembly or KCAKC coil box (KGASB
subbase not required)
22--- 1/2 19 23--- 1/2 20
FILTER ARRANGEMENT
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury, or death.
Never operate a furnace without a filter or with filter access
door removed.
!WARNING
There are no provisions for an internal filter rack in these
furnaces. An external filter rack is required.
This furnace is shipped with a factory--supplied Media Filter
Cabinet. The Media Filter Cabinet uses either a factory--supplied
standard 1--inch filter or 4--inch wide Media Filter which can be
purchased separately.
Refer to the instructions supplied with Media Cabinet for
assembly and installation options.
AIR DUCTS
General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA)
or American Society of Heating, Refrigerating and Air
Conditioning Engineers (ASHRAE) or consult The Air Systems
Design Guidelines reference tables available from your local
distributor. The duct system should be sized to handle the
required system design CFM at the design external static pressure.
The furnace airflow rates are provided in Table 5--Air
Delivery--CFM (With Filter). When a furnace is installed so that
the supply ducts carry air circulated by the furnace to areas
outside the space containing the furnace, the return air shall also
be handled by duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply-- and return--duct connections to furnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration.
Ductwork passing through unconditioned space should be
insulated to enhance system performance. When air conditioning
is used, a vapor barrier is recommended.
Maintain a 1--in. clearance from combustible materials to supply
air ductwork for a distance of 36 in. horizontally from the
furnace. See NFPA 90B or local code for further requirements.
Ductwork Acoustical Treatment
NOTE: Metal duct systems that do not have a 90 degree elbow
and 10 ft. of main duct to the first branch take--off may require
internal acoustical lining. As an alternative, fibrous ductwork may
be used if constructed and installed in accordance with the latest
edition of SMACNA construction standard on fibrous glass
ducts. Both acoustical lining and fibrous ductwork shall comply
with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid
air ducts.
315A

14
Supply Air Connections
For a furnace not equipped with a cooling coil, the outlet duct
shall be provided with a removable access panel. This opening
shall be accessible when the furnace is installed and shall be of
such a size that the heat exchanger can be viewed for possible
openings using light assistance or a probe can be inserted for
sampling the air stream. The cover attachment shall prevent leaks.
Upflow and Horizontal Furnaces
Connect supply--air duct to flanges on furnace supply--air outlet.
Bend flange upward to 90_with wide duct pliers. (See Fig. 14.)
The supply--air duct must be connected to ONLY the furnace
supply--outlet--air duct flanges or air conditioning coil casing
(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All accessories
MUST be connected to duct external to furnace main casing.
NOTE: For horizontal applications, the top most flange may be
bent past 90_to allow the evaporator coil to hang on the flange
temporarily while the remaining attachment and sealing of the
coil are performed.
UPFLOW OWNFLOW HORIZONTAL
YES
NOT
RECOMMENDED
YES
YES
YES
120û
MIN
YES 120û
MIN
YES
120û
MIN
90û 90û
NOT
RECOMMENDED
NOT
RECOMMENDE
D
D
A02329
Fig. 14 -- Duct Flanges
1/4
" THREADED ROD
4 REQ.
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x
3/4
" SCREWS
TYPICAL FOR 2 SUPPORTS
1" SQUARE, 1
1/4
" x 1
1/4
" x
1/4
" ANGLE IRON
OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
8" MIN FOR DOOR
REMOVAL
OUTER DOOR
ASSEMBLY
A02345
Fig. 15 -- Horizontal Unit Suspension
315A

15
METHOD 2
USE (42) #8 x 3/4 SHEET
METAL SCREWS TYPICAL
FOR EACH STRAPS.THE
STRAPS SHOULD BE
VERTICAL AGAINST THE
FURNACE SIDES AND NOT
PULL AWAY FROM THE
FURNACE SIDES.
METHOD 1
FOLD ALL STRAPS UNDER
FURNACE AND SECURE WTH
(42) #8 x 3/4 SHEET METAL SCREWS
(2 SCREWS IN SIDE AND 2 SCREWS
IN BOTTOM).
A03176
Fig. 16 -- Horizontal Suspension with Straps
30-IN. MIN
WORK AREA
6″ MIN*
TYPE-B
VENT
17 3/4 ″
22 ″
SHEET
METAL
SEDIMENT
TRAP
EQUIPMENT MANUAL
SHUT-OFF GAS VALVE
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OF THE FURNACE
JACKET AND BUILDING JOISTS,
STUDS, OR FRAMING.
GAS
ENTRY
17 3/4 ″ OVER ALL
4 3/4 ″ UNDER DOOR
1″UNDER FURNACE
EXTEND OUT 12″ OUT
FROM FACE OF DOOR
* WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
UNION
A03177
Fig. 17 -- Typical Attic Installation
Downflow Furnaces
Connect supply--air duct to supply--air outlet on furnace. Bend
flange inward past 90_with wide duct pliers (See Fig. 14.) The
supply--air duct must be connected to ONLY the furnace supply
outlet or air conditioning coil casing (when used). When installed
on combustible material, supply--air duct must be connected to
ONLY the accessory subbase, KGASB0201ALL, or a factory
approved air conditioning coil casing. DO NOT cut main furnace
casing to attach supply side air duct, humidifier, or other
accessories. All accessories MUST be connected to duct external
to furnace casing.
315A

16
A02075
Fig. 18 -- Upflow Return Air Configurations and Restrictions
A02163
Fig. 19 -- Downflow Return Air Configurations and Restrictions
315A

17
A02162
Fig. 20 -- Horizontal Return Air Configurations and Restrictions
315A

18
Table 5 – Air Delivery -- CFM (With Filter)*
070-12/036070
090-16/048090
110-20/060110
136-22/066135
155-22/066155
A04016
315A

19
Return Air Connections
FIRE HAZARD
A failure to follow this warning could cause personal injury,
death and/or property damage.
Never connect return--air ducts to the back of the furnace.
Follow instructions below.
!WARNING
Downflow Furnaces
The return--air duct must be connected to return--air opening
(bottom inlet) as shown in Fig. 3. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and
certain horizontal furnaces. Bypass humidifier connections
should be made at ductwork or coil casing sides exterior to
furnace. (See Fig. 19.)
Upflow and Horizontal Furnaces
The return--air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. 3. Bypass humidifier may be attached
into unused return air side of the furnace casing. (See Fig. 18 and
20.) Not all horizontal furnace models are approved for side
return air connections. (See Fig. 20.)
GAS PIPING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections.
!WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Use proper length of pipe to avoid stress on gas control
manifold and a gas leak.
!WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Gas valve inlet and/or inlet pipe must remain capped until
gas supply line is permanently installed to protect the valve
from moisture and debris. Also, install a sediment trap in the
gas supply piping at the inlet to the gas valve.
!WARNING
Gas piping must be installed in accordance with national and
local codes. Refer to current edition of NFGC in the U.S. and the
CAN/CSA--B149.1--05 in Canada.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a
separate line running directly from meter to furnace.
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a
licensed plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T--handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
Refer to Table 6 for recommended gas pipe sizing. Risers must be
used to connect to furnace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of 1 hanger
every 6 Ft. Joint compound (pipe dope) should be applied
sparingly and only to male threads of joints. Pipe dope must be
resistant to the action of propane gas.
NOMINAL
IRON PIPE
SIZE (IN.)
INTERNAL
DIAMETER
(IN.)
LENGTH OF PIPE (FT.)
10 20 30 40 50
1/2 0.622 175 120 97 82 73
3/4 0.824 360 250 200 170 151
11.049 680 465 375 320 285
1 --- 1 / 4 1.380 1400 950 770 660 580
1 --- 1 / 2 1.610 2100 1460 1180 990 900
FIRE OR EXPLOSION HAZARD
A failure to follow this warning could result in personal
injury, death, and/or property damage.
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously served another gas
appliance. Black iron pipe shall be installed at the furnace
gas control valve and extend a minimum of 2 in. outside the
furnace.
!WARNING
FURNACE DAMAGE HAZARD
Failure to follow this caution may result in furnace damage.
Connect gas pipe to furnace using a backup wrench to
avoid damaging gas controls and burner misalignment.
CAUTION
!
An accessible manual equipment shutoff valve MUST be
installed external to furnace casing and within 6 ft. of furnace. A
1/8--in. NPT plugged tapping, accessible for test gauge
connection, MUST be installed immediately upstream of gas
supply connection to furnace and downstream of manual
equipment shutoff valve.
NOTE: The furnace gas control valve inlet pressure tap
connection is suitable to use as test gauge connection providing
test pressure DOES NOT exceed maximum 0.5 psig (14--in. wc)
stated on gas control valve. (See Fig. 55.)
Some installations require gas entry on right side of furnace (as
viewed in upflow). (See Fig. 21 and 22)
Install a sediment trap in riser leading to furnace as shown in Fig
23. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of furnace gas controls. Place a ground
joint union between furnace gas control valve and exterior
manual equipment gas shutoff valve.
315A

20
A 1/8--in. NPT plugged tapping, accessible for test gauge
connection, MUST be installed immediately upstream of gas
supply connection to furnace and downstream of manual
equipment shutoff valve.
Piping should be pressure and leak tested in accordance with
NFGC in the United States or CAN/CSA--B149.1--05 in Canada,
local, and national plumbing and gas codes before the furnace has
been connected. After all connections have been made, purge
lines and check for leakage at furnace prior to operating furnace.
If pressure exceeds 0.5 psig (14--in. wc), gas supply pipe must be
disconnected from furnace and capped before and during supply
pipe pressure test. If test pressure is equal to or less than 0.5 psig
(14--in. wc), turn off electric shutoff switch located on furnace gas
control valve and accessible manual equipment shutoff valve
before and during supply pipe pressure test. After all connections
have been made, purge lines and check for leakage at furnace
prior to operating furnace.
The gas supply pressure shall be within the maximum and
minimum inlet supply pressures marked on the rating plate with
the furnace burners ON and OFF.
A05028
Fig. 21 -- Right Side Gas Entry Example 1
90°Elbow
2" Nipple
Street Elbow
Gas Valve
A02327
Fig. 22 -- Right Side Gas Entry Example 2
UNION
SEDIMENT
TRAP
MANUAL
SHUTOFF
VALVE
(REQUIRED
GAS
SUPPLY
A02035
Fig. 23 -- Typical Gas Pipe Arrangement
ELECTRICAL CONNECTIONS
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Blower access panel door switch opens 115--v power to
control. No component operation can occur. Do not
bypass or close switch with panel removed.
!WARNING
See Fig. 25 for field wiring diagram showing typical field 115--v
wiring. Check all factory and field electrical connections for
tightness.
Field--supplied wiring shall conform with the limitations of 63_F
(33_C) rise.
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
The cabinet MUST have an uninterrupted or unbroken
ground according to NEC ANSI/NFPA 70--2006 and
Canadian Electrical Code CSA C22.1 or local codes to
minimize personal injury if an electrical fault should occur.
This may consist of electrical wire, conduit approved for
electrical ground or a listed, grounded power cord (where
permitted by local code) when installed in accordance with
existing electrical codes. Refer to the power cord
manufacturer’s ratings for proper wire gauge. Do not use
gas piping as an electrical ground.
!WARNING
FURNACE MAY NOT OPERATE HAZARD
Failure to follow this caution may result in intermittent
furnace operation.
Furnace control must be grounded for proper operation or
else control will lock out. Control must remain grounded
through green/yellow wire routed to gas valve and manifold
bracket screw.
CAUTION
!
315A