Carrier KGACK0101HCK User manual

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KGACK0101HCK
Installation Instructions
HORIZONTAL INSTALLATION KIT
NOTE: Read the entire instruction manual before starting the
installation.SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
include in literature and attached to the unit. Consult local building
codes, the current editions of the National Fuel Gas Code (NFGC)
NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC)
NFPA 70.
In Canada, refer to the current editions of the National Standards of
Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation Codes, and Canadian Electrical Code CSA C22.1.
Recognize safety information. This is the safety--alert symbol .
When you see this symbol on the unit 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 hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability, or
operation.
FIRE, EXPLOSION, ELECTRICAL SHOCK
HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
The ability to properly perform maintenance on this
equipment requires certain knowledge, mechanical skills,
tools, and equipment. If you do not possess these, do not
attempt to perform any maintenance on this equipment
other than those procedures recommended in the User’s
Manual.
!WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow instructions 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
could result in personal injury or death. Consult your
distributor or branch for information or assistance. The
qualified installer or agency must use only
factory--authorized kits or accessories when servicing this
product.
!WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position and
install a lockout tag. There may be more than one electrical
supply to the furnace. Check accessories and cooling unit
for additional electrical supplies that must be shut off during
furnace servicing. Lockout and tag switch with a suitable
warning label. Verify proper operation after servicing.
!WARNING
INTRODUCTION
In the Horizontal orientation, a field supplied accessory drain trap
grommet is required to seal the gap between the casing and the
condensate trap for Direct Vent applications. The condensate trap
outlet extends 2 inches (51 mm) below the furnace casing. To
allow for servicing the trap, the condensate drain tube in the loose
parts bag can be modified to make a coupler to allow for future
service of the condensate trap and drain line.
DESCRIPTION AND USAGE
The drain trap grommet seals the burner compartment of the
furnace to prevent ambient air from being drawn into the furnace
vestibule. It is only required for Horizontal installations when a
Direct Vent (2--pipe) or Ventilated Combustion Air venting
application is used. It is not required for other orientations or when
a Non--Direct Vent (1--pipe) application is used. A Non--Direct
Vent application is when the combustion air for the furnace comes
from the same location as the furnace.

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Table 1 – Kit Contents
DESCRIPTION QUANTITY
Horizontal Trap Grommet 1
Installation Instructions 0
INSTALLATION
Unit Shut Down
1. Set room thermostat to lowest setting or “OFF”
2. Disconnect power at external disconnect, fuse or circuit
breaker.
3. Turn off gas at external shut--off or gas meter.
4. Remove outer doors and set aside.
5. Turn electric switch on gas valve to OFF.
Horizontal Orientation
1. Remove the knock--out for the condensate trap in the side of
the casing.
2. Install the drain trap grommet in the casing. If necessary, re-
move the trap, install the grommet and re--install the trap.
3. Remove the pre--formed drain tube and the two spring
clamps from the loose parts bag.
4. Remove the formed grommet on thetube to create an elbow
or straight connector. See Fig. 2.
5. To connect the modify drain tube and remaining condensate
drain, follow the steps below. Refer to Fig. 3.
6. Connect the cut tube to the outlet of the condensate trap
with 1 spring clamp.
7. Slide the other spring clamp down the plain end of the drain
tube.
8. Connect additional 1/2--in. CPVC piping to the open end of
the tube.
9. Slide the spring clamp down over the 1/2--in. CPVC pipe.
10. Connect additional 1/2--in. CPVC piping to a condensate
pump approved for use with acidic furnace condensate orto
a code--approved drain.
NOTE: When a condensate pump is not used, slope the pipe away
from the furnace to allow for proper drainage.
Freeze Protection
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
manufacturers recommendations. Prime the trap before furnace
operation.
Unit Checkout
1. Set thermostat to “OFF”.
2. Turn on power at external disconnect, fuse or circuit break-
er.
3. Turn on gas at external shut--off or gas meter.
4. Check for gas leaks with a soap and water solution.
5. Manually close blower door switch.
6. Initiate component test through circuit board by referring
to“Component Test” on status code label on blower access
door for complete test sequence information.
7. If any status codes are flashed, refer to status code label on
unit blower door.
8. 8.Turn thermostat fan switch to “ON”, “Continuous” or
jumper R to G terminals at furnace control board.
9. Check for air leakage around cell panel. It may benecessary
to remove heat exchanger assembly and top gasket between
cell panel and furnace casing top plate. Re--install and re--
check for blower air leaks.
10. Remove jumper(s) or set thermostat fan to “Auto” or “OFF”
11. Release blower door switch
12. Install blower access door
13. Set thermostat to call for heat.
14. Allow unit to initiate a complete call for heat cycle.
15. Check for air leakage around collector box. A whistling
noise may indicate air leak in collector box seal.
NOTE: As part of the system check--out, verify that the following
conditions are not affecting the operation of the furnace:
SShort Cycling--Defective thermostat: Incorrect thermostat
anticipator setting, dirty filter or over--sized furnace.
SUnder firing/low BTU input: Set manifold pressure and verify
firing rate as shown on rating plate by clocking the gas meter.
SOverfiring/high BTU input: Set manifold pressure and verify
Sfiring rate as shown on rating plate by clocking the gas meter.
SLow temperature rise: Set unit for correct temperature rise range
Sas shown on unit rating plate.
SContaminated combustion air:Remove contaminates orprovide
Sample fresh air for combustion.
SExcessive amounts of outside ventilation air: Return air
temperature cannot be below 60 degrees F for extended periods
of time.
SIncorrect venting or termination: Recirculation of products of
combustion into the combustion airpipe can damage the
furnace.
SVerify proper venting and vent termination per installation
instructions. For additional information, and a complete
sequence of furnace operation, refer to furnace Installation,
Start-- Up and Operating Instructions.
16. After System Check--out is complete, set thermostat below
room temperature.
17. Verify that burner shuts down and blower completes selec-
ted off delay time.
18. Verify furnace operates properly and set thermostat to de-
sired room temperature.
19. Re--install outer door.

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Remove knockout.
Install grommet before
relocating condensate
trap.
A11348
Fig. 1 -- Remove Knockout / Install Grommet
RIGHT SIDE DRAIN ELBOW
Cut and remove formed end of
drain tube for left side and horizontal
drain connection
A11343
Fig. 2 -- Modify Drain Tube
Attach tube to condensate trap
Cut formed end o
condensate drain tube
Field supplied 1/2” CPVC
drain extension
A11484
Fig. 3 -- Condensate Drain

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Copyright 2011 CAC / BDP D7310 W. Morris St. DIndianapolis, IN 46231 Printed in U.S.A. Edition Date: 09/11
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
C a t a l o g N o : A G --- K G A C K --- 0 1
Replaces: NEW