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Carrier 140/E Series Installation manual

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Installation, Start-up, Operating and
Service and Maintenance
Instructions Series 140/E
SAFETY CONSIDERATIONS ........................ 2
INTRODUCTION .................................. 4
CODES AND STANDARDS .......................... 5
Safety ........................................ 5
General Installation ............................... 5
Combustion and Ventilation Air ..................... 5
Duct Systems ................................... 5
Acoustical Lining and Fibrous Glass Duct ............. 5
Gas Piping and Gas Pipe Pressure Testing ............. 5
Electrical Connections ............................ 5
Venting ....................................... 5
ELECTROSTATIC DISCHARGE PRECAUTIONS
PROCEDURE ..................................... 5
LOCATION ....................................... 6
INSTALLATION .................................. 11
UpfJow Installation .............................. 11
Downflow Installation ........................... 11
Horizontal Installation ........................... 13
Filter Arrangement .............................. 14
Air Ducts ..................................... 14
Gas Piping .................................... 17
115-V Wiring .................................. 22
J-Box Relocation .............................. 23
Electrical Connection to J-Box ..................... 23
Electrical Box on Furnace Casing Side ............... 23
Power Cord Installation in Furnace J-Box ............ 23
BX CaMe Installation in Furnace J-Box .............. 23
24-V Wiring ................................... 24
Accessories
Venting ....................................... 28
General Venting Requirements ..................... 28
Masonry Chimney Requirements ................... 28
Appliance Application Requirements ................ 29
Additional Venting Requirements ................... 31
Sidewall Venting ................................ 31
START-UP, ADJUSTMENT, AND SAFETY CHECK ..... 36
General ....................................... 36
Start-up Procedures ............................. 36
Adjustments ................................... 36
Check Safety Controls ........................... 39
Checklist ...................................... 39
SERVICE AND MAINTENANCE PROCEDURES ....... 45
Introduction ................................... 45
Electrical Controls and Wiring ..................... 45
Care and Maintenance ........................... 46
Cleaning and/or Replacing Filter ................... 46
Sequence of Operation ........................... 50
Blower Motor and Wheel ......................... 46
Cleaning Heat Exchanger ......................... 47
Sequence of Operation ........................... 49
Wiring Diagrams ............................... 50
Troubleshooting ................................ 50
Accessory List ................................. 54
PARTS REPLACEMENT INFORMATION GUIDE ....... 55
ISO 9001:20O0
@UseoftheAHRiCertifiedTM Markindicatesa
manufactureCs pa_ictpationinthe program
Forverificationofcertificationfor individual
products,goto www.ahridirectory.org.
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1-2009©, with permission of National Fire Protection
Association, Quincy, MA 02269 and American Gas Association,
Washington DC 20001. This reprinted material is not the
complete and official position of the NFPA or ANSI on the
referenced subject, which is represented only by the standard in
its entirety.
SAFETY CONSIDERATIONS
FIRE, EXPLOSION, ELECTRICAL SHOCK,
AND CARBON MONOXIDE POISONING
HAZARD
Failure to follow this warning could result in dangerous
operation, serious iniury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use could cause carbon monoxide
poisoning, explosion, fire, electrical shock, or other
conditions which may cause personal iniury or property
damage. Consult a qualified service agency, local gas
supplier, or your distributor or branch for information or
assistance. The qualified service agency must use only
factory-authorized and listed kits or accessories when
modifying this product.
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.
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.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal iniury, 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.
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 iniury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal iniury or death. WARNING signifies hazards
which could result in personal iniury or death. CAUTION is
used to identify unsafe practices which may result in minor
personal iniury or product and property damage. NOTE is used
to highlight suggestions which will result in enhanced
installation, reliability, or operation.
1. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
2. Install this furnace only in a location and position as spe-
cified in the "Location" section of these instructions.
3. Provide adequate combustion and ventilation air to the
furnace space as specified in "Air for Combustion and
Ventilation" section.
4. Combustion products must be discharged outdoors. Con-
nect this furnace to an approved vent system only, as spe-
cified in the "Venting" section of these instructions.
5. Never test for gas leaks with an open flame. Use a com-
mercially 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 in-
tended 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 con-
taining the furnace, the return air shall also be handled by
duct(s) sealed to the furnace casing and terminating out-
side the space containing the furnace. See "Air Ducts" sec-
tion.
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 in-
structions.
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 install-
ation in alcoves, attics, basements, closets, utility rooms,
crawlspaces, and garages. The furnace is factory-shipped
for use with natural gas. A CSA listed accessory gas con-
version kit is required to convert furnace for use with pro-
pane gas.
11. See Fig. 2 for required clearances to combustible construc-
tion.
12. Maintain a 1-in. (25 mm) clearance from combustible ma-
terials to supply air ductwork for a distance of 36 in. (914
mm) horizontally from the furnace. See NFPA 90B or loc-
al code for further requirements.
13. These furnaces SHALL NOT be installed directly on car-
peting, tile, or any other combustible material other than
wood flooring. In downflow installations, factory access-
ory floor base MUST be used when installed on combust-
ible materials and wood flooring. Special base is not re-
quired when this furnace is installed on manufacturer's
Coil Assembly Part No. CNPV, CNRV, CAR and CAP, or
when Coil Box Part No. KCAKC is used. See Fig. 2 for
clearance to combustible construction information.
1/16
[4a_1
f_7/8
, --TOP O_¢.A_NG
_@/4 [1Z/1
_ 21.6
BOTTOM_
Q
_B
57/S--
27 @/4
_gfN
_de
° 12
1
--_L ! 1/4
I N_N
A10290
NOTES:
1. Two additional 7/8-in. (22 mm) 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. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.
b. For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle.
c. For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) 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. 1 - Dimensional Drawing
Table 1 -Dimensions
AB C D ACCESSORY
VENT FILTER
CABINET WIDTH OUTLET WIDTH TOP & BOTTOM SHIP WT
FURNACE SIZE BOTTOM FLUE iNLET WIDTH CONNECTION LB. (KG) MEDIA
COLLAR SIZE CABINET SIZE
IN. (MM)
14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 107 (47) 16 (406)
14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 107 (49) 16 (406)
14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 111 (50) 16 (406)
14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 115 (52) 16 (406)
17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 126 (57) 16 (406)
17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 127 (58) 16 (406)
21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 140 (64) 20 (508)
21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66) 20 (508)
17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 135 (61) 16 (406)
21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66) 20 (508)
21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 152 (69) 20 (508)
21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102)* 149 (68) 20 (508)
24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102)* 163 (74) 24 (610)
24-1/2 (622) 15-1/16 (383) 23 (584) 4 (102)* 170 (77) 24 (610)
mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for
045- 08/024045
045-12/036045
070- 08/024070
070-12/036070
070-16/048070
090-14/042090
090-16/048090
090- 20/060090
110-12/036110
110-16/048110
110-22/066110
135-16/048135
135-22/066135
155-20/060155 22-7/8 (581)
"135 and 155 size furnaces require a 5 or 6-in. (127 or 152
complete installation requirements.
INTRODUCTION
Series 140/E 4-way multipoise Category I fan-assisted furnace is
CSA 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. This furnace is designed for
naininmm continuous return-air temperature of 60°F (16 °C) db
or intermittent operation down to 55°F (13°C)db such as when
used with a night setback thermostat. Return-air temperature
nmst not exceed 80°F (27°C) db. Failure to follow these
return-air temperature limits may affect reliability of heat
exchangers, motors, and controls. (See Fig. 3.)
For accessory installation details, refer to the applicable
instruction literature.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
improperadjustment, alteration, service,
maintenance, or installationcancause
seriousinjuryor death,
Read and follow instructions and
precautions in User's information Manual
provided with this furnace, installation
and service must be performed by a
qualified service agency or the gas
supplier,
Check entire gas assembly for leaks after
lighting this appliance.
iNSTALLATION
1. This furnace must be installed in
accordance with the manufacturer's
instructions and local codes. In the
absence of local codes, follow the National
Fuel Gas Code ANSI Z223.1 /NFPA54
or CSA B-149. 1 Gas InstNlation Code.
2. This furnace must be installed so there are
provisions for combustion and ventilation
air. See manufacturer's installation
information provided with this appliance.
OPERATION
This furnace is equipped with manual reset
limit switch(es) in burner compartment to
protect against overheat conditions that
can result from inadequate combustion air
supply or blocked vent conditions.
1. Do not bypass limit switches.
2. If a limit opens, call a quallified
serviceman to correct the condition
and reset limit switch.
MINIMUMiNCHESCLEARANCETO COMBUSTIBLECONSTRUCTION
This forced air furnace is
equipped for use with natural
gas at Ntitudes 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 combustible material.
This furnace may be used with
a Type B-1 Vent and may be
vented in common with other
gas fired appliances.
This furnace is approved for
UPFLOW, DOWNFLOW, and
HORIZONTAL installations.
Clearancearrows
donotchangewith
furnaceorientation.
Clearancein inches
Vent Clearance to combustiNes:
For SingleWall vents 6 inches(6 po).
ForType B=Iventtype I inch(1 po).
MINIMUM INCHES CLEARANCE TO
COMBUSTIBLE CONSTRUCTION
DOWNFLOWPOSiTiONS:
Installation on non-combustible floors only.
For Installation on combustible flooring only when installed on special
base, Part No. KGASB0201ALL or NAHA01101SB, Coil Assembly,
Part No. CAR, CAP, CNPV, CNRV, END4X, ENW4X, WENC, WTNC,
WENW OR WTNW.
18 inches front clearance required for alcove.
1-
O
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. IIIIIIIIIIIIIIIIIIIIIIIIIII
336996-101 REV. C
Fig. 2 - Clearances to Combustibles
A10269
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these instructions. The installation nmst 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, follow all codes and standards for the
following:
Safety
• National Fuel (;as Code (NFGC) NFPA 54-2009/AN-
SI Z223.1-2009 and the Installation Standards, Warm
Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
ii !I
II I
A05004
Fig. 3 - Return Air Temperature
General Installation
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).
Combustion and Ventilation Air
Section 9.3 of the NFGC, NFPA 54/ANSI Z223.1-2009 Air for
Combustion and Ventilation.
Duct Systems
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 Lininq and Fibrous Glass Duct
Current edition of SMACNA and NFPA 90B as tested by UL
Standard 181 for Class I Rigid Air Ducts
Gas Pipinq and Gas Pipe Pressure Testinq
NFPA 54/ANSI Z223.1-2009 Chapters 5, 6, 7, and 8 and
National Plumbing Codes.
Electrical Connections
National Electrical Code (NEC) ANSI/NFPA 70-2008.
Venting
NFGC NFPA 54/ANSI Z223.1-2009 ; ch@ters 12 and 13.
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
FURNACE RELIABILITY HAZARD
Improper installation or service of furnace may cause
premature furnace component failure.
Electrostatic discharge can affect electronic components.
Follow the Electrostatic Discharge Precautions Procedure
listed below during furnace installation and servicing to
protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects
maybe required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY'S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the fur-
nace chassis which is close to the control. Firmly touch
the clean, unpainted, metal surface of the furnace chassis
which is close to the control. Tools held in 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 un-
grounded objects, etc.)
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch a clean, unpainted
metal surface of the furnace again before touching control
or wires.
5. Use this procedure for installed and uninstalled (ungroun-
ded) furnaces.
6. Before removing a new control from its container, dis-
charge your body's electrostatic charge to ground to pro-
tect the control from damage. If the control is to be in-
stalled in a furnace, follow items 1 through 4 before
bringing the control or yourself in contact with the fur-
nace. Put all used and new controls into containers before
touching ungrounded objects.
7. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
g
THE BLOWER IS LOCATED
TOTHE RIGHT OFTHE
BURNER SECTION, AND
AIR CONDiTiONED AiR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
AIRFLOW
d> THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDiTiONED AIR IS
DISCHARGED UPWARD.
t
\
HORIZONTAL LEFT
_AIRFLOW
HORIZONTAL RIGH-'_AIR FL_OW
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDiTiONED AIR IS
DISCHARGED TO THE RIGHT.
A02097
Fig. 4 - Multipoise Orientations
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.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
iniury or death, and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
This furnace must:
• be installed so the electrical components are protected
from water.
• not be installed directly on any combustible material
other than wood flooring for upflow applications.
Downflow installations require use of afactory-ap-
proved floor base or coil assembly when installed on
combustible materials or wood flooring (refer to
SAFETY CONSIDERATIONS).
• be located as close to the chimney or vent and attached
to an air distribution system. Refer to Air Ducts section.
• be provided ample space for servicing and cleaning.
Always comply with minimum fire protection clear-
ances shown on the furnace clearance to combustible
label.
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
• Commercial buildings
• Buildings with indoor pools
• Laundry rooms
• Hobby or craft rooms, and
• Chemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
All fuel-burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return-air duct to
prevent pulling air from the burner area and from draft safeguard
opening.
BACK
18qN. (457.2 mm)
MINIMUM TO BURNERS
A93044
Fig. 5 - Installation in a Garage
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
inches (457 mm) 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. (See Fig.
5.)
FIRE HAZARD
Failure to follow this warning could result in personal
iniury, 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.)
Fig. 6 - Prohibit Installation on Back
A02054
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Improper use or installation of this furnace may cause
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.
Table 2 - Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors
TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS
FURNACE (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)
iNPUT Free Area of Opening Round Duet Free Area of Opening Round Duet Free Area of Opening Round Duet
(BTUH) and Duet Dia. and Duet Dia. and Duet Dia.
Sq. In. (Sq. turn) In. (turn) Sq. In. (Sq. turn) In. (turn) Sq. In. (Sq. turn) In. (turn)
44,000 22 (14194) 6 (152) 14.7 (9484) 5 (127) 11 (7096) 4 (102)
66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)
88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152)
110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152)
132,000 66 (42580) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)
154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)
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 Openings
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
OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL
(1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE)
30 40 50 44 66 88 110 132 154
ACH Space Volume Ft3 (M3)
1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850
0.60 (29.7) (39.6) (49.5) (31.1) (46.7) (62.2) (77.8) (93.4) (109.0)
1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620
0.50 (35.6) (47.5) (59.4) (37.3) (56.0) (74.7) (93.4) (112.1 ) (130.8)
1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775
0.40 (44.5) (59.4) (74.3) (46.7) (70.0) (93.4) (116.8) (140.1 ) (163.5)
2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700
0.30 (59.4) (79.2) (99.1) (62.2) (93.4) (124.5) (155.7) (186.8) (218.0)
3,150 4,200 3,300 4,950 6,600 8,250 9,900 11,550
0.20 (89.1) (118.9) 5,250 (148.6) (93.4) (140.1) (186.8) (233.6) (280.3) (327.0)
6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100
0.10 (178.3) (237.8) (297.3) (186.8) (280.3) (373.7) (467.2) (560.6) (654.1)
0.00 NP NP NP NP NP NP NP NP NP
NP = Not Permitted
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion nmst not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
Location Relative to Cooling Equipment
The cooling coil nmst be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the
furnace. If the dampers are manually operated, they nmst be
equipped with means to prevent operation of either unit unless
the damper is in the full-heat or full-cool position.
AIR FOR COMBUSTION AND
VENTILATION
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
• Section 9.3 of the NFGC NFPA 54/ANSI
Z223.1-2009, Air for Combustion and Ventilation,
and applicable provisions of the local building codes.
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 Carbon
Monoxide Poisoning Hazard warning in venting section of
these instructions to determine if an adequate amount of
make-up air is available.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume
of at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
• Spaces having less than 50 cubic feet per 1,000 Btuh
require the OUTDOOR COMBUSTION AIR
METHOD.
• Spaces 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 combus-
tion, ventilation, and dilution of flue gases using perman-
ent 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.
e. One opening MUST commence within 12-in. (300 ram)
of the ceiling and the second opening MUST commence
within 12-in. (300 ram) of the floor.
f. Size openings and ducts per Fig. 7 and Table 2.
g. TWOHORIZONTALDUCTSrequire 1-in.2offreearea
per 2,000 Btuh (1,100 mm2/kW) of combined input for
all gas appliances in the space per Fig. 7 and Table 2.
h. TWO OPENINGS OR VERTICAL DUCTS require
1-in. 2 of free area per 4,000 Btuh (550 mm2/kW) for
combined input of all gas appliances in the space per Fig.
7 and TaMe 2.
3. ONE OUTDOOR OPENING requires:
a. 1-in. 2 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 ram) of the
ceiling. Appliances in the space shall have clearances of at least
l-in. (25 ram) from the sides and back and 6-in. (150 ram) from
the front. The opening shall directly conmmnicate 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.
/C- 1 SQ IN.
DUCTS --J /\ PER 4000
TO _ /_, BTUH*
OUTDOORSI "_'&.. _&
iii j i} /
I I J
(3osmm)12"MA_/I I D III 2"(3osmm)
1SQ_N.i I _ IVENT I I LJ MAX
PER2000T IBI _) ITHROUGH I I FN_
BTUH* _ DROOF T
oc_ PER
......... ] ] iDUCTS OO
TO
OUTDOORS / II
i!iiiiil _'Hii_ _ { ii ii
E 1 SQIN.
; PER
4000.
_,_ J I _N-_
PER2000_ :lAli _ 'G _ t___f
BTUH* f It _
__ __ • J
(3o_mm)_2"MAX C _' I_ (30_mm)
i, , i ! 12"MAX I _,
'r _ I 1 (305mm) ' ]"
LJ
CIRCULATING AIR DUCTS DUCTr x 1 SQ IN.
] TO PER 4000
OUTDOORS BTUH*
*Minimum dimensions of 3-in, (76 mm.)
Use any of the following combinations of openings:
A&BC&DD&EF&G A03174
Fig. 7-Air for Combustion, Ventilation, and Dilution for
Outdoors
Indoor Combustion Air -NFPA & AGA
Standard and Known-Air-Infiltration Rate Methods
Indoor air is pernfitted for combustion, ventilation, and dilution,
if the Standard or Known-Air-Infiltration Method is used,
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in death and/or
personal injury.
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.
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 deternfined per Table 3 or Equations 1 and 2.
Deternfine the minimum required volume for each appliance in
the space and add the volumes together to get the total nfininmm
required volume for the space.
Table 3-Minimum Space Volumes were deternfined by using
the following equations from the National Fuel Gas Code ANSI
Z223.1-2009/NFPA 54-2009, 9.3.2.2:
1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater:
Volume - 21ft3 _ [ °ther
Other ACH 000 Btu/hr
2. For fan-assisted appliances such as this furnace:
Volume _ 15ft 3 _ I fan
Fan ACH 000 Btu/hr
A04002
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 closeable doors between rooms.
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1 in.2/l,000 Btuh (2,000
mm2/kW) of the total input rating of all gas appliances
in the space, but not less than 100 in. 2 (0.06 m2). One
opening shall commence within 12-in. (300 ram) of the
ceiling and the second opening shall commence within
12-in. (300 ram) of the floor. The nfininmm dimension
of air openings shall be at least 3-in. (80 ram). (See Fig.
8.)
10
INTERIOR
HEATED
SPACE
1 1
I I
CIRCULATING AIR
DUCTS
I
III
I I
VENT THROUGH ROOF
:305mm)
1 SQ iN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6" MIN (152mm)
(FRONT)0
CIRCULATING AIR DUCTS
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
L 12" MAX (3O5mm)
* Minimum opening size is 100 sq in. (64516 sq, mm)with minimum dimensions
of 3 in. (76 mm)
1-Minimum of 3 in. (76 mm) when type-B1 vent is used. A03175
Fig. 8 -Air for Combustion, Ventilation, and Dilution from
Indoors
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 per-
manent openings in doors or floors having free area of
at least 2 in.2/l,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 conmmnicates with the outdoors provided there are
adequate permanent ventilation openings directly to out-
doors having free area of at least 1 -in.2/4,000 Btuh of total
input rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,in-
filtration should be adequate to provide air for combus-
tion, permanent ventilation and dilution of flue gases.
However, in buildings with unusually tight construction,
additional air MUST be provided using the methods de-
scribed in the Outdoor Combustion Air Method section.
Unusually tight construction is defined as construction with:
a. Walls and ceilings exposed to the outdoors have a con-
tinuous, sealed vapor barrier. Openings are gasketed or
sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include
joints around window and door frames, between sole
plates and floors, between wall-ceiling joints, between
wall panels, at penetrations for plumbing, electrical and
gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor Combus-
tion Air Method below and,