Carrier 160 Series Guide

58CVA/CVX
Variable—Speed, Induced—Combustion Deluxe
4—Way Multipoise Gas Furnace
Series 160
Carrier
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turn to the IZA
Installation, Start—up, Operating and
Service and Maintenance Instructions
SAFETY CONSIDERATIONS . 2.0.0.0... 0.00000 00 ee ee 2
INTRODUCTION 2.00... 0.0 eee ees 4
CODES AND STANDARDS ......0.0..0. 000.00 eee 4
Safety... eee eee tenes 4
General Installation 2.2... 0.0.0... eee eee 4
Combustion and Ventilation Air 2.6.0.0... 00.0. eee 4
Duct Systems 0... 6. eee eee 4
Acoustical Lining and Fibrous Glass Duct ............... 4
Gas Piping and Gas Pipe Pressure Testing ............... 4
Electrical Connections . 2.0.0... 0.0. eee eee 4
Venting oo. eee eee tenes 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE 2.0... ee eens 4
LOCATION 2.0... ee eens 5
AIR FOR COMBUSTION AND VENTILATION ......... 8
Outdoor Combustion Air Method ................000. 9
The Standard Method: .. 0.0.0.0... 0. eee eee eee 9
Combination of Indoor and Outdoor Air ............. 10
INSTALLATION 2.0.0... eee eens 10
Bottom Return Air Inlet 22.0.0... eee 10
Side Return Air Inlet... 0.0.0.0. ee eee 10
Leveling Legs (If Desired) . 2.0... 6... 11
Bottom Return Air Inlet... 0.0.0... eee 11
Suspended Furnace Support ... 0... ... 0.0.00. 000 ee 11
Platform Furnace Support .. 0.0.0.0... 0.00000 ee eee 11
Roll-Out Protection .. 0... 0.0.00. eee eee 12
Bottom Return Air Inlet... 0.00... ee eee 12
Side Return Air Inlet... 00... 0... eee 12
Filter Arrangement .. 0.0.0.0. 0.0.0 0. eee 13
AIR DUCTS . 0... eens 13
General Requirements .... 0.0.0.0. 0.00.0 13
Ductwork Acoustical Treatment ............. 0.0000. 13
Supply Air Connections .. 0.0... 00.0.0. 14
Uptiow and Horizontal Furnaces ............ 0.0000. 14
Downflow Furnaces .... 0.0.00... 0. eee eee 15
Return Air Connections . 2.0.0.0... 0.0.0 eee eee eee 18
Downflow Furnaces .... 0.0.0.0... 0. eee eee ee 18
Uptiow and Horizontal Furnaces ............ 0.0000. 18
GAS PIPING ... 0... . ee eens 19
ELECTRICAL CONNECTION ©... 00 ee 20
ACCESSORIES 2.0. een ee 22
VENTING 2.0 eee eens 22
START-UP, ADJUSTMENT, AND SAFETY CHECK ..... 34
General 2... eee ene 34
Start-Up Procedures 2.0.0.0... ce eee eee 37
Adjustments oo... 0... eee ee eens 37
Check Safety Controls... 0.0.0... ee eee 45
Checklist 2... eee 46
SERVICE AND MAINTENANCE PROCEDURES ....... 46
General 2. eee eae 46
Care and Maintenance . 2.6... eee 47
Sequence of Operation... 0.0... eee ee OZ
Wiring Diagram .. 6.0... ee eee 56
Troubleshooting»... 0.0.0... 0. eee eee ee 56
Accessory List... 0... eens 59
PARTS REPLACEMENT INFORMATION GUIDE....... 60
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SO 9001
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.

58CV
SAFETY CONSIDERATIONS
CA AUN LO:
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.
4& CAUTION
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.
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.
Wear safety glasses, protective clothing and work gloves. Have
fire extinguisher available during start-up and adjustment
procedures and service calls.
This is the safety-alert symbol AN 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
bo
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.
bo . 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 (A.G.A. and C.G.A.) lis-
ted accessory gas conversion kit is required to convert fur-
nace for use with propane gas.
11. See Fig. 1 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. CNRV, CNPV, CAP, or CAR or
when Coil Box Part No. KCAKC is used. See Fig. 1 for
clearance to combustible construction information.

Improper adjustment, alteration, service,
maintenance, or installation can cause
serious injury or 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.
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 2223.1 / NFPA54
or CSA B-149. 1 Gas Installation Code.
2. This furnace rnust be installed so there are
provisions for combustion and ventilation
air. See manufacturer's installation
information provided with this appliance.
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. Ifa limit opens, call a quallified
serviceman to correct the condition
and reset limit switch.
INSTALLATION
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
fy CAUTION
INSTALLATION
This forced air furnace is
equipped for use with natural
gas at altitudes 0 - 10,000 ft
- 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.
(0
This furnace is approved for
UPFLOW, DOWNFLOW, and
HORIZONTAL installations.
Clearance arrows
do not change with
furnace orientation.
+ @
BOTTOM
Clearance in inches
Vent Clearance to combustibles:
For Single Wall vents 6 inches (6 po).
For Type B-1 vent type 1 inch (1 po).
OPERATION
MINIMUM INCHES CLEARANCE TO
COMBUSTIBLE CONSTRUCTION
DOWNFLOW POSITIONS:
T Installation on non-combustible floors only.
For Installation on combustible flooring only when installed on special
base, Part No. KGASBO201ALL or NAHA01101SB, Coil Assembly,
Part No. CAR, CAP, CNPV, CNRV, END4X, ENW4X, WENC, WTNC,
WENW OR WTNW.
@ 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,
AAT
336996-101 REV. C
Fig. 1 - Clearances to Combustibles
A10269
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INTRODUCTION
The Series 160 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.
2
PEERREEERP
WNT
MAX80°F / 27 C
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ips
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RETURN
AIR
MIN6O°F /16C
crude THE
A06745
Fig. 2 - Return Air Temperature
This furnace is designed for minimum continuous return-air
temperature of 60°F (15°C) db or intermittent operation down to
55°F (13°C)db such as when used with a night setback
thermostat. Return-air temperature must 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. 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, follow all codes and standards for the
following:
Safety
NFPA 54/ANSI Z223.1-2009 and the Installation Standards,
Warm Air Heating and Air Conditioning Systems ANSI/NFPA
9OB .
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 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 Lining and Fibrous Glass Duct
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
NFPA 54/ANSI Z223.1-2009 ; chapters 5, 6, and 7 and National
Plumbing Codes .
Electrical Connections
National Electrical Code (NEC) ANSI/NFPA70-2011 .
Venting
NFPA 54/ANSI Z223.1-2009; chapters 12 and 13.
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
4& CAUTION
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.
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
ELECTROSTATIC CHARGE TO GROUND.
. Firmly touch the clean, unpainted, metal surface of the fur-
nace chassis which is close to the control. Tools held in a
person’s hand during grounding will be satisfactorily dis-
charged.
bo
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.).

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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. (868 x 495 mm) rectangle.
c. For 1600 CFM—22-in. (559 mm) round or 14 1/2 x 22 1/16—in. (868 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. 3 - Dimensional Drawing
Table 1 — Dimensions - In. (mm)
SIDE INLET
(BOTH SIDES)
A10290
A B c D VENT ACCESSORY
FURNACE SIZE CABINET OUTLET BOTTOM FLUE BOTTOM CONNECTION iB (kG) FILTER MEDIA
WIDTH WIDTH COLLAR INLET WIDTH SIZE CABINET SIZE
070—12/036070 | 14—3/16 (360) | 12-9/16 (319) 9—5/16 (237) 12-11/16 (622) 4 (102 115 62) 16 (406)
090—16/048090 17-1/2 (445) | 15—7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 130 (59) 16 (406)
110—20/060110 21 (533) 19—3/8 (492) 13—5/16 (338) 19—1/2 (495) 4 (102) 155 (70) 20 (508)
135—22/066135 24—1/2 (622) | 22—-7/8 (581) 15—1/16 (683) 23 (584) 4 (102)* 166 (75) 24 (610)
155—22/066155 24—1/2 (622) | 22—-7/8 (581) 15—1/16 (683) 23 (584) 4 (102)* 175 (79) 24 (610)
*135 and 155 size furnaces require a 5 or 6—in. (127 or
complete installation requirements.
52 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for
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.
GENERAL
LOCATION
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. (1676 M)
above sea level. Obtain high-altitude conversion kit from your
area authorized distributor.
wn
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a
AIRFLOW
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
gg
UPFLOW
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
~~
HORIZONTAL LEFT
a
AIRFLOW
THE BLOWER IS
LOCATED ABOVE THE
DOWNFLOW
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
V
AIRFLOW
HORIZONTAL RIGHT
c>
AIRFLOW
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
A02097
Fig. 4 - Multipoise Orientations
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 (refer to SAFETY
CONSIDERATIONS).
© — be located 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
construction label.
A A Se
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.
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 chemicais
© 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.
A A Se
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.
(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 NFPA 54/ANSI
Z223.1-2009 . (See Fig. 5.)

18-IN. (457.2 mm)
MINIMUM TO BURNERS
Ag3044
Fig. 5 - Installation in a Garage
4 WARNING
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.)
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.
4 CAUTION
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 drywail 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.
A02054
Fig. 6 - Prohibit Installation on Back
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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 SG. IN/2,000 BTUR) (1,100 SG. MM/KW) | (1 SQ. IN./3,000 BTUR) (734 SG. MM/KW) (1 $0. IN/4,000 BTUH) (550 SG. MIM/KW)
INPUT Free Area of Opening Round Duct Free Area of Opening Round Duct Free Area of Opening Round Duct
(BTUH) and Duct Dia. and Duct Dia. and Duct Dia.
Sq. In. (Sq. mm) In. (mm) Sq. In. (Sq. mm) In. (mm) Sq. In. (Sq. mm) In. (mm)
44,000 22 (14194) 6 (152) 147 (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 (83096) 9 (229) 38.5 (24839) 8 (203)
EXAMPLES: Determining Free Area
FURNACE WATER HEATER TOTAL INPUT
410,000 + 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)
ACH 30 | 40 | 50 44 | 66 | 88 | 110 | i32 | ss
Space Volume Ft? (M*)
0.60 1,050 1.400 1,750 1,100 1,650 2,200 2,750 3,300 3,850
. (29.7) (39.6) (49,5) (31.1) (46.7) (62.2) (77.8) (93.4) (109.0)
0.50 1,260 1,680 2,100 1.320 1,980 2,640 3,300 3,960 4,620
. (35.6) (47.5) (59.4) (37.3) (56.0) (74.7) (93.4) (112.1) (130.8)
0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775
, (44.5) (59.4) (74.3) (46.7) (70.0) (93.4) (116.8) (140.1) (163.5)
0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700
‘ (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
9.20 (89.1) (118.9) | 3-250 148.6) (93.4) (140.1) (186.8) (233.6) (280.3) (327.0)
0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100
. (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
AIR FOR COMBUSTION AND
VENTILATION 4& WARNING
Provisions for adequate combustion, ventilation, and dilution air CARBON MONOXIDE POISONING HAZARD
must be provided in accordance with: . ; . . .
Failure to follow this warning could result in personal
injury or death.
© USS. Installations: Section 9.3 of the NFPA 54/ANSI
2223.1-2009 , Air for Combustion and Ventilation and
applicable provisions of the local building codes.
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
FURNACE CORROSION HAZARD Carbon Monoxide Poisoning Hazard warning in the venting
section of these instructions to determine if an adequate
amount of make-up air is available.
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 The requirements for combustion and ventilation air depend upon
shorten furnace life. Air contaminants are found in aerosol whether or not the furnace is located in a space having a volume
sprays, detergents, bleaches, cleaning solvents, salts, air of at least 50 cubic feet per 1,000 Btuh input rating for all gas
fresheners, and other household products. appliances installed in the space.
© — Spaces having less than 50 cubic feet per 1,000 Btuh
require the OUTDOOR COMBUSTION AIR
METHOD.

PER 4000
DUCTS ~~~ Le
TO BTUH
OUTDOORS
—
T
I
! !
(305mm) 12” MAX 12”
305mm,
1 SQIN. Sey _|_MAX
PER 2000 B) 4&5 ES 4
BTUH* <3 Fa
Sa 1SQIN
oa PER
G x 4000
| BTUH*
n
oe
DUCTS 8
TO OS
OUTDOORS 5
5
1SQIN
PER
4000
BTUH*
1SQIN. a
PER 2000 i El] Gee 1
BTUH* VI 12"
(305mm) 12” MAX c { Max (805mm)
12" MAX {
OT | (305mm)
CIRCULATING AIR DUCTS
DUCT 1SQIN.
TO PER 4000
OUTDOORS BTUH*
*Minimum dimensions of 3-in. (76 mm).
NOTE: Use any of the following combinations of openings:
A&BC&DD&EF&G
A08174
Fig. 7 - Air for Combustion, Ventilation, and Dilution for
Outdoors
© 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.
. Fig. 7 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air opening, to the outdoors.
bo
e. 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.
f. Size openings and ducts per Fig. 7 and Table 2.
g. TWO HORIZONTAL DUCTS require 1 sq. in. (645
sq. mm) 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.
h. TWO OPENINGS OR VERTICAL DUCTS require 1
sq. in. (645 sq. mm) 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:
a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh
(734 mm2/kW) for combined input of all gas appli-
ances in the space per Table 2 and
b. Not less than the sum of the areas of all vent connect-
ors in the space.
CIRCULATING AIR
DUCTS VENT THROUGH ROOF
fo (1
Le bs (305mm)
ot
1 SQIN.
PER 1000
_| BTUH* IN DOOR
OR WALL
UNCONFINED
INTERIOR SPACE
HEATED
SPACE
6" MIN (152mm)
(FRONT)G
1 SQIN.
ER 1000
TUH* IN DOOR
ALL
CLEARANCE
IN
FRONT
OF
COMBUSTION
AIR
OPENINGS
SHALL
BE AT
LEASTS
IN.
12" MAX (305mm)
CIRCULATING AIR DUCTS
* Minimum opening size is 100 sq in. (64516 sq. mm)with minimum dimensions
of 3 in. (76 mm)
+ Minimum of 3 in. (76 mm) when type-B1 vent is used.
A03175
Fig. 8 - Air for Combustion, Ventilation, and Dilution from
Indoors
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 Air© NFPA & 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.
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.
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
58CV

58CV
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
£223.1-2009/NFPA 54-2009, 9.3.2.2:
1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater:
|
Volume = 217% )___" other__
Othe ACH 11000 Btu/hr
Ao4002
2. For fan-assisted appliances such as this furnace:
|
Volume — A5ft%)__ fan
Fan ACH |1000 Btu/hr
A04008
If: Iother = combined input of ail 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 shail 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.2/1,000 Btuh (2,000
mm2/kW) of the total input rating of all gas appliances
in the space, but not less than 100 in.? (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 af least 3 in. (80
mm). (See Fig. 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
mm_2/kW) of total input rating of all gas appliances.
bo . An attic or crawlspace may be considered a space that
freely communicates 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,
infiltration 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.
4. 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
wail 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,
2. Outdoor openings shall be located as required in the Out-
door Combustion Air Method mentioned previously and,
3. Outdoor openings shail 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 shail be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The min-
imum dimension of air openings shall be not less than
3 in. (80 mm).
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.)
. Rotate bottom filler panel downward to release holding
tabs.
bo
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.
Bottom
Closure Panel
Bottom Filler Panel
A10278
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 upfiow position with side return inlet(s), leveling legs may be
used, (See Fig. 10.) Install field-supplied, 5/16 X 1-1/2 in. (8 X
38 mm) (max) corrosion-resistant machine bolts, washers and
nuts.
10