Carrier 58CVA Guide

58CVA/58CVX
Variable-Speed, 4-Way
Multipoise Gas Furnace
Installation, Start-up, Operating, and Service
and Maintenance Instructions
-Series 100
THE WEATHERMAKER® 8000VS GAS FURNACE
The 58CVA/CVX Variable-Speed, 4-way Multipoise Gas Furnaces
offer unmatched comfort with ComfortHeatTechnology and
IdealHumidityin an 80% AFUE gas furnace. You get all the benefits of
a ComfortHeat Technology furnace: reduced drafts, reduced sound
levels, longer, more gentle cycles, less temperature swings between
cycles, and less temperature differences between rooms. With the
variable speed blower motor, homeowners can now economically run
constant fan to help eliminate temperature differences throughout the
house and to get better indoor air quality. This IdealHumidity furnace also
increases comfort in the summer by wringing out extra humidity when
needed. The 58CVA furnaces are approved for use with natural or
propane gas, and the 58CVX is approved for use in low Nox Air Quality
Management Districts.
STANDARD FEATURES
• ComfortHeatTechnology
Intelligent microprocessor control
Two-stage heating with single-stage thermostat
Very low operating sound through low-stage operation and QuieTechnoise
reduction system
• Integral part of the IdealHumiditySystem
Maximum dehumidification selection for summer time cooling
Full IdealHumidity benefits including “Super Dehumidify”
Variable-speed blower motor
Super-low electrical use, up to 80 percent less than standard models
Increased SEER ratings for AC and HP systems
Perfectly matches CFM to cooling system at all static points
• Media Filter Cabinet Included
• Microprocessor based "smart" control center
Automatically adjusts heating stage times to meet demand
Adjustable heating air temperature rise
• ComfortFan- Constant fan speed selectable from thermostat
Up to 12 cooling airflow selections with a wide range of capability
LED diagnostics and self test feature
Stores fault codes during power outages
Optional laptop and handheld PDA diagnostic software
• 4-way Multipoise furnace, 13 vent applications
• Shorter in height – only 33⅓” tall
• Hot surface ignition (HSI)
• Draft safeguard switch to ensure proper furnace venting
• Insulated blower compartment
• Heat pump compatible
• All models are Chimney Friendly when used with accessory vent kit
• Residential installations eligible for consumer financing through the
Retail Credit Program
• LIMITED WARRANTY
• 20-year warranty on "Super S™" heat exchanger
• 5-year parts warranty on all other components
Catalog No: 535-80057 Form No. 58CV-1SI 7-02

Variable Speed
Induced-Combustion Deluxe
4-Way Multipoise Furnace
Installation, Start-up, Operating, and
Service and Maintenance Instructions
Series 100/A
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS.....................................................2
INTRODUCTION..........................................................................2
CODES AND STANDARDS........................................................3
Safety.........................................................................................3
General Installation...................................................................3
Combustion and Ventilation Air..............................................3
Duct Systems ............................................................................3
Acoustical Lining and Fibrous Glass Duct..............................3
Gas Piping and Gas Pipe Pressure Testing..............................3
Electrical Connections..............................................................3
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE ................................................................................3
LOCATION....................................................................................5
General......................................................................................5
Location Relative to Cooling Equipment ................................5
AIR FOR COMBUSTION AND VENTILATION......................6
Unconfined Space.....................................................................6
Confined Space.........................................................................7
INSTALLATION...........................................................................8
Upflow Installation ...................................................................8
Bottom Return Air Inlet......................................................8
Side Return Air Inlet...........................................................8
Leveling Legs (If Desired)..................................................8
Downflow Installation ..............................................................8
Horizontal Installation ............................................................10
Suspended Unit Support....................................................10
Platform Unit Support.......................................................10
Roll-Out Protection............................................................10
Filter Arrangement..................................................................10
Air Ducts.................................................................................11
General Requirements .......................................................11
Ductwork Acoustical Treatment .......................................13
Supply Air Connections....................................................13
Return Air Connections.....................................................13
Gas Piping...............................................................................13
Electrical Connections............................................................15
115-V Wiring.....................................................................15
J-Box Relocation ...............................................................15
Electrical Connection to J-Box.........................................15
For Power Cord Installation..............................................15
For BX Cable Installation.................................................16
J-Box Cover Installation....................................................15
24-V Wiring.......................................................................16
Accessories ........................................................................17
Venting....................................................................................17
General Venting Requirements.........................................17
Masonry Chimney Requirements......................................20
Appliance Application Requirements ...............................22
Additional Venting Requirements.....................................25
Sidewall Venting ...............................................................25
START-UP, ADJUSTMENT, AND SAFETY CHECK............27
General....................................................................................27
Start-Up Procedures ...............................................................27
Adjustments ...........................................................................28
Check Safety Controls............................................................33
Checklist..................................................................................34
SERVICE AND MAINTENANCE PROCEDURES..................36
Introduction.............................................................................36
General...............................................................................36
Electrical Controls and Wiring .........................................36
Care and Maintenance............................................................37
Cleaning and/or Replacing Air Filter ...............................38
Blower Motor and Wheel..................................................38
Cleaning Heat Exchanger..................................................39
Sequence of Operation............................................................42
Wiring Diagrams.....................................................................45
Troubleshooting ......................................................................45
REGISTERED QUALITY SYSTEM
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EFFICIENCY
RATING
CERTIFIED
CERTIFIED
Cancels: New II 315A-70-1
7-02
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 6a 8a PC 101 Catalog No. See Cover Printed in U.S.A. Form 58CV-1SI Pg 1 7-02 Replaces: New

SAFETY CONSIDERATIONS
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.
Observe precautions in the literature, on tags, and on labels
attached to or shipped with the unit 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 residen-
tial construction practices. We require these instructions as a
minimum for a safe installation.
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, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which would 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 palte.
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. Conect
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 commer-
cially available soap aolution made specifically for the detec-
tion 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 speci-
fied in the “Start-Up, Adjustments, and Safety Check” section.
See furnace rating plate.
7. When a frunace 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 is not to be used for temporary heating of
buildings or structures under construction. See page 5 caution
box.
INTRODUCTION
The Series 100/A 4–way multipoise Category I furnace is CSA
(A.G.A. and C.G.A.) design-certified for natural and propane gas
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 gas
conversion kit is required to convert furnace for use with propane
gas. This furnace is not approved for installation in mobile homes,
recreational vehicles, or outdoors.
These furnaces shall not be installed directly on carpeting, tile, or
any other combustible material other than wood flooring. For
downflow installations, a factory accessory floor base must be
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 23 1/4-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. 1—Dimensional Drawing
A02096
C
B
A
2

used when installed on combustible materials and wood flooring.
This special base is not required when this furnace is installed on
the manufacturer’s coil assembly, or when the manufacturer’s coil
box is used. See Figure 2 for clearance to combustible material
information.
Improper installation, adjustment, alteration, service, mainte-
nance, or use can cause carbon monoxide poisoning, explo-
sion, fire, electrical shock, or other conditions which may
cause personal injury or property damage. Consult a qualified
installer, service agency, local gas supplier, or your distribu-
tor or branch for information and assistance. The qualified
installer or agency must use only factory-authorized and
listed kits or accessories when modifying this product.
Failure to follow this warning could result in electrical shock,
fire, personal injury or death.
This furnace is designed for minimum continuous return-air
temperature of 60°F db or intermittent operation down to 55°F db.
Return-air temperature must not exceed 85°F db. See Figure 3.
For accessory installation details, refer to the applicable instruction
literature.
NOTE: Remove all shipping brackets and materials before oper-
ating 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:
Step 1—Safety
• US: National Fuel Gas Code (NFGC) NFPA 54–1999/ANSI
Z223.1–1999 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
• CANADA: CAN/CGA-B149.1–and .2–M00 National Standard
of Canada. Natural Gas and Propane Installation Codes (NSC-
NGPIC)
Step 2—General Installation
• US: Current edition of the NFGC and the NFPA 90B. For
copies, contact the National Fire Protection Association Inc.,
Batterymarch Park, Quincy, MA 02269; or for only the NFGC,
contact the American Gas Association, 400 N. Capitol, N.W.,
Washington DC 2001 or www.NFPA.org.
• CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-
onto), Ontario, M9W 1R3 Canada
Step 3—Combustion and Ventilation Air
• US: Section 5.3 of the NFGC, Air for Combustion and
Ventilation
• CANADA: Part 7 of NSCNGPIC, Venting Systems and Air
Supply for Appliances
Step 4—Duct Systems
• US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Con-
tractors National Association (SMACNA), or American Soci-
ety of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE) 1997 Fundamentals Handbook Chapter 32.
Step 5—Acoustical Lining and Fibrous Glass Duct
• US and CANADA: current edition of SMACNA and NFPA
90B as tested by UL Standard 181 for Class I Rigid Air Ducts
Step 6—Gas Piping and Gas Pipe Pressure Testing
• US: NFGC; chapters 2, 3, 4, and 9 and National Plumbing
Codes
• CANADA: NSCNGPIC Part 5
Step 7—Electrical Connections
• US: National Electrical Code (NEC) ANSI/NFPA 70–2002
• CANADA: Canadian Electrical Code CSA C22.1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
Use this procedure for all installed and uninstalled furnaces. An
ESD service kit (available from commercial sources) may be used
to prevent ESD damage.
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 person-
nel and hand tools which are held during the procedure. These
precautions will help to avoid exposing the control to elec-
trostatic 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 DIS-
CHARGING YOUR BODY’S CHARGE TO GROUND.
2. Firmly touch a clean, unpainted metal surface on the furnace
chassis close to the control. Tools held in hand during
grounding will be discharged.
3. You may proceed to service the control or connecting wires as
long as you do nothing to recharge your body (moving or
shuffling feet, touching ungrounded objects, etc.)
Table 1—Dimensions (IN.)
UNIT SIZE A B C VENT CONN.* SHIP WT. (LB)
070-12/036070 14-3/16 12-9/16 12-11/16 4 126
090-16/048090 17-1/2 15-7/8 16 4 151
110-22/066110 21 19-3/8 19-1/2 4 161
135-22/066135 24-1/2 22-7/8 23 4 177
155-22/066155 24-1/2 22-7/8 23 4 183
* 5” or 6” vent connector may be required in some cases.
3

Fig. 2—Clearances to Combustibles
A02057
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
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 combustible
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 gaznaturel.
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 commun d´autres appareils à gaz..
DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES
INSTALLATION
327590-101 REV. A
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS
DE CONSTRUCTION COMBUSTIBLES
Ø
*
Installation onnon-combustiblefloors 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 linesformed by intersections of the Top andtwoSides of the furnace jacket, and building joists,
studs or framing.
Clearance in inches
Dégagement (po).
Clearance arrows
do not change with
furnace orientation.
Les fléches de dégagement
ne changent pas avec
l´orientation de la fournaise.
BOTTOM
DESSOUS
0"
3"
0"
0"
1"
0"
30"
MIN
SIDE
CÔTÉ
FRONT
AVANT
BCK
ARRIÈ
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R
SERVIE
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ENTRT
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I
V
AN
AT
FRONT
SIE
CÔTÈ
FOU
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FRNACS
EE
I
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RN
Ø
Vent Clearance tocombustibles:
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).
TOP / PLENUM
DESSUS / CHAMBRED’AIR
D
*
*
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.
MIN
Ø
*
†
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´ensembleserpentin, pièce n CD5ouCK5, oule carter deserpentin, pièce nº KCAKC.
Dans une alcôve, on doit maintenir un dégagement à l´avant de 18 po (450 mm).
La position 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 chemise de la fournaise et les solives, montant sous cadre de charpente.
POUR LA POSITION COURANT DESCENDANT:
DOWNFLOW POSITIONS:
4

4. If you touch ungrounded objects, firmly touch a clean,
unpainted metal surface again before touching control or
wires.
5. Before removing a new control from it’s container, discharge
your body’s charge to the ground. 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.
LOCATION
Step 1—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 Figure 4.
NOTE: For high-altitude installations, the high-altitude conver-
sion kit MUST be installed at or above 5500 ft above sea level.
Obtain high-altitude conversion kit from your area authorized
distributor.
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 INTRODUCTION).
• be located as close to the chimney/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 clearances shown on the
furnace rating plate.
Do not install furnace in a corrosive or contaminated atmo-
sphere. Make sure all combustion and circulating air require-
ments are met, in addition to all local codes and ordinances.
This gas furnace may be used for construction heat 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, selaers 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 no less
than 55 degrees F, 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 firing rate has been set to the
nameplate value.
-The filters used to clean the circulating air during the
construction process must be either changed ot 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.
DO NOT install the furnace on its back, or hang furnace with
control compartment facing down. Safety control operation
will not perform properly. A failure to follow this warning
can cause a fire, personal injury, or death. (See Fig. 5.)
Step 2—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
Fig. 3—Return Air Temperature
A02055
60
Fig. 5—Prohibit Installation on Back
A02054
5

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.
AIR FOR COMBUSTION AND VENTILATION
Provisions for adequate combustion and ventilation air must be
provided in accordance with Section 5.3 of the NFGC, Air for
Combustion and Ventilation, or applicable provisions of the local
building codes.
Canadian installations must be installed in accordance with NSC-
NGPIC Part 7 and all authorities having jurisdiction.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 inches
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 National Fire Protection Association,
Inc. requirements. (See Fig. 6.)
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements are found in aerosol sprays, deter-
gents, bleaches, cleaning solvents, salts, air fresheners, and
other household products.
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 blocked vent
safeguard opening.
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.
The requirements for combustion and ventilation air depend upon
whether the furnace is located in an unconfined or confined space.
Step 1—Unconfined Space
An unconfined space has a volume of at least 50 cu ft for each
1000 Btuh total input for all appliances (furnaces, clothes dryers,
water heaters, etc.) in the space.
For example:
If the unconfined space is constructed unusually tight, air for
combustion and ventilation must come from either the outdoors or
spaces freely communicating with the outdoors. Combustion and
Fig. 4—Multipoise Orientations
A02097
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
DISCHARGEDTOTHE RIGHT.
Fig. 6—Installation in a Garage
A93044
18-IN. MINIMUM
TO BURNERS
FURNACE
INPUT (BTUH) MINIMUM WITH 7–1/2 FT CEILING (SQ. FT.)
66,000 441
88,000 587
110,000 734
132,000 881
154,000 1028
6

ventilation openings must be equivalent to those used for a
confined space (defined below). Return air must not be taken from
the room unless an equal or greater amount of air is supplied to the
room.
Step 2—Confined Space
Aconfined space has a volume less than 50 cu ft per 1000 Btuh
of total input ratings of all appliances installed in that space. A
confined space must have provisions for supplying air for com-
bustion, ventilation, and dilution of flue gases using one of the
following methods in Table 2 and Fig. 7 and 8.
NOTE: When determining the free area of an opening, the
blocking effect of louvers, grilles, and screens must be considered.
If the free area of the louver or grille design is unknown, assume
wood louvers have a 20 percent free area and metal louvers or
grilles have a 60 percent free area. Screens must not be smaller
than 1/4-in. mesh. Louvers and grilles must be constructed so they
cannot be closed.
The opening size depends upon whether air comes from outside of
the structure or an unconfined space inside the structure.
1. Air from inside the structure requires 2 openings (for struc-
tures not of unusually tight construction):
a. Each opening must have a minimum free area of not less
than 1 sq in per 1000 Btuh of total input rating for all gas
utilization equipment in the confined space, but not less
than 100 sq in. The minimum dimension of air openings
should be no smaller than 3 in. (See Table 2 and Fig. 7.)
b. If building construction is unusually tight, a permanent
opening directly communicating with the outdoors shall be
provided. (See next section).
c. If the furnace is installed on a raised platform to provide a
return-air plenum, and return air is taken directly from the
hallway or space adjacent to furnace, all air for combustion
must come from outdoors.
2. Air from outside the structure requires 1 of the following:
a. If combustion air is taken from outdoors through 2 vertical
ducts, the openings and ducts must have at least 1 sq in. of
free area per 4000 Btuh of total input for all equipment
within the confined space. (See Fig. 8 and Table 2.)
b. If combustion air is taken from outdoors through 2 hori-
zontal ducts, the openings and ducts must have at least 1 sq
in. of free area per 2000 Btuh of total input for all
equipment within the confined space. (See Fig. 8 and Table
2.)
c. If combustion air is taken from the outdoors through a
single opening or duct (horizontal or vertical) commencing
within 12 in. of the top of the confined space, the opening
and duct must have at least 1 sq in. of free area per 3000
Btuh of the total input for all equipment within the confined
space and not less than the sum of the areas of all vent
connectors in the confined space. Equipment clearances to
Fig. 7—Confined Space: Air for Combustion and
Ventilation from an Unconfined Indoor Space
A02038
AIR
DUCTS
6″MIN
(FRONT) †
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 type-B1 vent is used.
UNCONFINED
SPACE
CONFINED SPACE
INTERIOR
HEATED
SPACE Fig. 8—Confined Space: Air for Combustion and
Ventilation from Outdoors
A02165
1 SQ IN.
PER
4000
BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
AIR
DUCTS
VENT
THROUGH
ROOF
D
B
A
C
E
1 SQ IN.
PER 4000
BTUH*
DUCT
TO
OUTDOORS
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.
CONFINED SPACE
12″
MAX
12″
MAX
OUTDOORS
1 SQ IN.
PER
4000
BTUH*
F
G
7

the structure shall be at least 1 in. from the sides and back
and 6 in. from the front of the appliances. See Table 2 and
Fig. 8.
When ducts are used, they must be of the same cross sectional area
as the free area of the openings to which they connect. The
minimum dimension of ducts must not be less than 3 in.
INSTALLATION
Step 1—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 front filler
panel. (See Fig. 9.)
2. Rotate front filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall front 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.
NOTE: Side return-air openings can be used in UPFLOW and
most HORIZONTAL configurations ONLY.
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 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 and 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.
Step 2—Downflow Installation
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the 3 accessories are
used:
• Special Base, KGASB0201ALL
• Cased Coil Assembly Part No. CD5 or CK5
Table 2–Minimum Free Area of Combustion Air Opening*
FURNACE
INPUT
(BTUH)
AIR FROM INDOOR
UNCONFINED SPACE OUTDOOR AIR THROUGH VERTICAL DUCTS OUTDOOR AIR THROUGH HORIZONTAL DUCTS OUTDOOR AIR THROUGH SINGLE DUCT
Free Area
of Opening
(Sq In.)
Free Area of
Opening and Duct
(Sq. In.) Round Pipe
(in. Dia) Free Area of
Opening and Duct
(sq In.) Round Pipe
(in. Dia) Free Area of
Opening and Duct
(Sq In.) Round Pipe
(In. Dia)
66,000 100 16.5 5 33 7 22.0 6
88,000 100 22.0 6 44 8 29.3 7
11,000 110 27.5 6 55 9 36.7 7
132,000 132 33 7 66 10 44.0 8
154,000 154 38.5 7 77 10 51.3 8
* Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances in
the space require combustion air.
Fig. 9—Removing Bottom Closure Panel
A02098
Fig. 10—Leveling Legs
A02071
1 3⁄4″
1 3⁄4″
1 3⁄4″
1 3⁄4″
5⁄16″
5⁄16″
5⁄16″
5⁄16″
8

• Coil Box Part No. KCAKC
1. Determine application being installed from Table 3.
2. Construct hole in floor per Table 3 and Fig. 11.
3. Construct plenum to dimensions specified in Table 3 and Fig.
11.
4. If downflow subbase, KGASB0201ALL is used, install as
shown in Fig. 12. If Coil Assembly Part No. CD5 or CK5 or
Coil Box Part No. KCAKC is used, install as shown in Fig. 13.
NOTE: Completely fold over or remove the perforated supply-air
duct flanges 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.)
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 Combustible Floor
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
FURNACE
SHEET METAL
PLENUM
FLOOR
OPENING
COMBUSTIBLE
FLOORING
A96284
Fig. 13—Furnace, Plenum, and Coil Assembly or Coil
Box Installed on a Combustible Floor
9

If duct flanges are not removed, bent up, or bent over more
than 120°, airflow across heat exchangers will be affected.
This may cause limit cycling or premature heat exchanger
failure.
Step 3—Horizontal Installation
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control opera-
tion will be adversely affected. Never connect return-air ducts
to the back of the furnace. Failure to follow this warning
could result in fire, personal injury, or death.
The furnace can be installed horizontally in an attic or crawl space
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
platform, non-combustible blocks, bricks or pad.
SUSPENDED UNIT 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
unit from each bottom corner. To prevent screws from pulling out,
use2#8x¾-in. screw into the side and2#8x¾-in. screw in the
bottom of the furnace casing for each strap. (See Fig. 15 and 16.)
PLATFORM UNIT 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 unit on non-combustible blocks,
bricks or angle iron. For crawlspace installations, if the unit is not
suspended from the floor joists, the ground underneath unit must
be level and the unit set on blocks or bricks.
ROLL-OUT PROTECTION
Provide a minimum 17 3/4″X22″piece of sheet metal for roll-out
protection in front of burner area for units closer than 12 inches
above the combustible deck or suspended units closer than 12-in.
to joists. The sheet metal MUST extend underneath the furnace
casing by 1 in. with the door removed.
The bottom closure pan on furnaces of widths 17 1/2 in. and larger
may be used for roll-out protection when bottom of furnace is used
for return air connection. See Fig. 17 for proper orientation of
roll-out shield.
Step 4—Filter Arrangement
There are no provisions for an internal filter rack in these furnaces.
An external filter rack is required.
Table 3—Opening Dimensions (In.)
FURNACE
CASING
WIDTH APPLICATION PLENUM OPENING FLOOR OPENING
ABCD
14–3/16
Upflow Applications on Combustible or Noncombustible
Flooring (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
subbase required) 11-13/16 19 13-7/16 20-5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 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
Flooring (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
subbase required) 15-1/8 19 16-3/4 20-5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 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
Flooring (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
subbase required) 18-5/8 19 20-1/4 20-5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required) 19 19 20 20
24-1/2
Upflow Applications on Combustible or Noncombustible
Flooring (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
subbase required) 22-1/8 19 23-3/4 20-5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase
not required) 22-1/2 19 23-1/2 20
10

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.
Never operate a furnace without a filter or with filter access
door removed. Failure to follow this warning could result in
fire, personal injury, or death.
Step 5—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
Fig. 14—Duct Flanges
A02020
UPFLOW DOWNFLOW HORIZONTAL
YES
NO NO
YES
YES
YES
NO
120°
MIN YES 120°
MIN YES
120°
MIN
90°90°
Fig. 15—Horizontal Unit Suspension
A02013
11

Engineers (ASHRAE). Or consult The Air Systems Design Guide-
lines 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.
When a furnace is installed so that the supply ducts carry air to
areas outside the space containing the furnace, the return air must
also be handled by a 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.
Installation tip:Flexible connections should be used between
ductwork and furnace to prevent transmission of vibration.
Ductwork passing through unconditioned space should be insu-
lated 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.
Fig. 16—Horizontal Suspension with Straps
A02014
Fig. 17—Typical Attic Installation
A02164
30-IN. MIN
WORK AREA
6″ MIN*
TYPE-B
VENT
17 3/4 ″
22 ″
SHEET
METAL
SEDIMENT
TRAP
MANUAL SHUTOFF
GAS VALVE
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OFTHE 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
12

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.
DUCTWORK ACOUSTICAL TREATMENT
Installation tip: 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 duct-
work 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.
SUPPLY AIR CONNECTIONS
Upflow and Horizontal Furnaces
Connect supply-air duct to flange on furnace supply-air outlet.
Bend flange upward to 90° with wide duct pliers. The supply-air
duct attachment must ONLY be connected to furnace supply-
outlet-air duct flanges or air conditioning coil casing (when used).
DO NOT cut main furnace casing to attach supply side air duct,
humidifier, or other accessories. All accessories MUST be con-
nected external to furnace main casing. Supply air opening duct
flanges must be modified per Fig. 14.
Installation tip:For horizontal applications, the top most flange
may be bent past 90 degrees to allow the evaporator coil to hang
on the flange temporarily while the remaining attachment and
sealing of the coil are performed.
Downflow Furnaces
Connect supply-air duct to supply-air opening on furnace. The
supply-air duct attachment must ONLY be connected to furnace
supply/outlet or air conditioning coil casing (when used). When
installed on combustible material, supply-air duct attachment must
ONLY be connected to the accessory subbase, KGASB0201ALL,
or 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 external to
furnace casing. Supply air opening duct flanges must be modified
per Fig. 14.
RETURN AIR CONNECTIONS
Never connect return-air ducts to the back of the furnace. A
failure to follow this warning can cause a fire, personal injury,
or death.
Downflow Furnaces
The return-air duct must be connected to return-air opening
(bottom inlet) as shown in Fig. 1. 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. 1. Bypass humidifier may be attached into
unused side return air portion of the furnace casing. See Fig. 18
and 20.
Not all horizontal furnace models are approved for side return air
connections. See Fig. 20.
Step 6—Gas Piping
Gas piping must be installed in accordance with national and local
codes. Refer to current edition of NFGC in the U.S. and the
NSCNGPIC 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.
Refer to Table 4 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.
If a flexible connector is required or allowed by the authority
having jurisdiction, black iron pipe shall be installed at the
gas valve and extend a minimum of 2 in. outside the furnace.
Use a new flexible connector for each installation. Never
re-use an old flexible connector.
Connect gas pipe to furnace using a backup wrench to avoid
damaging gas controls.
Never purge a gas line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition for
purpose of checking leakage. Use a commercially available
soap-and-water solution to check for leakage. A failure to
follow this warning could result in fire, explosion, personal
injury, or death.
Use proper length of pipe to avoid stress on gas control
manifold. Failure to follow this warning could result in a gas
leak resulting in fire, explosion, personal injury, or death.
Install a sediment trap in riser leading to furnace as shown in Fig
21. Connect a capped nipple into lower end of tee. Capped nipple
should extend below level of gas controls. Place a ground joint
union between gas control manifold and manual gas shutoff valve.
A 1/8-in. NPT plugged tapping, accessible for test gage connec-
tion, MUST be installed immediately upstream of gas supply
connection to furnace and downstream of manual shutoff valve.
Table 4–Maximum Capacity of Pipe*
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
* Cubic tf if gas per hr for gas pressure of 0.5 psig (14–in wc) or less, and a
pressure drop of 0.5–in wc (based on a 0.60 specific gravity gas).
Ref: Table 9.2 NFGC.
13

A02075
Fig. 18—Upflow Return Air Configurations and Restrictions
A02163
Fig. 19—Downflow Return Air Configurations and Restrictions
A02162
Fig. 20—Horizontal Return Air Configurations and Restrictions
14

Piping should be pressure tested in accordance with the NFGC,
national plumbing codes or local gas and plumbing codes before
the furnace has been attached. For test pressures above 14-in. wc
(0.5 psig), disconnect and cap the gas supply at the furnace. In
Canada, refer to current edition of NSCNGPIC.
If the test pressure is less than 14-in. w.c. (0.5 psig), turn off
electric shutoff switch located on the gas valve before the test. It
is recommended that the ground joint union be loosened before
pressure testing. After all connections have been made, purge the
lines and check for gas leakage with regulated gas supply pressure.
NOTE: The gas valve inlet pressure tap connection is suitable to
use as test gage connection providing test pressure DOES NOT
exceed maximum 0.5 psig (14-in. wc) stated on gas valve. (See
Fig. 47.)
Step 7—Electrical Connections
See Fig. 22 for field wiring diagram showing typical field 115-v
wiring. Check all factory and field electrical connections for
tightness.
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. Failure to follow this
warning could result in personal injury or death.
Furnace control must be grounded for proper operation or
control will lock out. Control is grounded through green wire
routed to gas valve and burner box screw.
115-V WIRING
Verify that the voltage, frequency, and phase correspond to that
specified on unit rating plate. Also, check to be sure that service
provided by utility is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 5 for equipment electrical
specifications. Make all electrical connections in accordance with
National Electrical Code (NEC) ANSI/NFPA 70-2002 and any
local codes or ordinances that might apply. For Canadian instal-
lations, all electrical connections must be made in accordance with
Canadian Electrical Code CSA C22.1 or authorities having juris-
diction.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
Use a separate branch electrical circuit with a properly sized fuse
or circuit breaker for this furnace. See Table 5 for wire size and
fuse specifications. A readily accessible means of electrical
disconnect must be located within sight of the furnace.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control LED status indicator light will flash
rapidly and furnace will NOT operate.
The cabinet MUST have an uninterrupted or unbroken ground
according to NEC ANSI/NFPA 70-2002 and Canadian Elec-
trical 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 maufacturer’s ratings for proper wire
gage. Do not use gas piping as an electrical ground. Failure to
follow this warning could result in electrical shock, fire, or
death.
J-BOX RELOCATION
NOTE: If factory location of J-Box is acceptable, go to next
section (J-Box Cover Installation).
NOTE: On 14″wide casing models, the J-Box cannot be relo-
cated to other side of furnace casing when the vent pipe is routed
within the casing.
1. Remove screws holding auxiliary J-box. (See Fig. 23.)
2. Cut wire tie on loop in wires to J-box.
3. Locate box to desired location.
4. Fasten J-Box to casing with screw.
5. Route J-box wires within furnace away from sharp edges and
hot surfaces.
6. Route electrical wires through hole in J-box and secure
electrical box or cable to J-box.
7. Attach electrical leads as shown in Fig. 22 and secure ground
wire to green ground screw in J-Box.
ELECTRICAL CONNECTION TO J-BOX
1. Attach electrical box to J-Box bracket.
2. Route wires through hole in electrical box and J-Box bracket.
3. Secure ground wire to green screw on J-Box bracket.
4. Connect line voltage leads as shown in Fig. 22.
FOR POWER CORD INSTALLATION
Power cords must be able to handle the electrical requirements
listed in Table 5. Refer to power cord manufacturer’s listings.
1. Route listed power cord through hole in J-Box.
2. Secure power cord to J-Box bracket with a strain relief
bushing or a connector approved for the type of cord used.
3. Secure ground wire to green screw on J-Box bracket.
4. Connect line voltage leads as shown in Fig. 22.
FOR BX CABLE INSTALLATION
1. Route BX cable to hole in J-Box.
2. Secure BX cable to J-Box bracket with connectors approved
for the type of cable used.
Fig. 21—Typical Gas Pipe Arrangement
A02035
UNION
SEDIMENT
TRAP
MANUAL
SHUTOFF
VALVE
(REQUIRED
GAS
SUPPLY
15

3. Secure ground wire to green screw on J-Box bracket.
4. Connect line voltage leads as shown in Fig. 22.
J-BOX COVER INSTALLATION
1. Remove J-Box cover from blower access door on furnace and
reinstall blower access door screw.
2. Insert tab of J-Box cover into slot of J-Box bracket.
3. Fold tab on J-Box bracket with pliers.
4. Secure J-Box cover to bracket with screw provided.
5. Remove U-shaped cut-out from outer door to clear J-box.
If manual disconnect switch is to be mounted on furnace,
select a location where a drill or fastener will not contact
electrical or gas components.
24-V WIRING
Make field 24-v connections at the 24-v terminal strip. (See Fig.
32.) Connect terminal Y/Y2 as shown in Fig. 22 or Fig. 24-31 for
proper cooling operation. Use only AWG No. 18, color-coded,
copper thermostat wire.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control. Any direct shorts during installation, service, or
Fig. 22—Field Wiring Diagram
A95236
115-VOLT FIELD-
SUPPLIED
FUSED
DISCONNECT
JUNCTION
BOX CONTROL
BOX
24-VOLT
TERMINAL
BLOCK
THREE-WIRE
HEATING-
ONLY
FIVE
WIRE
NOTE 2
NOTE 1
1-STAGE
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
CONDENSING
UNIT
FURNACE
COM
R
WCY RG
GND
GND
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
Connect Y/Y2-terminal as shown for proper operation.
Some thermostats require a "C" terminal connection as shown.
If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
208/230- OR
460-VOLT
THREE
PHASE
208/230-
VOLT
SINGLE
PHASE
WHT
BLK
WHT
BLK
W/W1
W2
Y/Y2
G
NOTES: 1.
2.
3.
Table 5—Electrical Data
UNIT SIZE VOLTS- HERTZ-
PHASE
OPERATING
VOLTAGE RANGE MAXIMUM
UNIT AMPS MAXIMUM WIRE LENGTH (FT)‡
MAXIMUM
FUSE OR CKT BKR
AMPS†
MINIMUM
WIRE GAGE
Maximum* Minimum*
070-12/036070 115-60-1 127 104 9.0 30 15 14
090-16/048090 115-60-1 127 104 9.6 29 15 14
110-22/066110 115-60-1 127 104 15.1 29 20 12
135-22/066135 115-60-1 127 104 14.9 30 20 12
155-22/066155 115-60-1 127 104 15.0 29 20 12
* Permissible limits of the voltage range at which the unit operates satisfactorily.
† Time-delay type is recommended.
‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
Fig. 23—Relocating J-Box
A02099
TWO
16

maintenance could cause this fuse to blow. If fuse replacement is
required, use ONLY a 3-amp fuse of identical size.
ACCESSORIES
1. Electronic Air Cleaner (EAC)
Connect an accessory Electronic Air Cleaner (if used) using
1/4-in female quick connect terminals to the two male 1/4-in
quick-connect terminals on the control board marked EAC-1
and EAC-2. The terminals are rated for 115VAC, 1.0 amps
maximum and are energized during blower motor operation.
See Fig. 32.
2. Humidifier (HUM)
Connect an accessory 24 VAC, 0.5 amp maximum humidifer
(if used) to the 1/4-in male quick-connect HUM terminal and
COM-24V screw terminal on the control board thermostat strip.
The HUM terminal is energized when blower is energized in
heating. See Fig. 32.
DO NOT connect furnace control HUM terminal to HUM
(humidifier) terminal on Thermidistat, Zone Controller or
similiar device. See Thermidistat™, Zone Controller, thermo-
stat, or controller manufacturer’s instructions for proper
connection.
Step 8—Venting
When an existing furnace is removed or replaced in a venting
system, the venting system may not be properly sized to vent the
attached appliances.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance
connected to the venting system being placed into operation
could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and
Propane Installation Codes and these instructions. Determine
that there is no blockage or restriction, leakage, corrosion and
other deficiencies, which could cause an unsafe condition.
3. As far as practical, close all building doors and windows
and all doors between the space in which the appliance(s)
connected to the venting system are located and other spaces
of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected to
the venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they are operating at
maximum speed. Do not operate a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance being
inspected into operation. Adjust the thermostat so appliance is
operating continuously.
7. Test for spillage from draft hood equipped appliances at the
draft hood relief opening after 5 minutes of main burner
operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above
tests, the venting system must be corrected in accordance wit
the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or
CSA B149.1, Natural Gas and Propane Installation Codes.
9. After it has been determined that each appliance connected
to the venting system properly vents when tested as outlined
above, return doors, windows, exhaust fans, fireplace damp-
ers and any other gas-fired burning appliance to their previous
conditions of use.
GENERAL VENTING REQUIREMENTS
Follow all safety codes for proper vent sizing and installation
requirements, including local building codes, the National Fuel
Gas Code (NFGC) ANSI Z223.1-1999/NFPA 54-1999, Parts 7 and
10 in the United States and the National Standard of Canada,
Natural Gas and Propane Installation Codes (NSCNGPIC) CSA-
B149.1-00, Section 7 and Appendix C in Canada.
These furnaces are design-certified as Category I furnaces in
accordance with ANSI Z21.47 CSA 2.3-2001 and operate with a
non-positive vent static pressure to minimize the potential for vent
gas leakage. Category I furnaces operate with a flue loss not less
than 17 percent to minimize the potential for condensation in the
venting system. These furnaces are approved for common venting
and multi-story venting with other fan assisted or draft hood
equipped appliances in accordance with the NFCG or the NSC-
NGPIC.
The following information and warning must be considered in
addition to the requirements defined in the NFGC and the
NSCNGPIC.
Fig. 24—Two-Stage Furnace with Single-Speed
Air Conditioner
A00275
17

Fig. 25—Two-Stage Furnace with Two-Speed
Air Conditioner
A00276 A00277
Fig. 26—Two-Stage Furnace with Single-Speed
Heat Pump (Dual Fuel)
A00278
Fig. 27—Two-Stage Furnace with Two-Speed Heat Pump (Dual Fuel)
18

A00279
Fig. 28—Dual Fuel Thermostat with Two-Stage
Furnace and Single-Speed Heat Pump
Fig. 29—Dual Fuel Thermostat with Two-Stage
Furnace and Two-Speed Heat Pump
A00280
A00281
Fig. 30—Two-Stage Thermostat with Two-Stage
Furnace and Two-Speed Air Conditioner
A00282
Fig. 31—Single-Stage Thermostat with
Two-Stage Furnace and Two-Speed Air Conditioner
19