Carrier 58ST Guide

1
58ST
Single ---Stage Deluxe
I n d u c e d --- C o m b u st i o n
4---Way Multipoise Furnace
Installation, Start---up, Operating and
Service and Maintenance
Instructions Series 120/C
SAFETY CONSIDERATIONS 2........................
INTRODUCTION 3..................................
CODES AND STANDARDS 4..........................
Safety 4.........................................
General Installation 5...............................
Combustion and Ventilation Air 5.....................
Duct Systems 5...................................
Acoustical Lining and Fibrous Glass Duct 5.............
Gas Piping and Gas Pipe Pressure Testing 5.............
Electrical Connections 5............................
Venting 5........................................
LOCATION 6.......................................
AIR FOR COMBUSTION AND VENTILATION 8.........
INSTALLATION 11..................................
Bottom Return Air Inlet 11..........................
Side Return Air Inlet 11.............................
Leveling Legs (If Desired) 11........................
Bottom Return Air Inlet 12..........................
Suspended Furnace Support 12.......................
Platform Furnace Support 13.........................
Roll--Out Protection 13.............................
Bottom Return Air Inlet 13..........................
Side Return Air Inlet 13.............................
General Requirements 14............................
Ductwork Acoustical Treatment 14....................
Supply Air Connections 14..........................
Return Air Connections 20..........................
START--UP, ADJUSTMENT, AND SAFETY CHECK 32.....
General 32.......................................
Start--Up Procedures 32.............................
Adjustments 35...................................
Check Safety Controls 39...........................
Checklist 39......................................
SERVICE AND MAINTENANCE PROCEDURES 46.......
Introduction 47...................................
Care and Maintenance 47...........................
Sequence of Operation 50...........................
Wiring Diagrams 51...............................
Troubleshooting 51................................
ama
REGISTERED
ISO 9001:2000
CERTIFIED
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1--2006E, with permission of Nation 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 entirely.

2
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory--authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes
and National Electrical Code (NEC) for special requirements.
Recognize safety information. This is the safety--alert symbol !
!.
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury. Understand
these signal words; DANGER, WARNING, and CAUTION.
These words are used with the safety--alert symbol. DANGER
identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to
highlight suggestions which will result in enhanced installation,
reliability, or operation.
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use could cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified service agency, local gas supplier, or your distributor
or branch for information or assistance. The qualified service
agency must use only factory--authorized and listed kits or
accessories when modifying this product.
!WARNING
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, unit leveling, and unit sizing.
!CAUTION
Installing and servicing heating equipment can be hazardous due
to gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with furnace and other safety
precautions that may apply.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential constructions practices. We require these instructions
as a minimum for a safe installation.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing furnaces.
CAUTION
!
58ST

3
2-7/16"
1-1/8"
28-7/8"
25-1/4"
22-9/16"
JUNCTION BOX
LOCATION
7/8" DIA
ACCESSORY 1/2" DIA THERMOSTAT
WIRE ENTRY
3-15/16"
LEFT HAND GAS
ENTRY
33-5/16" 24-7/8"
5-1/2"
7/8" DIA. ACCESSORY
11/16"
21-5/8"
BOTTOM INLET 1-11/16"
13/16"
11/16"
4-13/16"
AIRFLOW
19"
OUTLET
13/16"
11/16"
8-9/16"
VENT OUTLET
5 PLACES (TYP)
3-3/4"
1-3/4" DIA.RIGHT HAND
GAS ENTRY
7/8" DIA. K.O. WIRE ENTRY
SIDE INLET
14-7/8"
7/8" DIA. ACCESSORY
1-1/4"
1"
22-1/16"
A
D
F
E
(FLUE COLLAR)
5-15/16"
24"
CASING
1-5/16"
1/2" DIA. K.O.THERMOSTAT
WIRE ENTRY
ALTERNATE
JUNCTION BOX
LOCATIONS (TYP)
26-1/8"
1-1/2"
7-3/4" 9-5/8"
11-1/2"
5-1/2"
NOTES:
1. Two additional 7/8-in. diameter holes are located in the top plate.
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.
a. For 800 CFM-16-in. round or 14 1/2 x 12-in. rectangle.
b. For 1200 CFM-20-in. round or 14 1/2 x 19 1/2-in. rectangle.
c. For 1600 CFM-22-in. round or 14 1/2 x 22-in. rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets
a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
A04037
Fig. 1 --- Dimensional Drawing
1. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
2. Install this furnace only in a location and position as
specified in the “Location” section of these instructions.
3. Provide adequate combustion and ventilation air to the
furnace space as specified in “Air for Combustion and
Ventilation” section.
4. Combustion product must be discharged outdoors.
Connect this furnace to an approved vent system only as
specified in the “Venting” section of these instructions.
5. Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections, as specified
in the “Gas Piping” section.
6. Always install furnace to operate within the furnace’s
intended temperature--rise range with a duct system which
has an external static pressure within the allowable range,
as specified in the “Start--Up, Adjustments, and Safety
Check” section. See furnace rating plate.
7. When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space
containing the furnace, the return air shall also be handled
by duct(s) sealed to the furnace casing and terminating
outside the space containing the furnace. See Air Ducts
section.
8. A gas--fired furnace for installation in a residential garage
must be installed as specified in the warning box in the
Location section.
9. The furnace may be used for construction heat provided
that the furnace installation and operation complies with
the first CAUTION in the LOCATION section of these
instructions.
10. These Multipoise Gas--Fired Furnaces are CSA (formerly
A.G.A. and C.G.A.) design--certified for use with natural
and propane gases (see furnace rating plate) and for
installation in alcoves, attics, basements, closets, utility
rooms, crawlspaces, and garages. The furnace is
factory--shipped for use with natural gas. A CSA listed
accessory gas conversion kit is required to convert furnace
for use with propane gas.
11. See Fig. 2 for required clearances to combustible
construction.
12. Maintain a 1--in. clearance from combustible materials to
supply air ductwork for a distance of 36 inches
horizontally from the furnace. See NFPA 90B or local
code for further requirements.
13. These furnaces SHALL NOT be installed directly on
carpeting, tile, or any other combustible material other
than wood flooring. In downflow installations, factory
accessory floor base MUST be used when installed on
combustible materials and wood flooring. Special base is
not required when this furnace is installed on
manufacturer’s Coil Assembly Part No. CAPV, CAPMP,
or CNPVP, or when Coil Box Part No. KCAKC is used.
See Fig. 2 for clearance to combustible construction
information.
INTRODUCTION
Series 120/C 4--way multipoise Category I fan--assisted furnace is
CSA design--certified. A Category I fan--assisted furnace is an
appliance equipped with an integral mechanical means to either
draw or force products of combustion through the combustion
chamber and/or heat exchanger. The furnace is factory--shipped
for use with natural gas. This furnace is not approved for
installation in mobile homes, recreational vehicles, or outdoors.
This furnace is designed for minimum continuous return--air
temperature of 60_F db or intermittent operation down to 55_F
db such as when used with a night setback thermostat. Return--air
temperature must not exceed 85_F db. Failure to follow these
return--air temperature limits may affect reliability of heat
exchangers, motors, and controls. (See Fig. 3.)
58ST

4
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES
INSTALLATION
327590-101 REV. C
Ø
*
Clearance arrows
do not change with
furnace orientation.
BOTTOM
DESSOUS
0"
3"
0"
0"
1"
0"
24"
MIN
SIDE
CÔTÉ
FRONT
AVANT
BCK
ARRIÈ
A
E
R
SERVIE
C
ENTRT
E
N
E
I
V
AN
AT
FRONT
SIE
CÔTÈ
FOU
U
FRNAC
S
E
E
I
A
RN
Ø
TOP / PLENUM
DESSUS / CHAMBRED'AIR
D
*
*
†
MIN
Ø
*
†
This forced air furnace is equipped for use with
natural gas at altitudes 0-10,000 ft (0-3,050m).
An accessory kit, supplied by the
manufacturer, shall be used to convert to propane
gas use or may be required for some natural gas
applications.
This furnace is for indoor installation in a
building constructed on site.
This furnace may be installed on combustible
flooring in alcove or closet at minimum clearance
as indicated by the diagram from combusitble
material.
This furnace may be used with a Type B-1 Vent
and may be vented in common with other gas
fired appliances.
Cette fournaise à air pulsé est équipée
pour utilisation avec gaz naturel et altitudes
comprises entre 0-3,050m (0-10,000 pi).
Utiliser une trousse de conversion, fournie par
le fabricant, pour passer au gaz propane ou pour
certaines installations au gaz naturel.
Cette fournaise est prévue pour être
installée dans un bâtiment construit sur place.
Cette fournaise peut être installée sur
un plancher combustible dans une alcôve ou
dans un garde-robe en respectant le minimum
d'espace libre des matériaux combustibles, tel
qu
´ indiqué sur le diagramme.
Cette fournaise peut être utilisée avec un
conduit d
´ évacuation de Type B-1 ou connectée
au conduit ommun d 'autres appareils à gaz.
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
Installation on non-combusibible floors only.
For Installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL,
Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.
18 inches front clearance required for alcove.
Indicates supply or return sides when furnace is in the horizontal position. Line contact only permissible
between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists,
studs or framing.
DOWNFLOW POSITIONS:
DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS
DE CONSTRUCTION COMBUSTIBLES
Pour l ´ installation sur plancher non combustible seulement.
Pour l
´ installation sur un plancher combustible seulement quand on utilise la base spéciale, pièce
nº KGASB0201ALL, l
´ ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de serpentin, pièce
nº KCAKC.
Dans une alcôve, on doit maintenir un dégagement à l
´ avant de 18 po (450mm).
La poistion indiquée concerne le côté d
´ entrée ou de retour quand la fournaise est dans la
position horizontale.
Le contact n
´ est permis qu ´ entre les lignes formées par les intersections du dessus et des
deux côtés de la cherrise de la fournaise et les solives, montant sous cadre de charpente.
POUR LA POSITION COURANT DESCENDANT:
Cette fournaise est approuvée pour l 'installation HORIZONTALE
et la circulation d 'air VERS LE HAUT et VERS LE BAS.
This furnace is approved for UPFLOW, DOWNFLOW, and
HORIZONTAL installations.
Clearance in inches
Dégagement (po).
Les fléches de dégagement
ne change pas avec
l 'orientation de la fournaise.
Vent Clearance to combustibles:
For Single Wall vents 6 inches (6 po).
For Type B-1 vent type 1 inch (1 po).
Dégagement de l ´ évent avec combustibles:
Pour conduit d ´ évacuation à paroi simple 6 po (6 inches).
Pour conduit d
´ évacuation de Type B-1 1 po (1 inch).
†
A04123
Fig. 2 --- Clearances to Combustibles
60
A02055
Fig. 3 --- Return Air Temperature
For accessory installation details, refer to the applicable
instruction literature.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
CODES AND STANDARDS
Follow all national and local codes and standards in addition
to these instructions. The installation must comply with
regulations of the serving gas supplier, local building, heating,
plumbing, and other codes. In absence of local codes, the
installation must comply with the national codes listed below and
all authorities having jurisdiction. In the United States and
Canada, follow all codes and standards for the following:
Step 1 —Safety
SUS: National Fuel Gas Code (NFGC) NFPA
54--2006/ANSI Z223.1--2006 and the Installation
Standards, Warm Air Heating and Air Conditioning
Systems ANSI/NFPA 90B
58ST

5
SCANADA: CSA B149.1--05 National Standard of
Canada Natural Gas and Propane Installation Codes
(CAN/CSA--B149.1--05)
Step 2 —General Installation
SUS: Current edition of the NFGC and the NFPA 90B.
For copies, contact the National Fire Protection
Association Inc., Batterymarch Park, Quincy, MA
02269; (www.NFPA.org) or for only the NFGC,
contact the American Gas Association, 400 N. Capitol
Street, N.W., Washington, DC 20001 (www.AGA.org).
SCANADA: CAN/CSA--B149.1--05. For a copy,
contact Standard Sales, CSA International, 178
Rexdale Boulevard, Etobicoke (Toronto), Ontario,
M9W 1R3 Canada
Step 3 —Combustion and Ventilation Air
SUS: Section 9.3 of the NFGC, Air for Combustion and
Ventilation
SCANADA: Part 7 of CAN/CSA--B149.1--05, Venting
Systems and Air Supply for Appliances
Step 4 —Duct Systems
SUS and CANADA: Air Conditioning Contractors
Association (ACCA) Manual D, Sheet Metal and Air
Conditioning Contractors National Association
(SMACNA), or American Society of Heating,
Refrigeration, and Air Conditioning Engineers
(ASHRAE) 2001 Fundamentals Handbook Chapter 34
or 2000 HVAC Systems and Equipment Handbook
Chapters 9 and 16.
Step 5 —Acoustical Lining and Fibrous Glass
Duct
SUS and CANADA: current edition of SMACNA and
NFPA 90B as tested by UL Standard 181 for Class I
Rigid Air Ducts .
Step 6 —Gas Piping and Gas Pipe Pressure
Testing
SUS: NFGC; chapters 5, 6, and 7 and National
Plumbing Codes .
SCANADA: CAN/CSA--B149.1--05 Part 4, 5, 6, and 9,
and Appendices A, B, E, and H.
Step 7 —Electrical Connections
SUS: National Electrical Code (NEC) ANSI/NFPA
70--2005
SCANADA: Canadian Electrical Code CSA C22.1
Step 8 —Ven ting
SUS: NFGC; chapters 12 and 13
SCANADA: CAN/CSA--B149.1--05 Part 8 and
Appendix C
SELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in furnace
component 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 personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.
CAUTION
!
1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch the clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
a person’s hand during grounding will be satisfactorily
discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing to
recharge your body with static electricity (for example;
DO NOT move or shuffle your feet, do not touch
ungrounded objects, etc.).
4. If you touch ungrounded objects (and recharge your body
with static electricity), firmly touch a clean, unpainted
metal surface of the furnace again before touching control
or wires.
58ST

6
THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
A02097
Fig. 4 --- Multipoise Orientations
TABLE 1—DIMENSIONS (IN.)
FURNACE SIZE A
CABINET WIDTH
D
SUPPLY ---AIR
WIDTH (IN.)
E
RETURN---AIR
WIDTH (IN.)
F
C.L. TOP AND
BOTTOM FLUE
COLLAR (IN.)
FLUE
COLLAR*
(IN.)
SHIP WT (LB)
045---08/024045 14--- 3/16 12---9/16 12---11/16 9---5/16 4104
045---12/036045 14--- 3/16 12---9/16 12---11/16 9---5/16 4107
070---08/024070 14--- 3/16 12---9/16 12---11/16 9---5/16 4111
070---12/036070 14--- 3/16 12---9/16 12---11/16 9---5/16 4115
070---16/048070 17--- 1/2 15---7/8 16 11---9/16 4126
090---14/042090 17--- 1/2 15---7/8 16 11---9/16 4127
090---16/048090 21 19---3/8 19---1/2 13---5/16 4140
090---20/060090 21 19---3/8 19---1/2 13---5/16 4146
110---12/036110 17--- 1/2 15---7/8 16 11---9/16 4135
110---16/048110 21 19---3/8 19---1/2 13---5/16 4146
110---22/066110 21 19---3/8 19---1/2 13---5/16 4152
135---16/048135 21 19---3/8 19---1/2 13---5/16 4149
135---22/066135 24--- 1/2 22---7/8 23 15---1/16 4163
155---20/060155 24--- 1/2 22---7/8 23 15---1/16 4170
* 5 --- i n . o r 6 --- i n . v e n t c o n n e ct o r m a y b e r e qu i r ed i n s o m e c as e s.
5. Use this procedure for installed and uninstalled
(ungrounded) furnaces.
6. Before removing a new control from its container,
discharge your body’s electrostatic charge to ground to
protect the control from damage. If the control is to be
installed in a furnace, follow items 1 through 4 before
bringing the control or yourself in contact with the
furnace. Put all used and new controls into containers
before touching ungrounded objects.
7. An ESD service kit (available from commercial sources)
mayalsobeusedtopreventESDdamage.
LOCATION
GENERAL
This multipoise furnace is shipped in packaged configuration.
Some assembly and modifications are required when used in any
of the four applications shown in Fig. 4.
This furnace must:
Sbe installed so the electrical components are protected
from water.
Snot be installed directly on any combustible material
other than wood flooring (refer to SAFETY
CONSIDERATIONS).
Sbe located as close to the chimney or vent and attached
to an air distribution system. Refer to Air Ducts section.
Sbe provided ample space for servicing and cleaning.
Always comply with minimum fire protection
clearances shown on the furnace clearance to
combustible label.
58ST

7
CARBON MONOXIDE POISONING AND UNIT
DAMAGE HAZARD
Failure to follow this warning could result in personal
injury or death, and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
!WARNING
SThe following types of furnace installations may
require OUTDOOR AIR for combustion due to
chemical exposures:
SCommercial buildings
SBuildings with indoor pools
SLaundry rooms
SHobby or craft rooms, and
SChemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
SPermanent wave solutions
SChlorinated waxes and cleaners
SChlorine based swimming pool chemicals
SWater softening chemicals
SDe--icing salts or chemicals
SCarbon tetrachloride
SHalogen type refrigerants
SCleaning solvents (such as perchloroethylene)
SPrinting inks, paint removers, varnishes, etc.
SHydrochloric acid
SCements and glues
SAntistatic fabric softeners for clothes dryers
SMasonry acid washing materials
All fuel--burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return--air duct to
prevent pulling air from the burner area and from draft safeguard
opening.
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage. or explosion.
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 NFGC or
CAN/CSA--B149.1--05 (See Fig. 5.)
!WARNING
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Failure to follow this caution may result in furnace
component damage.
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 roll--out and/or drawing combustion
products into the structure.
--The furnace is controlled by a thermostat. It may not be
hot wired to provide heat continuously to the structure
without thermostatic control.
--Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the
entrainment of drywall dust into combustion air, which can
cause fouling and plugging of furnace components.
--The temperature of the return air to the furnace is
maintained between 55_F(13_C) and 80_F(27_C), with
no evening setback or shutdown. The use of the furnace
while the structure is under construction is deemed to be
intermittent operation per our installation instructions.
--The air temperature rise is within the rated rise range on
the furnace rating plate, and the gas input rate has been set
to the nameplate value.
--The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
--The furnace, ductwork and filters are cleaned as necessary
to remove drywall dust and construction debris from all
HVAC system components after construction is completed.
--Verify proper furnace operating conditions including
ignition, gas input rate, air temperature rise, and venting
according to these installation instructions.
CAUTION
!
58ST

8
18-IN. MINIMUM
TO BURNERS
A93044
Fig. 5 --- Installation in a Garage
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace. (See Fig. 6.)
!WARNING
A02054
Fig. 6 --- Prohibit Installation on Back
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.
AIR FOR COMBUSTION AND
VENTILATION
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
SU.S. installations: Section 9.3 of the NFGC, Air for
Combustion and Ventilation, and applicable provisions
of the local building codes.
SCanadian installations: Part 8 of
CAN/CSA--B149.1--05, Venting Systems and Air
Supply for Appliances, and all authorities having
jurisdiction.
FURNACE CORROSION HAZARD
Failure to follow this caution may result in furnace damage.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
CAUTION
!
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make--up air MUST be provided for the ventilation devices,
in addition to that required by the furnace. Refer to Carbon
Monoxide Poisoning Hazard warning in venting section of
these instructions to determine if an adequate amount of
make--up air is available.
!WARNING
The requirements for combustion and ventilation air depend
upon whether or not the furnace is located in a space having a
volume of at least 50 cu/ft. per 1,000 Btuh input rating for all gas
appliances installed in the space.
SSpaces having less than 50 cu/ft. per 1,000 Btuh
require the OUTDOOR COMBUSTION AIR
METHOD.
SSpaces having at least 50 cu/ft. per 1,000 Btuh may use
the INDOOR COMBUSTION AIR, STANDARD or
KNOWNAIR INFILTRATION METHOD.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper
combustion, ventilation, and dilution of flue gases using
permanent horizontal or vertical duct(s) or opening(s)
directly communicating with the outdoors or spaces that
freely communicate with the outdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air opening, to the outdoors.
a. One opening MUST commence within 12 in. (300
mm) of the ceiling and the second opening MUST
commence within 12 in. (300 mm) of the floor.
b. Size openings and ducts per Fig. 7 and Table 2.
c. TWO HORIZONTAL DUCTS require 1 sq./in. of free
area per 2,000 Btuh (1,100 mm2/kW) of combined
input for all gas appliances in the space per Fig. 7 and
Table 2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
sq./in. 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.
58ST

9
TABLE 2—MINIMUM FREE AREA REQUIRED FOR EACH COMBUSTION AIR OPENING OR DUCT TO OUTDOORS
FUR-
NACE IN-
PUT
(BTUH)
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW)
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)
TWO OPENINGS OR VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)
Free Area of Opening
and Duct (Sq.. In.)
Round Duct (in.
Dia)
Free Area of Open-
ing and Duct (sq.
In.)
Round Duct
(in. Dia)
Free Area of Open-
ing and Duct (Sq.
In.)
Round Duct
(In. Dia)
44,000 22 614.7 511 4
66,000 33 722 616.5 5
88,000 44 829.3 722 6
110,000 55 936.7 727.5 6
132,000 66 10 44 833 7
154,000 77 10 51.3 938.5 8
EXAMPLES: Determining Free Area
FURNACE WATER HEATER TOTAL INPUT
110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or 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
ACH
OTHER THAN FAN---ASSISTED
TOTAL
(1,000’S BTUH GAS INPUT RATE)
FAN---ASSISTED TOTAL
(1000’S BTUH GAS INPUT RATE)
30 40 50 44 66 88 110 132 154
SpaceVolume(ft.
3)
0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850
0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620
0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775
0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700
0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550
0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100
0.00 NP NP NP NP NP NP NP NP NP
3. ONE OUTDOOR OPENING requires:
a. 1 square inch of free area per 3,000 Btuh (734
mm2/kW) for combined input of all gas appliances in
the space per Table 2 and
b. Not less than the sum of the areas of all vent
connectors in the space.
The opening shall commence within 12 in. (300 mm) of the
ceiling. Appliances in the space shall have clearances of at least 1
in. (25 mm) from the sides and back and 6 in. (150 mm) from the
front. The opening shall directly communicate with the outdoors
or shall communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely communicate with
the outdoors.
Indoor Combustion Air NFPA
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 death and/or
personal injury.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
!WARNING
The Standard Method:
1. The space has no less volume than 50 cu/ft. per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40
air changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 3 or Equations 1 and 2.
Determine the minimum required volume for each appliance in
the space and add the volumes together to get the total minimum
required volume for the space.
58ST

10
1 SQ IN.
PER
4000
BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
CIRCULATING
AIR DUCTS
VENT
THROUGH
ROOF
D
B
A
C
E
1 SQ IN.
PER 4000
BTUH*
DUCT
TO
OUTDOORS
CIRCULATING AIR DUCTS
1 SQ IN.
PER 2000
BTUH*
1 SQ IN.
PER 2000
BTUH*
DUCTS
TO
OUTDOORS
12″MAX
12″MAX
12″MAX
Use any of the following
combinations of openings:
A & B C & D D & E F & G
NOTE:
*
Minimum dimensions of 3 in.
12″
MAX
12″
MAX
OUTDOORS
1 SQ IN.
PER
4000
BTUH*
F
G
CLEARANCE IN FRONT
OF COMBUSTION AIR
OPENINGS SHALL BE
AT LEAST 3 IN.
A03174
Fig. 7 --- Air for Combustion, Ventilation, and Dilution for
Outdoors
Table 3--Minimum Space Volumes were determined by using
the following equations from the National Fuel Gas Code ANSI
Z223.1--2006/NFPA 54--2006, 9.3.2.2:
1. For other than fan--assisted appliances, such as a draft
hood--equipped water heater:
Volume
Other
=21ft
3
ACH
I
other
1000 Btu/hr
A04002
2. For fan--assisted appliances such as this furnace:
Volume
Fan
=15ft
3
ACH
I
fan
1000 Btu/hr
A04003
If:
Iother = combined input of all other than fan--assisted
appliances in Btuh/hr
Ifan = combined input of all fan--assisted appliances in Btuh/hr
ACH = air changes per hour (ACH shall not exceed 0.60.) The
following requirements apply to the Standard Method and to the
Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closable doors between rooms.
CIRCULATING AIR
DUCTS
6" MIN
(FRONT)
†
CIRCULATING AIR DUCTS
VENT THROUGH ROOF
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12" MAX
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12" MAX
* Minimum opening size is 100 sq in. with
minimum dimensions of 3 in.
†
Minimum of 3 in.. when t
yp
e-B1 vent is used.
UNCONFINED
SPACE
INTERIOR
HEATED
SPACE
CLEARANCE IN FRONT OF COMBUSTION AIR
OPENINGS SHALL BE AT LEAST 3 IN.
A03175
Fig. 8 --- Air for Combustion, Ventilation, and Dilution From
Indoors
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1 in.2/1,000 Btuh (2,000
mm2/kW) of the total input rating of all gas appliances
in the space, but not less than 100 in.2(0.06 m2). One
opening shall commence within 12 in. (300 mm) of
the ceiling and the second opening shall commence
within 12 in. (300 mm) of the floor. The minimum
dimension of air openings shall be at least 3 in. (80
mm).(SeeFig.8.)
c. Combining space on different floor levels. The
volumes of spaces on different floor levels shall be
considered as communicating spaces if connected by
one or more permanent openings in doors or floors
having free area of at least 2 in.2/1,000 Btuh (4,400
mm2/kW) of total input rating of all gas appliances.
2. An attic or crawlspace may be considered a space that
freely communicates with the outdoors provided there are
adequate permanent ventilation openings directly to
outdoors having free area of at least 1--in.2/4,000 Btuh of
total input rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for
combustion, permanent ventilation and dilution of flue
gases. However, in buildings with unusually tight
construction, additional air MUST be provided using the
methods described in the Outdoor Combustion Air
Method section.
58ST

11
Unusually tight construction is defined as Construction with:
a. Walls and ceilings exposed to the outdoors have a
continuous, sealed vapor barrier. Openings are
gasketed or sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include
joints around window and door frames, between sole
plates and floors, between wall--ceiling joints, between
wall panels, at penetrations for plumbing, electrical
and gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor
Combustion Air Method below and,
2. Outdoor openings shall be located as required in the
Outdoor Combustion Air Method mentioned previously
and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air
Method below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The
minimum dimension of air openings shall be not less
than3in.(80mm).
INSTALLATION
UPFLOW INSTALLATION
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
A02098
Fig. 9 --- Removing Bottom Closure Panel
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
only side return air is used.
NOTE: Side return--air openings can be used in UPFLOW and
most HORIZONTAL configurations. Do not use side return--air
openings in DOWNFLOW configuration.
In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 10.) Install field--supplied, 5/16 X 1--1/2 in. (max)
corrosion--resistant machine bolts, washers and nuts.
NOTE: Bottom closure must be used when leveling legs are
used. It may be necessary to remove and reinstall bottom closure
panel to install leveling legs. To remove bottom closure panel, see
Item 1. in Bottom Return Air Inlet section.
1 34″
1 34″
1 34″
1 34″
516″
516″
516″
516″
A89014
Fig. 10 --- Leveling Legs
Leveling Legs (If Desired)
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.
DOWNFLOW INSTALLATION
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 3
accessories are used:
SSpecial Base, KGASB
SCased Coil Assembly Part No. CAPVP, CAPMP, or
CNPVP
SCoil 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, KGASB is used, install as shown in
Fig. 12. If Coil Assembly Part No. CAPVP, CAPMP, or
CNPVP or Coil Box Part No. KCAKC is used, install as
shown in Fig. 13.
58ST

12
PLENUM
OPENING
C
A
BD
FLOOR
OPENING
A96283
Fig. 11 --- Floor and Plenum Opening Dimensions
NOTE: It is recommended that the perforated supply--air duct
flanges be completely folded over or removed from furnace when
installing the furnace on a factory--supplied cased coil or coil box.
To remove the supply--air duct flange, use wide duct pliers or
hand seamers to bend flange back and forth until it breaks off. Be
careful of sharp edges. (See Fig. 14.)
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
A04140
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
FURNACE
SHEET METAL
PLENUM
FLOOR
OPENING
COMBUSTIBLE
FLOORING
A04140
Fig. 13 --- Furnace, Plenum, and Coil Assembly or Coil Box
Installed on a Combustible Floor
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
HORIZONTAL INSTALLATION
FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Do not install the furnace on its back or hang furnace with
control compartment facing downward. Safety control
operation will be adversely affected. Never connect
return--air ducts to the back of the furnace.
!WARNING
The furnace can be installed horizontally in an attic or 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 non--combustible platform, blocks, bricks or pad.
Suspended Furnace Support
The furnace may be supported under each end with threaded rod,
angle iron or metal plumber’s strap as shown. (See Fig. 15 and
16.) Secure angle iron to bottom of furnace as shown.
Heavy--gauge sheet metal straps (plumber’s straps) may be used
to suspend the furnace from each bottom corner. To prevent
screws from pulling out, use 2 #8 x .--in. screws into the side and
2 #8 x .--in. screws in the bottom of the furnace casing for each
strap. (See Fig. 15 and 16.)
58ST

13
If the screws are attached to ONLY the furnace sides and not the
bottom, the straps must be vertical against the furnace sides and
not pull away from the furnace sides, so that the strap attachment
screws are not in tension (are loaded in shear) for reliable support.
Platform Furnace Support
Construct working platform at location where all required furnace
clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in.
clearance requirement on side, set furnace on noncombustible
blocks, bricks or angle iron. For crawl space installations, if the
furnace is not suspended from the floor joists, the ground
underneath furnace must be level and the furnace set on blocks or
bricks.
Roll--Out Protection
Provide a minimum 17--3/4 in. X 22 in. piece of sheet metal for
flame roll--out protection in front of burner area for furnaces
closer than 12 inches above the combustible deck or suspended
furnaces closer than 12 inches to joists. The sheet metal MUST
extend underneath the furnace casing by 1 in. with the door
removed.
The bottom closure panel on furnaces of widths 17--1/2 in. and
larger may be used for flame roll--out protection when bottom of
furnace is used for return air connection. See Fig. 17 for proper
orientation of roll--out shield.
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. Remove and discard this panel when
bottom return air is used. To remove bottom closure panel,
perform the following:
1. Tilt or raise furnace and remove 2 screws holding bottom
filler panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding
tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return--air opening. This panel MUST be in place when
side return air inlet(s) is used without a bottom return air inlet.
Not all horizontal furnaces are approved for side return air
connections. (See Fig. 20.)
FILTER ARRANGEMENT
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
Never operate a furnace without a filter or with filter access
door removed.
!WARNING
There are no provisions for an internal filter rack in these
furnaces.
Refer to the instructions supplied with Media Cabinet for
assembly and installation options.
A field--supplied accessory external filter rack is required.
This furnace requires KGAFR030ALL 1 in. external filter rack or
a suitable field--supplied substitute, such as the media cabinet.
Refer to the instructions supplied with external filter rack for
assembly and installation options.
58ST

14
TABLE 4—OPENING DIMENSIONS (IN.)
FURNACE
CASING
WIDTH
APPLICATION PLENUM OPENING FLOOR OPENING
A B C D
14–3/16
Upflow Applications on Combustible or Noncombustible Floor-
ing (KGASB subbase not required) 12---11/16 21---5/8 13---5/16 22---1/4
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required) 12---9/16 19 13---3/16 19---5/8
Downflow applications on combustible flooring (KGASB sub-
base required) 11---13/16 19 13---7/16 20---5/8
Downflow Applications on Combustible Flooring with 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 Floor-
ing (KGASB subbase not required) 16 21---5/8 16---5/8 22---1/4
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required) 15---7/8 19 16---1/2 19---5/8
Downflow applications on combustible flooring (KGASB sub-
base required) 15---1/8 19 16---3/4 20---5/8
Downflow Applications on Combustible Flooring with 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 Floor-
ing (KGASB subbase not required) 19---1/2 21---5/8 20---1/8 22---1/4
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required) 19---3/8 19 20 19---5/8
Downflow applications on combustible flooring (KGASB sub-
base required) 18---5/8 19 20---1/4 20---5/8
Downflow Applications on Combustible Flooring with 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 Floor-
ing (KGASB subbase not required) 23 21---1/8 23---5/8 22---1/4
Downflow Applications on Noncombustible Flooring (KGASB
subbase not required) 22---7/8 19 23---1/2 19---5/8
Downflow applications on Combustible flooring (KGASB sub-
base required) 22---1/8 19 23---3/4 20---5/8
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase not
required)
22---1/2 19 23---1/2 20
AIR DUCTS
General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA)
or American Society of Heating, Refrigerating and Air
Conditioning Engineers (ASHRAE) or consult The Air Systems
Design Guidelines reference tables available from your local
distributor. The duct system should be sized to handle the
required system design CFM at the design external static pressure.
The furnace airflow rates are provided in Table 5--AIR
DELIVERY--CFM (With Filter).
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by duct(s) sealed to
the furnace casing and terminating outside the space containing
the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply-- and return--duct connections to furnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and furnace to prevent transmission of vibration. Ductwork
passing through unconditioned space should be insulated and
sealed to enhance system performance. When air conditioning is
used, a vapor barrier is recommended.
Maintain a 1--in. clearance from combustible materials to supply
air ductwork for a distance of 36 in. horizontally from the
furnace. See NFPA 90B or local code for further requirements.
Ductwork Acoustical Treatment
NOTE: Metal duct systems that do not have a 90 degree elbow
and 10 ft. of main duct to the first branch take--off may require
internal acoustical lining. As an alternative, fibrous ductwork may
be used if constructed and installed in accordance with the latest
edition of SMACNA construction standard on fibrous glass
ducts. Both acoustical lining and fibrous ductwork shall comply
with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid
air ducts.
Supply Air Connections
For a furnace not equipped with a cooling coil, the outlet duct
shall be provided with a removable access panel. This opening
shall be accessible when the furnace is installed and shall be of
such a size that the heat exchanger can be viewed for possible
openings using light assistance or a probe can be inserted for
sampling the air stream. The cover attachment shall prevent leaks.
58ST

15
TABLE 5—AIR DELIVERY -- CFM (WITH FILTER)*
FURNACE
SIZE
RETURN---AIR
INLET SPEED EXTERNAL STATIC PRESSURE (IN. WC)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
045---08 /
024045 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
1085
920
820
1035
875
775
975
830
730
915
770
680
845
710
620
770
640
555
675
555
470
565
440
360
390
250
190
195
--- ---
--- ---
045---12 /
036045 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
1440
1360
1250
1375
1300
1210
1305
1240
1160
1240
1175
1100
1160
1115
1040
1070
1040
965
975
950
885
870
850
790
730
725
670
560
575
520
070---08 /
024070 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
1030
835
725
1010
815
700
980
790
675
945
760
645
900
720
600
845
675
555
775
610
475
680
490
390
490
375
300
335
265
--- ---
070---12 /
036070 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
1425
1320
1200
1375
1280
1175
1320
1240
1145
1265
1205
1105
1200
1140
1050
1125
1075
990
1035
995
920
940
905
840
830
790
725
655
620
555
070---16 /
048070 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
1805
1630
1460
1740
1585
1420
1670
1530
1385
1600
1470
1325
1530
1405
1280
1445
1330
1220
1360
1255
1155
1280
1170
1080
1180
1080
995
1075
990
910
090---14 /
042090 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
1650
1515
1385
1600
1485
1360
1535
1440
1320
1465
1380
1260
1385
1300
1195
1285
1220
1120
1175
1115
1025
1055
990
915
895
830
710
645
600
565
090---16 /
048090 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
2060
1790
1505
1985
1765
1505
1915
1715
1480
1820
1645
1440
1720
1560
1375
1610
1470
1300
1490
1345
1190
1340
1195
1045
1135
1010
890
925
820
740
090---20 /
060090
Bottom Only
High
M e d --- H i g h
M e d --- L o w
2405
2225
2020
2310
2155
1955
2220
2080
1880
2130
1995
1805
2025
1895
1730
1920
1785
1630
1790
1675
1535
1660
1565
1420
1530
1420
1275
1350
1260
1135
Both Sides or 1
Side & Bottom
High
M e d --- H i g h
M e d --- L o w
2530
2285
1995
2450
2215
1945
2365
2150
1900
2270
2075
1840
2165
1985
1770
2065
1890
1685
1940
1780
1600
1805
1660
1480
1670
1525
1350
1505
1360
1180
1Side Only
High
M e d --- H i g h
M e d --- L o w
2475
2260
1950
2395
2190
1910
2300
2110
1855
2200
2035
1795
2090
1940
1730
1985
1845
1650
1865
1735
1555
1730
1620
1445
1585
1475
1310
1425
1325
1150
110---12 /
036110 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
1625
1510
1360
1575
1470
1335
1515
1415
1295
1445
1355
1250
1355
1285
1180
1260
1185
1100
1165
1070
985
990
890
810
785
725
--- ---
--- ---
--- ---
--- ---
110---16 /
048110 Bottom or Side(s)
High
M e d --- H i g h
M e d --- L o w
2035
1745
1530
1965
1710
1515
1880
1650
1470
1790
1560
1400
1680
1450
1310
1495
1340
1215
1365
1205
1095
1215
1090
990
1075
955
830
875
750
670
110---22 /
066110
Bottom Only
High
M e d --- H i g h
M e d --- L o w
2530
2230
1920
2470
2205
1900
2400
2165
1880
2320
2110
1845
2220
2035
1795
2115
1950
1730
2000
1855
1650
1865
1740
1555
1730
1615
1460
1590
1485
1340
Bottom Sides or 1
Side & Bottom
High
M e d --- H i g h
M e d --- L o w
--- ---
2235
1920
--- ---
220
1900
2415
2155
1880
2350
2100
1845
2250
2040
1795
2145
1955
1730
2015
1850
1650
1875
1740
1555
1715
1595
1460
1560
1470
1340
1Side Only
High
M e d --- H i g h
M e d --- L o w
2540
2125
--- ---
2495
2120
1795
2430
2105
1790
2355
2060
1765
2265
2010
1720
2175
1940
1650
2065
1840
1585
1935
1730
1500
1785
1615
1390
1650
1485
1280
* A filter is required for each return---air inlet. Airflow performance included 1---in. washable filter media such as contained in factory---authorized accessory filter
rack. To determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.
--- --- Indicates unstable operating conditions.
58ST

16
TABLE 5⎯AIR DELIVERY -- CFM (WITH FILTER)* (CONTINUED)
FURNACE
SIZE
RETURN---AIR
INLET SPEED EXTERNAL STATIC PRESSURE (IN. WC)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
048135 Bottom or Side(s)
High
M e d ---
High
M e d --- L o w
2090
1790
1545
2010
1755
1525
1930
1705
1500
1835
1640
1450
1710
1550
1380
1590
1465
1315
1470
1360
1215
1335
1210
1005
1025
945
855
835
785
670
066135
Bottom Only
High
M e d ---
High
M e d --- L o w
2485
2195
1880
2400
2150
1850
2310
2090
1820
2215
2000
1780
2110
1920
1715
2000
1825
1635
1880
1720
1540
1725
1565
1415
1535
1405
1290
1355
1255
1160
Bottom, Sides or
1 Side & Bottom
High
M e d ---
High
M e d --- L o w
--- ---
“2180
1880
--- ---
2145
1850
2385
2060
1820
2305
2010
1780
2195
1945
1715
2085
1865
1635
1960
1765
1540
1825
1660
1415
1670
1515
1290
1465
1325
1160
1SideOnly
High
M e d ---
High
M e d --- L o w
--- ---
2135
1880
--- ---
2085
1850
2245
2035
1820
2155
1975
1780
2055
1895
1715
1940
1795
1635
1825
1685
1540
1695
1565
1415
1555
1445
1290
1385
1265
1160
060155
Bottom Only
High
M e d ---
High
M e d --- L o w
2465
2115
1800
2430
2105
1790
2375
2075
1770
2305
2030
1735
2230
1980
1695
2110
1910
1640
2000
1830
1570
1865
1725
1465
1725
1590
1345
1545
1425
1225
Both Sides Or 1
Side & Bottom
High
M e d ---
High
M e d --- L o w
--- ---
2155
1800
--- ---
2135
1790
2375
2095
1770
2285
2040
1735
2200
1975
1695
2105
1895
1640
1995
1790
1570
1870
1685
1465
1730
1550
1345
1570
1400
1225
1Side Only
High
M e d ---
High
M e d --- L o w
--- ---
2140
1800
--- ---
2095
1790
2260
2040
1770
2180
1975
1735
2085
1890
1695
1975
1810
1640
1865
1705
1570
1740
1595
1465
1605
1480
1345
1455
1325
1225
* A filter is required for each return---air inlet. Airflow performance included 1---in. washable filter media such as contained in factory---authorized accessory filter
rack. To determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.
--- --- Indicates unstable operating conditions.
UPFLOW OWNFLOW HORIZONTAL
YES
NOT
RECOMMENDED
YES
YES
YES
120˚
MIN
YES 120˚
MIN
YES
120˚
MIN
90˚90˚
NOT
RECOMMENDED
NOT
RECOMMENDED
D
A02329
Fig. 14 --- Duct Flanges
58ST

17
1
/ 4 " THREADED ROD
4 REQ.
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x
3
/ 4 " SCREWS
TYPICAL FOR 2 SUPPORTS
1" SQUARE, 1
1
/ 4 " x 1
1
/ 4 " x
1
/ 8 " ANGLE IRON
OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS
REQ. PER ROD
8" MIN FOR DOOR
REMOVAL
OUTER DOOR
ASSEMBLY
A05027
Fig. 15 --- Horizontal Unit Suspension
A02014
Fig. 16 --- Horizontal Suspension with Straps
58ST

18
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 OF THE FURNACE
JACKET AND BUILDING JOISTS,
STUDS, OR FRAMING.
GAS
ENTRY
17 3/4 ″ OVER ALL
4 3/4 ″ UNDER DOOR
1″UNDER FURNACE
EXTEND OUT 12″ OUT
FROM FACE OF DOOR
* WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
A02164
Fig. 17 --- Typical Attic Installation
A02075
Fig. 18 --- Upflow Return Air configurations and Restrictions
58ST

19
A02163
Fig. 19 --- Downflow Return Air Configurations and Restrictions
A02162
Fig. 20 --- Horizontal Return Air Configurations and Restrictions
Upflow and Horizontal Furnaces
Connect supply--air duct to flanges on furnace supply--air outlet.
Bend flange upward to 90_with wide duct pliers. (See Fig. 14.)
The supply--air duct must be connected to ONLY the furnace
supply--outlet--air duct flanges or air conditioning coil casing
(when used). DO NOT cut main furnace casing side to attach
supply air duct, humidifier, or other accessories. All accessories
MUST be connected to duct external to furnace main casing.
NOTE: For horizontal applications, the top--most flange may be
bent past 90_to allow the evaporator coil to hang on the flange
temporarily while the remaining attachment and sealing of the
coil are performed.
Downflow Furnaces
Connect supply--air duct to supply--air outlet on furnace. Bend
flange inward past 90_with wide duct pliers. (See Fig. 14.) The
supply--air duct must be connected to ONLY the furnace
supplyoutlet or air conditioning coil casing (when used). When
installed on combustible material, supply--air duct must be
connected to ONLY the accessory subbase KGASB0201ALL or
a factory approved air conditioning coil casing. DO NOT cut
main furnace casing to attach supply side air duct, humidifier, or
58ST

20
other accessories. All accessories MUST be connected to duct
external to furnace casing.
FIRE HAZARD
A failure to follow this warning could result in personal
injury, or death and/or property damage.
Never connect return--air ducts to the back of the furnace.
Follow instructions below.
!WARNING
Return Air Connections
Downflow Furnaces
The return--air duct must be connected to return--air opening
(bottom inlet) as shown in Fig. 19. DO NOT cut into casing sides
(left or right). Side opening is permitted for only upflow and most
horizontal furnaces. (See Fig. 19.) Bypass humidifier connections
should be made at ductwork or coil casing sides exterior to
furnace.
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. 18 and 20. Bypass humidifier may be
attached into unused return air side of the furnace casing. (See
Fig. 18 and 20.)
Not all horizontal furnaces are approved for side return air
connections. (See Fig. 20.)
GAS PIPING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection
of leaks to check all connections.
!WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Use proper length of pipe to avoid stress on gas control
manifold and a gas leak.
!WARNING
Gas piping must be installed in accordance with national and
local codes. Refer to current edition of NFGC in the U.S., the
CAN/CSA--B149.1--05 in Canada.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a
separate line running directly from meter to furnace.
NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be performed by a
licensed plumber or gas fitter.
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 mm).
3. When lever handle type manual equipment shutoff valves
are used, they shall be T--handle valves.
4. The use of copper tubing for gas piping is NOT approved
by the state of Massachusetts.
Refer to Table 6 for recommended gas pipe sizing. Risers must be
used to connect to furnace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of 1 hanger
every 6 ft.. Joint compound (pipe dope) should be applied
sparingly and only to male threads of joints. Pipe dope must be
resistant to the action of propane gas.
TABLE 6—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
1 --- 1 / 4 1.380 1400 950 770 660 580
1 --- 1 / 2 1.610 2100 1460 1180 990 900
* Cubic ft. of natural gas per hr for gas pressures 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 12.2 ANSI Z223---2006/NFPA 54 ---2006.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously served another gas
appliance. Black iron pipe shall be installed at the furnace
gas control valve and extend a minimum of 2 in. outside the
furnace.
!WARNING
FURNACE OVERHEAT HAZARD
Failure to follow this caution may result in unit component
damage.
Connect gas pipe to gas valve using a backup wrench to
avoid damaging gas controls and burner misalignment.
CAUTION
!
An accessible manual equipment shutoff valve MUST be
installed external to furnace casing and within 6 ft. of furnace. A
1/8--in. NPT plugged tapping, accessible for test gauge
connection, MUST be installed immediately upstream of gas
supply connection to furnace and downstream of manual
equipment shutoff valve.
58ST