Carrier 59SC2A Guide

59SC2A
Single Stage 4—Way Multipoise
Condensing Gas Furnace
Series 100
Carrier
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turn to the IZA
Installation, Start—up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS ..................0.0005- 3
INTRODUCTION .......... 00.000. 4
CODES AND STANDARDS ..............0. 500. 000005- 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ... 4
ACCESSORIES .. 0.2... 0... ee 5
LOCATION ... 00.0.0... ees 8
General... ee eens 8
AIR FOR COMBUSTION AND VENTILATION .......... 9
Introduction 22... 0. ee ee eee 9
CONDENSATE TRAP... 2.2.0... eee 13
Uptlow 2... eens 13
Downflow .. 0.0... eee eens 13
Horizontal 2... eens 13
CONDENSATE DRAIN ............. 0.0.00 002 eee eee 17
INSTALLATION .........0.. 00.000 eee eee 20
Uptlow 2... eens 20
Downflow .. 0.0... eee eens 20
Horizontal 0... eee 21
Filter Arrangement .. 0.0.0.0... 00. eee eee 21
AIR DUCTS . 10. ee 29
General Requirements .. 0.0.0.0... 00.0 cee eee ee 29
Ductwork Acoustical Treatment ........... 0. 0.000005 29
GAS PIPING ... 00.0... ee 31
ELECTRICAL CONNECTIONS ....................... 32
115-V Wiring 2... eee eee 32
J-Box Installation .. 0.0... eee ee 33
24-V Wiring... eee eee 33
ACCESSOTIES 2. eee eee eee 33
Alternate Power Supplies ... 0.0.0.0... 0.0.0.0... 000-4 33
VENTING .... 0... ee 37
Special Venting Requirements for Installations in Canada . 37
General... ee eens 38
Materials 0... eee 38
Venting Systems ©... 0.0... eee ene 38
Locating the Vent Termination .................+.... 39
Combustion Air and Vent Piping Insulation Guidelines ... 41
START-UP, ADJUSTMENT, AND SAFETY CHECK ...... 62
General 2... eee eee 62
Prime Condensate Trap 2.0.0.0... 0.0. e eee eee 62
Purge Gas Lines 2... eee 62
Adjustments 2.00.0... eee eee 62
SERVICE AND MAINTENANCE PROCEDURES ........ 70
Cleaning Heat Exchangers... 0.0. ene 75
SEQUENCE OF OPERATION ... 0.0.00. 0 0 eee eee 79
PARTS REPLACEMENT GUIDE ...................... 83
TABLES
Loose Parts Bago... ee eee 5
Minimum Clearances to Combustible Materials ............. 5
Minimum Free Area Required 2.0.0.0... 0.0.0.0 cee ee eee 11
Minimum Space Volumes .. 2.0.0.0... 0.0000 eee eee 11
Filter Size Information ©... 66.0.0 ees 24
Opening Dimensions ......... 0.0.00 ce eee ee eee 25
Air Delivery CFM 0... eee 30
Maximum Capacity of Pipe ....... 0.0.0... 0. eee eee eee 32
Electrical Data 2.0. ees 34
Vent Termination Kit for Direct Vent (2-Pipe) System ....... 39
Combustion-Air Vent Pipe, Fitting & Cement Material. ..... 45
Maximum Allowable Exposed Vent Lengths Insulation ...... 46
Maximum Equivalent Vent Length ...................00- 47
Deductions from Maximum Equivalent Vent Length ........ 47
Blower Off Delay Setup Switch .... 0.0.0.0... 0.00000 eee 64
Altitude Derate Multiplier for U.S.A. 00.0... ee ee 65
Gas Rate 2... eee nee 67
Orifice Size and Manifold Pressure .. 0.00... eee eee 68
Always Ask For
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www. ahridirectory.org:
Use of the AHRI Certified tm Mark indicates a
manufacturer’s participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
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QMI-SAI Giobal
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1-2009©, with permission of National Fire Protection
Association, Quincy, MA 02269 and American Gas Association,
Washington DC 20001. This reprinted material is not the complete
and official position of the NFPA or ANSI on the referenced
subject, which is represented only by the standard in its entirety.

59SC2A
Required Notice for Massachusetts Installations
IMPORTANT
The Commonweaith of Massachusetts requires compliance with regulation 248 CMR as follows:
5.08: Modifications to NFPA-54, Chapter 10
2) Revise 10.8.3 by adding the following additional requirements:
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a. For all side wail horizontally vented gas fueled equipment installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following requirements shail be satisfied:
. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gasfitter shail observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing
plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on
each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It
shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of
hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall
have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day
period, a battery operated carbon monoxide detector with an alarm shall be installed.
. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shail not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a)1 through 4.
. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
(1.) The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from
the dwelling, building or structure used in whole or in part for residential purposes.
ce. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the
manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design
or venting system components with the equipment, the instructions provided by the manufacturer for installation of
the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
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. A complete parts list for the venting system design or venting system.
d. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When
the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the
parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be
satisfied by the manufacturer:
. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,
all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain
with the appliance or equipment at the completion of the installation.
For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers and
Gas Fitters, 239 Causeway Street, Boston, MA 02114. 617-727-9952.
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SAFETY CONSIDERATIONS
CA UN Le
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, personal injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified service agency, local gas supplier, or your
distributor or branch for information or assistance. The
qualified service agency must use only factory-authorized
and listed kits or accessories when modifying this product.
4 WARNING
FIRE HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Solvents, cements and primers are combustible. Keep away
from heat, sparks and open flame. Use only in well-ventilated
areas. Avoid breathing in vapor or allowing contact with skin
or eyes.
4 CAUTION
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
air temperature rise, unit leveling, and unit sizing.
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.
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions such
as cleaning and replacing air filters. All other operations must be
performed by trained service personnel. When working on heating
equipment, observe precautions in literature, on tags, and on labels
attached to or shipped with furnace and other safety precautions
that may apply.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as a
minimum for a safe installation.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit.
4 CAUTION
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.
This is the safety-alert symbol A, When you see this symbol on
the furnace and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death, WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify hazards which may result in minor personal injury or
product and property damage. NOTE and NOTICE are used to
highlight suggestions which will result in enhanced installation,
reliability, or operation.
1. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
bo . Install this furnace only in a location and position as spe-
cified in the “Location” section of these instructions.
3. Provide adequate combustion and ventilation air to the fur-
nace space as specified in “Air for Combustion and Ventila-
tion” section.
4. Combustion products must be discharged outdoors. Con-
nect this furnace to an approved vent system only, as spe-
cified in the “Venting” section of these instructions.
a . Never test for gas leaks with an open flame. Use a commer-
cially available soap solution made specifically for the de-
tection of leaks to check all connections, as specified in the
“Gas Piping” section.
6. Always install furnace to operate within the furnace’s inten-
ded temperature-rise range with a duct system which has an
external static pressure within the allowable range, as spe-
cified 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 contain-
ing 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 instruc-
tions.
10. These Multipoise Gas-Fired Furnaces are CSA design-cer-
tified for use with natural and propane gases (see furnace
rating plate) and for installation in alcoves, attics, base-
ments, 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 accessory gas conversion kit is
required to convert furnace for use with propane gas.
11. See Table 2. for required clearances to combustible con-
struction.
12. Maintain a 1-in. (25 mm) clearance from combustible ma-
terials to supply air ductwork for a distance of 36 in. (914
mm) horizontally from the furnace. See NFPA 90B or local
code for further requirements.
59SC2A

59SC2A
13. These furnaces SHALL NOT be installed directly on carpet-
ing, combustible tile, or any other combustible material oth-
er than wood flooring. In downflow installations, factory
accessory floor base MUST be used when installed on com-
bustible materials and wood flooring. Special base is not re-
quired when this furnace is installed on manufacturer’s Coil
Assembly Part No. CNRV, CNPV, CAP, or CAR or when
Coil Box Part No. KCAKC is used. See Table 2 for clear-
ance to combustible construction information.
INTRODUCTION
This 4-way multipoise Category IV condensing furnace is CSA
design-certified as a direct-vent (2-pipe) or non-direct vent
(1-pipe) furnace. See Fig. 2. The furnace is factory-shipped for
use with natural gas. The furnace can be converted in the field for
use with propane gas when a factory-supplied conversion Kit is
used. Refer to the furnace rating plate for conversion kit
information.
These furnaces are not approved for installation in recreational
vehicles or outdoors. Single-stage furnaces (40,000 through
120,000) are approved for installation in manutactured
housing/mobile homes with manufacturer-approved accessory.
The conversion kit is required for use with both natural and
propane gas. The furnace must also be installed on a
factory-supplied accessory combustible floor base or evaporator
coil casing.
This furnace is designed for minimum continuous returm-air
temperature of 60°F (15°C) db or intermittent operation down to
55°F (13°C) db such as when used with a night setback
thermostat. Return-air temperature must not exceed 80°F (27°C)
db. Failure to follow these return-air temperature limits may affect
reliability of heat exchangers, motors, and controls. See Fig. 3.
The furnace should be sized to provide 100 percent of the design
heating load requirement plus any margin that occurs because of
furnace model size capacity increments. Heating load estimates can
be made using approved methods available from Air Conditioning
Contractors of America (Manual J); American Society of Heating,
Refrigerating, and Air-Conditioning Engineers; or other approved
engineering methods. Excessive oversizing of the furnace could
cause the furnace and/or vent to fail prematurely.
For accessory installation details, refer to the applicable instruction
literature.
NOTE: Remove ail shipping materials, loose parts bag, and
literature before operating the furnace. See Table 1.
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:
Safety
¢ US: National Fuel Gas Code (NFGC) NFPA 54-2009/ANSI
2223,1-2009 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
¢ A manufactured (Mobile) home installation must conform with
the Manufactured Home Construction and Safety Standard, Title
24 CFR, Part 3280, or when this standard is not applicable, the
Standard for Manufactured Home Installation (Manutactured
Home Sites, Communities, and Set-Ups),ANSI/NCS A225.1,
and/or CAN/CSA-Z240, MH Series Mobile Homes
¢ CANADA: National Standard of Canada, Natural Gas and
Propane Installation Code (NSCNGPIC) CAN/CSA
B149,.1-2010
General Installation
¢ US: 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 20001
¢ CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke
(Toronto), Ontario, M9OW 1R3, Canada
Combustion and Ventilation Air
¢ US: Section 9.3 of the NFPA54/ANSI Z223.1-2009 Air for
Combustion and Ventilation
¢ CANADA: Part 8 of the CAN/CSA B149.1-2010, Venting
Systems and Air Supply for Appliances
Duct Systems
¢ US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors
National Association (SMACNA), or American Society of Heating,
Retrigeration, and Air Conditioning Engineers (ASHRAE) 2005
Fundamentals Handbook Chapter 35
Acoustical Lining and Fibrous Glass Duct
¢ US and CANADA: current edition of SMACNA, NFPA 90B as
tested by UL Standard 181 for Class I Rigid Air Ducts
Gas Piping and Gas Pipe Pressure Testing
¢ US: NFPA 54/ANSI Z223.1-2009 NFGC; Chapters 5, 6, 7, and 8
and national plumbing codes.
CANADA: CAN/CSA-B149.1-2010, Parts 4, 5, 6, and 9.
In the state of Massachusetts:
¢ This product must be installed by a licensed plumber or gas fitter.
¢ When flexible connectors are used, the maximum length shall
not exceed 36 in. (914 mm).
¢ When lever type gas shutoffs are used they shall be T-handle type.
¢ The use of copper tubing for gas piping is not approved by the
state of Massachusetts.
Electrical Connections
¢ US: National Electrical Code (NEC) ANSI/NFPA 70-2011
¢ CANADA: Canadian Electrical Code CSA C22.1
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS PROCEDURE
4& CAUTION
FURNACE RELIABILITY HAZARD
Failure to follow this caution may result in unit component
damage.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing
to protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These
precautions will help to avoid exposing the control to
electrostatic discharge by putting the furnace, the control,
and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL
OR ANY WIRE CONNECTED TO THE CONTROL
PRIOR TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE TO GROUND.
. Firmly touch the clean, unpainted, metal surface of the fur-
nace chassis which is close to the control. Tools held in a
person’s hand during grounding will be satisfactorily dis-
charged.
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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.
5. Use this procedure for installed and uninstalled (ungroun-
ded) 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 con-
trol 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)
may also be used to prevent ESD damage.
ACCESSORIES
See Product Data Sheet for a list of accessories for this product.
Table 1 — Factory-Supplied Installation Parts
DESCRIPTION QUANTITY
Outlet Choke Plate (provided with 40K BTUH furnaces only; see Note)
Air Intake Pipe Flange
Vent Pipe Flange
Pipe Flange Gaskets
Sharp Tip Screws (Vent and Inlet Flanges)
Vent Pipe Coupling
Vent Pipe Coupling Clamps
Pressure Switch Tube
Rubber Drain Elbow
Drain Tube Clamps
1/2-in. CPVC to 3/4—in. PVC Pipe Adapter
Gas Line Grommet
Junction Box Cover
Junction Box Base
Green Ground Screw
Blunt Tip Screws (Junction Box)
Thermostat Wire Grommet
Drain Extension Tube (Z—pipe) (Provided separately in furnace) +)
4)
a)
+)
+)
4)
+)
+)
a8)
+)+)m)
=)
S)m)s)-)-
NOTE: Only used for 40K BTUH furnaces from 0-2000 ft. (0 to 610 M) above sea level for total equivalent vent lengths under 10 ft. (3 M)
Table 2 — Minimum Clearances to Combustible Materials for All Units
POSITION CLEARANCE
REAR oO
FRONT (Combustion air openings in furnace and in structure) 1 in. (25 mm)
Required for service *24 in. (610 mm)
All Sides of Supply Plenum *41 in. (25 mm)
Sides 0
Vent 0
Top of Furnace 1 in. (25 mm)
*Consult local building codes.
59SC2A

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NOTES:
1. Doors may vary by model.
59SC2A
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturer's recommendations for equivalent diameters.
a. For 800 CFM-16-in. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.
b. For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle.
c. For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) rectangle.
i d. Return air above 1800 CFM at 0.5 in. w.c. ESP on 24.5" casing, requires one of the following
3, configurations: 2 sides, 1 side and a bottom or bottom only. See Air Delivery table in this
AIR INTAKE document for specific use to allow for sufficient airflow to the furnace.
ropuew wl ene be 3. Vent and Combustion air pipes through blower compartment must 2912
(170.1 use accessory “Vent Kit - Through the Cabinet”. See accessory list for (7493)
current part number. 2634 ________-|
oan 16 (730,5]
: 26.11/16 ———_»|
26 3/8 [678.1]
[670.0]
ava
26
3/8
|
[638.7]
[669.9]
#23 5/16
[592.9]
ier
—
|g ee —— & ———_ 211/16 =»
2058
[535.8]
8 205/8 ————__»
asa} OUTLET WIDTH 522.7]
O ts
[76.2]
AIR INTAKE
AIR FLOW 13/4 [15.8] AIR FLOW AIRFLOW
fas Ht ven oN
[22.2]
y
e134
CONDENSATE DRAIN TRAP. 3 . GAS CONN
LOCATION
4
VENT
| |
Drie
[101.6]
[22.2]
z D3
[762] B78
| (22.2)
Bre rt 212 JAD
[22.2] 22 35 [63.5] 4
O78 = as 28 3/16 \@ _-@| Bere jisto
[22.2] POWER CONN 32 78
(222) Ng 1715.9] (8295) > i 22.2] POWER CONN
r — t 28 5/8 ® ® ene 28/8 —_ q
SIDE INLET 237/16 1726] M50 | ipo) gh 7/@ SDE INLET
20 1/4
B78 (595.6) 25 3/16 285/8 (22.2]
(oy rears ] 1639.1] (72691 | ggg i776 Ko dm
THERMOSTAT ENTRY 22 15/16 . [22.2]
14 13/16 17 5/16 [5819] e 20/4 169/16 THERMOSTAT ENTRY
[376.3] [439.2] 1513.9] 18/16 | iay69)
[458.6] .
t _— oe J
|
p— 1 {BOTH SIDES} 1iie | c 1116 BOTTOM INLET
[25.4]
SEE
NOTE
#3
BOTTOM
RETURN
(175)
pean
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22 WIDTH ’ 2
[558.3] (BOTH SIDES} p< 23 3/8 ———_______»»
21
NOTE:
ALL
DIMENSIONS
IN
INCH [MM]
15/16
[592.0]
(534.0) [33.3] 26 5/16
bx 265/16 {668.2}
[668.3]
=
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‘EE

THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED TO THE LEFT.
Lg
a HORIZONTAL LEFT
AIRFLOW
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
AIRFLOW
UPFLOW
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
>
DOWNFLOW
VV
AIRFLOW
HORIZONTAL RIGHT
>
AIRFLOW
THE BLOWER IS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDITIONED AIR IS
DISCHARGED TO THE RIGHT.
Fig. 2 - Multipoise Orientations
SUPPLY AR ==
32° F/ 0° C MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
Ni
“TR
FRONT
2
PEPEERREEE
ENS
TH
Dieerenerne
ta
t
2
PEN
EET
RETURN
AIR
russ
BEEBEEE
Fig. 3 - Freeze Protection and Return Air Temperature
B
A
SO c
K
BACK POSITIONED
DOWNWARD O
? q
BACK POSITIONED rronr_— | ‘ 4
UPWARD rN
ye Je
\ FRONT y
Fig. 4 - Prohibited Installations
AIR RETURN
CUT IN BACK
A12182
MAX 80°F / 27°C
MIN60°F / 16°C
At2181
A10490
18-IN. (457.2 mm)
MINIMUM TO BURNERS
AQ93044
Fig. 5 - Installation in a Garage
59SC2A

59SC2A
LOCATION
4 CAUTION
PERSONAL INJURY AND/OR PROPERTY
DAMAGE HAZARD
Improper use or installation of this furnace may result in
premature furnace component failure. This gas furnace may
be used for heating buildings under construction provided
that:
-The furnace is permanently installed with all electrical
wiring, piping, venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the
space containing the furnace. This prevents a negative
pressure condition as created by the circulating air blower,
causing a flame rollout and/or drawing combustion
products into the structure.
-The furnace is controlled by a thermostat. It may not be
“hot wired” to provide heat continuously to the structure
without thermostatic control.
-Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and
other construction materials. It also prevents the
entrainment of drywall dust into combustion air, which can
cause fouling and plugging of furnace components.
-The temperature of the return air to the furnace is
maintained between 55°F (13°C) and 80°F (27°C), with
no evening setback or shutdown. The use of the furnace
while the structure is under construction is deemed to be
intermittent operation per our installation instructions.
-The air temperature rise is within the rated rise range on
the furnace rating plate, and the gas input rate has been set
to the nameplate value.
-The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
-The furnace, ductwork and filters are cleaned as necessary
to remove drywail dust and construction debris from all
HVAC system components after construction is completed.
-Verify proper furnace operating conditions including
ignition, gas input rate, air temperature rise, and venting
according to these installation instructions.
General
These furnaces are shipped with materials to assist in proper
furnace installation. These materials are shipped in the main
blower compartment.
See Table 1 for loose parts bag contents.
This furnace must:
¢ be installed so the electrical components are protected from
water.
¢ not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS).
* be located close to the chimney or vent and attached to an air
distribution system. Refer to Air Ducts section.
¢ be provided ample space for servicing and cleaning. Always
comply with minimum fire protection clearances shown in Table
2 or on the furnace clearance to combustible construction label.
CA UN Le:
CARBON MONOXIDE POISONING / COMPONENT
DAMAGE HAZARD
Failure to follow this warning could result in personal injury
or death and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
¢ Commercial buildings
¢ Buildings with indoor pools
¢ Laundry rooms
¢ Hobby or craft rooms
* Chemical storage areas
If air is exposed to the following substances, it should not be used
for combustion air, and outdoor air may be required for
combustion:
¢ Permanent wave solutions
¢ Chlorinated waxes and cleaners
¢ Chlorine based swimming pool chemicals
¢ Water softening chemicals
¢ De-icing salts or chemicals
¢ Carbon tetrachloride
¢ Halogen type refrigerants
¢ Cleaning solvents (such as perchloroethylene)
¢ Printing inks, paint removers, varnishes, etc.
¢ Hydrochloric acid
* Cements and glues
¢ Antistatic fabric softeners for clothes dryers
¢ Masonry acid washing materials
All fuel-burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return-air duct to
prevent pulling air from the burner area.
A A SS
FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in personal
injury,
death
and/or
property
damage.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 in.
(457 mm) above the floor. The furnace must be located or
protected to avoid damage by vehicles. When the furnace is
installed in a public garage, airplane hangar, or other
building having a hazardous atmosphere, the furnace must
be installed in accordance with the NFPA 54/ANSI
Z223.1-2009 or CAN/CSA B149.2-2010. See Fig. 5.

CA UN Le:
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. 4.
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
Introduction
Direct Vent (2-pipe) Applications
When the furnace is installed as a direct vent (2-pipe) furnace, no
special provisions for air for combustion are required. However,
other gas appliances installed in the space with the furnace may
require outside air for combustion. Follow the guidelines below to
insure that other gas appliances have sufficient air for combustion.
Non-Direct Vent (1-pipe) Applications
When the furnace is installed as a non-direct vent (1-pipe) furnace,
it will be necessary to insure there is adequate air for combustion.
Other gas appliances installed with the furnace may also require air
for combustion and ventilation in addition to the amount of
combustion air and ventilation air required for the furnace. Follow
the guidelines below to insure that the furnace and other gas
appliances have sufficient air for combustion.
Ventilated Combustion Air Applications
When the furnace is installed using the ventilated combustion air
option, the attic or crawlspace must freely communicate with the
outdoor to provide sufficient air for combustion. The combustion
air pipe cannot be terminated in attics or crawlspaces that use
ventilation fans designed to operate during the heating season. If
ventilation fans are present in these areas, the combustion air pipe
must terminate outdoors as a Direct Vent/ 2-Pipe system.
All air for combustion is piped directly to the furnace from a space
that is well ventilated with outdoor air (such as an attic, crawl space
or equipment closet) and the space is well isolated from the living
space or garage. In addition, other gas appliances installed in the
space with the furnace may require outside air for combustion.
Follow the guidelines below to insure that the roof or crawlspace
wails have sufficient free area to provide sufficient air for
combustion and ventilation for the furnaces. The guidelines below
can be used to insure that other gas appliances have sufficient air
for combustion.
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
¢ U.S.A. Installations: Section 9.3 of the NFPA 54/ANSI
2223.1-2009 , Air for Combustion and Ventilation and
applicable provisions of the local building codes.
¢ Canada: Part 8 of the CAN/CSA-B149.1-2010, Venting
Systems and Air Supply for Appliances.
4 CAUTION
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.
CA UA Le:
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 the
Carbon Monoxide Poisoning Hazard warning in the venting
section of these instructions to determine if an adequate
amount of make-up air is available.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume of
at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
¢ Spaces having less than 50 cubic feet per 1,000 Btuh (4.8 cubic
meters per kW) require the Outdoor Combustion Air Method.
¢ Spaces having at least 50 cubic feet per 1,000 Btuh (4.8 cubic
meters per kW) may use the Indoor Combustion Air,
Standard or Known Air Infiltration Method.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper combustion,
ventilation, and dilution of flue gases using permanent hori-
zontal or vertical duct(s) or opening(s) directly communicat-
ing with the outdoors or spaces that freely communicate
with the outdoors.
. Fig. 6 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and vent-
ilation air opening, to the outdoors.
bo
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. 6 and Table 3.
c. TWO HORIZONTAL DUCTS require 1 sq. in. (645 sq.
mm) of free area per 2,000 Btuh (1,100 mm2/kW) of com-
bined input for all gas appliances in the space per Fig. 6 and
Table 3.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
sq. in. (645 sq. mm) of free area per 4,000 Btuh (550
mm_2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.
3. ONE OUTDOOR OPENING requires:
a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh (734
mm_2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.
b. Not less than the sum of the areas of all vent connectors in
the space.
59SC2A

59SC2A
The opening shall commence within 12 in. (300 mm) of the
ceiling. Appliances in the space shall have clearances of at least 1
in. (25 mm) from the sides and back and 6 in. (150 mm) from the
front. The opening shall directly communicate with the outdoors or
shall communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely communicate with the
outdoors.
Indoor Combustion Air© NFPA & AGA
Standard and Known-Air-Infiltration Rate Methods
Indoor air is permitted for combustion, ventilation, and dilution, if
the Standard or Known-Air-Infiltration Method is used.
CA UA Le:
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
Many homes require air to be supplied from outdoors
for furnace combustion, ventilation, and dilution of flue
gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
Standard Method
1. The space has no less volume than 50 cubic feet per 1,000
Btuh of the maximum input ratings for all gas appliances
installed in the space and
2. The air infiltration rate is not known to be less than 0.40 air
changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shail not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 4 or Equations 1 and 2.
Determine the minimum required volume for each appliance in the
space and add the volumes together to get the total minimum
required volume for the space.
Table 4 - Minimum Space Volumes were determined by using the
following equations from the current edition of the National Fuel
Gas Code ANSI 2223.1/NFPA 54, 9.3.2.2:
1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater:
—_ 21ft | other
Vol = 21TY | ____other__
ee other AGH (7000 Btu/hr
A04002
2. For fan-assisted appliances such as this furnace:
3 |
Volume = 15ft fan
Fan = =ACH |1000 Btu/hr
A04008
If: lother = 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 shail not exceed 0.60.)
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closeable doors between rooms.
b. Combining spaces on same floor level. Each opening shail
have free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW)
of the total input rating of all gas appliances in the space,
but not less than 100 in.? (0.06 m?). 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). See Fig. 7.
c. Combining space on different floor levels. The volumes of
spaces on different floor levels shall be considered as com-
municating 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.
bo . An attic or crawlspace may be considered a space that freely
communicates with the outdoors provided there are ad-
equate permanent ventilation openings directly to outdoors
having free area of at least 1-in.7/4,000 Btuh of total input
rating for all gas appliances in the space.
3. In spaces that use the Indoor Combustion Air Method, in-
filtration should be adequate to provide air for 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.
4. Unusually tight construction is defined as Construction
with:
a. Walls and ceilings exposed to the outdoors have a continu-
ous, 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 wail-ceiling joints, between wail panels,
at penetrations for plumbing, electrical and gas lines, etc.
Combination of Indoor and Outdoor Air
1. Indoor openings shail comply with the Indeor Combus-
tion Air Method below and,
2. Outdoor openings shail be located as required in the Out-
door Combustion Air Method mentioned previously and,
3. Outdoor openings shail be sized as follows:
a. Calculate the Ratio of ail Indoor Space volume divided by
required volume for Indoor Combustion Air Method be-
low.
b. Outdoor opening size reduction Factor is 1 minus the Ra-
tio in a. above.
c. Minimum size of Outdoor openings shall be the size re-
quired in Outdoor Combustion Air Method above multi-
plied by reduction Factor in b. above. The minimum di-
mension of air openings shall be not less than 3 in. (80 mm).
10

Table 3 - Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING NO ea Gore
(1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) (1 SQ. IN./4,000 BTUH)
FURNACE (1,100 SQ. MM/KW) (734 SQ. MM/KW) (550 sa "MM/KW)
INPUT :
(BTUH) Free Area of Free Area of Free Area of
Opening and Round Duct Opening and Round Duct Opening and Round Duct
Duct In. (mm) Dia Duct In. (mm) Dia Duct In. (mm) Dia.
Sq. In (Sq. mm) Sq. In (Sq. mm) Sq. In (mm)
40,000* 20 (12904) 5 (127) 14 (8696) 5 (127) 10 (6452) 4 (102)
60,000 30 (19355) 6 (152) 20 (13043) 5 (127) 15 (9678) 5 (127)
80,000 40 (25807) 7 (178) 27 (17391) 6 (152) 20 (12904) 5 (127)
100,000 50 (82258) 8 (208) 34 (21739) 7 (178) 25 (16130) 6 (152)
120,000 60 (88709) 9 (229) 40 (26087) 7 (178) 30 (19355) 6 (152)
140,000* 70 (45161) 10 (254) 47 (80435) 8 (208) 35 (22581) 7 (178)
*Not all families have these models.
EXAMPLES: Determining Free Area
FURNACE
100,000 +
60,000 +
80,000 +
WATER HEATER
30,000
40,000
30,000
TOTAL INPUT
(130,000 divided by 4,000)
= (100,000 divided by 3,000) =
= (110,000 divided by 2,000)
32.5 Sq. In. for each two Vertical Ducts or Openings
33.3 Sq. In. for each Single Duct or Opening
55.0 Sq. In. for each two Horizontal Ducts
Table 4 - Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors
OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE) (1,000’S BTUH GAS INPUT RATE)
ACH 30 | 40 | 50 40 | 60 | 80 | 100 | 120 | 140
Space Volume Ft? (M°)
0.60 1,050 1,400 1,750 1,400 1,500 2,000 2,500 3,000 3,500
: (29.7) (39.6) (49.5) (39.6) (42.5) (66.6) (70.8) (84.9) (99.1)
0.50 1,260 1,680 2,100 1,680 1,800 2,400 3,000 3,600 4,200
: (35.6) (47.5) (69.4) (47.5) (61.0) (67.9) (84.9) (101.9) (118.9)
0.40 1,575 2,100 2,625 2,100 2,250 3,000 3,750 4,500 5,250
: (44.5) (69.4) (74.3) (69.4) (63.7) (84.9) (106.1) (127.3) (148.6)
0.30 2,100 2,800 3,500 2,800 3,000 4,000 5,000 6,000 7,000
: (69.4) (79.2) (99.1) (79.2) (84.9) (113.2) (141.5) (169.8) (198.1)
0.20 3,150 4,200 5,250 4,200 4,500 6,000 7,500 9,000 10,500
: (89.1) (118.9) (148.6) (118.9) (127.3) (169.8) (212.2) (254.6) (297.1)
0.10 6,300 8,400 10,500 8,400 9,000 12,000 15,000 18,000 21,000
: (178.0) (237.8) (297.3) (237.8) (254.6) (339.5) (424.4) (609.2) (694.1)
0.00 NP NP NP NP NP NP NP NP NP
NP = Not Permitted
11
59SC2A

59SC2A
PER 4000
DUCTS“
BTUHE
CIRCULATING
AIR
VENT
TO
DUCTS
OUTDOORS (|
l Cy
pe 114
I ttl
| | rtd
| jf
(308rom)_ 12" MAX 12” cc | ‘
1SQIN, o. Max (05mm) < [_}2" MAX (@05mm)
PER
2000
Eb
=
a
ft
BTUM*
&
=
Fz
=i1sSQin.
Ra
1
SQIN.
Boo
=&
PER
1000
Ze aaa a BTUH* IN DOOR
5 Bron 2 OR WALL
Y ee
&
INTERIOR
8
UNCONFINED
DUCTS 8 HEATED tt | | SPACE
TO E SPACE Sz
OUTDOORS © Xr || 6" MIN (152mm)
o Za || (FRONT)O
1SQIN. 28
4000
QO
||
1SQ
IN.
BTUH*
2
ffi
|_|
PER
1000
1
SQIN
=
©
=
BTUH*
INDOOR
bee oo cL! o& 1 iO 2 ORWALL
Brun
|
12",
(305
© 1
(305mm) 12" MA MAX (805mm)
| ee -
12”
MAX
|
12"
MAX
(805mm)
__ 5 (305mm) Lo
CIRCULATING AIR DUCTS CIRCULATING AIR DUCTS
DUCT 1SQ IN,
TO PER 4000
OUTDOORS BTUH* ‘
Minimum opening size is 100 sq in. (64516 sq. mm) with
*Minimum dimensions of 3-in. (76mm) minimum dimensions of 3-in. (76mm)
NOTE: Use any of the following combinations of openings:
A&B, C&D, D&E, F&G + Minimum of 3-in. (76mm) when type-B1 vent is used.
L12F012 L12F013
Fig. 6 - Air for Combustion, Ventilation, and Dilution for Fig. 7 - Air for Combustion, Ventilation, and Dilution from
Outdoors Indoors

CONDENSATE TRAP
Condensate Trap - Upflow Orientation
When the furnace is installed in the upflow position, it is not
necessary to relocate the condensate trap or associated tubing.
Refer to Fig. 8 for upflow condensate trap information. Refer to
Condensate Drain section for information how to install the
condensate drain.
Condensate Trap - Downflow Orientation.
When the furnace is installed in the downflow position, the
condensate trap will be initially located at the upper left corner of
the collector box, as received from the factory. See the top image
in Fig. 9. When the furnace is installed in the downflow
orientation, the condensate trap must be relocated for proper
condensate drainage. See the bottom image in Fig. 9.
To Relocate the Condensate Trap:
* Orient the furnace in the downflow position.
¢ Fig. 9 shows the condensate trap and tubing before and after
relocation. Refer to Fig. 9 to begin the trap conversion.
¢ Refer to Condensate Drain section for information how to install the
condensate drain.
Condensate Trap - Horizontal Orientation.
When the furnace is installed in the horizontal right position, the
condensate trap will be initially located at the bottom of the collector
box, as received from the factory. See the top image in Fig. 10.
When the furnace is installed in the horizontal left position, the
condensate trap will be initially located at the top of the collector box,
as received from the factory. See the top image in Fig. 11. In both
cases the trap must be repositioned on the collector box for proper
condensate drainage. See the bottom images in Fig. 10 and 11.
A. field-supplied, accessory Horizontal Installation Kit — (trap
grommet) is required for all direct-vent horizontal installations (only).
The kit contains a rubber casing grommet designed to seal between
the furnace casing and the condensate trap. See Fig. 16.
Condensate Trap
The field-supplied, accessory horizontal drain trap grommet is
ONLY REQUIRED FOR DIRECT VENT APPLICATIONS.
It it NOT required for applications using single-pipe or
ventilated combustion air venting.
The condensate trap extends below the side of the casing in
the horizontal position. A minimum of 2-in. (51 mm) of
clearance is required between the casing side and the furnace
platform for the trap to extend out of the casing in the
horizontal position. Allow at least 1/4-in. per foot (20 mm
per meter) of slope down.
59SC2A
To Relocate the Condensate Trap:
¢ Remove the knockout in the casing for the condensate trap.
¢ Install the grommet in the casing when required for direct-vent
horizontal applications.
* Orient the furnace in the desired position.
¢ Allow for 2 in. (51 mm) of clearance underneath the furnace for the
condensate trap and drain line.
¢ Fig. 10 shows the condensate trap and tubing before and after
relocation in the horizontal right position.
¢ Fig. 11 shows the condensate trap and tubing before and after
relocation in the horizontal left position.
¢ Refer to the appropriate figure to begin the trap conversion.
¢ Refer to Condensate Drain section for information how to install the
condensate drain.
Vent Pipe Clamp
Vent Elbow Clamp
Relief Port
Collector Box °
Plugs
©
°
= *
°
° ®
° ©
©
Vent Elbow
Collector Box
— Plug
°o 3
Condensate Trap
C) Relief Port
‘e.
ae
Condensate Trap
Pressure Switch Outlet
Port
UPFLOW TRAP CONFIGURATION
1 & 2 Stage Units
A11807
Fig. 8 - Upflow Trap Configuration
(Appearance may vary)
13

59SC2A
front pressure switch and discard. A
new tube is shipped in the loose parts bag.
Remove relief tube from relief 3 Remove tube from relief port.
port on condensate trap.
(4) Remove pressure switch tube from
Remove the screw
that secures the trap
to the collector box and
remove trap.
Loosen clamp on inlet (1 and 2 Stage Units) Remove middle and bottom
to vent elbow. plugs. DO NOT DISCARD.
Unconverted Factory Configuration as
Viewed in the Downflow Orientation
Connect the new pressure switch
tube from Loose Parts bag to
port on front pressure switch.
Route tube through inducer
stand-—offs to adjust position
of the tube.
(9) Trim excess tube.
Connect pressure switch
tube to port on collector
box.
8
Install the two plugs
previously removed
on the open ports
of the collector box.
Attach condensate trap
with screw to collector box.
Connect relief tube
to port on collector
box.
Rotate elbow to
desired position and
tighten clamp to
3
Connect relief tube to
relief port on condensate
trap.
5
2.
(1 and 2 Stage Units)
Align condensate trap
over middie and bottom
ports of collector box.
15 lb.-in.
2
Slide tube in stand-offs
to adjust length.
Downflow Trap Configuration
A11587
Fig. 9 - Downflow Trap Configuration
(Appearance may vary)
14

If alternate vent position
is required, loosen clamp
Remove plug from
collector box.
DO
NOT
DISCARD.
on
inlet
of
vent
elbow.
Remove the screw that secures
the trap to the collector box and
(1 AND 2 STAGE UNITS) remove trap.
59SC2A
Unconverted Factory Configuration
As Viewed in the Horizontal Right Orientation
NOTE: Remove knockout in
casing before re-installing the
condensate trap.
Slide relief tube in stand-offs
to adjust length.
Attach condensate
trap with screw to
collector box.
to’ Vent elbow shown in alternate
(5) orientation. Tighten clamp on
Hl inlet to vent elbow 15 |b.-in.
Install plug on
(1)
open
port
of
Align
trap
over
middie
and
collector box (1 AND 2 STAGE UNITS) right-hand port on collector box.
Horizontal Right Trap Configuration
A11573
Fig. 10 - Horizontal Right Trap Configuration
(Appearance may vary)
15

59SC2A
Remove relief tube
(4) from port on collector
box.
NOTE: Remove knockout in
casing before re-installing the
condensate trap.
If alternate vent position
is required, loosen clamp
on vent elbow inlet.
(1 AND 2 STAGE UNITS)
Remove the screw that secures the
condensate trap to the collector box
and remove trap.
Remove relief tube from
relief port on condensate
trap.
Remove front pressure
switch tube and discard.
Anew tube is shipped in
the Loose Parts bag.
Remove middle and right
plug from collector box.
DO NOT DISCARD.
Unconverted Factory Trap Configuration
As Viewed in the Horizontal Left Orientation
Rotate
elbowto
_
@Oe@
O@
desired position NG 3
and torque clamp
on inlet 15 Ib.-in. 3 °
Slide relief tube in
stand-offs to adjust
length.
{ Install two plugs previously
removed in open ports on
collector box.
4 Connect relief tube to port
on collector box.
J Connect the new pressure switch
' 7 ) tube from Loose Parts bag to port
trap with screw to ©
collector box. +
q . Oo
Align trap over middle :
and right-hand port on ©.
(3) Attach condensate
collector box.
(1 AND 2 STAGE UNITS)
on front pressure switch.
Route pressure switch tube
8 } undermeath relief tube and
connect to port on
collector box.
6 Connect relief tube to relief
port on condensate trap.
Horizontal Left Trap Configuration
Fig. 11 - Horizontal Left Configuration
(Appearance may vary)
16
At1574

CONDENSATE DRAIN CONNECTION
4& CAUTION
FROZEN AND BURST WATER PIPE HAZARD
Failure to protect against the risk of freezing may result in
property damage.
Special precautions MUST be made if installing furnace in an
area which may drop below freezing. This can cause improper
operation or damage to equipment. If furnace environment
has the potential of freezing, the drain trap and drain line must
be protected. The use of accessory drain trap heaters, electric
heat tape and/or RV antifreeze is recommended for these
installations.
4& CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in burst water pipes
and/or property damage.
If a condensate pump is installed, a plugged condensate drain
or a failed pump may cause the furnace to shut down. Do not
leave the home unattended during freezing weather without
turning off water supply and draining water pipes or otherwise
protecting against the risk of frozen pipes.
DO NOT trap the drain line in any other location than at the
condensate drain trap supplied with the furnace. If possible, DO
NOT route the drain line where it may freeze. The drain line must
terminate at an inside drain to prevent freezing of the condensate
and possible property damage.
Special precautions MUST be made if installing furnace in an area
which may drop below freezing. This can cause improper
operation or damage to the equipment. If the furnace environment
has the potential of freezing, the drain trap and drain line must be
protected. A self-regulating, shielded and waterproof heat tape
rated at 3 to 6 watt per foot (10 to 20 watt per meter) at 115 volt,
40°F (4°C) may be used to help provide freeze protection. Wrap
the drain trap and drain line with the heat tape and secure with
appropriate plastic ties. Follow the heat tape manufacturer’s
recommendations. Prime the trap before furnace operation.
Upflow/Downflow Orientation
In the Upflow or Downtlow orientation, the condensate trap is
inside the furnace casing. The condensate drain must be routed
from the trap through the furnace casing. The condensate drain can
be routed through the left or right side of the casing. (The left or
right side is as you are viewing/tacing the furnace from the front.)
The furnace condensate drain can be connected to the indoor coil
condensate drain, humidifier or auxiliary drain traps as shown in
Fig. 13.
NOTE: On narrower casings, it may be easier to remove the
condensate trap, connect the drain line components and re-install
the condensate trap. Read the steps thoroughly to familiarize
yourself with the required steps.
For Right Side Condensate Drain:
1. Remove the 7/8-in. knock-out from the right side of the
casing. See Fig. 12 for suggested knockout removal tech-
nique.
bo . Remove the pre-formed rubber drain elbow and two spring
clamps from the loose parts bag.
3. Slide a spring clamp 1-inch (25 mm) down the plain end
(the end without the formed grommet) of the drain elbow.
4. From inside the casing, insert the formed grommet end of
the elbow through the 7/8-in. knockout in the casing.
5. Pull the grommet through the casing from the outside until
it is seated in the knockout
6. Attach the plain end of the drain elbow to the outlet stub on
the drain trap. Secure the drain elbow to the trap with the
spring clamp.
The remaining drain line can be constructed from field supplied
1/2-in. CPVC or 3/4-in. PVC pipe, in compliance with local
building codes. A factory-supplied 1/2-in. CPVC to 3/4-in. PVC
adapter is supplied in the loose parts bag for use as required.
7. Install the adapter or connect the 1/2-in. CPVC pipe by
sliding a spring clamp over the open end of the grommet on
the outside the furnace casing.
8. Open the spring clamp and insert the long end of the
adapter or the 1/2-in. CPVC pipe into the outlet stub on the
drain tube.
9, Connect additional condensate piping to a code-approved
drain, or to a condensate pump approved for use with acidic
furnace condensate and compatible with mineral and
vegetable oils, such as canola oil.
Allow at least 1/4-in. per foot (20 mm per meter) of slope down
and away from the furnace in horizontal sections of drain line.
TIP FROM CONTRACTORS: Contractors have found that
temporarily removing the inducer assembly in upflow applications
while performing the steps, below, makes upflow left-side drain
connections easier.
For Left Side Condensate Drain Connection:
1. For left side condensate drainage, the drain line is routed
from the condensate trap, behind the inducer (upflow) or
gas valve (downflow) and out through the left side of the
furnace casing. A pre-formed 1/2-in. CPVC “Z-pipe” is
provided with the furnace. The Z-pipe is long enough to
extend across the casing for drain connections.
bo . Locate the Z-pipe. Remove the pre-formed drain elbow and
four spring clamps from the loose parts bag.
3. The Z-pipe is connected to the condensate trap and the
outside of the furnace by modifying the formed rubber
drain elbow as shown in Fig. 15.
4. Remove the formed grommet from the rubber drain elbow
by cutting the elbow along the vertical line located about
1-3/8 in. (35 mm) away from the formed grommet. See Fig.
15. DO NOT DISCARD THE FORMED GROMMET
OR THE RUBBER ELBOW. Both of these pieces will be
used.
Assemble and route the drain line to the opposite side of the
furnace as detailed below:
5. Remove the knock-out from the left side of the casing. See
Fig. 12 for suggested knockout removal technique.
6. From the outside of the casing, insert the angled end of the
Z-pipe through drain hole in the left side of the casing and
behind the inducer or gas valve. Allow the Z-pipe to
temporarily rest on the blower shelf (upflow) or burner box
(downflow). (NOTE: When the inducer housing has been
removed to ease installation in upflow applications, this step
is not needed.)
7. After inserting the Z pipe through the casing, slide a spring
clamp over each end of the Z pipe.
8. From inside the casing, insert the short end of the formed
grommet cut from the rubber drain elbow through the
7/8-in. drain knockout in the casing.
9, Pull the grommet through the casing from the outside until
it is seated in the knockout.
10. Align the Z-pipe with the long end of the grommet inside
the furnace and insert slightly. The angled end of the tube at
17
59SC2A

59SC2A
the other side of the casing should be facing the front of the
furnace.
11. Slide a spring clamp over the end of the remaining rubber
drain elbow.
12. Attach the drain elbow to the angled end of Z-pipe and the
drain trap outlet stub. Adjust the length of Z-pipe inserted
into the grommet at the opposite side of the furnace as
necessary for proper fit and positioning. In both upflow and
downflow orientations, the Z-pipe should NOT be resting
on any sheet metal parts.
13. Secure the rubber elbow to the drain trap and the Z-pipe
with spring clamps.
14. Secure the grommet to the Z-pipe with the spring clamp.
The remaining drain line can be constructed from field supplied
1/2-in. CPVC or 3/4-in. PVC pipe, in compliance with local
building codes. A factory-supplied 1/2-in. CPVC to 3/4-in. PVC
adapter is supplied in the loose parts bag for use as required.
15. Install the adapter or connect the 1/2-in. CPVC pipe by
sliding a spring clamp over the open end of the grommet on
the outside the furnace casing.
16. Open the spring clamp and insert the long end of the
adapter or the 1/2-in. CPVC pipe into the outlet stub on the
drain tube.
17. Connect additional condensate piping to a code-approved
drain, or to a condensate pump approved for use with acidic
furnace condensate and compatible with mineral and
vegetable oils, such as canola oil.
Allow at least 1/4-in. per foot (20 mm per meter) of slope down
and away from the furnace in horizontal sections of drain line.
The field-supplied, accessory horizontal drain trap grommet is
ONLY REQUIRED FOR DIRECT VENT APPLICATIONS.
It is NOT required for applications using single-pipe or
ventilated combustion air venting.
TIP FROM CONTRACTORS: When installing the furnace
horizontally, use the entire drain elbow (that is, do NOT cut as
shown in Fig. 15 to connect the trap to the drain line. This helps to
prevent bumps and shocks to the drain line from damaging the
furnace drain trap. Avoid misalignment of the drain pipe which
may cause kinks in the elbow.
Horizontal Orientation
1. The condensate trap outlet extends 2-in. (51 mm) below the
furnace casing. Leave enough clearance between the furnace
and the furnace platform for the trap.
bo . To allow for servicing the trap, the condensate drain elbow
in the loose parts bag can be used to make a coupler to
allow for future service of the condensate trap and drain
line.
3. Remove the knock-out for the condensate trap in the side of
the casing.
4. Install the drain trap grommet in the casing if required for
direct-vent applications. If necessary, remove the trap,
install the grommet and re-install the trap.
5. Remove the pre-formed rubber drain elbow, and two spring
clamps from the loose parts bag.
6. Connect the full or modified elbow and/or grommet to the
outlet of the condensate trap with one spring clamp. Avoid
misalignment of the drain pipe which may cause kinks in
the elbow or grommet.
7. The remaining drain line can be constructed from field-
supplied 1/2-in. CPVC or 3/4-in. PVC pipe, in compliance
with local building codes. A factory-supplied 1/2-in.
CPVC to 3/4-in. PVC adapter is supplied in the loose parts
bag for use as required.
8. Install the adapter or connect the 1/2-in. CPVC pipe by
sliding a spring clamp over the open end of the elbow or
grommet on the outside the furnace casing.
9, Open the spring clamp and insert the long end of the
adapter or the 1/2-in. CPVC pipe into the outlet stub on the
drain tube.
10. Connect additional condensate piping to a code-approved
drain, or to a condensate pump approved for use with acidic
furnace condensate and compatible with mineral and
vegetable oils, such as canola oil.
Allow at least 1/4-in. per foot (20 mm per meter) of slope down
and away from the furnace in horizontal sections of drain line.
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.
L12F019B
Fig. 12 - Knockout Removal
TTT
OPEN STAND
PIPE FOR
AIC OR
HUMIDIFIER
eo
® @ TEE
ct
TO OPEN
DRAIN
A11276
Fig. 13 - Example of Field Drain Attachment
18

INSTALL CLAMPS ON DRAIN TUBE
DRAIN TRAP /
PULL DRAIN STUB /
THROUGH CASING,
os NOTE: Trap grommet is required only for direct-vent
\ applications.
Remove knockout.
Install grommet before
OPEN
SPRING
CLAMP
relocating
condensate
INSERT FACTORY-SUPPLIED 1/2-IN. CPVC trap.
TO 3/4-IN. PVC ADAPTER OR 1/2-IN. CPVC PIPE
*CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN
TUBE
59SC2A
RIGHT SIDE DRAIN INSTALLATION
A11342A A11582
Fig. 14 - Formed Rubber Drain Grommet Fig. 16 - Horizontal Drain Trap Grommet
Attach elbow to condensate trap
Cut formed end off
condensate drain
Formed end of elbow
grommet
Connect short end
of “Z” pipe to modified
Cut line for left side condensate drain.
Do not discard parts after NA
Factory supplied 1/2-in. CPVC to
3/4-in. PVC adapter
TRAP, DRAIN ELBOW WITH DISCHARGE PIPE
f . Formed end of grommet
J Open spring clamp. Insert — Modified drain elbow connect to
1/2-in, to 3/4-in. CPVC to condensate trap and “Z” pipe
PVC adapter or 1/2-in.
CPVC pipe
4-3/8 in
mn Ginn) Be]
LEFT SIDE DRAIN ROUTED BEHIND INDUCER
NOTE: Remove Inducer Housing for easier access, if desired.
A11581 Li2FO1s
Fig. 15 - Modify Rubber Drain Elbow Fig. 17 - Drain Trap Connection and Routing
(Appearance may vary)
19

59SC2A
INSTALLATION
This furnace is certified to leak 2% or less of nominal air
conditioning CFM delivered when pressurized to 1-in. water
column with all present air inlets, including bottom closure in
upflow and horizontal applications, air outlets, and plumbing
and electrical ports sealed.
Upflow Installation
NOTE: The furnace must be pitched as shown in Fig. 24 for
proper condensate drainage.
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.
Connect supply-air duct to flanges on furnace supply-air outlet.
Bend flange upward to 90° with wide duct pliers. See Fig. 21.
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 supply side
accessories MUST be connected to duct external to furnace main
casing.
Return Air Connections
CUA Le:
FIRE HAZARD
A failure to follow this warning could cause personal injury,
death and/or property damage.
Never connect return-air ducts to the back of the furnace.
Follow instructions below.
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. Bypass humidifier may be attached into unused return air
side of the furnace casing. See Fig. 25, 26, and 27.
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 4 screws holding bottom
plate. See Fig. 23.
. Remove bottom plate.
Ww
be
. Remove bottom closure panel.
fs . Reinstall bottom plate 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
some HORIZONTAL configurations. Do not use side return-air
openings in DOWNFLOW configuration. See Fig. 25, 26, and 27.
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be
used. See Fig. 22. Install field-supplied, 5/16 x 1-1/2 in. (8 x 38
mm) (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 in Step 1 above.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in each
bottom corner of furnace.
bo . For each leg, install nut on bolt and then install bolt with
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 in-
side nut to secure arrangement.
5. Reinstall bottom closure panel if removed.
Downflow Installation
NOTE: The furnace must be pitched as shown in Fig. 24 for
proper condensate drainage.
Supply Air Connections
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when any one of the following 3
accessories are used:
¢ Special Base, KGASB
* Cased Coil Assembly Part No. CNPV, CNRV, CAP, or CAR
¢ Coil Box Part No. KCAKC
1. Determine application being installed from Table 8.
2, Construct hole in floor per Table 8 and Fig. 20.
3. Construct plenum to dimensions specified in Table 8 and
Fig. 20.
4. Install special base coil assembly or coil box as shown in
Fig. 20.
NOTE: It is recommended that the perforated supply-air duct
flanges be completely 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. 21.
4& CAUTION
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.
Connect supply-air duct to supply-air outlet on furnace. Bend
flange inward past 90° with wide duct pliers See Fig. 21. The
supply-air duct must be connected to ONLY the furnace supply
outlet or air conditioning coil casing (when used). When installed
on combustible material, supply-air duct must be connected to
ONLY the factory-approved accessory subbase, or a
factory-approved air conditioning coil casing. DO NOT cut main
furnace casing to attach supply side air duct, humidifier, or other
accessories. All supply side accessories MUST be connected to
duct external to furnace casing.