Carrier 59MN7A Guide

Installation, Start-up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS ......................... 3
INTRODUCTION ................................... 4
CODES AND STANDARDS ........................... 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ... 4
ACCESSORIES ..................................... 5
LOCATION ........................................ 5
AIR FOR COMBUSTION AND VENTILATION .......... 9
CONDENSATE TRAP ............................... 11
Upflow ........................................ 11
Downflow ..................................... 11
Horizontal ...................................... 11
CONDENSATE DRAIN ............................. 16
INSTALLATION ................................... 18
Upflow ........................................ 18
Downflow ..................................... 18
Horizontal ...................................... 19
Filter Arrangement ............................... 19
AIR DUCTS ....................................... 26
Ductwork Acoustical Treatment ..................... 26
GAS PIPING ...................................... 29
ELECTRICAL CONNECTIONS ....................... 30
115-V Wiring ................................... 30
J-Box Installation ................................ 31
24-V Wiring .................................... 31
Accessories ..................................... 31
Alternate Power Supplies .......................... 32
VENTING ........................................ 38
Special Venting Requirements for Installations in Canada . 38
Materials ....................................... 39
Venting Systems ................................. 39
Locating Vent Termination ......................... 39
Size the Vent and Combustion Air Pipes ............... 40
Combustion Air and Vent Piping Insulation Guidelines ... 40
Configure the Furnace ............................ 40
Installing the Vent Termination ...................... 41
Venting System Length Calculations ................. 44
START-UP, ADJUSTMENT, AND SAFETY CHECK ...... 57
Select Setup Switch Positions ........................ 57
Prime Condensate Trap ............................. 57
Purge Gas Lines ................................... 57
Adjustments ...................................... 58
Check Safety Controls .............................. 60
Checklist ........................................ 61
SERVICE AND MAINTENANCE PROCEDURES ........ 67
Cleaning Heat Exchangers ........................... 72
SEQUENCE OF OPERATION ........................ 79
PARTS REPLACEMENT GUIDE ...................... 85
TABLES
Loose Parts Bag Contents .............................. 6
Minimum Clearances to Combustible Materials ............. 6
Minimum Free Area Required ......................... 10
Minimum Space Volumes ............................. 10
Filter Size Information ............................... 20
Opening Dimensions ................................ 22
Air Delivery CFM ................................... 27
Maximum Capacity of Pipe ........................... 30
Electrical Data ...................................... 32
Vent Termination Kit for Direct Vent (2-Pipe) Systems ...... 39
Combustion-Air Vent Pipe, Fitting 8: Cement Material ....... 42
Maximum Allowable Exposed Vent Lengths Insulation ...... 43
Maximum Equivalent Vent Length ...................... 44
Deductions from Maximum Equivalent Vent Length ........ 44
Altitude Derate Multiplier for U.S.A ..................... 64
Blower Off Delay Setup Switch ........................ 64
Gas Rate .......................................... 64
Orifice Size and Manifold Pressure ..................... 65
_Always Ask For
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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.

Required Notice for Massachusetts Installations
IMPORTANT
The Commonwealth 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:
a. For all side wall 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 shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gasfitter shall 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.
2. 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.
3. 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".
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall 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.
5. 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.
c. 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
2. 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:
1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation
instructions; and
2. 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.

SAFETY CONSIDERATIONS
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, personal iniury, 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 iniury or property damage. Consult a
qualified service agency, local gas supplier, or your
distributor or branch for information or assistance. The
qualified service agency nmst use only factory-authorized
and listed kits or accessories when modifying this product.
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 nmst 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.
CUT HAZARD
Failure to follow this caution may result in personal iniury.
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'x When you see this symbol on
the furnace and in instructions or manuals, be alert to the potential
for personal iniury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal iniury or death. WARNING signifies a hazard
which could result in personal iniury or death. CAUTION is used
to identify hazards which may result in nfinor personal iniury or
product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability, or
operation.
1. Use only with type of gas approved for this furnace. Refer
to the furnace rating plate.
2. Install this furnace only in a location and position as spe-
cified in the "Location" section of these instructions.
3. Provide adequate combustion and ventilation air to the 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.
5. 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 ternfinating outside
the space containing the furnace. See "Air Ducts" section.
8. A gas-fired furnace for installation in a residential garage
nmst 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 ram) clearance from combustible ma-
terials to supply air ductwork for a distance of 36 in. (914
ram) horizontally from the furnace. See NFPA 90B or local
code for further requirements.
13. These furnaces SHALL NOT be installed directly on carpet-
ing, tile, or any other combustible material other than wood
flooring. In downflow installations, factory accessory floor
base MUST be used when installed on combustible materi-
als and wood flooring. Special base is not required 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 clearance to com-
bustible construction information.
II

H
INTRODUCTION
This 4-way multipoise Category IV condensing furnace is CSA
design-certified as a direct (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.
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 (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 all 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 (;as Code (NFGC) NFPA 54-2009/ANSI
Z223.1-2009 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
• 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, Mgw IR3, 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,
Refrigeration, 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 @proved 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
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.
2. 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.
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.AnESDservicekit(availablefromcommercialsources)
mayalsobeusedtopreventESDdamage.
ACCESSORIES
See Product Data Sheet for a list of accessories for this product
LOCATION
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 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.
General
These furnaces are shipped with the following 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.
CARBON MONOXIDE POISONING /COMPONENT
DAMAGE HAZARD
Failure to follow this warning could result in personal iniury
or death and unit component damage.
Corrosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Do not install
furnace in a corrosive or contaminated atmosphere. Make
sure all combustion and circulating air requirements are met,
in addition to all local codes and ordinances.
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.

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 nmst be located at least 18 in.
(457 ram) 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 nmst
be installed in accordance with the NFPA 54/ANSI
Z223.1-2009 or CAN/CSA B149.2-2010. (See Fig. 5.)
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 nmst be installed parallel with, or on the
downstream side of the unit to avoid condensation in the heat
exchangers. When installed parallel with the furnace, dampers or
other flow control must prevent chilled air from entering the
furnace. If the dampers are manually operated, they nmst be
equipped with means to prevent operation of either unit unless the
damper is in the full-heat or full-cool position.
Table 1 -Loose Parts Bag Contents (Provided in blower compartment)
DESCRIPTION
Air Intake Pipe Flange
Vent Pipe Flange
Coupling Flange Gaskets
Sharp Tip Screws (Vent and Inlet Flanges)
Vent Pipe Coupling
Vent Pipe Coupling Clamps
Pressure Switch Tube
Outlet Choke Plate (used with 40k BTUH furnaces, only)
Drain Tube Elbow
Drain Extension Tube
Drain Tube Clamps
Drain Line Grommet
Gas Line Grommet
Gas Line Knockout Plug
Junction Box Cover
Junction Box Base
Green Ground Screw
Blunt Tip Screws (Junction Box)
Thermostat Wire Grommet
QUANTITY
1
1
2
10
1
2
1
1
1
1
2
1
1
1
1
1
1
3
1
Table 2 - Minimum Clearances to Combustible Materials for All Units
POSITION CLEARANCE
Rear 0 (0 mm)
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 1 in. (25 mm)
Sides 0 (0 mm)
Vent 0 (0 mm)
Top of Furnace 1 in. (25 mm)
*Recommended

,,,j
:Z
©
,.<
I
=
r_
=
=.
615/1
[176+1] 23/10
pS+4l
[1_.11
FURNACE SIZE A
(MODELS) (CABINET WIDTH)
(59MN7) inches mm
060-14 171/2 445
0_0-14
100-20 21 533
120-22 241/2 622
B C
(OUTLET WIDTH) BOTTOM INLET WIDTH) D
Inches mm Inch_ mm Inchu
157/8 4_1 16 406 83/4
t93/8 4_Z 161/2 495 101/2
22 7/8 581 23 584 12 1/4
SHIPPING
WEIGHT
mm LB8 KG
154.0 69.3
222 164.0 73.8
267 178.5 80.5
311 20_.5 _1.1
2611116
[678,1]
26 3/8
[670.01
25 1/8
[63S.7]
233/16 _
ps2,91
¢7/8--
AIR FLOW [_2.2]
CONDENSATE DRAIN TRAP
LOCATION _\\ \
[22.2]
THERMOSTAT ENTRY
122.2[ "_
7SIDE INLET
ires,4[ 22
1658.3]
21
[sa4.o]
265/16
pSS+_
[17.5] BOTTOM RETURN
WIDTH
11116
[17.5]
_3_
176.2[
AIR iNTAKE
+>
pa.3!
NOTE: ALL DIMENSIONS IN INCH [MM]
29 1/2
1749.3]
28 3/4
[73o.5]
26 11/16
[67e.1[
26_
[370+0]
•_2 7116
[67o.o]
_/ 13/4
144.6]
GAS _NN
_l z ¢7/8
_,-F+ 122.21
................_!7/8
[22.21
THERMOSTAT ENTRY
_7/8
[22+2] POWER CONN
[,22,_
p7 SIDE INLET
[_,2.0]
25 5/15
[sse.5]
[25.4[ .

AIRFLOW
THE BLOWER IS LOCATED
TOTHE RIGHT OFTHE
BURNER SECTION, AND
AIR CONDiTiONED AiR iS
DISCHARGED TO THE LEFT.
THE BLOWER iS
LOCATED ABOVE TH E
BURNER SECTION, AND
CONDiTiONED AIR IS
DISCHARGED DOWNWARD AIRFLOW
THE BLOWER iS
LOCATED BELOW THE
BURNER SECTION, AND
CONDiTiONED AiR iS
DISCHARGED UPWARD.
AIRFLOW
THE BLOWER iS
LOCATED TO THE LEFT
OF THE BURNER SECTION,
AND CONDiTiONED AiR IS
DISCHARGED TO THE RIGHT.
A02097
Fig. 2 - Multipoise Orientations
SUPPLYAIR
MAX80 °F /27°C
32° F/0 ° C MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
FRONT
RETURN
AIR MIN60°F /16°O
Fig. 3 -Freeze Protection and Return Air Temperature
BACK FRONT
A10490
Fig. 4 -Prohibited Installations
A10494
18-iN. (457.2 mm)
MiNiMUM TO BURNERS
A93044
Fig. 5 - Installation in a Garage

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 airfor combustion. Follow the guidelines below to
insure thatother 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 or crawl
space) 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 walls 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
Z223.1-2009, 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.
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.
2. Fig. 6 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and vent-
ilation 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. 6 and Table 3.
c. TWO HORIZONTAL DUCTS require I 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. 6and
Table 3.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
sq. in. (645 sq. mm) of free area per 4,000 Btuh (550
mm2/kW) for combined input of all gas appliances in the
space per Fig. 6 and Table 3.
3. ONE OUTDOOR OPENING requires:
a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh (734
mm2/kW) for combined input of all gas 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.
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.
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.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
iniury 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.

Table 3- Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR
(1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) VERTICAL DUCTS
FURNACE (1,100 SQ. MM/K3N) (734 SQ. MM/K3N) (1 SQ. IN./4,000 BTUH)
INPUT (550 SQ. MM/K3N)
(BTUH) Free Area of Round Duct Free Area of Round Duct Free Area of Open- Round Duct
Opening and Duct Opening and Duct ing and Duct
Sq. In (Sq. mm) In. (mm) Dia Sq. In (Sq. mm) In. (mm) Dia Sq. In (mm) In. (mm) Dia.
40,000* 20 (12904) 5 (127) 14 (8696) 5 (127) 10 (6452) 4 (102)
00,000 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 (32258) 8 (203) 34 (21739) 7 (178) 25 (16130) 6 (152)
120,000 60 (38709) 9 (229) 40 (26087) 7 (178) 30 (19355) 6 (152)
140,000" 70 (45161) 10 (254) 47 (30435) 8 (203) 35 (22581) 7 (178)
*Not all families have these models.
EXAMPLES: Determining Free Area
FURNACE WATER HEATER TOTAL INPUT
100,000 + 30,000 = (130,000 divided by 4,000) = 32.5 Sq. In. for each two Vertical Ducts or Openings
60,000 + 40,000 = (100,000 divided by 3,000) = 33.3 Sq. In. for each Single Duct or Opening
80,000 + 30,000 = (110,000 divided by 2,000) = 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)
30 40 50 40 60 80 100 120 140
ACH Space Volume Ft3 (M3)
1,050 1,400 1,750 1,400 1,500 2,000 2,500 3,000 3,500
0.60 (29.7) (39.6) (49.5) (39.6) (42.5) (56.6) (70.8) (84.9) (99.1)
1,260 1,680 2,100 1,680 1,800 2,400 3,000 3,600 4,200
0.50 (35.6) (47.5) (59.4) (47.5) (51.0) (67.9) (84.9) (101.9) (118.9)
1,575 2,100 2,625 2,100 2,250 3,000 3,750 4,500 5,250
0.40 (44.5) (59.4) (74.3) (59.4) (63.7) (84.9) (106.1 ) (127.3) (148.6)
2,100 2,800 3,500 2,800 3,000 4,000 5,000 6,000 7,000
0.30 (59.4) (79.2) (99.1) (79.2) (84.9) (113.2) (141.5) (169.8) (198.1 )
3,150 4,200 5,250 4,200 4,500 6,000 7,500 9,000 10,500
0.20 (89.1) (118.9) (148.6) (118.9) (127.3) (169.8) (212.2) (254.6) (297.1)
6,300 8,400 10,500 8,400 9,000 12,000 15,000 18,000 21,000
0.10 (178.0) (237.8) (297.3) (237.8) (254.6) (339.5) (424.4) (509.2) (594.1)
0.00 NP NP NP NP NP NP NP NP NP
NP = Not Permitted
TO
OUTDOORS
1 SQIN.
PER 4000
BTUH*
t
(305mm) 12" MAX
1SQIN. _
PER 2000 -
BTdH*
iL
DUCTS
TO
3UTDOORS
I'
1 SQIN.
PER 2000
BTUH* _
mm) 12" MAX
:__-
SQ
PE
40C
BTU
o
1 so
PE
4oc
BTU
--_=,
MJ
(305mm)
(305mm)
CIRCULATING AIR DUCTS t SQIN.
TO PER 4000
OUTDOORS BTUH*
*Minimum dimensions of 3-in. (76 mm).
NOTE: Use any of the following combinations of openings:
A&BC&DD&EF&G
Fig. 6 -Air for Combustion, Ventilation, and Dilution for Outdoors
A03174
10

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. 7 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
factory-installed trap will be located at the upper left corner of the
collector box. When the furnace is installed in the downflow
orientation, the factory-installed trap must be relocated for proper
condensate drainage.
To Relocate the Condensate Trap:
• Orient the furnace in the downflow position.
• Fig. 8 shows the condensate trap and tubing before and after
relocation.
• Refer to the appropriate figure to begin the trap conversion.
• Remove the relief tube from the condensate trap.
• Remove the screw that secures the condensate trap to the
collector box.
• Remove the trap.
• Remove the relief tube from of the port on the collector box. It is
not necessary to remove the hose from the inducer assembly.
• Remove the pressure switch tube from the port on the collector
box.
• Remove the pressure switch tube from the stand-offs on the
inducer assembly
• Loosen the clamp around the inlet of the vent elbow on the
inducer.
• Remove the middle and bottom plugs from the lower right side
of the collector box and set aside. Do Not Discard Plugs.
• Refer to the appropriate figure to begin the trap conversion.
• Install the 2 plugs previous removed from the collector box in
the ports where the condensate trap was removed.
• Install the trap over the ports on the lower right side of the
collector box.
• Secure the trap to the collector box with the screw.
• Connect the relief tube to the condensate trap to the relief port of
the condensate trap.
• If necessary, slide the relief tube in the inducer stand-offs to
adjust the position of the tube,
• Connect the relief tube to the relief port of the condensate trap,
• Route the pressure switch tube to the port on the collector box
next to the condensate trap, Trim off any excess tube to avoid
sags or kinks in the tube,
• Rotate the vent elbow to the desired position and tighten the
clamp 15 lb-in.
• 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
factory-installed trap will be located at the bottom left corner of the
collector box. When the furnace is installed in the horizontal left
position, the factory-installed trap will be located at the top of the
collector box. The trap must be repositioned on the collector box
for proper condensate drainage.
When the furnace is installed as a direct-vent furnace, a field
supplied, accessory Horizontal Installation Kit is required for all
horizontal installations. The kit contains a rubber Casing Grommet
designed to seal between the furnace casing and the condensate
trap.
NOTE: 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. In areas where the ambient temperature will fall below
32 ° F. (0°C), a field-supplied condensate freeze protection kit is
required. See Product Data for current kit offering. Follow the
instructions included in the kit.
To Relocate the Condensate Trap:
• Remove the knockout in the casing for the Casing Grommet.
• Install the grommet in the casing.
NOTE: This grommet is only required for Direct-Vent
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. 9 shows the condensate trap and tubing before and after
relocation in the horizontal right position.
• Fig. 10 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.
• Remove the relief tube from the condensate trap.
• Remove the screw that secures the condensate trap to the
collector box.
• Remove the trap.
Horizontal Left only:
• Remove therelief tube from the port on the collector box. It is
not necessary to remove the tube from the inducer assembly.
• Remove thepressure switch tube from the port on the collector
box.
• Remove the pressure switch tube from the stand-offs on the
inducer assembly.
For Horizontal Right only:
• The pressure switch tube location is not modified.
• Loosen the clamp around the inlet of the vent elbow on the
inducer.
• Remove the plugs from the collector box and set aside. Do Not
Discard Plugs.
For Horizontal Left only:
• Remove themiddle and right plug from the ports at the bottom
of the collector box.
For Horizontal Right only:
• Remove theplug to the right of the condensate trap.
• Refer to the appropriatefigure to begin the trapconversion.
•Install the plugs previous removed from the collector box in the
ports where the condensate trapwas removed.
• Install the trap over the ports on the lower side of the collector
box.
• Secure the trap to the collector box with the screw.
• Connect the relief tube to the condensate trap to the relief port of
the condensate trap.
• If necessary, slide the relief tube in the inducer stand-offs to
adjust the position of the tube.
11
II

For Horizontal Left only:
• Connect the relief tube to the relief port of the condensate trap.
• Connect the pressure switch tube to the port on the collector box
next to the condensate trap. Trim off any excess tube to avoid
sags or kinks in the tube.
• Rotate the vent elbow to the desired position and tighten the
clamp 15 lb-in.
• Refer to Condensate Drain section for information how to install
the condensate drain.
Condensate Drain Protection
Freezing condensate left in condensate trap and drain line may
cause cracks, and possible water damage may occur. Freeze
protection of the condensate trap is required when the furnace is
installed in the horizontal position and the attic temperature is
below 32 deg. F (0 deg. C).
If freeze protection for the condensate trap is required, use
condensate freeze protection accessory.
See Product Data for current kit offering.
The remaining condensate drain line can be protected by using a 3
to 6 watt per ft. (.3M) at 120v and 40°F (4.4°C) self--regulating,
shielded, and waterproof heat tape. Wrap field drain pipe with heat
tape, approximately 1 wrap per ft. (.3M). Follow manufacturer's
recommendations and installation instructions supplied with heat
tape.
Condensate Trap
Relief Port
Vent Pipe Clamp Vent Elbow Clamp
Plugs Vent Elbow
Collector Box
Plug
Condensate Trap
Relief Port
Pressure Switch Outlet
Port
UPFLOW TRAP CONFIGURATION
MODULATING UN{TS
Fig. 7 - Upflow Trap Configuration
(Appearance May Vary)
Trap
Al1306
12

Remove relief tube from relief
port on condensate trap.
Remove pressure switch tube from
pressure switch port.
(_ emove trap fromcollector box. Remove tube from
relief port.
(_) Loosen clamp on inlet
to vent elbow. /_/_ (MODULATING UNITS) Remove middle and bottom plugs.
DO NOT DISCARD.
Unconverted Factory Configuration
As Viewed in the Downflow Orientation
©
@
Install plugs on
open ports on
collector box.
Connect relief tube
port on collector box.
Rotate elbow to
desired position
tighten clamp to
15 lb.-in.
Slide tube in stand-offs
to adjust length.
Route tube through
inducer stand-offs
(MODULATING UNITS)
Trim excess tube.
Connect pressure switch
tube to port on collector box.
Attach condensate trap
with screw to collector
box.
Connect relief tube to
relief port on condensate
trap.
Align condensate trap
over middle and bottom
ports of collector box.
Downflow Trap Configuration
Fig. 8- Downflow Trap Configuration
(Appearance May Vary)
Al1277
13

Remove plug from
collector box.
DO NOT DISCARD.
\
(MODULATING UNITS) ©
If alternate vent position
is required, loosen clamp
on inlet of vent elbow.
Remove trap from
collector box.
Unconverted Factory Trap Configuration
As Viewed in the Horizontal Right Orientation
Slide relief tube in
stand-offs to adjust length.
Attach condensate trap
tOscrew.COllectorbox with -_.. \
Vent elbow shown in alternate
orientation. Tighten clamp on
inlet to vent elbow 15 lb.-in.
Install plug in open
port on collector box.
(MODULATING UNITS)
Align trap over middle and
right-hand port on collector box.
Horizontal Right Trap Configuration
Fig. 9 -Horizontal Right Trap Configuration
(Appearance May Vary)
Al1278
14

[f alternate vent position
is required, loosen clamp
on vent elbow inlet.
Remove trap from
collector box.
Remove relief tube
from relief port on
condensate trap.
Remove pressure switch tube
from port on collector box.
©Remove relief tube
from port on collector
box.
(MODULATING UNITS)
Remove middle and right
plug from collector box.
Unconverted Factory Trap Configuration
As Viewed in the Horizontal Left Orientation
(_ otate elbow to
desired position and
torque clamp on inlet
15 lb.-in.
Install plugs in open
ports on collector box.
Connect relief tube to
port on collector box.
(_ Slide relief tube in
stand-offs to adjust
length.
(_ ttach condensate
trap to collector box
with screw.
Trim excess tube.
Route pressure switch tube
underneath relief tube and
connect to port on collector box.
©Align trap over middle
and right-hand port on
collector box. (MODULATING UNITS)
Connect relief tube to
relief port on condensate
trap.
Horizontal Left Trap Configuration
Fig. 10 - Horizontal Left Configuration
(Appearance May Vary)
Al1279
15

CONDENSATE DRAIN CONNECTION
Upflow/Downflow Orientation
In the Upflow or Downflow 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 the furnace.) The furnace
condensate drain can be connected to the Air Conditioning
condensate drain as shown in Fig. 12.
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. 11 .)
2. Remove the pre-formed drain tube and two spring clamps
from the loose parts bag.
3. Slide a spring clamp 1 inch (25 mm) down the plain end of
the drain tube.
4. From inside the casing, insert the formed grommet end of
the tube through the 7/8-in. knockout in the casing.
5. Pull the tube through the casing from the outside until it is
seated in the knockout
6. Attach the plain end of the drain tube to the outlet stub on
the drain trap. Secure the drain tube to the trap with the
spring clamp.
7. Slide a spring clamp over the open end of the drain tube
outside the casing.
8. Open the spring clamp and connect a field-supplied 1/2-in.
CPVC street elbow to the open end of the drain tube. (See
Fig. 13.)
9. Connect additional 1/2-in. CPVC piping to a condensate
pump approved for use with acidic furnace condensate or to
a code-approved drain.
For Left Side Condensate Drain Connection:
1. For left side condensate drainage, the drain line is routed
from the condensate trap, behind the inducer and out
through the left side of the casing. A pre-formed "Z" pipe is
provided in the loose parts bag shipped with the furnace.
The "Z" pipe is long enough to extend out of the casing on
the 14 3/16-in. (360 mm) wide furnace. Larger casings will
require a field supplied CPVC pipe and to extend the drain
line out of the furnace.
2. The "Z" pipe is connected to the condensate trap by
modifying the formed rubber drain tube. Connect the drain
line as shown below:
3. Remove the knock-out from the left side of the casing. (See
Fig. 11.)
4. Install the grommet for the l/2-in. CPVC drain line in the
7/8-in. knockout in the casing.
5. Remove the pre-formed drain tube, the offset l/2-in. CPVC
pipe and two spring clamps from the loose parts bag.
6. Remove the formed grommet on the tube by cutting the
tube along the vertical line located about 1 inch (25 mm)
away from the formed grommet.(See Fig. 14.)
7. Slide a spring clamp 1 inch (25 mm) down the plain end of
the drain tube.
8. With the bend in the tube oriented horizontally and plain
end of the tube pointing away from you, insert the l/2-in.
CPVC pipe into the other end of the drain tube. Rotate the
tube so the offset in the tube points away from you. Slide a
spring clamp over the open end of the l/2-in. CPVC tube
and secure the cut end of drain tube to the pipe. (See Fig.
15)
9. Prime the bare end of the pipe with CPVC primer.
10. Route the offset pipe behind the inducer assembly and
through the grommet in the casing, if the "Z" pipe is long
enough. If the "Z" pipe is not long enough, continue with
installation.
11. Attach the plain end of the drain tube to the outlet stub on
the drain trap. Secure the drain tube to the trap with the
spring clamp.
12. If the "Z" pipe does not extend through the casing, slide a
piece of field supplied CPVC through the grommet in the
casing, otherwise, go to Step 17.
13. Cement a 1/2-in. CPVC coupling to the end of the CPVC
pipe.
14. Apply cement to the end of the "Z" pipe connected to the
condensate trap.
15. Connect the field-supplied CPVC pipe to the CPVC pipe
connected to the condensate trap.
16. Cut off excess CPVC pipe outside the casing.
17. Connect additional 1/2-in. CPVC piping to a condensate
pump approved for use with acidic furnace condensate or to
a code-approved drain.
18. When a condensate pump is not used, slope the pipe away
from the furnace to allow for proper drainage.
Horizontal Orientation
1. In the Horizontal orientation, a field supplied accessory
drain trap grommet is required to seal the gap between the
casing and the condensate trap for direct vent applications,
only. The condensate trap outlet extends 2 in. (51 mm)
below the furnace casing. To allow for servicing the trap,
the condensate drain tube in the loose parts bag can be
modified to make a coupler to allow for future service of the
condensate trap and drain line.
2. Remove the knock-out for the condensate trap in the side of
the casing.
3. Install the drain trap grommet in the casing. (For direct vent
applications.) If necessary, remove the trap, install the
grommet and re-install the trap.
4. Remove the pre-formed drain tube, the offset l/2-in. CPVC
pipe and two spring clamps from the loose parts bag.
5. Remove the formed grommet on the tube to create an elbow
or straight connector. (See Fig. 14.)
6. Connect the cut tube to the outlet of the condensate trap
with 1 spring clamp.
7. Slide the other spring clamp down the plain end of the drain
tube.
8. Connect additional l/2-in. CPVC piping to the open end of
the tube.
9. Slide the spring clamp down over the l/2-in. CPVC pipe
10. Connect additional l/2-in. CPVC piping to a condensate
pump approved for use with acidic furnace condensate or to
a code-approved drain.
11. When a condensate pump is not used, slope the pipe away
from the furnace to allow for proper drainage.
16

/
o!
®
CUT HAZARD
Failure to follow this caution may result in personal iniury.
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.
Fig. 11 - Knockout Removal
......®....................................®
• iiii
OPEN STAND
PIPE FOR
A/C OR
HUMIDIFIER
DRAIN
U
,_----TEE
TO OPEN
DRAIN
Fig. 12 - Example of Field Drain Attachment
A11305
A11276
INSI'ALL CLAMPS ON DRAIN TUBE
ATI'ACH DRAINTUBE TOCONDENS/_]E 7
DRAIN IRAP //
/
PUrL DRAIN S'IUB
THROUGH CASING /
\
\
Cut and remove formed end of
drain tube for left side and horizontal
drain connection \
RIGHT SIDE DRAIN ELBOW
Fig. 14 -Modify Drain Jhbe
Attach tube to condensate trap
\
Cut formed end off \
condensate drain tube \
Field supplied 1/2"CPVC Connect short end _
_71PI_I,I gt, df2in extensi o n' of "Z" pipe to modified \[_ \_ il l
TRAP, DRAIN ELBOW WITH DISCHARGE PIPE
A11388
Field supplied 1/2"
CPVCto drain
Modified drain tube connect to
condensate trap and"Z" pipe
:asing grommet from
parts bag
Field-supplied 1/2" CPVC coupling & drain
pipe 17 1/2", 21"and 24 1/2"casings
LEFT SIDE DRAIN ROUTED BEHIND INDUCER
Fig. 15 - Drain Trap Connection and Routing
(Appearance May Vary)
A11344
__ _ ORemove knockout
trap.
A11348
Fig. 16 - Horizontal Drain Trap Grommet
OPEN SPRING CLAMP
INSERT FIELD -SUPPLIED
1/2'" CPVC DRAIN PIPE
* CLAMP MAY BE LOCATED
ON OUTSIDE OF DRAIN TUBE
RIGHT SIDE DRAIN INSTALLATION
Fig. 13 - Formed 1hbe Grommet
A11342
17

H
INSTALLATION
Upflow Installation
NOTE: The furnace nmst be pitched forward as shown in Fig. 22
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. 19.)
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.
Return Air Connections
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 acombination 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. 23, 24, 25.)
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove this panel when bottom return
air is used. This panel may be used as the bottom closure of an
accessory bottom return air box, or discarded. To remove bottom
closure panel, perform the following:
1. Tilt or raise furnace and remove 4 screws holding bottom
plate. (See Fig. 21.)
2. Remove bottom plate.
3. Remove bottom closure panel.
4. 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. 23, 24, 25.)
Leveling Legs (If Desired)
In upflow position with side return inlet(s), leveling legs may be
used. (See Fig. 20.) Install field-supplied, 5/16 x 1-1/2 in. (8 x 38
ram) (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.
2. 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 nmst be pitched forward as shown in Fig. 22
for proper condensate drainage.
Supply Air Connections
NOTE: For downflow @plications, this furnace is @proved 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. Deternfine application being installed from Table 6.
2. Construct hole in floor per Table 6 and Fig. 18.
3. Construct plenum to dimensions specified in Table 6 and
Fig. 18.
4. Install special base coil assembly or coil box as shown in in
Fig. 18.
NOTE: It is recommended that the perforated supply-air duct
flanges be completely removed from furnace when installing the
furnace on afactory-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. 19.)
CUT HAZARD
Failure to follow this caution may result in personal iniury.
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. 19.) The
supply-air duct nmst 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-@proved accessory subbase, or a
factory-@proved air conditioning coil casing. DO NOT cut main
furnace casing to attach supply side air duct, hunfidifier, or other
accessories. All accessories MUST be connected to duct external to
furnace casing.
Return Air Connections
FIRE HAZARD
A failure to follow this warning could cause personal iniury,
death and/or property damage.
Never connect return-air ducts to the back of the furnace.
Follow instructions below.
The return-air duct nmst be connected to return-air opening
(bottom inlet). DO NOT cut into casing sides (left or right).
Bypass hunfidifier connections should be made at ductwork or coil
casing sides exterior to furnace. (See Fig. 24.)
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
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bottomreturnairisusedindownflowapplications.Toremove
bottomclosurepanel,performthefollowing:
1.Tiltorraisefurnaceandremove4screwsholdingbottom
plate.(SeeFig.21.)
2.Removebottomplate.
3.Removebottomclosurepanel.
4.Reinstallbottomplateandscrews.
Horizontal Installation
NOTE: The furnace must be pitched forward as shown in Fig. 22
for proper condensate drainage.
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.
The furnace can be installed horizontally in an attic or crawlspace
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.
Platform Furnace Support
Construct working platform at location where all required furnace
clearances are met. (See Table 2 and Fig. 26.) For furnaces with
1-in. (25 mm) clearance requirement on side, set furnace on
non-combustible blocks, bricks or angle iron. For crawlspace
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.
Suspended Furnace Support
The furnace must be supported under the entire length of the
furnace with threaded rod and angle iron. (See Fig. 27.) Secure
angle iron to bottom of furnace as shown.
Roll-Out Protection
Provide a minimum 12-in. x 22-in. (305 x 559 mm) piece of sheet
metal for flame roll-out protection in front of burner area for
furnaces closer than 12-in, (305 mm) above the combustible deck
or suspended furnaces closer than 12-in. (305 mm) to joists, The
sheet metal MUST extend underneath the furnace casing by 1-in,
(25 mm) with the door removed.
The bottom closure panel on furnaces of widths 17-1/2-in, (445
mm) and larger may be used for flame roll-out protection when
bottom of furnace is used for return air connection, See Fig. 26 for
proper orientation of roll-out shield.
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. 19.)
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.
Return Air Connections
The return-air duct must be connected to bottom of the furnace,
The side of casing that faces downward may also be used for return
air connection. A combination of the bottom and downward
facing side may also be used. Bypass humidifier may be attached
into unused return air side of the furnace casing. (See Fig. 25.)
Bottom Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove this panel when bottom return
air is used. This panel may be used as a roll-out shield or discard.
To remove bottom closure panel, perform the following:
1. Tilt or raise furnace and remove 4 screws holding bottom
plate. (See Fig. 21.)
2. Remove bottom plate.
3. Remove bottom closure panel.
4. 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
side return air inlet(s) are used without a bottom return air inlet.
Not all horizontal furnaces are approved for side return air
connections (See Fig. 25.)
Filter Arrangement
FIRE, CARBON MONOXIDE AND POISONING
HAZARD
Failure to follow this warning could result in fire, personal
iniury or death.
Never operate a furnace without a filter or filtration device
installed. Never operate a furnace with filter or filtration
device access doors removed.
There are no provisions for an internal filter rack in these furnaces.
An external filter is required.
The furnace is shipped with a factory-supplied Media Filter
Cabinet. The Media Filter Cabinet uses either a standard I-inch (25
mm) filter or 4-inch (102 mm) wide Media Filter which can be
purchased separately. A field supplied accessory air cleaner may
also be used in place of the media cabinet.
The Media Cabinet is sized for bottom return applications for use
in upflow, downflow and horizontal applications. A 16-inch (406
mm) Media Cabinet is shipped with the 14-3/16-in. (360 mm)
furnace and includes block-off plates
For upflow side return applications, the Media Cabinet (or field
supplied accessory air cleaner) can be installed on the side of the
furnace or side and bottom when a bottom plenum is used. (See
Fig. 17 and 23.)
For downflow applications, the Media Cabinet (or field supplied
accessory air cleaner) must only be connected to the bottom
opening on the furnace. See Fig. 17 and 24.
For horizontal applications, the Media Cabinet (or field supplied
accessory air cleaner) for all models can be connected to the
bottom opening on the furnace. For side return use in the
horizontal position, refer to Fig. 25. If both side and bottom
openings are used in Fig. 25, each opening used will require a
filter.
The media cabinet (or field supplied accessory air cleaner) can also
be installed in the common return duct prior to entering the return
air opening in any orientation.
Refer to the instructions supplied with Media Cabinet or accessory
air filter for assembly and other details. See Table 5 for filter size
details.
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FURNACE CASING WIDTH
17-1/2 (445)
21 (533)
Table 5-Filter Size Information - In. (mm)
FILTER SIZE
SIDE RETURN BOTTOM RETURN
16 x25 x 3/4 16 x25 x 3/4
(405 x 535 x 19) (405 x 535 x 19)
16 x 25 x 3/4 20 x 25 x 3/4
(405 x 535 x 19) (508 x 535 x 19)
16 x 25 x 3/4 24 x 25 x 3/4
24-1/2 (622) (405 x 535 x 19) (610 x 535 x 19)
Recommended to maintain air filter face velocity. See Product Data for part number.
FILTER TYPE
Washable*
Washable*
Washable*
Air Filter Located in Filter Cabinet
FILTER CABINET HEIGHT - IN (MM) FILTER SIZE - IN (MM) FILTER TYPE
(1) 16 x 25 x 3/4"
(406 x 635 x 19) or Washable or Media*
16 (406) (1) 16 x 25 x 4-5/16
(406 x 635 x 11 O)
(1) 20 x 25 x 3/4"
(508 x 635 x 19) or Washable or Media*
20 (508) (1) 20 x 25 x 4-5/16
(508 x 635 x 11 O)
(1) 24 x 25 x 3/4"or
(610 x 635 x 19) or Washable or Media*
24 (610) (1) 24 x 25 x 4-5/16
(610 x 635 x 11 O)
Filters with a side return-air may have a different filter size. Measure the filter to obtain the correct size.
Recommended to maintain air filter face velocity. See Product Data for part number.
20