Payne PG8JAA042090AAJA User manual

PG8M/PG8J
Installation, Start-up, Operating, and
Service and Maintenance Instructions
-Series C
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The Payne PG8M/PG8J 80% AFUE Gas Furnaces feature 4-
way multipoise design and through-the-furnace downflow
venting. The PG8M/PG8J furnaces are approved for use with
natural or propane gas and the PG8J is also approved for use in
Low Nox Air Quality Management Districts.
STANDARD FEATURES
•Four-position furnace: upflow, horizontal right, horizontal
left, downflow
•Electronic control center
Adjustable heating air temperature rise
LED diagnostics and self test feature
•Hot surface ignition (HSI)
•Twinning in Upflow, Downflow and Horizontal
LIMITED WARRANTY
• 20-year warranty on "Super STM''heat exchanger
• 5-year parts warranty on all other components
Catalog No: 53PG-8J5 Form No. IM-PG8J-05 5-05

4-W
Singme-Stage
Induced-Combustion
{nstallation,
Service and
Cancers: II 310A-45°4/IM-PG8J-04
li310_k-45-5/IM-PG8Jo0_5
Start-up, upera mng, ane
Maintenance Instructions
Series 120/0
NOTE: Read the entire instruction manual before starting the
installation.
This symbol --> indicates a change since the last issue,
--> PoItions of the text and tables are repiinted fiom NFPA 54/ANSI Z223 1-2002"<',
with permisslol_ of National Fire Protection Association, Quincy, MA 02269 and
Ameiican Gas Association. Washingto_ DC 20001 This reprinted material is l_ot/he
complete and official position of the NFPA or ANSI on the ref?renced suNect, which
is repiesented only by the standmd in its entirety
TABLE OF CONTENTS
SAFETY CONSIDERATIONS 2
INTRODUCTION ..................................... 4
CODES AND STANDARDS ........................................................ 4
Safety ......................................................................................... 5
General Installation ................................................................... 5
(onfhustion and Ventilation Air .............................................. 5
Duct Systems ............................................................................ 5
Acoustical Lining and Fibrous Glass Duct .............................. 5
Gas Piping and Gas Pipe Pressure Testing .............................. 5
Electrical Connections .............................................................. 5
ELECTROSTATI( DISCHARGE (ESD) PRECAUTIONS
PRO(EDURE ................................................................................ 5
LOCATION .................................................................................... 5
General ...................................................................................... 5
Location Relative to Cooling Equipment ................................ 7
AIR FOR COMBUSTION AND VENTILATION ...................... 7
INSTALLATION ......................................................................... 10
Lpftow Installation ................................................................. i0
Bottom Return Air Inlet .................................................... i0
Side Return Air Inlet ......................................................... 10
Leveling Legs (If Desired) ................................................ 10
Downftow Installation ............................ 10
Bottom Return Air Inlet ......................... 11
Horizontal Installation ............................. 11
Suspended Furnace Support ...................... 11
Platfbrm Furnace Support ........................ i 1
Roll-Out Protection .............................. 11
Bottom Return Air Inlet ......................... 1l
Side Return Air Inlet ........................... 11
Filter Arrangement ................................ 11
Air Ducts ........................................ 11
General Requirements ............................ 11
Ductwork Acoustical Treatment .................... 12
Supply Ai* (onnections ......................... 12
Return Air Connections .......................... 14
Gas Piping ...................................... 15
Electrical ( onnections ............................ 19
115=V Wiring ................................ 19
J°Box Relocation .............................. 20
Electrical Connection to J°Box ..................... 21
Power Cord Installation in Furnace J=Box ............. 21
BX Cable Installation in Furnace J°Box .............. 22
RSO 9001:2000
24-V Wiring ....................................................................... 22
Accessories ........................................................................ 22
Venting .................................................................................... 22
General Venting Requirements ......................................... 23
Masonry (himney Requirements ...................................... 23
Appliance Application Requirements ............................... 24
Additional Venting Requirements ..................................... 26
Sidewall Venting ............................................................... 26
START°UP, ADJE STMENT, AND SAFETY CHECK ............ 27
General .................................................................................... 27
Start-Up Procedures ................................................................ 27
Adjustments ............................................................................. 3l
Check Safe w Controls ............................. 34
Checklist .......................................... 35
SERVICE AND MAINTEiN'ANCE PROCEDURES ........... 35
Intro&ction ....................................... 35
General ........................................ 35
Electrical Controls and Wiring ..................... 36
(are and Maintenance .............................. 37
Cleaning and/or Replacing Air Fiher ................. 37
Blower Motor and Wheel ......................... 37
Cleaning Heat Exchanger ........................ 40
Sequence of Operation ............................. 44
Wiring Diagrams .................................. 45
Troubleshooting .................................. 45
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations,
PC 101 Catalog No See Cover Printed in USA Form 58S%13SI Pg 1 5-05 Replaces: 58S%12SI

26 I/8"
(FLI JE COLLAR)
5 15/16"--
78" DIA I I
ACCESSORY --
33 5¸'¸¸[6,`
JUN( TION BOX
LOCATION
WIRE ENTRY_
3 15_/6" J
LEFT HAND GAS_
CAStNG
_A--
-- U --
.-F-- 1t
478"
NOTES:
1. Two additional 7/8-in diameter holes are located in the top plate•
2. Minimum return-air openings ar furnace, based on metal duct• Ifflex duct is used, see flex duct manufacturer's recommendationsfor equivalent diameters
a For 800 CFM-16qn round or 14 1/2 x 12qn.rectangle
b For 1200CFM-20-in. round or 14 1/2 x 19 1/2qn rectangle•
c. For 1600 CFM-22qn. roundor 14 1/2x 224n rectangle•
d For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for spedfic
use of single side inlets• The use of both side inlets, a combination of 1 side and the bottom, or the
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM
-_ Fig. 1--Dimensional Drawing
SAFETY CONSIDERATIONS
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow d-fis warning could result in dangerous
operatiom serious injury, death, or property damage
Improper installation, adjustment, alteration, service, mainte-
nance, or use can cause carbon monoxide poisoning, explo-
sion, fire, electrical shock, or other conditions which may
cause personal inju V or property dan?age. Consult a qualified
service agency, local gas st@plier, or your distributor or
branch J:br infbrmation or assistance. The qualified service
agency must use only J:Sctory=authorized and listed kits or
accessories when modi_}'ing this product.
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of fknl_ace may re=
quire excessive servicing or cause premature component
failm'e
Application of this tktrnace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, unit leveling, and unit sizing
Installing and servicing heating eq_lipment can be hazardous due to
gas and electrical components. Only trained and qualified
personnel should instMl, repair, or service heating equipment.
Untrained personnel can perfoma basic maintenance _imctions
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 Nrnace and other safety
precautions that may apply.
A04037
These instructions cover minimum requirements and con%*m to
existing national standards and safety codes In some instances_
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing residen=
tial construction practices. We require these instructions as a
minimum fbr a saf_ installation,
CUT HAZARD
Failure to J:bllow d_is caution may result in personal ir_jnry.
Sheet metal parts may have sharp edges or butts Use care and
wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing filrnaces,
Wear safety glasses and work gloves. Have fire extinguisher
available daring start-up and adjustn_ent procedures and service
calls.
This is the sa_)ty=alert syn£bol Z_ • When you see this syngbol on
the fiu_aace and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING, and (AU=
TION These words are used with the saJ:kty=alert symbol. DAN-
GER 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 ir_.im'y or
product and property damage. NOTE is used to highlight sugges=
tions which will result in enhanced installation, reliability, or
operation.
1. Use only with type of gas approved tbr this filrnace. ReJ:kr to
the/_urnace rating plate.
2. Install this Nmace only in a location and position as specified
in the "Location" section of these instructions.

MINIMUMINCHESCLEARANCETOCOMBUSTIBLECONSTRUCTION
DISTANCEMINIMALEENPOUCESAUX CONSTRUCTIONSCOMBUSTIBLES
Thisforced air furnace is equippedfor use wi_ PqisflJmaceisapprovedforUPFLOW,DOWNFLOW,and
naturalgas ataltitudes0-10,000ft (0-3,050m). HORIZONTALinstallations.
An accessory kit, supplied by De CettefoumaiseestaporouveepourI'installationHORIZONTALE
manuf_turer, shall beused toconvertto propane etlac_oulatbnd'airVERSLEHAUTetVERSLEB.AS.
gas use or may berequiredfor some naturalgas /_,,_-'_
applications. Clearancearrows /',_: Lesfbchesded@agement
This furnace is for indoor installation in a donotchangew}th _/ _ nechangepasavec
furnace orientatior_ z u._ I 'orientation de la foumaise,
buildingconstructedon site. ,_
Thisfumase maybeinstalledon combustible _
oonngn v o co ,mnmumc r n
as indicated by the diagram from combusiible _.
msterial. _I
Thisfurnacemay beusedwitha TypeB-1Vent
and may be vented in common wi_ other gas .._ _ _ o_._._%://
firedappliances. _{:_o_,
Cettefournaisea airpulseest equipee _ r_._,- i s=_
pour utilisation avec gaz nafurel et altitudes
comprisesentreG3,050m (0-I0,000 pi). e\O_
Utiliserune troussede conversion,fournie par co_
lefabrinant,pourpasserau gaz propaneou pour _.,
certainesinstallationsaugaz naturel. ",_ oz_; V"
Cettefoumaiseest p@vuepour@e
installeedans unbStimentconstruitsurplace. Clearanceininches
Cettefournaisepeut6treinstalleesur _/z'7 Dggagernent(po},
unplanc'hercombustibledansunealc6veou
dans ungarde-robeen respectantle minimum <_'/
d'espacelibredes materiauxcombustibles,tel Vent Clearancetocombustibles:
qu'indique surle diagramme. ForSingleWalJvents6 inches(6po).
Cettefournaisepeut@-eutiliseeavec un For Type B-1venttype 1inch(1 po).
Degagementde I'@entaveccombustibles:
conduitd'@acuationdeTypeB-1ou connectee Pourconduitd'@aouationaparoisimpb6po(6inches).
au conduitommun d'autresappareilsa gaz. Pourcor_duitd'evaouatbndeTypeB-11po(1inch).
MINIMUMINCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
DOWNFLOWPOSITIONS:
1" Installationonnon-combusibiblefloorsonly.
For Installationoncombustibleflooringonlywheninstalledonspecialbase,PartNo.KGASB020IALL
CoilAssembly,PartNo.CD5 orCK5, orCoilCasing,Part[/o. KCAKC.
O 18inchesfrontclearancerequiredforalcove.
_r Indicatessupplyor returnsideswhen furnace isin [he horizontalposition.Linecontactonlypermissible
betweenlinesformed by intersectionsofthe Top and bJvoSides ofthe furnacejacket,and buildingjoists,
studsor framing.
DC:GAGEMENTMiNIMUm,f1EN POUCESAVEC €:LE_ENTS
DECONSTRUCTIONCOMBUSTIBLES
POURLAPOSITIONCOURANTDESCENDANT:
1_ Pourrinstallationsur planchernoncombustibleseulement.
Pourrinstallafionsur un planchercombustibleseulementquandon utilisela basespedale, piece
n° KGASB020IALL rensembleserpentin,piecen° CD5 ouCKS,ou le narterdeserpentin,piece
n° KCAKC.
Dans une alc6ve,on dolt maintenirun decjagementa ravant de18po (450mm).
.k La poistionindiqueeconceme lec6ted'en_-eeou deretourquand lafournaiseestdans la
positionhorizontale.
Lecontact n'est permisqu'entreles lignesformeespar lesintersectionsdu dessusetdes
deuxc6tes de lacherfise dela fournaiseet lessolives,montantsous cadre decharpenta.
327590-101 REV. C j
--> Fig. 2--Clearances to Combustibles
A04123

-_ Table 1--Dimensions (iN.)
F
D E C.L TOP AND FLUE
FURNACE A SUPPLY-AIR RETURN-AiR BOTTOM COLLAR* SHIP W% (LB}
$tZE CABINET W_DTH WIDTH WIDTH FLUE COLLAR {BN.}
(tN.) (IN.) (RN.}
045=08t024045 14-3/16 12=9/16 12-11/16 9=5/16 4 104
045=12t036045 14-%16 12-9/16 12-11/16 9=5/16 4 107
070=08t024070 14-3/16 12=9/16 12-11/16 9=5/16 4 111
070=12t036070 14-%16 12-9/16 12-11/16 9-5/16 4 115
070-161048070 17-1/2 15-7/8 16 11-9/16 4 126
090_14/042090 17-1/2 15-7/8 16 11-9/16 4 127
090-18/048090 21 19-3/8 19=1/2 13-5/16 4 140
090-20t060090 21 19-3/8 19-1/2 13-5/16 4 146
t10-12/036110 17-1/2 15-7/8 16 11-9/16 4 135
110_181048110 21 19-3/8 19-1/2 13-5/16 4 146
t10=22/066110 21 19-3/8 19=1/2 13-5/16 4 152
135-16/048185 21 19-3/8 19-1/2 13-5/16 4 149
t35-22/066188 24-1/2 22-7/8 23 15-1/16 4 163
188-20t080155 24-1/2 22-7/8 23 15-1/16 4 170
* 5" or 6 _vent connector may be required in some cases.
--> 9,
3. Provide adequate combustion and ventilation air to the furnace
space as specified in "Air _br Combustion and Ventilation _'
section.
4. (ombustion products must be discharged outdoors. Connect
this _i/mace to an approved vent system only, as specified in
the "Venting" section of these instructions.
5. Never test for gas leaks with an open flame. Use a commer-
cially available soap solution made specifically for the detec-
tion of leaks to check all connections, as specified in the "Gas
Piping" section.
d. Always install Nmace to operate within the fmnace's intended
temperature-rise range with a duct system which has an
external static pressure within the allowable range, as speci-
fied in the "Start-Up, Adjustments, and Safety Check" section.
See Nmace rating plate.
7. When a fitrnace is installed so that supply ducts cat_T air
circulated by the t_urnace to areas outside the space containing
the furnace, the remm air shall also be handled by duct(s)
sealed to the _i/raace casing and terminating outside the space
containing the Nrnace. See "Air Ducts" section.
8. A gas-fired _lrnace fbr installation in a residential garage must
be installed as specified in the warning box in the "Location _'
section.
The furnace is not to be used [br temporary heating of
buildings or stl_ctures under construction. See page 7 caution
box regarding the heating of buildings under construction.
10. These Multipoise Gas-Fired Furnaces are (SA (fbrmerly
A.G.A. and (LG.A0 design-certified for use with natural and
propane gases (see furnace rating plate) and for installation in
alcoves, attics, basements, closets, utility rooms, crawlspaces,
and garages. The furnace is factory°shipped _br use with
natural gas. A CSA listed gas conversion kit is required to
convert furnace [or use with propane gas.
11. See Fig. 2for required clearances to combustible construction.
12. Maintain a l-in. clearance from combustible materials to
supply air ductwork J:br a distance of 36 inches horizontally
_?om the Nmace. See NFPA 90B or local code for Nrther
requirements,
--€
13. These _amaces SHALL NOT be installed directly on carpet-
ing, tile, or any other combustible material other than wood
flooring. In downflow installations, _i_ctow- accessow- floor
base MUST be used when installed on combustible materials
and wood flooring. Special base is not required when this
_i/mace is installed on manu_hcturer's (;oil Assernhly Part No.
(D5 or CK5, or when (Toil Box Part No. KCAKC is used. See
Fig. 2 for clearance to combustible constluction information.
INTRODUCTION
This Stoics 120/( 4 way multipoise Category I _m-assisted
furnace is (SA design=certified. A Category I fan-assisted furnace
is an appliance equipped with an integral mechanical means to
either &aw or force products of combustion through _he combus=
tion chamber and/or heat exchanger. The _urnace is factor'-
shipped fbr use with natural gas. A CSA (A.G.A. and C.G.A.)
listed gas conversion kit is required to convert [:urnace for use with
propane gas. This Nmace is no{ approved fbr installation in
mobile homes, recreational vehicles, or outdoors.
This Nrnace is designed for minimuna continuous return-air
temperature of 60_>F db or intermittent operation down to 55°F db
such as when used with a night setback thermostat. Return-air
temperature must not exceed 85°F db. Failure to follow these
return-air temperature limits may afi:kct reliability of heat exchang-
ers, motors, and controls. (See Fig. 3.)
For accessoQ" installation details, re['cr to the applicable instruction
literature.
NOTE: Remove all shipping brackets and materials before oper-
ating the furnace.
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these ins{factions. The installation must comply with regulations
of the serving gas supplier, local building, heating, plurnhing, and
other codes. In absence of local codes, the installation must
comply with the national codes listed below and all authorities
having jurisdiction.

MAX 85°F
--> Step 8--Venting
* US: NFO(: chapters 10 and 13
CANADA: NS(NGPIC Part 7 and Appendix C
ELECTROSTATIC DBSCHARGE {ESD) PRECAUTIONS
PROCEDURE
FRONT
MIN 60°F
Fig, 3--Return Air Temperature
A02055
In the [ nited States and Canada, follow all codes and standards for
the ibllowing:
Step l--Safety
* US: National Fuel Gas Code (NFGC) NFPA 54 2002/ANSI
Z223.1 2002 and the Installation Standards, Wam_ Air Heating
and Air Conditioning Systems ANSI NFPA 90B
--> * CANADA: CSA B149.1-00 National Standard of Canada
Natural Gas and Propane Installation Codes (NSCNGPIC)
Step 2--General hstaHation
* US: Current edition of the NFGC and the NFPA 90B. For
copies, contact the National Fire Protection Association Inc.,
BattelTmarch Park, Quincy, MA 02269 (www.NFPA.org); or
for only the NFGC, contact the American Gas Association, 400
N. Capitol Street, N.W., Washington, DC 20001
(www.AGA.org).
* CANADA: NSCNGPI(. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke (Tor-
onto), Ontario, M9W 1R3 Canada
Step a--Combustion and Ventilation Air
--> * US: Section 8.3 of the NFGC, Air for (ombustion and
Ventilation
* CANADA: Part 7 of NSCNGPIC, Venting Systems and Air
Supply fbr Appliances
Step 4--Duct Systems
--> * US and CANADA: Air (onditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Con=
tractors National Association (SMACNA), or American Soci=
ety of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000
HVAC Systems and Equipment Handbook Chapters 9 and 16.
Step 5--Acoustical Lining and Fibrous Gtass Duct
* US and CANADA: current edition of SMA(NA and NFPA
90B as tested by [L Standard 181 _br Class I Rigid Air Ducts
Step 6--Gas Piping and Gas P{pe Pressure Testing
* US: NFGC; chapters 5, 6, 7, and 12 and National Phnnbing
Codes
* CANADA: NSCNGPIC Parts 3, 4, and 5, and Appendices A,
B, E and H
Step 7--Electrical Connections
* US: National Electrical Code (NEC) ANSI NFPA 70 2002
* CANADA: Canadian Electrical Code CSA C22 1
--€ FURNACE RELIABILITY HAZARD
Improper installation or service of furnace may cause prema-
ture furnace component failure
Electrostatic discharge can affect electronic components.
Take precautions during thrnace installation and servicing to
protect tl_e furnace electronic control. Precautions will pre-
vent electrostatic discharges ti'om 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 thrnace, the control, and the person at the same
electrostatic potential.
1 Disconnect all power to the furnace. Multiple disconnects may
be required. DO NOT TOUCH THE CONTROL OR ANY
WIRE CONNECTED TO THE CONTROL PRIOR TO DIS-
CHARGING YOUR BODY'S ELECTROSTATIC CHARGE
TO GROUND.
2 Firmly touch the clean, unpainted, metal surface of the f_maace
chassis which is close to the control. Tools held in a person's
hand dtlring grounding will be satisfactorily discharged.
3. After touching the chassis, you may proceed to service the
control or connecting wires as tong 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 ohjects (and recharge your body with
static electricity), firmly touch a clean, unpainted metal
surface of the fiul_ace again be:_bre touching control or wires.
5. Use this procedure for installed and uninstalled (ungrounded)
_i/rnaces
6. Before removing a new contact fi'om its container, discharge
your bo@'s electrostatic charge to ground to protect the
control _i'om damage. If t!_e control is to be installed in a
_i/mace, _bltow items 1 through 4 befbre bringing the control
or yourself in contact with the furnace. Put all used and new
controls into containers be_bre touching ungrounded objects.
7. An ESD service kit (available from commercial sources) may
also be used to prevent ESD dan?age.
LOCATION
GENERAL
Some assembly and modifications are required when used inany
of the four applications shown in Fig. 4,
This lhrnace 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)
* he located close to d-_echinmey or vent and attached to an air
distribution system, Refer to Air Ducts section,
* be provided ample space fbr servicing and cleaning. Always
comply with mininmm fire protection clearances shown on the
fro'hate clearance to combustible consm/ction 1abel

THE BLOWER IS LOCATED
TO THE RIGHT OF THE
BURNER SECTION, AND
AIR CONDITIONED AIR IS
DISCHARGED TO THE LEFT
HORIZONTAL LEF[
AIRFLOW
THE BLOWER IS
LOCATED BELOW THE
BURNER SECTION. AND
CONDITIONED AIR IS
DISCHARGED UPWARD.
THE BLOWER IS
LOCATED ABOVE THE
BURNER SECTION, AND
CONDITIONED AIR IS
DISCHARGED DOWNWARD
J
J
AURFLOW A02097
Fig. 4_Multipoise Orientations
--€ CARBON MONOXIDE POISONING HAZARD
Failure to fbllow this warning could result in personal injuU
or death, and unit component damage.
CmTosive or contaminated air may cause failure of parts
containing flue gas, which could leak into the living space.
Air for con_bustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromid< and
iodide. These elements can con'ode heat exchangers and
shorten Nrnace life. Air contaminants are found ix 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 confbustion and circulating air requirements are reel
ix addition to all local codes and ordinances.
All f_el-burning equipment n-rest be supplied with air %r fuel
combustion Sufficient air must be provided to avoid negative
pressure ix the equipment room or space A positive seal must be
made between the filrnace cabinet and the return-air duct to
prevent pulling air fl'om the burner area and from draft safeguard
opening.
--> The %llowing types of furnace installations may require OLT°
DOOR AIR [br combustion due to chemical exposures:
Commercial buildings
Buildings with indoor pools
Laundv rooms
Hobby or craft rooms, and
Chemical storage areas
--> If air is exposed to the fbllowing substances, it should not be used
fbr combustion air, and outdoor air may be required fbr combus°
tion:
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 fi_bric softeners fbr clothes dwers
Mason U- acid washing materials
18-1N. MINIMUM
TO BURNERS
Fig. 5--Installation in a Garage
A93044
FIRE, INJURY OR DEATH HAZARD
Improper location or inadequate protection could result in fire
or explosion
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18 inches
above the floor The furnace must be located or protected to
avoid damage by vehicles. When the furnace is installed in a
public garage, airplane hangar, or other building having a
hazardous atmosphere, the furnace must be installed in
accordance with the NFGC or NS(NGPI(. (See Fig 5)

___>
---€
m
PERSONAL IN !! RY AND/OR PROPERTY DAMAGE
HAZARD
Improper use or installation of this furnace may cause
premature iqmmce component fitih*re.
This gas Nmace may be used for heating buildings under
construction provided that:
-The Nmace is permanently installed with all electrical
wiring, piping, venting and dacting installed according to
these installation instructions. A retom air duct is provided,
sealed to the fimaace casing, and tem_inated outside the space
containing the fk*mace. 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 Nmace is controlled by a thermostat. It *nay not be "hot
wired" to provide heat continuously to the structure without
thermostatic control.
-Clean outside air is provided %r combustion. This is to
minimize the corrosive effects of adhesives, sealers and oNer
construction materials. It also prevents the entrainment of
&ywall dust into combustion air, which can cause fouling
and plugging of ihmace components.
-The temperature of the remm air to the furnace is main°
rained between 55°F (13%?) and 80+F (27°C), with no
evening setback or shutdown. The use of the furnace while
the structure is under construcfion is deemed to be intermit°
tent operation per our installation instructions.
-The air temperature rise is within the rated rise range on the
ihmace rating plate, and the firing rate has been set to the
nameplate value.
-The filters used to clean the circulating air &*ring the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
-The Nmace, ductwork and filters are cleaned as necessaw
to remove d_-wall dust and construction debris fiom all
HVAC system components after construction is completed.
-Verify proper Nmace operating conditions including ignio
tiom gas input rate, air temperature rise, and venting
according to these installation instructions.
!
FIRE, INJURY OR DEATH HAZARD
Failure to fbllow this warning could result in unsafe furnace
operation.
DO NOT install the furnace on its back or hang fhmace with
control compartment facing downward. Safety control opera°
tion will be adversely affected Never connect retumoair dacts
to back of furnace. (See Fig 6.)
LOCATION RELATIVE TO (OOLING EQL IPMENT
The cooling coil must be installed parallel with, or on d_e
downstream side of the unit to avoid condensation in the heat
exchangers, When installed parallel with the farnace, dampers or
other flow contlol must prevent chilled air fi'om entering d_e
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 fldl-cool position
BACK
AA02054
Fig. 6--Prohibit InstNlation on Back
AIR FOR COMBUSTION AND VENTILATION
Provisions %r adequate combustion, ventilation, and dilution air
must be provided in accordance with:
U.S. installations: Section 8.3 of the NFGC, Air for (ongbus-
tion and Ventilatiom and applicable provisions of the local
building codes
(anadian installations: Part 7 of the NSCNGPI(, Venting
Systems and Air Supply _br Appliances, and all authorities
having jurisdiction
---> FURNACE CORROSION HAZARD
Failure to £+llow this caution may result in htmace damage.
Air _br combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements can corrode heat exchangers and
shorten Nrnace tifk. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fi'esheners, and other household prodocts.
---€ CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning coutd result in personal inju W
or death.
The operation of exhaust farts, kitchen ventilation gins,
clothes &yers, attic exhaust farts or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the fm'nace.
Make-up air MIDST be provided for the ventilation devices, in
addition to that required by the fl_rnace. Refer to (arbon
Monoxide Hazard warning in venting section of these instruco
tions to determine if"an adequate amount of" make-up air is
available.
---->The requirements %r combustion and ventilation air depend upon
whether or not the fl*mace is located in a space having a volume
of at least 50 cubic f_et per 1,000 Btuh input rating _br all gas
appliances installed in the space
Spaces having less than 50 cubic feet per 1,000 Btah require
the OUTDOOR (OMBUSTION AIR METHOD.
Spaces having at least 50 cubic f_et per 1,000 Btnh may use the
INDOOR COMB! STION AIR, STANDARD or KNOWN-
AIR INFILTRATION METHOD

--> Table 2=Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS
FURNACE[ (1 SQ. IN.t2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN.i3,000 BTUH) (734 SQ. NNIKW) (1 $Q. IN./4,000 BTUH) (880 SQ. MM/KW)
INPUT Free Area of Free Area of Free Area of
{BTUH) Opening and Duct Round Duct Opening and Duct Round Duct Opening and Duct Round Duct
(Sq. in.) (in. Dia) (sq in.) (in. Dia) (Sq In.) (In. Dia)
44,000 22 6 14.7 5 11 4
06,000 33 7 22 6 16.5 5
88,000 44 8 29.3 7 22 6
110,000 55 9 36.7 7 27.5 6
132,000 66 10 44 8 33 7
154,000 77 10 51.3 9 38.5 8
EXAMPLES: Determining Free Area
FURNACE WATER HEATER TOTAL INPUT
110,000 + 30,000 (t40,000 divided by 4,000) 35.0 Sq. In. for each two Verticat Ducts or Openings
66,000 + 40,000 (106,000 divided by 3,000) 35.3 Sq. In. for a Singte Duct or Opening
88,000 + 30,000 (118,000 divided by 2,000) 59.0 Sq. In. for each of two Horizontal Ducts
--> Table 3=Minimum Space Volumes for 100% Combustion, Ventilation, and
Dilution from Indoors
OTHER THAN FAN=ASSISTED TOTAL FAN-ASSISTED TOTAL
(1,000'S BTUH GAS INPUT RATE) (1,O00'S BTUH GAS INPUT RATE)
ACH 30 I 40 I 50 44 166 I 88 1110 I 132 1154
Space Volume (ft3)
0.00 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850
0.80 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620
0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775
0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700
0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550
0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100
0.00 NP NP NP NP NP NP NP NP NP
NP = Not Permitted
---> Outdoor Combustion Air Method
1. Provide the space with sufficient air _br proper combustion,
ventilation, and dilution of flue gases using permanent hori=
zontal or vertical duct(s) or opening(s) directly communicat=
ing with the ontdoors or spaces that freely communicate with
the ontdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR OPEN°
INGS, one inlet and one outlet combustion and ventilation air
opening, to the outdoors.
a. One opening MUST commence within 12" (300 ram) of
the ceiling and the second opening MUST commence
within 12" (300 ram) of the floor.
b. Size openings and ducts per Fig. 7 and Table 2.
c. TWO HORIZONTAL DUCTS require 1 square inch of
flee area per 2,000 Bmh (1.100 mm2ikW) of combined
input fbr all gas appliances in the space per Fig. 7 and Table
2.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
square inch of flee area per 4,000 Bmh (550 mm2ikW) for
combined input of all gas appliances in the space per Fig.
7 and Table 2.
3. ONE OUTDOOR OPENING requires:
a. 1 square inch of flee area per 3,000 Btuh (734 mm2&W)
for combined input of all gas appliances in the space per
Table 2and
b. Not less than the sum of the areas of all vent connectors in
the space.
The opening shall commence within 12" (300 ram) of the ceiling.
Appliances in the space shall have clearances of at least 1" (25
ram) fiom d-_esides and back and 6" (150 ram) from the front. The
opening shall directly communicate with the outdoors or shall
communicate through a vertical or horizontal duct to d_e outdoors
or spaces (crawl or attic) that fieely communicate with the
outdoors.
Indoor Combustion Air<) NFPA & AGA
---> Standard and Known-Air-Infiltration Rate Methods
Indoor air is permitted fbr combustion, ventilation, and dilution,
if the Standard or Known=Air-Infiltration Method is used.
q
CARBON MONOXIDE POISONING HAZARD
Failure to supply outdoor air via grilles or ducts could result
in death and/or personal injury.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The /'umace combustion air supply must be provided in
accordance with this instruction manual.

TO
OUTDOORS
SQ tN.
PER4000
BTUH*
t
12"MAX
1SQ IN A
PER2000
BTUH*
DUCTS
TO
OUTDOORS
1SQ IN.
PER2000
BTUH*
12 _
MAX
1SQ tN
PER
4000
BTUH*
c0
o
o
C3
S
o
1SO iN.
PER
4000
BTUH*
12 _
MAX
CIRCULATING AIR DUCTS
TO
OUTDOORS
*Minimum dimensions of 3 in
NOTE: Use any of the following
combinations of openings:
A&B C&D D&E F&G
I SQ IN.
PER 4000
BTUH*
A03174
-e Fig. 7--Air for Combustion, Ventilation and
Dilution for Outdoors
_ CIRCULATING[DUCTS AIR
I I
I I
I I
INTERIOR
HEATED
SPACE
VENT THROUGH ROOF
I I
I I
I I UI L
i
1 SO IN.
i ER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6" MIN
(FRONT)t
1 SQ IN.
PER 1000
BTUH* tN DOOR
OR WALL
- l
CIRCULATING AIR DUCTS
* Minimum opening size is 100 sq in with
minimum dimensions of 3 in.
t Minimum of 3 in. when type-B1 vent is used.
12" MAX
A03175
--> Fig. 8--Air for Combustion, Ventilation and
Dilution from Indoors
The Stalidard Method:
1. The space has no tess volume than 50 cubic feet per 1.000
Bmh 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 Kno_n Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
mininlum required volume of the space varies with the number of
A(H and shall be detem_ined per Table 3 or Equations 1 and 2.
Determine the mininmm required volume for each appliance in the
space and add the volumes together to get the total n_inin-mm
required volume for the space.
Table 3-Minimum Space Volumes were determined by using the
following equations fiom the Yationa/ F_el Gas Cn&_ zl:\W]
Z223.J-2002/i\TP_ 54-2002.&3.2.2:
1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater:
21fts _ I °tt'er )/
Volumeother _ A===0_p0_) _/hr) A04002
2. For fan-assisted appliances such as this fl/rnace:
A04003
If:
Ioti_ = combined input of all other than fan-assisted appli-
ances in Btuhr
I_,,, = combined input of all fan-assisted appliances in Btuhr
ACH air changes per hour (ACH shall not exceed 0.60.)
--> The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if!
a. There are no closable doors between rooms.
b. (ombining spaces on same floor level. Each opening shall
have flee area of at least 1 in.2/1,000 Btuh (2,000 mm2ikW)
of the total input rating of all gas appliances in the space.
but not less than 100 in. 2 (0.06 m2). One opening shall
commence within 12" (300 ram) of the ceiling and the
second opening shall commence within 12" (300 ram) of
the floor. The minimum dimension of air openings shall be
at least 3 in. (80 ram). (See Fig. g.)

c.(ornbiningspaceondiff?rentfloorlevels.Thevolumesof
spacesondifferentfloorlevelsshallbeconsideredas
communicatingspacesifconnectedbyoneormoreperma=
nentopeningsindoorsorfloorshavingfi'eeareaofatleast
2in.2/1,000 Bmh (4,400 mma&W) of total input rating of
all gas appliances.
2. An attic or crawlspace may be considered a space that fieely
communicates with the outdoors provided there are adequate
pet_nanent ventilation openings directly to outdoors having
_?ee area of at least i-in.2/4,000 Bmh of total input rating for
all gas appliances in the space.
3. In spaces that use tlle Indoor Combustion Air Method,
infiltration should be adequate to provide air for combustion,
pemlanent 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.
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 fi'ames, between sole plates and
floors, between wall-ceiling joints, between wall panels, at
penetrations _br plumbing, electrical and gas lines, etc.
---> Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with tlle Indoor Combustion
Air Method below and,
2. Outdoor openings shall be located as required in tlle Outdoor
Combustion Air Method mentioned previously and,
3. Outdoor openings shall be sized as follows:
a. (alculate the Ratio of all Indoor Space volume divided by
required volume _br Indoor Combustion Air Method
below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor (ombusIiou Air Method above
nmltiplied by reduction Factor in b. above. The nlininlum
dimension of air openings shall be not tess than 3 in. (80
111111)
INSTALLATION
LPFLOW INSTALLATION
Bottom Return Air Inlet
These fhmaces are shipped with bottom closure panel installed in
bottom return-air opening. Remove and discard this panel when
bottom remm air is use& To remove bottom closure panel
perfbrrn die following:
1. Tilt or raise furnace and remove 2screws holding bottom filler
panel (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closm'e panel
4. Reinstall bottom filler panel and screws
Side Return Air Inlet
These fk/rnaces are shipped with bottom closure panel installed in
bottom return=air opening. This panel MUST be in place when
only side remm air is used.
BOTTOM FILLER
PANEL
I I
BOTTOM CLOSURE
PANEL
A02098
Fig. g--Removing Bottom Closure Panel
10
NOTE: Side return=air openings can be used in UPFLOW and
most HORIZONTAL coni:igurations Do not use side return-air
openings in DOWNFLOW configuration.
Leveling Legs (If Desired)
In upfluw position with side remm inlet(s), leveling legs may be
used. (See Fig. 10.) Install field=supplied, 5/16 X 1-1/2 in. (max)
con'osion-resistant machine bolts, washers and nuts.
NOTE: Bottom closure most 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.
To install leveling legs:
1. Position furnace on its back. Locate and drill a hole in each
bottom corner of fi/mace. (See Fig. 10.)
2. For each leg, install nut on bolt and then install bolt and nut in
hole. (Install flat washer if desired.)
3. Install another nut on other side of fi/rnace base. (Install flat
washer if desired.)
4. Adjust outside nut to provide desired height, and tighten inside
nut to secure arrallgement.
5. Reinstall bottom closure panel if removed.
DOVvL\'FLOW INSTALLATION
NOTE: For downflow applications, this furnace is approved fbr
use on combustible flooring when any one of the following 3
accessories are used:
° Special Base, KGASB
° Cased (oil Assembly Part No. (D5 or (K5
° (?oil Box Part No. KCAKC
1. Determine application being installed from Table 3.
2. (onstruct hole in floor per Table 3 and Fig. 11.
3. (onstruct plenum to dimensions specified in Table 3 and Fig.
11.
4. If downfluw subbase, KOASB is used, install as shown in Fig.
12. If Coil Assernbly Part No. (D5 or (K5 or (Toil Box Part
No. K(AKC is used, install as shown in Fig. 13.
NOTE: It is recommended that the perI:brated supply-air duct
flanges be completely _blded over or removed flora fi_rnace when
installing the _i/rnace on a fhctory-supplied cased coil or coil box.
To remove the supply-air dact flange, use wide duct pliers or hand
seamers to bend flange back and _:Prth until it breaks of LBe careful
of sharp edges. (See Fig. 14.)

A02071
Fig. 10--Leveling Legs
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,
per_brm the following:
1. Tilt or raise fi/mace and remove 2screws holding bottom filler
panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
HORIZONTAL INSTALLATION
--€ FIRE, EXPLOSION, AND CARBON MONOXIDE
POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, serious injury, death or property damage
Do not instal1 the fttrnace on its back or hang fimaace with
control compartment facing downward. Safety control opera=
tion will be adversely affected. Never connect return=air ducts
to the back of the furnace.
The filrnace car* be installed horizontally in an attic or crawl space
on either the left-hand (LH) or right=hand (RH) side The furnace
can be hung fiom floor joists, rafters or trusses or installed on a
non-combustible plat_brm, blocks, bricks or pad.
Suspended Furnace Suppmq _
The furnace may be supported under each end with threaded rod,
angle iron or metal plumber's strap as shown. (See Fig. 15 and 16.)
Secure angle iron to bottom of l\tmace as shown. Heavy-gauge
sheet metal straps (plumber's straps) may be used to suspend the
furnace fiom each bottom corner. To prevent screws fiom pulling
out, use 2#S x %-in. screws into the side and 2 #8 x -%-in. screws
in the bottom of the fl/mace casing for each strap. (See Fig. 15 and
16,)
--> If the screws are attached to ONLY the fitmace sides and not the
bottom, the straps must be vertical against the fm'nace sides and
not pull away fiom the _amace sides, so that the strap attachment
screws are not in tension (are loaded in shear) for reliable support,
11
Plat_brm Furnace Support
Construct working platform at location where all required furnace
clearances are met. (See Fig 2and 17.) For fi/rnaces with l-in.
clearance requirement on side, set fllmace on non=congbustible
blocks, bricks or angle iron For crawlspace installations, if the
fm'nace is not suspended fi'om the floor joists, the ground under-
neath furnace must be level and the furnace set on blocks or bricks.
Roll=Out Protection
Provide a minimum 17-3/4" X 22" piece of sheet metal for flame
roll-out protection in fl'ont of burner area tbr fhmaces closer than
12 inches above the combustible deck or suspended furnaces
closer than 12-in. to joists. The sheet metal MUST extend
underneath the fllmace casing by 1 in. with the door removed.
The bottom closure panel on furnaces of widths 17=i/2 in. and
larger may be used for flame roll-out protection when bottom of
furnace is used _br remm air connection. See Fig. 17 _br proper
orientation of roll=out shield.
Bottom Return Air Inlet
These ti_maces are shipped with bottom closure panel installed in
bottom return=air opening. Remove and discard this panel when
bottom remm air is used. To remove bottom closure panel,
perform the tbllowing:
1. Tilt or raise fi/mace and remove 2screws holding bottom filler
panel. (See Fig. 9.)
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.
Side Return Air Inlet
These furnaces are shipped with bottom closure panel installed in
bottom return=air opening. This panel MUST be in place when side
return air inlet(s) is used without a bottom return air linlet.
Not all horizontal furnaces are approved for side return air
connections (See Fig. 20.)
FILTER ARRANGEMENT
FIRE, CARBON MONOXIDE AND POISONING
HAZARD
Failure to %tlow this warning could result in fire, personal
inju W, or death,
Nero* operate a fin'nace without a filter or with filter access
door remove&
There are no provisions for an internal filter rack in these fllrnaces.
A field=supplied accessory external filter rack is required.
This fllmace requires KGAFR0301ALL 1" external filter rack or a
suitable field-supplied substitute, such as the Media Cabinet.
Refer to the instructions supplied with external filter rack _br
assembly and installation options
AIR D[CTS
General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA) or
American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE) or consuh Yhe Ai_' 5)'stems Desigr_ G_ide-
[i_ve.s reference tables available fi'om your tocal distributor. The
duct system should be sized to handle the required system design

FURNACE
CASRNG
WIDTH
TaNe 4_Opening Dimensions (in.)
APPLICATION C
Upflow Applications on Combustible or Noncombustible
Flooring (KGASB subbase not required) 13-5/16
Downflow Applications on Noncombustible Flooring 13-3/16
(KGASB subbase not required)
t4-3/16 Downflow applications on combustible flooring (KGASB 13-7/16
subbase required)
Downflow Applications on Combustible Ftooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase 13-5/16
not required)
Upflow Applications on Combustible or Noncombustible 16-5/8
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring 16-1/2
(KGASB subbase not required)
17=1/2 Downflow applications on combustible flooring (KGASB 16-3/4
subbase required)
Downflow Applications on Combustible Ftooring with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase 16-1/2
not required)
Upflow Applications on Combustible or Noncombustible 20-1/8
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring 20
(KGASB subbase not required)
21 Downflow applications on combustible flooring (KGASB 20-1/4
subbase required)
Downflow Applications on Combustible Flooring with CD5 or
CK5 Coit Assembly or KCAKC coit box (KGASB subbase 20
not required)
Upflow Applications on Combustible or Noncombustible 23-5/8
Flooring (KGASB subbase not required)
Downflow Applications on Noncombustible Flooring 23-1/2
(KGASB subbase not required)
24-1/2 Downflow applications on Combustible flooring (KGASB 23-3/4
subbase required)
Downflow Applications on Combustible Ftoonng with CD5 or
CK5 Coil Assembly or KCAKC coil box (KGASB subbase 23-1/2
not required)
PLENUM OPENING
A B
12-11/16 21-5/8
12-9/16 19
11-13/16 19
12-5/16 19
16 21-5/8
15-7/8 19
15-1/8 19
15-1/2 19
19-1/2 21-5/8
19-%8 19
18-5/8 19
19 19
23 21-1/8
22-7/8 19
22-1/8 19
22-1/2 19
FLOOR OPENING
D
22-1/4
19-5/8
20-5/8
20
22-1/4
19-5/8
20-5/8
20
22-1/4
19-5/8
20-5/8
20
22-1/4
19-5/8
20-5/8
2O
(FM at d_e design external static pressure The furnace airflow
rates are provided in Table 5=AIR DELIVERY=( FM (With Filter)
When a J:\lmace is installed so that the supply ducts car_- air
circulated by the J:\_mace to areas outside the space containing the
_/rnace, the return air shall also be handled by a duct(s) sealed to
the furnace casing and terminating outside the space containing the
_/rnace.
Secure ductwork with proper fasteners for type of doctwork used.
Seal supply_ and return-duct connections to _./rnace with code
approved tape or duct sealer.
NOTE: Flexible connections should be used between ductwork
and L_urnace to prevent transmission of vibration. Ductwork pass=
ing through unconditioned space should be insulated and sealed to
enhance system perfbrmance. When air conditioning is used, a
vapor barrier is recommended.
Maintain a l-in. clearance fiom combustible materials to supply air
ductwork for a distance of 36 in. horizontally fiom the Nmace. See
NFPA 90B or local code _br Nrther requirements.
Ductwork Acoustical Treatment
NOTE: Metal duct systems that do not have a 90 degree elbow
and 10 ft of main duct to the first branch take-off may require
internal acoustical lining. As an alternative, fibrous ductwork may
be used if constructed and installed in accordance with the latest
edition of SMACNA construction standard on fibrous glass ducts.
--€
12
Both acoustical lining and fibrous ductwork shall comply with
NFPA 90B as tested by _L Standard 181 for (?lass 1 Rigid air
ducts.
Supply Air Connections
For a f_u'nace 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 fbr possible openings using
light assistance or a probe can be inserted for sampling the air
stream. The cover attachment shall prevent leaks.
Upflow and Horizontal Furnaces
(onnect supply-air duct to flange on fulnace supply=air outlet.
Bend flange upward to 90 ° with wide duct pliers (See Fig. 14)
The supply-air duct must be connected to ONLY the furnace
supply=outlet-air duct flanges or air conditioning coil casing (when
used) DO NOT cut main J:_m'nace casing side to attach supply air
duct, humidifier, or other accessories All accessories MI_ST be
connected external to furnace main casing
NOTE: For horizontal applications, the top-most flange may be
bent past 90 degrees Go allow d_e evaporator coil to hang on the
flange temporarily while the remaining attachment and sealing of
the coil are performed.

FURNACE
(OR COIL CASING
WHEN USED)
_ COMBUSTIBLE
FLOORING
SUBBASE
PLENUM
__ FLOOR __
OPENING
A96283
Fig. 11--Floor and Plenum Opening Dimensions
A96285
Fig. 12--Furnace, Plenum, and Subbase InstNted on
a Combustible Floor
FURNACE
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
_ COMBUSTIBLE "_X
FLOORING "_
SHEET METAL _
PLENUM
__ FLOOR __
OPENING
A04140
___> Fig. 13--Furnace, Plenum, and Coil AssemNy or Coil Box Installed on a Combustible Floor
Downflow Furnaces
Connect supply-air duct to supply-air outlet on _iu_ace. Bend
flange inward past 90 ° with wide duct pliers_ (See Fig. 14.) The
supply=air duct must be connected to ONLY the fi/rnace supply=
outlet or air conditioning coil casing (when used). When installed
on combustible material, supply-air duct must be connected to
ONLY the accessory subbase, KGASB0201ALL, or _Sctory ap=
proved air conditioning coil casing. DO NOT cut main furnace
casing to attach supply side air duct, humidifier, or other accesso-
ries. All accessories MUST be connected external to furnace
casing.
13

UPFLOW
\
120\
MIN
DOWNFLOW HORIZONTAL
_'_ r
PREFERRED i PREFERRED
I
PREFERRED 20 i PREFERRED 120\
PREFERRED
PREFERRED
PERMITTED PERMITTED PERMITTED
Fig. 14--Duct FJanges
114"THREADED ROD
4 REQ
I
I
I
I
I
J
A02329
ASSEMBLY
L_,
%
8" MIN FOR DOOR
REMOVAL
¢
SECURE ANGLE
IRON TO BOTTOM
OF FURNACE WITH
3 #8 x 3/2'SCREWS
TYPICAL FOR 2 SUPPORTS
1" SQUARE, 1W' x 1 W' x %" ANGLE IRON
OR UNI-STRUT MAY BE USED
(2) HEX NUTS, (2)WASHERS & (2) LOCK WASHERS
REQ PER ROD
A05027
=e Fig. 18--Horizontal Unit Suspension
Return Air Connections
FIRE HAZARD
Failure to %l!ow this warning could cause a fire, personal
injury, or death
Never connect return-air ducts to the back of the furnace
Follow instl-t/ctions below.
DownJ:'low Furnaces
The return=air duct must be connected to return-air opening
(bottom inlet) as shown in Fig. 19. DO NOT cut into casing sides
(left or right). Side opening is pem_itted for only upflow and most
horizontal Parnaces. Bypass humidifier connections should be
made at ductwork or coil casing sides exterior to furnace
Upflow and Horizontal Furnaces
The return-air duct must be connected to bottom, sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig lg and 20. Bypass humidifier may be
attached to unused side return air side of the [:urnace casing (See
Fig 18 and 20.)
Not all horizontal fm'naces are approved for side return air
connections. (See Fig 20.)
14

22 GAUGE GALVANIZED
/Fs; 4PsS R\AL
OUTER DOOR
ASSEMB_ X
F
Illl
Illl
1Ill
Illl
x 314
SHEET METAL SCREWS
TYPICAL FOR ALL
STRAPS
BACK OF
FURNACE
FOLD ALL STRAPS
UNDER FURNACE AND
SECURE W(2) #8 x 3/4
SHEET METAL SCREWS
Fig. 16--HorizontN Suspension with Straps
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OF THE FURNACE
JACKET AND BUILDING JOISTS,
STUDS, OR FRAMING.
30-tN. MIN
17 3/4" OVER ALL
4 3/4" UNDER DOOR
1" UNDER FURNACE
EXTEND OUT t2" OUT
FROM FACE OF DOOR
*WHEN USED WITH
SINGLE WALL VENT
CONNECTIONS
A02014
GAS VALVE
SEDIMENT
TRAP
Fig. 17--Typical Attic Installation
A02164
GAS PIPING
U
_ _ _ _ _ iiii_
iiii
FIRE OR EXPLOSION HAZARD
Failure to L'ollow this warning could result in personal injury,
death and/or property damage,
Never purge a gas line into a combustion chamber Never test
for gas leaks with an open flame Use a commercially
available soap solution made specifically for the detection of
leaks to check all connections.
--+ FIRE OR EXPLOSION HAZARD
Failure to %llow this warning coud result in personal inju W,
death, and/or property damage,
tse proper length of pipe to avoid stress on gas contloi
manifbld and a gas leak,
Gas piping must be installed in accordance with national and tocal
codes. Refer to current edition of NFG( in the US, the NSCNG-
PIC in Canada,
15

-4_ Table 5--Air Delivery - CFM (With Filter)*
FURNACE
SIZE
024045
038049
024070
038070
048070
042090
048090
080090
038110
048110
099110
RETURN-AIR
INLET
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
or
Bide(s)
Bottom
or
Side(s)
Bottom
or
Side(s)
Bottom
or
Bide(s)
Bottom
or
Side(s)
Bottom
Only
Both Sides or
1 Side & Bottom
1 Side Only
Bottom
or
Bide(s)
Bottom
or
Side(s)
Bottom
Only
Bottom Sides or
1 Side & Bottom
1 Side Only
EXTERNAL STATIC PRESSURE (_N. WC)
SPEED 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
High 1085 1035 975 915 845 770 675 565 390 195
Med-High 920 875 830 770 710 640 555 440 250 --
Med-Low 820 775 730 680 620 555 470 360 190 --
High 1440 1375 1305 1240 1160 1070 975 870 730 560
Med-High 1360 1300 1240 1175 1115 1040 950 850 725 575
Med-Low 1250 1210 1160 1100 1040 965 885 790 670 520
High 1030 1010 980 945 900 845 775 680 490 335
Med-High 835 815 790 760 720 675 610 490 375 265
Med_Low 725 700 675 645 600 555 475 390 300 --
High 1425 1375 1320 1265 1200 1125 1035 940 830 655
Med-High 1320 1280 1240 1205 1140 1075 995 905 790 620
Med-Low 1200 1175 1145 1105 1050 990 920 840 725 555
High 1805 1740 1670 1600 1530 1445 1360 1280 1180 1075
Med-High 1630 1585 1530 1470 1405 1330 1255 1170 1080 990
Med-Low 1460 1420 1385 1325 1280 1220 1155 1080 995 910
High 1650 1600 1535 1465 1385 1285 1175 1055 895 645
Med-High 1515 1485 1440 1380 1300 1220 1115 990 830 600
Med-Low 1385 1360 1320 1260 1195 1120 1025 915 710 565
High 2060 1985 1915 1820 1720 1610 1490 1340 1135 925
Med-High 1790 1765 1715 1645 1560 1470 1345 1195 1010 820
Med-Low 1505 1505 1480 1440 1375 1300 1190 1045 890 740
High 2405 2310 2220 2130 2025 1920 1790 1660 1530 1350
Med-High 2225 2155 2080 1995 1895 1785 1675 1565 1420 1260
Med-Low 2020 1955 1880 1805 1730 1630 1535 1420 1275 1135
High 2530 2450 2365 2270 2165 2065 1940 1805 1670 1505
Med-High 2285 2215 2150 2075 1985 1890 1780 1660 1525 1360
Med-Low 1995 1945 1900 1840 1770 1685 1600 1480 1350 1180
High 2475 2395 2300 2200 2090 1985 1865 1730 1585 1425
Med-High 2260 2190 2110 2035 1940 1845 1735 1620 1475 1325
Med-Low 1950 1910 1855 1795 1730 1650 1555 1445 1310 1150
High 1625 1575 1515 1445 1355 1260 1165 990 785 --
Med_High 1510 1470 1415 1355 1285 1185 1070 890 725 --
Med-Low 1360 1335 1295 1250 1180 1100 985 810 ....
High 2035 1965 1880 1790 1680 1495 1365 1215 1075 875
Med-High 1745 1710 1650 1560 1450 1340 1205 1090 955 750
Med-Low 1530 1515 1470 1400 1310 1215 1095 990 830 670
High 2530 2470 2400 2320 2220 2115 2000 1865 1730 1590
Med-High 2230 2205 2165 2110 2035 1950 1855 1740 1615 1485
Med-Low 1920 1900 1880 1845 1795 1730 1650 1555 1460 1340
High .... 2415 2350 2250 2145 2015 1875 1715 1560
Med-High 2235 2200 2155 2100 2040 1955 1850 1740 1595 1470
Med-Low 1920 1900 1880 1845 1795 1730 1650 1555 1460 1340
High 2540 2495 2430 2355 2265 2175 2065 1935 1785 1650
Med-High 2125 2120 2105 2060 2010 1940 1840 1730 1615 1485
Med-Low 1795 1790 1765 1720 1650 1585 1500 1390 1280
*A filter is required for each return-air inlet Airflow performance included 1-in. washable filter media such as contained in factory-authorized accessory fi{ter rack. To
determine airflow pedormance without this filter, assume an additional 0 1 in. wc available external static pressure
-- Indicates unstable operating conditions
16

-+ Table5--Air Delivery - CFM (With Filter)* (Continued)
FURNACE
SIZE
048185
868135
080155
RETURNoA_R
INLET
Bottom
or
Side(s)
Bottom
Onty
Bottom, Sides or
1 Side & Bottom
1 Side Only
Bottom
Onty
Both Sides Or
1 Side & Bottom
1 Side Only
SPEED EXTERNAL STATIC PRESSURE (IN. WC)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
High 2090 2010 1930 1835 1710 1590 1470 1335 1025 835
Med-High 1790 1755 1705 1640 1550 1465 1360 1210 945 785
Med-Low 1545 1525 1500 1450 1380 1315 1215 1005 855 670
High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355
Med-High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255
Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160
High .... 2385 2305 2195 2085 1960 1825 1670 1465
Med-High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325
Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160
High .... 2245 2155 2055 1940 1825 1695 1555 1385
Med-High 2135 2085 2035 1975 1895 1795 1685 1565 1445 1265
Med-Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160
High 2465 2430 2375 2305 2230 2110 2000 1865 1725 1545
Med-High 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425
Med-Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225
High .... 2375 2285 2200 2105 1995 1870 1730 1570
Med-High 2155 2135 2095 2040 1975 1895 1790 1685 1550 1400
Med-Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225
High .... 2260 2180 2085 1975 1865 1740 1605 1455
Med-High 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325
Med-Low 1800 1790 1770 1735 1695 1640 1570 1465 1345 1225
*A filter is required for each return-air inlet Airflow performance included lqn washable filter media such as contained in factory-authorized accessory filter rack To
determine airflow performance without this fi{ter, assume an additional 01 in wc available external static pressure.
Indicates unstable operating conditions.
Installations must be made in accordance with all authorities
having jurisdiction. If possible, the gas supply line should be a
separate line running directly fi'om meter to f_/ruace.
--> NOTE: In the state of Massachusetts:
1. Gas supply connections MUST be per_brmed by a licensed
plumber or gas fitter
2. When flexible connectors are used, the maximum length
shall not exceed 36 inches (915 ram).
3. When lever handle type manual equipment shutoffvalves are
used, they shall be T-handle valves.
4. The use of copper robing _br gas piping is NOT approved by
the state of Massachusetts.
Re_r to Table 6 for recommended gas pipe sizing Risers must be
used to connect to fiu'nace and to meter. Support all gas piping
with appropriate straps, hangers, etc. Use a minimum of 1 hanger
every 6 J:'t.Joint compound (pipe dope) should be applied sparingly
and only to male threads of joints. Pipe dope must be resistant to
the action of propane gas.
--€
--€
FIRE OR EXPLOSION HAZARD
Failure to %llow this warning could result in death, personal
injury an_or property damage.
If local codes allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a
connector which has previously served another gas appliance
Black iron pipe shall be installed at the furnace gas control
valve and extend a minimum of 2-in outside the f_/rnace.
FURNACE OVERHEAT HAZARD
Failure to _bllow this caution may result in property damage.
( onnect gas pipe to gas valve using a backup wrench to avoid
damaging gas controls.
An accessible manual equipment shutoff valve MUST be installed
external to fi_mace casing and within 6 ft of _i/rnace. A 1/8-in. NPT
plugged tapping, accessible _br test gauge connection, MUST be
installed immediately upstleam of gas supply connection to
furnace and downstream of manual equipment shutoff valve.
NOTE: The gas valve inlet pressuie tap connection is suitable to
use as test gauge connection providing test pressure DOES NOT
exceed maximum 0.5 psig (14-in. we) stated on gas control valve.
(See Fig. 46.)
Some installations require gas entry on right side of ft_rnace (as
viewed in upflow). (See Fig. 21a.)
Install a sediment trap in riser leading to fitmace as shown in Fig
2 lb. ( onnect a capped nipple into lower end of tee. ( upped nipple
should extend below level of furnace gas controls. Place a ground
joint union between furnace gas control valve and exterior manual
equipment gas shutoff valve. A 1/8-in. NPT plugged tapping,
accessible fbr test gauge connection. MUST be installed immedi-
ately upstream of gas supply connection to _i/ruace and down-
sheam of manual equipment shutoff valve.
Piping should be pressure and leak tested in accordance with
NFG( in the United States or NSCNGPIC in Canada, local, and
national plumbing and gas codes before the Nmace has been
connected. After all connections have been made. purge lines and
check for leakage at fi/ruace prior to operating ft_mace.
--> If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be
disconnected fi'om Nmace and capped before and during supply
pipe pressure test. If test pressure is equal to or less than 0.5 psig
(14-in. wc), turn off electric shutoff switch located on Nruace gas
conhol valve and accessible manual equipment shutoff valve
before and during supply pipe pressure test. After all connections
have been made, purge lines and check for leakage at furnace prior
to operating [:tm_ace.
The gas supply pressure shall be within the maximum and
mininmm inlet supply pressures marked on the rating plate with
the _./ruace burners ON and OFF.
17

R_TU_N
AIR
i UPFLOW RETURN AR CONFiGURATiONS AND RESTRiCTiONS
$
AiR FLOW MODELS RETURN AiR RETURN AiR RETURN AiR
CONNECTION 1 CONNECTION 2 CONNECTION 3
ONLY ONLY ONLY
066.060, _22 AND YES YES YES
-20 MODELS
ALL OTHER MODELS YES YES YES
i _ETU_N
Ak_
i//.
AIn F_ETU_NA_
Fig. 18--Upflow Return Air Configurations and Restrictions
RETURN AiR
COMBIN/_I]ONS
OF 1,2, AND 3
YES
YES
A02075
EX:Tv_/NFLOWRE-TURNAmRCONFmGURATONSANDRESTR_CT_NS
AiR FLOW MODELS RETURN AiR RETURN AiR RETURN AiR RETURN AiR
CONNECTION 1 CONNECTION 2 CONNECTUON 3 COMBUN,_]]ONS
ONLY ONLY ONLY OF 1, 2, AND 3
066.060, -22 AND YES NO NO NO
-20 MODELS
ALL OTHER MODELS YES NO NO NO
Fig. 19--Downflow Return Air Configurations and Restrictions
®_ErURN
A02163
" suPP_
. i !J
"_ S_DERETURNA_R /
O66O6O-22-20 i ' i
'HORIZONA L
RETURN R URNA[R
HORIZONAL•NOTE RESTRICTIONE?_ SAME FOR _ A_R RESTR_CTIONS
@ | HORIZONTAL RETURN A_RCONFIGURATIONS AND RESTRICTIONS
AiR FLOW MODELS RETURN AiR RETURN AiR RETURN AiR RETURN AiR
CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBiNATiONS
ONLY ONLY ONLY OF 1,2, AND 3
066.060, -22 AND YES NO NO NO
-20 MODELS
ALL OTHER MODELS YES YES YES YES
Fig. 20--Horizonta{ Return Air Configurations and Restrictions
lg
A02162

-+ Table 6--Ma×imum Capacity of Pipe*
NOMINAL
IRON
PIPE
SIZE
(BN.)
1/2
3/4
1
1-1/4
1-tt2
iNTERNAL
DIAMETER
(N.)
0.622
0.824
1.049
1.380
1.610
LENGTH OF PRPE (FT}
10 20 30 40 50
175 120 97 82 73
360 250 200 170 151
680 465 375 320 285
1400 950 770 660 580
2100 1460 1180 990 900
* Cubic ft of natural gas per hr for gas pressures of 0.5 psig (14-in. wc) or less
and a pressure drop of 0.5-in wc (based on a 0.60 specific gravity gas)
Ref: TaMe 122 ANSI Z223-2002/NFPA 54-2002
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in serious inju U,
death, or property damage.
The cabinet MUST have an uninterrupted or unbroken ground
according to NEC ANSI NFPA 70-2002 and Canadian Elec=
tdcal (7ode CSA (22.1 or local codes to minimize personal
injury if an electrical _Sult should occur. This may consist of
electrical wire, conduit approved for electrical ground or a
listed, grounded power cord (where permitted by local code)
when installed in accordance with existing electrical codes.
Refer to the power cord manufacturer's ratings for proper
wire gauge. Do not use gas piping as an electrical ground.
TOP VEW OF BURNER AND MANIFOLD ASSEMBLY
2" Nipple
90° Elbow
Close NippBe L Gas Valve
-e Fig. 21a--Right Side Gas Entry Example
GAS
SUPPLY j'_
MANUAL =J II
SHUTOFF £ _
VALVE :D _=
(REQUIRED/#',
SEDIMENT --
TRAP /
UNION -_
Supply
A02327
A02035
Fig. 21b--Typical Gas Pipe Arrangement
ELECTRICAL CONNECTIONS
ELECTRICAL SHOCK HAZARD
Failure to %llow this warning could result in serious personal
in.ju_ or death.
Blower access panel door switch opens l15=v power to
control No component operation can occur. Do not bypass or
close switch with panel removed.
See Fig 25 %r field wiring diagram showing typical field 115-v
wiring. Check all factoQ' and field electrical connections for
tighmess,
Field=snpplied wiring shall con£_m_ with the limitations of 63°F
(33°C) rise
---> F[ RNACE MAY NOT OPERATE
Failure to _bllow this caution may result in £u'nace operation
stopping and water pipes fi'eezing during cold weather
Furnace control must be grounded _br proper operation or
control will lock out (ontrol is grounded through
green@ellow wire routed to gas valve and manifbld bracket
SCrew,
15-V Wiring
Verif}_" tl_at the voltage, frequency, and phase correspond to that
specified on unit rating plate. Also, check to be sure that service
provided by udlity is sufficient to handle toad imposed by this
equipment. Refer to rating plate or Table 7 _br equipment electrical
specifications.
[.S. installations: Make all electrical connections in accordance
with National Electrical (?ode (NEC) ANSI NFPA 70-2002 and
any local codes or ordinances that might apply.
Canadian installations: Make all electrical connections in accor-
dance with Canadian Electrical (?ode CSA C22.1 or authorities
having jurisdiction.
---> FIRE HAZARD
Failure to %llow this warning could result in serious inju V,
death, or property damage.
Do not connect aluminum wire between disconnect switch
and Nmace. Use only copper wire.
Use a separate, Nsed branch electrical circuit with a properly sized
Nse or circuit breaker for this Nmace. See Table 7 tbr wire size
and Nse specifications. A readily accessible means of electrical
disconnect must be located within sight of the furnace.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, contIol LED status indicator light will flash
rapidly and Nmace will NOT operate.
J=BOX RELOCATION
NOTE: If factory location of J-Box is acceptable, go to next
section (Electrical Connection to J=Box).
NOTE: On 14" wide casing models, the J=Box shall not be
relocated to other side of £umace casing when tiae vent pipe is
routed within the casing.
1. Remove and save two screws holding J-box. (See Fig. 22.)
---> NOTI=: The J=Box cover need not be removed L'rom the J=Box in
order to move the J=Box. Do NOT remove green ground screw
inside J=Box. The ground screw is not threaded into the casing
flange and can be lifted out of the clearance hole in casing while
swinging the t?ont edge of the J-Box outboard of the casing.
19