Philco KG6T(C,L) Installation guide

Installation Instructions

These instructions are primarily intended

to assist qualified individuals experienced

in the proper installation of this appliance.

Some local codes require licensed installa-

tion/service personnel for this type of equip-

ment. Read all instructions carefully before

starting the installation.

DO NOT DESTROY. PLEASE READ CARE-

FULLY AND KEEP IN A SAFE PLACE FOR

FUTURE REFERENCE.

*TC 92+ Upflow/Horizontal *TL 90+ Downflow

*TC Series 92+ Upflow/Horizontal Two-Stage Condensing Furnace

*TL Series 90+ Downflow Two-Stage Condensing Furnace

Gas Fired Central Furnaces

WARNING:

Improper installation, adjustment, al-

teration, service, or maintenance can

cause injury or property damage. Re-

fer to this manual for assistance. For

additional information consult a quali-

fied installer, service agency, or the

gas supplier.

FOR YOUR SAFETY:

Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance.

FOR YOUR SAFETY:

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• Immediately call your gas supplier

from a neighbor's phone. Follow the

gas supplier's instructions.

• If you cannot reach your gas supplier,

call the fire department.

• Extinguish any open flame.

Table of Contents

Furnace Specifications ..................................................................................................................................... 4

Furnace Airflow Data ................................................................................................................................. 6

Safety Information ............................................................................................................................................. 7

Clearances to Combustible Materials .............................................................................................................. 7

Installation Requirements ................................................................................................................................. 7

Location .................................................................................................................................................... 8

Downflow Model Warning .................................................................................................................................. 8

Horizontal Installations ..................................................................................................................................... 8

Conversion of the *TC Upflow Furnace for a Horizontal Right Installation ................................................ 8

Conversion of the *TC Upflow Furnace for a Horizontal Left Installation .................................................. 9

Supply Air Plenum Installation ........................................................................................................................10

Installation on a Concrete Slab ................................................................................................................ 10

Installation on a Combustible Floor .......................................................................................................... 10

Circulating Air Supply ..................................................................................................................................... 10

Return Air ................................................................................................................................................. 11

Configuring the Blower .................................................................................................................................... 13

Determining Nominal AC System Capacity ............................................................................................... 13

Selecting the AC Cooling Airflow .............................................................................................................. 13

Selecting the Heating Airflow ................................................................................................................... 13

Venting and Combustion Air Requirements .................................................................................................... 13

Air Requirements for One-Pipe Installation .............................................................................................. 14

Installation in An Unconfined Space ........................................................................................................ 14

Installation in A Confined Space .............................................................................................................. 14

• Air From Inside ....................................................................................................................................... 15

• Air Directly Through An Exterior Wall ..................................................................................................... 15

• Outdoor Air Through Vertical Openings or Ducts ................................................................................... 15

• Outdoor Air Through Horizontal Openings or Ducts ............................................................................... 15

Venting Requirements ......................................................................................................................................16

Vent Pipe Material ....................................................................................................................................20

Vent Pipe Length and Diameter ................................................................................................................ 20

Vent Pipe Installation ............................................................................................................................... 21

Pipe Routing & Support ............................................................................................................................ 21

Location of Outdoor Terminations ............................................................................................................ 22

Horizontal Venting .................................................................................................................................... 22

Vertical Venting ........................................................................................................................................ 24

Vent Freezing Protection .......................................................................................................................... 24

Concentric Vent Termination .................................................................................................................... 24

Drainage of Condensate From Furnace ........................................................................................................... 25

Gas Supply and Piping ..................................................................................................................................... 25

Leak Check .............................................................................................................................................. 2 7

Manifold Pressure Adjustment ................................................................................................................. 27

Conversion ............................................................................................................................................... 28

High Altitude Conversion ................................................................................................................................. 28

High Altitude Application .......................................................................................................................... 28

Pressure Switch Conversion for High Altitude Applications ..................................................................... 28

Natural Gas High Altitude Conversion ...................................................................................................... 28

LP/Propane Gas Sea Level and High Altitude Conversion ....................................................................... 29

Electrical Wiring .............................................................................................................................................. 29

Line Voltage Wiring .................................................................................................................................. 32

Low Voltage Wiring ................................................................................................................................... 32

Start-up and Adjustments ................................................................................................................................33

Start-Up Procedure .................................................................................................................................. 34

Verifying and Adjusting Firing Rate .......................................................................................................... 3 4

Configuring the Blower ............................................................................................................................. 3 5

Selecting Heat Airflow .............................................................................................................................. 35

Selecting the Cooling/Heat Pump Airflow ................................................................................................. 35

Selecting the Delay Profile ....................................................................................................................... 35

Optional Humidistat .................................................................................................................................. 3 7

Verifying and Adjusting Temperature Rise ............................................................................................... 38

Verifying Burner Operation ....................................................................................................................... 38

Verifying Operation of the Supply Air Limit Switch ................................................................................... 38

Description of Components .............................................................................................................................. 40

Maintenance ...................................................................................................................................................... 40

Location of Major Components ................................................................................................................. 39

Combustion Air and Vent System ............................................................................................................ 40

Air Filter(s) ............................................................................................................................................... 40

Lubrication ............................................................................................................................................... 41

Condensate Drain Assembly .................................................................................................................... 41

Blower Compartment ................................................................................................................................41

Heat Exchanger and Burner Maintenance ................................................................................................ 41

System Operation Information ........................................................................................................................ 41

Sequence of Operation ............................................................................................................................ 41

Furnace Fails to Operate .......................................................................................................................... 42

Installation/Performance Checklist ................................................................................................................. 43

FURNACE SPECIFICATIONS

7/8" Dia. Electric

Connection

2 1/4"

23 1/4"

19 3/4"

3/4"

43"

25 1/8"

25 1/4"

23"

28"

15"

25 1/4"

33"

Return Air Opening

(Bottom)

Side Return

Bottom Return Opening

Condensate Drain Outlets

‡

Combustion Air

Vent 3"

(See Fig. 15

for sizes)

1 1/2" x 3 1/2" Dia.

Opening for

Gas Connection

3/4"

22 1/2"

Exhaust Vent

Combustion Air

Inlet

1 1/2" x 3 1/2" Dia.

Opening for

Gas Connection

‡

2" PVC

Exhaust

Vent

(See Fig. 15

for sizes)

25 5/8"

20 1/2"

23"

7/8" Dia. Electric

Connection

30 1/4"

1 1/4"

‡

27 5/8"

Upflow/Horizontal Furnace Models

Figure 1. Upflow/Horizontal Unit Dimensions

‡

See Table 2

7/8" Dia. Electric

Connection

1 1/2" x 3 1/2" Dia.

Opening for

Gas Connection

27 7/8"

24 1/2"

22 1/2"

3/4"

43"

Exhaust Vent

2" Dia.

1 1/2" x 2 1/2"

Knockout For

Gas Connection

21 7/8"

15 1/2"

21 1/2"

21 7/8"

3/4"

Bottom Supply

Air Opening

24 7/8"

Combustion Air Inlet

Exhaust Vent

21 1/4"

Condensate

Drain Outlet

Condensate

Drain Outlet

7/8" Dia. Electric

Connection

21 1/2"

24 7/8"

10 1/4"

2 1/2"

Combustion

Vent

(3" for 80/100

2" for 40/60)

19 3/4"

3/4"

Bottom Opening

19 3/4"

‡

Downflow Furnace Models

Figure 2. Downflow Unit Dimensions

‡

See Table 2

Table 2. Furnace Dimensions and Shipping Weights

Table 1c. Heating Airflow Settings

CAPACITIES —Furnace Airflow Data

Notes:

1. Recommended temperature rises are highlighted in bold.

2. Airflow rates of 1800 CFM or more require two return air connections. Data is for operation with filter(s).

3. Temperature rises in the table are approximate. Actual temperature rises may vary.

4. Temperature rises that are shaded grey are for reference only. These conditions are not recommended.

5. For single stage cooling, the indoor blower will operate at the CFM listed in the high column.

Table 1a. *TC/L 060 (1/2 HP)

Cooling/Heat Pump Airflow Settings

# Switch not used - Can be 0 or 1.

Note: O = Off 1 = On

Table 1b. *TC/L 080/100/120 (3/4 HP)

Cooling/Heat Pump Airflow Settings

Note: O = Off 1 = On

60,000 42,000 14 1/2 12 3/4 5 1/8 11 3/4 155

*TC080 80,000 56,000 19 3/4 18 1/4 7 7/8 17 1/4 195

100,000 70,000 19 3/4 18 1/4 7 7/8 17 1/4 200

120,000 84,000 22 1/2 21 9 1/4 20 220

60,000 42,000 14 1/2 12 3/4 4 5/8 12 3/4 155

*TL080 80,000 56,000 19 3/4 18 1/4 7 7/8 18 1/4 195

100,000 70,000 19 3/4 18 1/4 7 7/8 18 1/4 200

120,000 84,000 22 1/2 21 12 1/2 21 1/4 220

Dimensions (inches)

High Fire

Furnace

Btuh C D

Shipping

Weight

(lbs)

Model

Number

Low Fire

Furnace

*TC100

*TL100

*TC060

*TC120

*TL120

*TL060

567

600 60 700 75

660 72 1090 63 660 90 1090 80 660 108 1090 96

660 54 800 65

750 64 1240 57 750 80 1240 70 750 95 1240 84

800

1048

1220

1680

1220

1680

1220 59 1680 62

900 40 1296 40

1300 37 1880 37 1300 46 1880 46 1300

1880

Nominal Airflow (CFM) and Temperature Rises (degree F)

*T(C,L)-080(CN)-VB *T(C,L)-100 (CN)-VB *T(C,L)-120(CN)-VC

Models

*T(C,L)-060(CN)-VA

Models Models Models

Switches

High Fire

Input

60,000

Low Fire

Input

43,000

Low Fire

Input

56,000

Low Fire

Input

70,000

Low Fire

Input

84,000

High Fire

Input

80,000

High Fire

Input

100,000

High Fire

Input

120,000

Switch Number Nominal A/C and H/P

LOW HIGH 1 2 3 4

56789 Capacity

500 720

0001

550 800

0000

610 880

0010

650 990

1001

720 1100

1000

800 1210

1010

900 1305

0101

1000 1450

0100

1060 1530

1101

1100 1595

0110

1170 1700

1100

1290 1870

1110

CFM

5 TON

4 TON

3.5 TON

3 TON

2.5 TON

2 TON

Switch Number Nominal A/ C and H/P

LOW HIGH 1 2 3 4

56789

Capacity

300 400

0001

330 480

0000

390 550

0010

420 600

1001

500 720

1000

550 800

1010

580 830

0101

640 930

0100

700 1010

1101

730 1070

0110

780 1140

1100

850 1230

1110

CFM

3 TON

2.5 TON

2 TON

1.5 TON

1 TON

CLEARANCES TO COMBUSTIBLE MATERIALS

This furnace is Designed Certified by CSA International for the minimum clearances to combustible

material listed in Table 4. See the furnace name plate, located inside the furnace cabinet, for specific

model number and clearance information.

SAFETY INFORMATION

1. Use only with type of gas approved for this

furnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and

position as specified on Table 3 of these

instructions.

3. Provide adequate combustion and ventila-

tion air to the furnace space as specified on

Pages 10 through 13.

4. Provisions for adequate clearances around

the vent air intake terminal(s) as specified

on Figures 19a through 22 of these instruc-

tions.

5. Combustion products must be discharged

outdoors. Connect this furnace to an ap-

proved vent system only, as specified on

Pages 16 through 23.

6. Never test for gas leaks with an open flame.

Use a commercially available soap solution

made specifically for the detection of leaks

to check all connections, as specified on

Page 27 of these instructions.

7. Always install furnace to operate within the

furnace’s intended temperature-rise range

with a duct system which has an external

static pressure within the allowable range,

as specified on Table 1a of these instruc-

tions. See furnace rating plate.

8. When a furnace is installed so that supply

ducts carry air circulated by the furnace to

areas outside the space containing the

furnace, the return air shall also be handled

by duct(s) sealed to the furnace casing and

terminating outside the space containing

the furnace.

9. A gas-fired furnace for installation in a

residential garage must be installed as

specified on Page 8 of these instructions.

10. The furnace is not to be used for temporary

heating of buildings or structures under

construction.

INSTALLATION REQUIREMENTS

Requirements and Codes

This furnace must be installed in accordance

with these instructions, all applicable local building

codes, and the current revision of the National

Fuel Gas Code (ANSI-Z223.1, NFPA-54). The

current revision of the National Fuel Gas Code

is available from:

American National Standards Institute, Inc.

1430 Broadway

New York, New York 10018

Canada installations shall comply with CAN/

CGA-B149 installation codes, local plumbing or

waste water codes and other applicable codes.

Additional helpful publications are:

• NFPA-90A - Installation of Air Conditioning

and Ventilating Systems.

• NFPA-90B - Warm Air Heating and Air

Conditioning Systems.

These publications are available from:

National Fire Protection Association, Inc.

Batterymarch Park

Quincy, Massachusetts 02269

Table 3. Minimum Clearances to Combustible Materials

‡

24 inches is the minimum clearance for servicing.

36 inches is the recommended clearance for service.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIAL

High Fire Cabinet Minimum Clearances (Inches)

Rated Input Width

(Btuh) (Inches) Side Vent Back Top Front

60,000 14 1/4 0 0 0 1 1

‡

80,000 19 3/4 0 0 0 1 1

‡

92,000 19 3/4 0 0 0 1 1

‡

110,000 22 1/2 0 0 0 1

‡

WARNING:

This furnace is not approved for instal-

lation in mobile homes. Installation in

a mobile home could cause fire, prop-

erty damage, and/or personal injury.

Location

The furnace must be installed on a level surface,

and as close to the center of the air distribution

system as possible. See Table 3 for overall

dimensions to determine the required clear-

ances in hallways, doorways, stairs, etc. to allow

the furnace to be moved to the installation point.

The furnace must be installed so that all electri-

cal components are protected from water.

Minimum clearances to combustible materials

are listed in Table 4. Access for positioning and

servicing must be considered when locating the

unit. 24 inches is the minimum required clear-

ance for servicing the unit. 30 inches is the

minimum required clearance for positioning the

unit. 36 inches is the recommended clearance

from the front of the unit. Please note that a

panel or door can be located such that the

minimum clearance on the rating plate is satis-

fied, but that panel or door must be removable

so as to allow the appropriate clearance.

This furnace is certified for use on wood flooring.

The furnace must be installed on a solid surface

and must be level front to back and side to side.

This furnace must not be installed directly on

carpeting, tile, or any combustible material other

than wood flooring.

DOWNFLOW MODEL WARNING

The design of the downflow furnace is certified

for natural or propane gas and for installation on

non-combustible flooring. A special com-

bustible floor sub-base is required when install-

ing on a combustible floor. Failure to install the

sub-base may result in fire, property damage

and personal injury. The special downflow sub-

bases are factory supplied accessories, part

numbers 902974, 902677, 904108 and 904165.

904165 is an adjustable sub-base kit and it can

be used on all cabinet sizes. When the furnace

is installed on a factory or site-built cased air

conditioning coil, the sub-base is not neces-

sary. However, the plenum attached to the coil

casing must be installed such that its surfaces

are at least 1" from combustible construction.

A gas-fired furnace installed in a residential

garage must be installed so that the bottom of the

furnace is located a minimum of 18" from the

floor. The furnace must be located or protected

to avoid physical damage by vehicles.

HORIZONTAL INSTALLATIONS

The upflow model furnaces are approved for

horizontal installation. Installation Kit #903568 is

available for horizontal applications. The parts

may also be field supplied. The parts that are

field supplied should conform to Figures 3 and

4. NOTE: Downflow models are NOT approved

for horizontal installation.

CAUTION:

Damage to the product resulting from

failure to follow instructions or use of

unauthorized parts may void the

manufacturer's product warranty cov-

erage.

The 90+ upflow furnace can be installed hori-

zontally in an attic, basement, crawl space or

alcove. This furnace can be installed horizon-

tally to the clearances listed in Table 2 on a

platform or on the ceiling rafters. Note that the

platform and the ceiling rafters must be able to

support the weight of the furnace being installed.

It can also be suspended from a ceiling in a

basement or utility room in either a right to left

airflow or left to right airflow.

When installed horizontally, the furnace must be

raised above the surface to allow a drain trap to

hang vertically below the furnace. This will allow

for proper drainage of the condensate from the

furnace.

Conversion of the *TC Upflow Furnace for

a Horizontal Right Installation.

Refer to Figure 3.

1. Remove the hard “J” tube drain trap

assembly.

2. Place the 5/8" cap plug over the drain trap

in the header box from which the “J” drain

trap assembly was removed.

3. Remove the piece of soft tubing running

from the in-line drain assembly to the

header box and place a ½” vinyl cap over

the drain tap in the in-line drain assembly.

4. Remove the gray tubing from the pres-

sure tap on the header box. Remove the

¼” cap from the pressure tap on the right

side of the header box and place it on the

corresponding pressure tap on the oppo-

site of the header box.

5. Place the gray tubing that was removed,

to the corresponding pressure tap on the

right side of the header box. ( Refer to

Figure 3)

6. If field supplied parts are used, discon-

nect both soft tubes from the hard “J” tube

drain trap after loosing 7/8" clamps.

Shorten long side of the “J” trap by 8-1/2".

7. Feed the 10" piece of soft tubing through

the round hole located in the right side of

the cabinet wrapper Note: A downward

slope must be maintained on the tube as

it is routed through the furnace (when the

furnace is in the horizontal position).

8. Assemble the 10" piece of soft tube to 5"

tall end of the hard (J) tube to the end of

the 10" soft tube located outside of the

furnace. Secure the connection using

one of the clamps that was removed, from

the “J” trap. Secure the connection with

the 7/8” hose clamp.

9. Reassemble the 30" piece of soft tubing

removed from the factory installed “J”

tube drain trap to the 2’ tall end of the

modified “J” tube drain trap.

Note: Ensure the clamps in step 7 and 8 are

securely tightened in order to avoid any con-

densate leakage.

Note: PVC “T” drain assembly must be in-

stalled so that condensate does not get into the

induced draft blower.( refer to Figure 3).

Figure 3. 90+ Upflow Converted for Horizontal Installation (Horizontal Right)

5/8" Vinyl Cap

1/4" Vinyl Cap

Drain Trap

1/2" Vinyl

Cap

Soft

Tubing

PVC Tee

Soft Tubing

Looped to Provide

a Drain Trap

3" to 2"

Reducer

(Optional)

PVC Reducer

Bushing

Pressure Switch

Grey

Tubing

Soft Tubing

1/4" Vinyl Cap

Grey

Tubing

Drain Trap

Soft

Tubing

PVC Tee

Soft Tubing

Looped to Provide

a Drain Trap

3" to 2"

Reducer

(Optional)

Drainage Port

is Downward

Reducer

Bushing

Alternative

for

Horizontal

Vent

Pressure

Switch

Pressure Switch

(Condensate)

Vinyl Cap

Figure 4. 90+ Upflow Converted for Horizontal Installation (Horizontal Left)

Note: To avoid condensate freezing in the

drain trap assembly and tubing, insulate around

the drain trap assembly and all tubing located

in unconditioned space.

Conversion of the *TC Upflow Furnace for

a Horizontal Left Installation.

Refer to Figure 4.

1. Remove the hard “J” tube drain trap as-

sembly.

2. If field supplied parts are used, discon-

nect both soft tubes from the hard “J” tube

drain trap after loosing 7/8" clamps.

Shorten long side of the “J” trap by 8-1/2".

3. Feed the 10" piece of soft tubing through

the round hole located in the left side of the

cabinet wrapper. Note: A downward slope

must be maintained on the tube as it is

routed through the furnace (when the

furnace is in the horizontal position).

4. Assemble the 5" tall end of the hard “J”

tube to the end of the 10" soft tube located

outside of the furnace. Secure the con-

nection using one of the 7/8" hose clamps

that were removed from the “J” trap.

5. Assemble the 30" piece of soft tubing that

was removed from the “J” trap o the 2" tall

end of the modified “J” drain trap. Secure

the connection with the 7/8" hose clamp.

NOTE: To avoid condensate freezing in the

drain trap assembly and tubing, insulate around

the drain trap assembly and all tubing located in

unconditioned space. See note in Figure 4.

NOTE: When converting

the furnace, to horizontal

left, ensure that the drain-

age port on the in-line

drain assembly is down-

ward as shown in this fig-

ure. If the in-line drain as-

sembly is not rotated, then

the furnace may not drain

properly.

Downflow

Wood

Sub-base

Floor

Furnace

Sheet

Metal

Plenum

Figure 7. Opening in Wood Floor

Figure 8. Furnace on a Wood Floor

SUPPLY AIR PLENUM

INSTALLATION FOR DOWNFLOW

MODELS

A. Installation on a concrete slab - downflow

models

1. Construct a hole in the floor per the

dimensions in Figure 5.

2. Place the plenum and the furnace as

shown in Figure 6.

B. Installation on a combustible floor - *TL

1. Cut hole and frame the hole per the

dimensions in Figure 7.

2. Place sub-base for combustible floors

over the hole with its duct collar extended

downward. Attach the supply air plenum

to the base in a manner which will assure

1” clearance to the flooring or other com-

bustible material. Place furnace on the

combustible base as shown in Figure 8.

3. When the furnace is installed on a factory

or site-built cased air conditioning coil,

the sub-base is not necessary. How-

ever, the plenum attached to the coil

casing must be installed such that its

surfaces are at least 1” from combustible

material in Figure 9.

CIRCULATING AIR SUPPLY

Plenums and air ducts must be installed in

accordance with the Standard for the Installa-

tion of Air Conditioning and Ventilating Systems

(NFPA No. 90A) or the Standard for the Instal-

lation of Warm Air Heating and Air Conditioning

Systems (NFPA No. 90B).

Concrete

Floor

Furnace

Sheet

Metal

Plenum

Figure 6. Downflow Furnace

on a Concrete Slab

Figure 5. Opening for Concrete Slab

Figure 9. Downflow Sub-Base Dimensions

1 inch thick fiberglass 3 lb density

28.38"

9.25"

19.63"

19.75"

or 14.25 or 22.50"*

2.0"

1.58"

1.50"

16.75"

or *19.50"

*Larger dimension

for TL110

18.75"

or 13.25 or 21.50

MODEL A B

*TL 060 13.25” 19.25”

*TL 080/100 18.75” 19.25”

*TL 120 21.50” 19.25”

MODEL A B

*TL 060 13.25” 19.63”

*TL 080/100 18.75” 19.63”

*TL 120 21.50” 19.63”

If outside air is utilized as return air to the furnace

for ventilation or to improve indoor air quality, the

system must be designed so that the return air

to the furnace is not less than 50°F (10°C) during

heating operation. If a combination of indoor and

outdoor air is used, the ducts and damper system

must be designed so that the return air supply to

the furnace is equal to the return air supply under

normal, indoor return air applications.

When a cooling system is installed which uses

the furnace blower to provide airflow over the

indoor coil, the coil must be installed down-

stream (on the outlet side) or in parallel with the

furnace.

If a cooling system is installed in parallel with the

furnace, a damper must be installed to prevent

chilled air from entering the furnace and con-

densing on the heat exchanger. If a manually

operated damper is installed, it must be de-

signed so that operation of the furnace is pre-

vented when the damper is in the cooling posi-

tion and operation of the cooling system is

prevented when the damper is in the heating

position.

Return Air

The return air ductwork may be connected to

any or all of the following: left side return, right

side return, or bottom return. Table 1 shows the

airflow data for each furnace model. Where

maximum airflow is 1800 CFM or more two

openings must be used.

Figure 10. Protective Screen for One

Pipe Installations

Protective Screen

Downflow Models

IMPORTANT:

The variable speed blower kit has been

designed to give the installer maxi-

mum flexibility to optimize system per-

formance, efficiency, and comfort.

Because there are so many ways to

configure the kit it is important to read

and follow these instructions carefully.

Upflow Models

WARNING:

Products of combustion must not be allowed to enter the return air ductwork or

the circulating air supply. Failure to prevent products of combustion from being

circulated into the living space can create potentially hazardous conditions

including carbon monoxide poisoning that could result in personal injury or death.

All return ductwork must be secured to the furnace with sheet metal screws. For

installations in confined spaces, all return ductwork must be adequately sealed

and joints must be taped. When return air is provided through the bottom of the

furnace, the joint between the furnace and the return air plenum must be sealed.

The floor or platform on which the furnace is mounted must provide sound physical

support of the furnace with no gaps, cracks, or sagging between the furnace and

the floor or platform.

Return air and circulating air ductwork must not be connected to any other heat

producing device such as a fireplace insert, stove, etc.

Each opening

to outside must

be at least

1 sq. in. per

4000 Btuh of

total input

rating.

12" Max

Total Input

Rating (Btuh)

40,000

60,000

80,000

100,000

120,000

140,000

160,000

Minimum

Free Area

(Each Opening)

10 sq. in.

15 sq. in.

20 sq. in.

25 sq. in.

30 sq. in.

35 sq. in.

40 sq. in.

Round Duct

Diameter

Furnace

Water Heater

Vent or

Chimney

12"

Max

Figure 12. Equipment in a Confined

Space with all Combustion Air drawn

from Outdoors through Exterior Wall

Water

Heater

Vent or

Chimney

Furnace

Ventilation Louvers For

Unheated Crawl Space

Inlet Air

Ventilation Louvers

(each end of attic)

NOTE: Air open-

ings shall each

have a free area

of not less than

one square inch

per 4,000 Btuh of

the total input rat-

ing of all equipment

in the enclosure.

Alternate

Air Inlet

Outlet

Air

Figure 14. Equipment in a Confined

Space with all Combustion Air drawn

from Outdoors through Ventilated Crawl

Space and Ventilated Attic

Air Duct must be

at least 1 sq. in.

per 4,000 Btuh of

total input rating.

Ducts must

extend above

attic insulation.

Air Duct must be

at least 1 sq. in.

per 4,000 Btuh of

total input rating.

Ventilation Louvers at each end of attic

Attic

Insulation

12" Max

Total Input

Rating (Btuh)

40,000

60,000

80,000

100,000

120,000

140,000

160

000

Minimum

Free Area

(Each Opening)

10 sq. in.

15 sq. in.

20 sq. in.

25 sq. in.

30 sq. in.

35 sq. in.

40 s

. in.

Round Duct

Diameter

Furnace

Water Heater

Vent or

Chimney

Figure 13. Equipment in a Confined

Space with all Combustion Air drawn

from Outdoors through Vertical Ducts –

from Ventilated Attic

Total Input

Rating (Btuh)

40,000

60,000

80,000

100,000

120,000

140,000

160,000

Round Duct

Diameter

12"

13"

14"

15"

Minimum

Free Area

(Each Opening)

100 sq. in.

120 sq. in.

140 sq. in.

160 sq. in.

Furnace

12" Max.

Water Heater

Vent or

Chimney

Each opening must

be at least 100 sq. in.

or 1 sq. in. per 1000

Btuh of total input

rating, whichever is

greater. See minimum

area per table.

Figure 11. Equipment in a Confined

Space with all Combustion Air drawn

from Inside

Figure 15. Equipment in a Confined Space

with all Combustion Air Drawn from the

Outside through Horizontal Ducts

Determining Nominal AC System

Capacity

In order to select the appropriate airflow for AC

operation the nominal system capacity must be

known. The nominal system capacity is

ALWAYS the nominal capacity of the outdoor

unit. In some cases the nominal system

capacity is not the same as the nominal capacity

of the indoor coil.

NOTE: In order to change the speed settings

for heating or cooling, power to the unit

must be disconnected before the new speed

will be effective.

Selecting the AC Cooling Airflow

The cooling airflow is selected by setting switches

1 through 4 on the motor control board located in

the blower control panel. Table 1 shows the

airflow values versus the airflow selector switch

settings, and the range of airflow settings

recommended for each nominal system capacity.

Selecting the Heating Airflow

The heating airflow is selected by setting

switches 5 and 6 on the motor control board

located in the blower control panel. Note that

switch 7 is not used for heating or cooling in

these furnaces. Therefore, switch 7 can be

either “on” or “off” without affecting the operation

of the furnace. Table 1 shows the airflow values

versus the airflow selector switch settings, and

the range of airflow settings recommended for

each heating capacity.

NOTE: The airflow values (CFM) listed in the

tables are not dependent on duct static pres-

sure. The motor automatically compensates for

changes in duct static pressure (within the limits

of the motor).

VENTING AND COMBUSTION AIR

REQUIREMENTS

These condensing furnaces may be installed

with outdoor combustion air piped directly to the

furnace, or without such special piping. Codes

refer to the former as "direct vent" or "two pipe"

installation. Installation with air taken from

around the furnace is sometimes referred to as

"one pipe" installation - i.e. only the vent (ex-

haust) pipe is provided.

Provisions must be made for adequate supply of

air for combustion and ventilation. For United

States installations, the adequacy of air provi-

sions can be determined by consulting the cur-

rent version of the National Fuel Gas Code (ANSI

Z223.1/NPFA-54). For Canadian installations,

requirements are specified in the National Stan-

dard of Canada (CAN/CGA B149.1 & .2). Consult

local codes for special requirements.

An important consideration in selecting one or

two pipe installation is the quality of the combus-

tion air. Indoor air is sometimes contaminated

with various household chemicals which can

cause severe corrosion in the furnace combus-

tion system.

NOTE: If the furnace is operated without ad-

equate air for combustion and ventilation, it may

not perform properly. Furnace components

may be strained by high temperature and could

fail prematurely.

Each openin

to out

side

st be at lea

1 sq. in. per 2000

Btuh of total input

ratin

12" Max

Total Input

Rating (Btu/hr)

40,000

60,000

80,000

100,000

120,000

140,000

160,000

Minimum

Free Area

(Each Opening)

20 sq. in.

30 sq. in.

40 sq. in.

50 sq. in.

60 sq. in.

70 sq. in.

80 sq. in.

Round Duct

Diameter

10"

Furnace

Air Duct

Water Heater

Vent or

Chimney

WARNING:

Furnace installation using methods

other than those described in the fol-

lowing sections must comply with the

National Fuel Gas Code and all appli-

cable local codes to provide sufficient

combustion air for the furnace.

Combustion Air Quality

The recommended source of combustion air is

to use the outdoor air supply. However, the use

of indoor air in most applications is acceptable

except as follows:

1. If the furnace is installed in a confined space

it is recommended that the necessary com-

bustion air come from the outdoors by way

of attic, crawl space, air duct, or direct

opening.

2. If outdoor combustion air is used, there

must be no exposure to the installations or

substances listed in Item 3 below.

3. The following types of installation may re-

quire Outdoor Air for combustion, due to

chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces installed in hobby or craft rooms

• Furnaces installed near chemical stor-

age areas

Exposure to the following substances in the

combustion air supply may also require

Outdoor Air for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemi-

cals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroet-

hylene)

• Printing inks, paint removers, varnishes,

etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dry-

ers

• Masonry acid washing materials

Air Requirements For One-Pipe

Installation

When air for combustion is to be taken from

around the furnace, a protective screen must be

installed over the combustion air intake opening.

This screen is provided with the furnace instal-

lation instructions and functions to prevent de-

bris from entering the combustion system. It

should be installed on the combustion air intake

collar or inlet PVC. If furnace location is such that

this opening might be unintentionally obstructed,

a 3" PVC elbow should be installed on the collar,

and the screen placed inside the inlet of the

elbow. See Figure 10.

Installation In An Unconfined Space

CAUTION:

"Tight" buildings (with weather strip-

ping and caulk to reduce infiltration),

may require special provisions for in-

troduction of outside air to ensure

satisfactory combustion and venting,

even though the furnace is located in

an unconfined space.

An unconfined space is an area including all

rooms not separated by doors with a volume

greater than 50 cubic feet per 1,000 Btuh of the

combined input rates of all appliances which draw

combustion air from that space. For example, a

space including a water heater rated at 45,000

Btuh and a furnace rated at 75,000 Btuh requires

a volume of 6,000 cubic feet [50 x (45 + 75) =

6,000] to be considered unconfined. If the space

has an 8 foot ceiling, the floor area of the space

must be 750 square feet (6,000 / 8 = 750). In

general, a furnace installed in an unconfined

space will not require outside air for combustion.

WARNING:

Furnaces installed with combustion air

drawn from a heated space which in-

cludes exhaust fans, fireplaces, or

other devices that may produce a nega-

tive pressure should be considered

confined space installations.

Installation In A Confined Space

A confined space is one which does not meet the

unconfined space volume requirements, and

typically involves installation in a small room. All

such installations must have specific provisions

for introduction of combustion and ventilation

air.

Codes require that two openings be pro-

vided for this - one with bottom edge within 12"

of the floor and one with top edge within 12" of

the ceiling.

The size and other criteria for these

openings must be per the following sections.

Combustion air openings must not be restricted

in any manner.

Furnaces installed in a confined space which

supply circulating air to areas outside of the

space must draw return air from outside the

space and must have return air ducts tightly

sealed to the furnace.

Air From Inside

Air for combustion and ventilation may be taken

from inside the building through an interior wall

if the building is not "tight" and if the total volume

of the furnace space and the space from which

air is drawn meets the volume requirements for

an unconfined space.

In such cases, the two

openings in the wall must each have free area of

at least one square inch per 1000 Btuh of

total

appliance input, but not less than 100 square

inches of free area. See Figure 11. For example,

if the combined input rate of all appliances is less

than or equal to 100,000 Btuh,

each

opening

must have a free area of at least 100 square

inches. If the combined input rate of all appli-

ances is 120,000 Btuh,

each

opening must have

a free area of at least 120 square inches.

Air Directly Through An Exterior Wall

If combustion air is provided directly through an

exterior wall, the two openings must

each

have

free area of at least one square inch per 4000

Btuh of

total

appliance input. (See Figure 12.)

Outdoor Air Through Vertical Openings or Ducts

If combustion air is provided through vertical

ducts or openings to attics or crawl spaces, the

two openings must each have free area of at

least one square inch per 4000 Btuh of total

appliance input. Ducts must have cross-sec-

tional areas at least as large as the free area of

their respective openings to the furnace space.

Attics or crawl spaces must communicate freely

with the outdoors if they are the source of air for

combustion and ventilation. (See Figures 13

and 14.)

Outdoor Air Through Horizontal

Openings or Ducts

If combustion air is taken from outdoors through

horizontal ducts, the openings must

each

have

free area of at least one square inch per 2000

Btuh of total appliance input. Ducts must have

cross-sectional area at least as large as the free

area of their respective openings to the furnace

space. (See Figure 15.)

**NOTES

1. Subtract 2.5 ft. for each additional 2" long radius elbow, 5 ft. for each additional 2" short radius elbow, 3.5’ for each

additional 3” long radius elbow, and 7’ for each additional 3” short radius elbow.

2. Two 45 degree elbows are equivalent to one 90 degree elbow.

3. Do not include termination elbows in calculation of vent length

4. This table is applicable for elevations from sea level to 2000 ft. For higher elevations decrease vent pipe lengths

by 8% per 1000 ft. of altitude.

5. Only the above pipe materials are approved for use with these condensing furnaces.

Table 4. Vent Table

APPLICATION SINGLE PIPE LENGTH (ft.) DIRECT VENT, DUAL PIPE LENGTH (ft.)

with 1 long radius elbow** with 1 long radius elbow on each pipe**

PVC,CPVC or ABS Outlet Outlet Inlet/Outlet Inlet/Outlet Inlet/Outlet

SCH. 40 Pipe Size 2" 3" 2" 2" 3" 2" 3" 3"

Models

*T(C,L) 65 200 40 40 40 40 110 110

060

Models

*T(C,L) 45 200 35 35 40 40 110 110

Models

*T(C,L) 40 200 25 25 40 40 110 110

100

Models

*T(C,L) 40 200 20 20 40 40 110 110

120

CAUTION:

Do not supply combustion air from an

attic space that is equipped with power

ventilation or any other device that

may produce a negative pressure.

VENTING REQUIREMENTS

This section specifies installation requirements

for vent and "2-pipe" combustion air piping. For

"one pipe" installations, install vent piping per

this section and provide air for combustion and

ventilation per the previous section. The capac-

ity table provided in this section applies to the

total of vent and combustion air piping for either

type of installation.

5/8"

Inlet

Exhaust

Combustion

Offset with

Exhaust Pipe

for Adequate

Dimensional

Clearance

PVC or

ABS Pipe

See Vent Table 4

Straps or Other Suitable

Supports at Minimum of 5 ft. Intervals

Upward Pitch - 1/4" per Foot

Outlet Exhaust Vent

First Support Placed

as Close to Furnace

Connection as Possible

Exhaust Vent

Wall

Seal/Caulk

around Pip

at Building

90˚ Elbow

12" Min.

Normal Snow Level

Straight Neoprene Coupling

with 2 Hose Clamps*

(Optional - Not Shown)

5/8"

Inlet

Exhaust

Combustion Air

Inlet

Offset with Exhaust

Pipe for Adequate

Dimensional

Clearance

PVC or

ABS Pipe

See Vent Table 4

Straps or Other Suitable

Supports at Minimum of 5 ft. Intervals

Upward Pitch - 1/4" per Foot

Outlet Exhaust Vent

First Support Placed

as Close to Furnace

Connection as Possible

Exhaust Vent

Wall

Seal/Caulk

around Pipe

at Building

90˚ Elbow

12" Min.

Normal Snow Level

Straight Neoprene

Coupling with

2 Hose Clamps*

Figure 16. Horizontal Venting

* These neoprene couplings are field-supplied and can be used if the installation requires breakable connections

in the piping. Note that a maximum of two couplings per pipe are allowed.

Upflow Furnaces

Downflow Furnaces

Combustion

Air Pipe

Exhaust

Vent

Cabinet

Support System on

Vertical Rise Below Joints

Support System with

first support as close

to furnace as Possible

Upward Pitch

1/4" per Foot

Furnace Front

Straight Neoprene

Rubber Couplings

with 2 Hose Clamps*

Combustion

Air Pipe

Exhaust

Vent

Cabinet

Support System on

Vertical Rise Below Joints

Support System with

first support as close

to furnace as Possible

Upward Pitch

1/4" per Foot

Furnace Front

Straight Neoprene

Couplings with

2 Hose Clamps*

(Optional - Not

Shown)

Combustion Air Inlet Pipe

3" PVC

Furnace Top

2" PVC

Exhaust Vent

Use 2" to 3" reducer

Combustion Air Inlet Pipe Collar

Diameter 3" for coupling

Furnace Top

2" PVC

Exhaust Vent

Use 2" to 3" reducer

Downflow Furnaces

Upflow Furnaces

Downflow Furnaces

Upflow Furnaces

Figure 18. Furnace Pipe Adaptions

Figure 17. Vertical Venting

* These couplings are field-supplied and can be used if the installation requires breakable connections in the piping.

Note that a maximum of two couplings per pipe are allowed.

Figure 19a. Vent Termination Clearances for Direct Vent Furnaces

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

In accordance with the current CSA B149.1

Natural Gas and Propane Installation Code

In accordance with the current ANSI Z223.1 / NFPA 54

National Fuel Gas Code

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and

serves both dwellings.

‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA B149.1, the following statement shall be included:

“Clearance in accordance with local installation codes, and the requirements of the gas supplier

and the manufacturer’s installation instructions.”

These condensing furnaces are classified as

"Category IV" appliances, which require special

venting materials and installation procedures.

Category IV appliances operate with positive

vent pressure and therefore require vent sys-

tems which are thoroughly sealed. They also

produce combustion condensate, which is

slightly acidic and can cause severe corrosion

of ordinary venting materials. Furnace opera-

tion can be adversely affected by restrictive

vent and combustion air piping. Therefore,

vent

and combustion air piping lengths must conform

completely to the requirements of Table 4.

The furnace must be vented to the outdoors. It

must not be vented in common with any other

Canadian Installations

US Installations

A =

Clearanc e above grade, veranda, porch,

deck, or balcony

12 inches (30 cm) 12 inches (30 cm)

B =

Clearanc e to window or door that may be

opened

6 inches (15 cm) for appliances

≤

10,000

Btuh (3 kW), 12 inches (30 cm) for

appliances > 10,000 Btuh (3 kW) and

≤

100,00 Btuh (30 k W), 36 inches (91 cm) for

appliances >100,00 Btuh (30 kW)

6 inches (15 cm) for appliances

≤

10,000

Btuh (3 kW), 9 inches (23 cm) for

appliances > 10,000 Btuh (3 kW) and

≤

50,000 Btuh (15 kW), 12 inches (30 cm) for

appliances > 50,000 Btuh (15 kW)

C =

Clearance to permanentl

clos ed windo

D =

Vertical clearance to ventilated soffit

located above the terminal within a

horiz ontal distance of 2 feet (61 cm) from

the center line of the terminal

E =

Clearanc e to unventilated soffit

F =

Clearance to outside corner

G =

Clearance to inside corner

H =

Clearanc e to each side of center line

extended above meter/re

ulator assembl

3 feet (91 cm) within a height 15 feet

abov e the meter/re

ulator assembl

I =

Clearance to service regulator vent outlet 3 feet (1.83 m)

J =

Clearanc e to nonmechanical air supply inlet

to building or the combustion air inlet to any

other applianc e

6 inches (15 cm) for appliances

≤

10,000

Btuh (3 kW), 12 inches (30 cm) for

appliances > 10,000 Btuh (3 kW) and

≤

100,00 Btuh (30 k W), 36 inches (91 cm) for

appliances >100,00 Btuh (30 kW)

6 inches (15 cm) for appliances

≤

10,000

Btuh (3 kW), 9 inches (23 cm) for

appliances > 10,000 Btuh (3 kW) and

≤

50,000 Btuh (15 kW), 12 inches (30 cm) for

appliances > 50,000 Btuh (15 kW)

K =

Clearance to a mechanical air supply inlet 6 feet (1.83 m) 3 feet (91 cm) above if within 10 feet (3 m)

horizontally

L =

Clearanc e above paved sidewalk or paved

driveway located on public property

7 feet (2.13 m) †

M =

Clearanc e under veranda, porch dec k, or

balcon

12 inches (30 cm) ‡

Figure 19b. Vent Termination Clearances for other than Direct Vent Furnaces

In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code

In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and

serves both dwellings.

‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA B149.1, one of the following statement shall be included:

“Clearance in accordance with local installation codes, and the requirements of the gas supplier

and the manufacturer’s installation instructions.”

appliance, even if that appliance is of the con-

densing type. Common venting can result in

severe corrosion of other appliances or their

venting and can allow combustion gases to

escape through such appliances or vents. Do

not vent the furnace to a fireplace chimney or

building chase.

WARNING:

FURNACE MUST NOT BE COMMON

VENTED WITH OTHER APPLIANCES.

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

Canadian Installations

US Installations

A =

Clearance above grade, veranda, porch,

deck, or balcony

12 inches (30 cm) 12 inches (30 cm)

B =

Clearance to window or door that may be

opened

6 inches (15 cm) for appliances

≤

10,000

Btuh (3 kW), 12 inches (30 cm) for

appliances > 10,000 Btuh (3 kW) and

≤

100,00 Btuh (30 kW), 36 inches (91 cm) for

appliances >100,00 Btuh (30 kW)

4 feet (1.2 m) below or to side of opening;

1 foot (300 mm) above opening

C =

Clearance to permanentl

closed window

D =

Vertical clearance to ventilated soffit

located above the terminal within a

horizontal distance of 2 feet (61 cm) from

the center line of the terminal

E =

Clearance to unventilated soffit

F =

Clearance to outside corner

G =

Clearance to inside corner

H =

Clearance to each side of center line

extended above meter/re

ulator assembl

3 feet (91 cm) within a height 15 feet

abov e the meter/re

ulator assembl

I =

Clearance to service re

ulator vent outlet 3 feet (1.83 m)

J =

Clearance to nonmechanical air supply inlet

to building or the combustion air inlet to any

other appliance

6 inches (15 cm) for appliances

≤

10,000

Btuh (3 kW), 12 inches (30 cm) for

appliances > 10,000 Btuh (3 kW) and

≤

100,00 Btuh (30 kW), 36 inches (91 cm) for

appliances >100,00 Btuh (30 kW)

4 feet (1.2 m) below or to side of opening;

1 foot (300 mm) above opening

K =

Clearance to a mechanical air supply inlet 6 feet (1.83 m) 3 feet (91 cm) abov e if within 10 feet (3 m)

horizontally

L =

Clearance above paved sidewalk or paved

driv eway located on public property

7 feet (2.13 m) † 7 feet (2.13 m)

M =

Clearance under veranda, porch deck, or

balcony

12 inches (30 cm) ‡

WARNING:

CARBON MONOXIDE POISONING

HAZARD

1. Seal any unused openings in the

venting system

2. Inspect the venting system for proper

size and horizontal pitch, as required

in the National Fuel Gas Code, ANSI

Z223.1 or the CAN/CGA B149 Instal-

lation Codes and these instructions.

Determine that there is no blockage

or restriction, leakage, corrosion and

other deficiencies which could cause

an unsafe condition.

3. So far as is practical, close all building

doors and windows and all doors

between the space in which the

appliance(s) connected to the

venting system are located and other

spaces of the building.

4. Follow the lighting instructions. Place

the appliance being inspected in

operation. Adjust thermostat so

appliance shall operate

continuously.

5. Turn on clothes dryers and any other

appliance not connected to the

venting system. Turn on any exhaust

fans, such as range hoods and

bathroom exhausts, so they shall

operate at maximum speed. Do not

operate a summer exhaust fan.

6. Close fireplace dampers.

7. Test for spillage from draft hood

equipped appliance at the draft hood

relief opening after 5 minutes of main

burner operation. Use the flame of a

match or candle.

8. If improper venting is observed during

any of the above tests, the venting

system must be corrected in

accordance with the

National Fuel

Gas Code, ANSI Z223.1/NFPA 54

and/

CSA B149.1, Natural Gas and

Propane Installation Codes.

9. After it has been determined that

each appliance connected to the

venting system properly vents when

tested as outlined above, return

doors, windows, exhaust fans,

fireplace dampers and any other gas

burning appliance to their previous

conditions of use.

Vent Pipe Material

Vent and combustion air pipe and fittings must

be one of the following materials and must

conform to the indicated ANSI/ASTM stan-

dards:

Material Standard

Schedule 40 PVC D1785

PVC-DWV D2665

SDR-21 D2241

& SDR-26

ABS-DWV D2661

Schedule 40 ABS F628

Foam/Cellular Core PVC F891

Note: In Canada, vent materials must be certi-

fied to the Standard for Type BH Gas Venting

System, ULC S636. Any certified ULC S636

material must not be interchanged with unlisted

or non certified pipes and/or fittings. The plastic

components, specified primers and glues of the

certified vent system must not be intermixed with

any other manufacturer’s vent systems or parts.

Cement and primer must conform to ATSM

Standard D2564 for PVC and Standard D2235

for ABS. When joining PVC piping to ABS, use

PVC solvent cement. (See procedure specified

in ASTM Standard D3138.)

Vent Pipe Length and Diameter

In order for the furnace to operate properly, the

combustion air and vent piping must not be exces-

sively restrictive. To ensure this use Table 4,

which indicates the maximum allowable piping

length for a furnace of specified input rate, when

installed with piping of selected diameter and

number of elbows. This table applies to the length

Figure 20. Alternate Horizontal Vent

Installation

Outside

Wall

Support

Vent Configuration to

Provide 12" Minimum

height above

Snow Level.

1/2"

Armaflex

Insulation or

Equivalent

(if required)

12" Above

Normally

Expected

Snow

Level

12" Min.

19" Max.

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