Kelvinator Furnace Installation Manual

The Kelvinator Furnace is a high-efficiency residential heating system designed for reliable performance and energy savings. This manual covers proper installation procedures, safety guidelines, electrical connections, gas line hookups, ventilation requirements, and initial startup procedures. Below are key sections for safety, installation steps, wiring, testing, and troubleshooting.

Features at a Glance

Key components: High-efficiency heat exchanger, Electronic ignition system, Multi-speed blower motor, Electronic thermostat interface, Safety shut-off switches, Filter access panel.

Pre-Installation Requirements

Verify local codes and obtain necessary permits before installation.

1. Location Selection: Choose well-ventilated area with adequate clearance (minimum 24 inches front, 6 inches sides, 12 inches rear).
2. Gas Supply: Verify gas type (natural gas or propane) and pressure requirements.
3. Electrical: Ensure proper 120V dedicated circuit available.
4. Venting: Plan vent routing with proper slope and termination clearances.
5. Combustion Air: Verify adequate combustion air supply per local codes.

WARNING! Installation must comply with all local building codes and regulations. Only qualified technicians should perform installation.

Installation Steps

Follow these steps in sequence for proper installation.

1. Position Furnace: Place unit on level surface, ensuring proper clearances.
2. Install Vent Pipes: Connect PVC vent pipes with proper slope (1/4" per foot).
3. Connect Gas Line: Use approved gas pipe with drip leg and shut-off valve.
4. Electrical Wiring: Connect 120V power and thermostat wires per wiring diagram.
5. Duct Connections: Attach supply and return ducts securely.
6. Condensate Drain: Route condensate line to proper drainage.

CAUTION! Use two people for lifting; furnace is heavy. Ensure all connections are leak-tight.

Specifications

• Input Capacity: 40,000 - 120,000 BTU/h (model dependent)
• Efficiency: 80% - 96% AFUE (model dependent)
• Electrical: 120V, 60Hz, 15A circuit
• Gas Connection: 1/2" NPT for natural gas, 3/8" for propane
• Vent Size: 2" or 3" PVC (model dependent)
• Blower Capacity: 800 - 1600 CFM
• Dimensions: Varies by model (typical: 21"W x 48"H x 26"D)
• Weight: 80 - 150 lbs (model dependent)
• Operating Temp Range: -30°F to 120°F ambient

Electrical Connections

All electrical work must be performed by qualified electrician.

Main Power: Connect black (hot), white (neutral), green (ground) to terminal block.

Thermostat: Connect R (24V hot), W (heat), G (fan), C (common) to control board.

Verify: Circuit breaker properly sized, Ground connection secure, Wire gauge appropriate (14 AWG minimum).

Gas Line Connections

Gas piping must be pressure tested before connection to furnace.

1. Turn off gas supply at main valve.
2. Install sediment trap/drip leg before furnace connection.
3. Use approved pipe compound on threaded connections.
4. Install manual shut-off valve within 6 feet of furnace.
5. Pressure test at 14" WC for 10 minutes (no drop).

Tip: Use soap solution to check for leaks at all connections after pressurizing.

Ventilation System

Proper venting is critical for safe operation and efficiency.

1. Vent Material: Use only approved PVC pipe for Category IV venting.
2. Vent Slope: Maintain 1/4" per foot upward slope toward termination.
3. Termination: Keep 12" minimum from ground, 3' from operable windows.
4. Combustion Air: Provide adequate combustion air per local codes.
5. Clearances: Maintain required clearances to combustible materials.

WARNING! Improper venting can cause carbon monoxide buildup. Test with combustion analyzer after installation.

Initial Startup

Follow startup sequence carefully to ensure proper operation.

1. Verify all connections are complete and secure.
2. Open gas shut-off valve slowly.
3. Turn on electrical power to furnace.
4. Set thermostat to heat mode above room temperature.
5. Observe ignition sequence: inducer motor, hot surface igniter, gas valve.
6. Check flame appearance (steady blue flame).
7. Verify proper airflow and temperature rise.
8. Test safety controls by interrupting flame signal.

CAUTION! Do not bypass safety controls. If furnace fails to start properly, shut off power and gas, then diagnose.

Maintenance Guidelines

Regular maintenance ensures optimal performance and longevity.

Monthly: Check and replace air filter if dirty. Quarterly: Inspect vent system for obstructions. Annually: Professional inspection including heat exchanger, burners, blower, and safety controls.

CAUTION! Always turn off power and gas before performing any maintenance.

Regulatory Information

UL Certified: Meets UL 1995 standards for heating equipment. ANSI Compliance: Conforms to ANSI Z21.47 standards for gas-fired central furnaces. CSA Certified: CSA International certification for safety and performance. For technical support, contact Kelvinator at 1-800-555-HEAT or visit www.kelvinator.com.

Troubleshooting

Reset: Turn power off for 30 seconds, then restart.

Service: 1-800-555-HEAT; www.kelvinator.com