Installation Instructions External Filter Rack KGAFR0301ALL NOTE: Read the entire instruction manual before starting the installation. INTRODUCTION The External Filter Rack is designed to fit on either the side or bottom of a multipoise furnace. The rack is adjustable in height for 14, 16, 20 or 24 filters. A filler plate is included to fit the rack for bottom return on 17.5 and 21 wide furnaces. SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained personnel should install or service heating equipment. Untrained personnel can perform basic maintenance functions such as cleaning coils, or cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating equipm ent, observe precautions in the literature, on tags, and on labels attached to the unit. Recognize safety information. This is the safety-alert symbol you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.. When Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. Follow all safety codes. Wear safety glasses and work gloves. Have a fire extinguisher available. WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which could result in personal injury or death. Consult your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized kits or accessories when servicing this product. Failure to follow instructions could result in serious injury or property damage. KIT CONTENTS The kit includes the following items: Outside filter frame rail 1 Inside filter frame rail 1 Filter Inlet Rails 2 Plastic Filter Access Door 1 Filler Plate 1 24 x 25 Washable Filter 1 Form: AG-GAFR-03 Cancels: AG-GAFR-02 Printed in U.S.A. 6/02 Pg. 1 Catalog No. 63GA-FR0
The rails have slots that are numbered with the filter size for that slot and the lock-tabs are lettered to aid in assembly of the filter rack. The frame and inlet rails nest together and are marked INSIDE and OUTSIDE. If it is difficult to nest the rails together, verify that the rails are in the correct orientation for assembly. Filter Frame Rails Filter Inlet Rails Filler Plate Filter Access Door ASSEMBLY Filter Frame Rails Fig. 1 1. Orient all the sheet metal parts in the kit in the order they are shown in Fig. 1. CAUTION: Sheet metal parts may have sharp edges. Gloves should be worn when handling sheet metal parts. Failure to follow this warning could result in personal injury. 2. Metal parts should be oriented so furnace tap-lock tabs are on bottom (See Fig. 1). 3. Bend the unmarked tab on Outside Filter Frame Rail tab (located on the short end of the rail) IN 90 degrees (See Fig 2). 4. Bend the unmarked tab on the Inside Filter Frame Rail (located on the short end of the rail) OUT 90 degrees (See Fig. 2). 5. Insert the Inside Filter Frame Rail inside the Outside Filter Frame Rail (See Fig 2). 6. Insert unmarked tabs into the slots marked for the filter size being used (14, 16, 20 or 24 inches). 7. Bend the tabs over to form a final bend of 180 degrees on the tabs. Tap tabs flat with a sheet metal hammer. 2
Inside rail - Bend tab on end, OUT 90 degrees Outside rail - Bend tab on end, IN 90 degrees Fig. 2 Filter Frame Rails Outside rail - Bend tab on end, IN 90 degrees Inside rail - Bend tab on end, OUT 90 degrees Fig. 3 Filter Inlet Rails ASSEMBLY Filter Inlet Rails 1. Bend unmarked tabs on the Outside Filter Inlet Rail in 90 degrees (See Fig 3). 2. Bend unmarked tabs on the Inside Filter Inlet Rail out 90 degrees (See Fig. 3). 3. Insert the Filter Rail Inlet with the tabs bent out inside the Filter Rail Inlet with the tabs bent in. 4. Insert the tabs in the slots marked for the filter size being used (14, 16, 20 or 24 inches). 5. Fold tabs over to form a final bend of 180 degrees on the tabs. Tap tabs flat with a sheet metal hammer. Assemble Filter Inlet Rails and Filter Frame Rails Together Fig. 4 3
1. Insert Tab A of the Filter Frame Rail into slot A on the Filter Inlet Rail. (See Fig 4). 2. Bend the Tab over to form a final bend of 180 degrees on the tabs. 3. Insert Tab B of the Filter Frame Rail into slot B on the Filter Inlet Rail. 4. Bend the Tab over to form a final bend of 180 degrees on the tabs. SIDE RETURN INSTALLATION 1. Measure and cut a 15 by 22 opening in the desired side-return airside of the furnace casing. 2. Align the Filter Rack on the return air opening and fold lock-tabs over (See Fig. 5). Flatten the lock-tabs with hand seamers or duck-billed pliers. 3. Attach return duct to side of filter rack and secure with sheet metal screws. Note: Do not screw return duct into External Filter Rack so that screws interfere with filter removal. Screw return duct into duct flanges provided on External Filter Rack. Completed side return installation without return air duct installed is shown in Fig. 6. Fig. 5 Lock-tabs Fig. 6 Side-return Filter Installed BOTTOM RETURN INSTALLATION 1. With the furnace lying on its side or upside down, remove bottom closure pan from the furnace per the furnace installation instructions. Note: For 14 and 24 wide casings, skip Steps 2 & 3 2. Align the Filler Plate along the bottom edge of the casing side as shown in Fig. 7. 3. Mark casing using holes in Filler Plate as a guide and drill 1/8 holes in furnace casing. 4. The Filler Plate can be field adjusted to fit different casing sizes. (See Fig 8.) 14 Casings -No Filler Plate required for 14 Filter. 17 Casing-Do not bend flange or remove flange on Filler Plate 21 Casing- Remove flange by bending flange back and forth (See Fig 8) 24 Casing-No Filler Plate required when used with a 24-inch filter 5. Secure the Filler Plate to the furnace casing with sheet metal screws (if required). 6. Align the Filter Rack against the bottom opening with the lock-tabs against the furnace casing and fold lock tabs over (See Fig. 10 and 11). Flatten the lock-tabs with hand seamers or duck-billed pliers. 7. Install Furnace and Filter Rack on return air duct or opening. 8. Connect return air duct to Filter Rack. Refer to the furnace installation instructions for complete duct system requirements. Note: It may be necessary to install a short piece of return air duct to Filter Rack before setting furnace in place. 4
Fig. 7 Installing Filler Plate Fig. 8 Removing Flange for 21 cabinet Fig. 9 Filter Rack with Filler Plate Fig. 10 Filter Rack w/o Filler Plate Note: Do not screw return duct into External Filter Rack so that screws interfere with filter removal. Screw return duct into duct flanges provided on External Filter Rack. INSTALL FILTER 1. Insert filter into filter rack. For sizes other than 24 x 25, the filter must be cut as follows: a. Remove rods from filter. b. Measure and mark filter at desired width (14, 16, 20 ). c. Cut filter with scissors or a utility knife and straight edge as a guide. d. Measure and cut support rods ¼ smaller than desired filter width using a hacksaw or bolt cutters. e. Re-install support rods in filter. CAUTION: Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves, and appropriate protective clothing. Failure to follow this caution could result in personal injury. 5
2. Install filter in filter rack (See Fig. 11) 3. The plastic Filter Access Door is cut to fit the required filter opening. Use the V notches on the edge of the Filter Access Door as a measuring guide. Cut the Filter Access Door with a hacksaw to the required length. 4. Install Filter Access Door on External Filter Rack by slipping the door inside the filter rack (See Fig 12). Fig. 11 Installing Filter Fig. 12 Installing Filter Access Door 5. Complete the furnace installation per the steps listed in the furnace Installation, Start-up and maintenance Instructions. 6
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2002 CAC/BDP P.O. Box 70, Indianapolis, IN 46206 aggafr03 Pg. 8 Catalog No. 63GA-FR0