CARRIER Furnace/Heater, Gas Manual L0503144

User Manual: CARRIER CARRIER Furnace/Heater, Gas Manual CARRIER Furnace/Heater, Gas Owner's Manual, CARRIER Furnace/Heater, Gas installation guides

Open the PDF directly: View PDF .
Page Count: 48

88MSA

4-Way MuMtipoise Fixed-Capacity

Condensing Gas Furnace

\isit _ v_w carrier.corn

Installation, Start-Up, and Operating

For Sizes 040--120 Series t50

HEATUNG & COOUNG

I mlCI[NCY

A93040

NOTE: Read the entire instl_action manual be%re starting the

installation

This symbol -->indicates a change since the last issue,

Index Page

DIMENSIONAL DRAWING 3

SAFETY CONSIDERATIONS 2

(learances to ( ombustibles 4

CODES AND STANDARDS ........................................................ 5

ELE< TROSTATIC DIS<HARGE (ESD) PRE(AUTIONS ........ 5

INTRODU< TION .......................................................................... 5

APPLICATIONS ..................................... 6

General ........................................... 6

[pflow Applications ............................... 6

Downflow Applications ............................. 8

Horizontal Lek (Supply-Air Dischmge) Applications ....... 9

Horizontal Right {Supply-Air Discharge) Applications ..... 11

LO< ATION ........................................ 13

Gene*al .......................................... 13

Furnace Location Relative to ( ooling Equipment ......... I4

Hazardous Locations .............................. 14

AIR FOR COMBUSTION AND VENTILATION .......... 14

INSTALLATION ........................................ 18

Leveling Legs (If"Desired) .............................. 18

Installation in Upflow and Downflow Applications ......... 18

Installation In Horizontal Applications .................. 18

Air Ducts ....................................... ! 8

General ........................................ 18

Ductwork Acoustical Treatment .................... 20

Supply Air Connections ......................... 20

Return Air Connections .......................... 20

Filter Arrangement ................................ 20

Bottom Closure Panel ............................ 21

Gas Piping ....................................... 22

Electrical ( onnections ............................. 23

115-v Wiring ................................... 23

24-v Wiring .................................... 24

Accessories .................................. 24

Venting ............................................ 27

Removal of Existing Furnaces from

( ommon Vent Systems .......................... 27

Combustion-Air and Vent Piping ................... 28

Vent Te*mination .............................. 35

Multiventing ................................. 35

As an FNFR(JY ST4Rx¢

Pa_ner Carrier Corpora-

tion has determined that

this pro_tct meets the EN'-

FRGY S fARaV g/iidelines

_r energy efflc{ency

I$O 9001:2000

AIRFLOW

42>

¢ _ HORLIZOTNTA _ _ _ HO _II_C_NTALN'NI 0

AIRFLOW AIRFLOW

AIRFLOW A93041

Fig. 1--NuRipoise Orientations

Condensate Drain .................................................................... 35

General ....................................... 35

Application ....................................... 35

Condensate Drain Protection ...................... 36

START°UP, ADJL STMENTS AND SAFETY (HECK ....... 37

General .......................................... 37

Prime ( ondensate Trap With Warm .................... 37

Purge Gas Lines ................................... 38

Sequence of Operation ............................. 38

Heating Mode ................................. 38

Cooling Mode ................................ 38

Continuous Blowe* Mode ........................ 38

Heat Pump Mode .............................. 39

Component Test ............................... 39

Adjustments....................................... 39

Set Gas Input Rate .............................. 39

Set Temperature Rise ................................ 44

Blower Off"Delay (Heat Mode) .................... 44

Set Thermostat Heat Anticipator .................... 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 535-80154 Printed in U.S.A. Form 58MSA-11SI Pg 1 2-05 Replaces: 58MSA-10SI

Check Safhty Controls 45

Check Prima_ Limit Control 45

Check Pressure Switch 45

CHECKLIST ...................................... 45

SAFETY CONSIDERATIONS

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of fml_ace may re=

quire excessive servicing o1" cause premature component

failm'e

Application of this fm'nace should be indoors with special

attention given to vent sizing and material, gas input rate, air

temperature rise, unit leveling, and unit sizing.

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in electrical shock,

firQ personal ir!inry, or death,

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 Jr!ire'y.,-or property damage. Consult a qualified

installer, smwice agency, local gas supplier, or your distribu-

tor or branch fbr information or assistance. The qualified

installer or agency must use only [itctory=authorized and

listed kits or accessories when modi_)ing this product.

Installing and servicing heating equipment can be hazardous due to

gas and electrical components. Only trained and qualified

persomiel should instMl, repair, or service heating equipment.

Untrained personnel can perform basic maintenance fimctions

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 unit and other safety

precautions that may apply

These instructions cover the minimum requirements and confoml

to existing national standards and safkty codes In some instances,

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing resider>

tial construction practices. We require these instrnctions as a

minimum ibr a saf_ installation

Wear safety glasses and work gloves. Have a fire extinguisher

available during start=up and adjustment procedures and service

calls,

CUT HAZARD

Failure to %tlow this caution may result in personal injury.

Sheet metal parts may have sharp edges or bun's Use care and

wear appropriate protective clothing and gloves when ban=

dling parts.

Recognize safety information. This is the safety=alert symbol Z_

When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury.

--€

-->

Understand these signal words DANGER, WARNING, and (AU°

TION These words are used with the safkty=alert symbol. DAN-

GER identifies the most serious hazards which will result in severe

personal injury or death. WARNING signifies hazards which

could result in personal injury or death. CAUTION is used to

identify unsafe practices which ma? 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.

The 58MSA Muhipoise Condensing Gas-Fired Furnaces are CSA

(fbm_erly AGA and (GA) design-certified for natural and propane

gases (see ftmmce rating plate) and fbr installation in alcoves,

attics, basements, closets, utility rooms, erawlspaces, and garages.

The fi/rnace is factory=shipped fbr use with natural gas. A CSA

listed gas conversion kit is required to convert furnace for use with

propane gas.

See Fig. 3 for required clearances to combustibles.

Maintain a l-in. clearance fiom combustible materials to supply air

ductwork for a distance of 36 inches horizontally fiom the fimaace.

See NFPA 90B or local code fbr further requirements.

These furnaces SHALL NOT be installed directly on carpeting,

tile, or any other combustible material other than wood flooring. In

downflow installations, factory accessow floor base MUST be

used when installed on combustible materials and wood flooring.

Special base is not required when this Nmace is installed on

manufacturer's (:oil Assembly Part No. CD5 or CK5, or when Coil

Box Part No. KCAKC is used. The design of this fi/rnace line is

NOT CSA (formerly AGA and CGA) designocertified fbr instal-

lation in recreation vehicles, manufi_ctured mobile homes, or

outdoors.

This furnace is designed for continuous return-air mininmm

temperature of 60_>F db or intermittent operation down to 55°F db

such as when used with a night setback thermometer. Return-air

temperature must not exceed 80°F db. Failure to follow these

return-air limits may affect reliability of heat exchangers, motors,

and controls. (See Fig. 4.)

These Nrnaces are shipped with the drain and pressure robes

connected for UPFLOW applications. Minor modifications are

required when used in DOWNFLOW, HORIZONTAL RIGHT, or

HORIZONTAL LEFT (supply=air discharge direction) applica-

tions as shown in Fig. 1. See details in Applications section.

Install this Nmace only in a location and position as specified in

LOCATION and INSTALLATION sections of these instnlctions.

Combustion products must be discharged outdoors. Connect this

furnace to an approved vent system only, as specified in the

Combustion Air and Vent piping sections of d_ese instructions.

Never test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for detection of leaks to

check all connections as specified in the GAS PIPING section of

these instructions.

Always install the furnace to operate within the fitrnace's intended

rise range with a duct system which has an external static pressure

within the allowable range as specified in the SET TEMPERA-

TURE RISE section of these instructions.

When a Nrnace is installed so that supply ducts carry air circulated

by tl_e fi/rnace to areas outside the space containing the f:umace,

the return air shall also be handled by ducts sealed to the Nrnace

casing and terminating outside the space containing the fhrnace.

22 _"_

I4 _" SIDE INLET

TYP

S{OEiNLET

26 _,e"TVp

HORIZONTAL LEFT)

POWER CONN

ACCESSORY [ J

POWERENTRY 2]

_ CONDENSATE

DRAINTRAP

LODATION

(ALTERNATE

UPFLOW) 24

17 :,i_"

9/6" !

TiP

CONDENSATE

DRAIN LO CATION

(UPFLOW)

A_RFLOW

OaT TYP

{DOWNFLOW&

HORIZONTALRIGHT)

ORALTERNATE

gqN DIAGAS CONN

30 _;"

DRA_N LOCATION

(UPFLO\M)

DIMPLE LOCATORS

FOR HORIZONTAL

HANGING

qN DIA

THERMOSTAT ENTRY

2qN VENT CONN

SIDE iNLET

BOTTOM iNLET

UNIT SIZE

040-08

040-t2

080-08

080-t2

080-t6

080-t2

080-t6

080_20

100-16

100-20

120_20

NOTES: 1. Minimum return-air openings at furnace, based on metal duct if flex duct is used,

see flex duct manufacturer's recommendations for equivalent diameters

2 Minimum return-air opening at furnace:

a, For 800 CFM-16-in, round or 14/_ x 12-in rectangle

b For 1200 CFM-20qn, round or 14'h x 19 Lqn, rectangle

c, For 1600 CFM-22qn, round or 14/;, x 23 L-in, rectangle

d For airflow requirements above 1800 CFM see Air Delivery table in Product Data

literature for specific 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 at 0_5 WC ESP

17-I/2

24-I/2

Dimensions (In.)

15-7/8

19-3/8

22-7/8

19-1/2

A02149

Fig. 2--Dimensional Drawing

--->A gas-fired fire, ace %1"installation in a residential garage must be

installed as specified in the Hazardous Locations section of these

insm/etions,

--> The [:urnaee is not to be used %r tempora Uheating of buildings or

structures under construction unless the furnace installation and

operation complies with the first CAUTION in the LOCATION

section of these instructions,

These fi.u'naces are shipped with the %llowing materials to assist in

proper furnace installation, These materials are shipped in the main

blower compartment,

Installer Packet includes:

Installation, Startup, and Operating instructions

Service and Maintenance instructions

User's Information Manual

Warranty Certificate

Loose Parts Bag includes: Quantity

Pressure tube extension 1

Collector Box or condensate trap extension tube 1

Inducer housing drain tube 1

1/2-in CPVC street elbow 2

Drain tube coupling 1

Drain tube coupiing grommet 1

Vent and combustion-air pipe support 2

Condensate trap hole filler plug 3

Vent and combustion-air intake hole filler ptug 2

Combustion-air pipe perforated disk assembly 1

Vent Pipe Extension 1"

* ONLY supplied with some furnaces.

e This forced air lurnace is equipped for use with natural gas at altitudes 0 -10.000 ff (0 -3,050m), except 140 size _rnaces are only approved for altitudes 0 -7.000 ft.

(0 -2,135m).

¢ An accessory kit, supptied by tbe manufacturer, shall be used to convert to propene gas use or rr_ay be required for some natural gas apptications.

o This furnace is for indoor installation in a building constructed on site. This furnace may be ins"tailed in a manufactiJred (mobile) home when stated on rating plate and

using factory authorked kit..

This furnace may be tilstalled on combustible floodng in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below.

® This furnace requires a special venting system Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC.

PVC-DW%L CPVC. or ABS-DWV pipe, and must not be vented in common with other gas-tired apptiances. Construction tbrough which vent/air intake pipes may be

installed is maximum 24 inches (600 ram), minimum 3/4 inches (19 ram) thickness (including roofing materials)

e Cetta fournalse &air puls6 est 6quip6e peur utitisation avec gaz naturel et altitudes compdees entre 0 - 3.050m (0 - 10,000 pi),except6 queles fournaises de 140 taille

sont pour altitudes comprises entre 0 - 2,135m 0 - 7,000pi).

® Ut set une trousse de cenvers on. fourn e par e fabr can, pour passer au gaz propane ou pour certaines installations au gaz natureL

o Cetta fournaise a air puls6 es"t pour installation a Fint6rieur darts un bNiment construit sur place. Cetta fournalse a air pulse peut 6tre install6e dens une maison

pr6fabdqu6e (maison mobile) si prescht par la plaque signN6tique et si r on utitise une trousse specifi6e par le labdcant.

e C'etta fournaise peut _tre instati6e sur un plancher combustible darts un enfoncement ou un placard en observant les D_gagement Minimum En Pouces Ave¢

Elements De Construction Combustibles,

® Cetta fournaise n6cessite un systeme d'evaoJation special La m6thede d'installation et la tiste des pieces n6cessaires figurent dens les instructions d'instatiation. Cetle

fournalse doit s'u!itiser avec la tuyautede des nomendatures 40 PVC. PVC-DWV, CPVC, oN ABS-DVW et elle ne peut pas 6tre ventil6e conjointment avec d'autres

appereils a gaz. Epalsseur de la construction au travers de laquetie il est pcesible de laire passer les tuyaux d'a6ration (admlssion/6vacuation): 24 po ('600 ram)

maximum. 3/4 po (19ram) minimum (y cornprls la toiture)

For uptiow and downtiow applications, furnace mu_t be installed level, or pitched within 1/2" of level For a M IN 1/4" TO 1/2" MAX

horizontal apptication, the furnace must be pitched minimum 1/4" to maximum of 1/2" forward for proper

draina:je. See Installation Manual for IMPORTANT unit supped details on horizontal apptications,

Pour des appticatises de flux ascendent et descendant. _ fournaise ddt 8tre install6e de niveau ou indti%,e

pes plus de 1/2" du niveau. Pour une apptication hodzontale, la fournalse doit g,tre inciinde entre minimum

1/4" et maximum 1/2" du nNeau pour le drainage appropd6. En _ d'instatiation en position beCEontale.

consulter les renseignements tMPORTANTS sur le support dens le manuel d'instatiation. HORIZON TAL

NtNINUN iNCHES CLEARANCE TO CONBUSTtBLE CONSTRUCTION

ALL POSITIONS:

Minimum front clearance for service 24 inches (610mm),

? ? 140 size furnaces require 1 inch back clearance to combustible materials,

DOWNFLOW POSITIONS:

t For ir_stallation on cembustible floors only when installed on special base No, KGASB0201ALL,

Coil Assembly Part No, CD5 or CKS, or Coil Casing, Part No, KCAKC,

HORIZONTAL POSITIONS:

Line contact is permissible only between lines formed by intersections of top and two sides of

furnace jacket, and building joists, studs, or framing,

§ Clearance shown is for air inlet and air outlet ends.

O 120 and 140 size furnaces require 1 inch bottom clearance to combustible materials,

DEGAGEMENT MINIMUM EN POUCESAVEC _LEMENTS DE CONSTRUCTIONCOMBUSTIBLES

POUR TOUS LES POSITIONS:

Degagen_ent avant minimum de 610mm (24 po ) pour l'entretien,

tt Pourlesfoumaissede 140taille,1 po (25mm)degagen-entdesn_t@iauxcombustiblseest

requis au-arriere.

POUR LA POSITION COURANT DESCENDANT:

1 Pour Iinstallation sur le plancher combustible seulement quand on utilise la base speciale, piece

n ° KGASB0201ALL, I'sesemble serpentin, piece n° CD5 ou CKS, ou le carter de serpentin,

piece n° KCAKC.

POUR LA POSITION HORIZONTALE:

Le contact n'est pem?is qdentre les ligses forages par les intersections du dessus et des

deuxoStes de la chemise de la foumaise et des selives, des n_ntan% ou de la charpente du

b4,timent,

§ La distance indiquee cenceme I'extr@mit6 du tuyau d'arrivde d'air et Fextremite du tuyau de sortie

d'air,

Pour Ise foumaises de 120 et 140 taille 1 po (25ram) d&Jagement des mat@iaux combusitbles

est requis au<l_'ssous.

TNs furnace is approved for UPFLOW, DOWNFLOW aed

HORIZONTAL instNlations,

Cette toumaise est approuv¢e pour Iinstallaflon HORIZONTALE

e! la circulaJion d'air VERS LE HAUT et VERS LE BAS

Cleat_nce arrows

do not change with ne change pas avec

furnace onentation I'odentation de la

gen@aIeur d'air cbaud.

Vent clearance to

combustibles 0",

Clearance in inches 0 (po) Ocgagement

Degagetnent (po), d'@vent avec combustibles

3280_201 REV, B LITTOP

Fig. 3--Clearances to Combustibles

A04110

"} MAX 80°F

FRONT

RETURN

AHR MHN60°F

A05004

--9 Fig. 4_Retum-Air Temperature

For accessory installation details, refer to accesse D' installation

instructions

--@ ,

CODES AND STANDARDS

Follow all national and local codes and standards in addition to

these instructions° The installation must comply with regulations

of the serving gas supplier, local building, heating, plumbing, and

other codes. In absence of local codes, the installation must

comply with the national codes listed below and all authorities

having jurisdiction.

In the United States and Canada, follow all codes and standards for

the _bllowing:

Step l--Safety

* US: National Fuel Gas (ode (NFGC) NFPA 54-2002/ANSI

Z223.1 °2002 arid the Installation Standards, Warm Air Heating

and Air (onditioning Systems ANSI NFPA 90B

* CANADA: National Standard of Canada, Natnral Gas and

Propane Installation Code (NS(NGPIC) CSA BI49J-00.

Step 2--General Installation

*US: NFG( and the NFPA 90B. For copies, contact the National

Fire Protection Association Inc, BatteD-march Pad< Quincy,

MA 02269; or for only the NFG( contact the American Gas

Association, 400 N. Capitol, N.W., Washington DC 20001

A manu_hctured (Mobile) home installation must con_brrn with

the Mam!/actured h2)me d'onstl'z¢ctior_ as_d &{fi.-t3' Sta,c/ard

Tide 24 (iFR, Part 3230, or when this standard is not

applicable, the Standard _br _l,Ian@tctz¢red Hnme l_Tst_d]ation

(.hIclmt/act_lred D))me Sites, ('omm_¢nitie.s, and Set-L_.s),

AXIST/A'C_' A225. l, an&or (14A',( %-l-Z240, liD" Serie.s 3/obiIe

Hom_,s'

* CANADA: NSCNGPI& For a copy, contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke

(Toronto), Ontario, M9W IR3, Canada.

Step a--Combustion and Ventilation Air

* US: Section 8.3 of the NFGC, Air for (ombnstion arid

Ventilation

* CANADA: Part 7 of d-ie NSCNGPIC, Venting Systems and Air

Supply _k}r Appliances

Step 4--Duct Systems

* US and (ANADA: Air (onditioning (ontractors Association

(AC(A) Manual D, Sheet Metal and Air Conditioning (7on-

tlactors National Association (SMACNA), or American Soci-

ety of Heating, Refrigeration, and Air Conditioning Engineers

(ASHRAE) 2001 Fundamentals Handbook Chapter 34.

Step 5--Acoustical Lining and Fibrous Glass Duct

* US and (ANADA: current edition of SMACNA, NFPA 90B as

tested by UL Standard 181 for (;lass I Rigid Air Ducts

Step g--Gas Piping and Gas Pipe Pressure Testing

*US: NFG( chapters 2, 3, 4_ and 9 and national phn'nbing codes

In the state of Massachusetts:

This product must be installed by a licensed plumber or gas

fitter.

When flexible connectors are used, the maxinmm length shall

not exceed 36 inches.

When lever type gas shutof_is are used they shall not exceed 36

inches.

CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E, and H.

Step 7--Emectrical Connections

* US: National Electrical (ode (NE() ANSIiNFPA 70°2002

CANADA: (anadian Electrical (ode CSA C22.1

ELECTROSTATIC DISCHARGE {ESD) PRECAUTIONS

[NIT DAMAGE HAZARD

Faihn'e to follow this caution may result in damage to unit

components.

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing to

protect d_e t:umace electronic control. Precautions will pre-

vent electrostatic discharges fiom personnel and hand tools

which are held during the proce&re. These precautions will

help to avoid exposing the control to electrostatic discharge

by putting d_e [:urnace, the control, and the person at the same

electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may

be required. DO NOT TOU(H THE CONTROL OR ANY

WIRE CONNE(TED TO THE ( ONTROL PRIOR TO DIS-

(HARGING YOUR BODY'S ELECTROSTATI( CHARGE

TO GROUND.

2 Firefly touch a clean, unpainted, metal surface of the fmTlace

chassis which is close to the control. Tools held in a person's

hand during 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 that

recharges your body with static electricity (fbr example; DO

NOT move or shuffle your feet, DO NOT touch ungrounded

objects, etc)

4 If you touch ungronnded objects (recharge your bo@ with

static electricity), firmly touch the unpainted metal surfi_ce of

the furnace again be_bre touching control or wires.

5. Use this procedure for installed and urdnstalled (ungrounded)

_i/rnaces

6. Befbre removing a new control fiom its container, discharge

your body's electrostatic charge to ground to protect dae

control from damage. If d_e control is to be installed in a

ii/mace, _bllow items 1 through 5 be_bre bringing the control

or yourself into contact with the furnace. Put all used and new

controls into containers be_bre touching ungrounded objects.

7. An ESD service kit (available ti'om commercial sources) may

also be used to prevent ESD damage.

INTRODUCTION

The model 58MSA 4-way multipoise, Gas-Fired, Category IV,

condensing furnaces are available in model sizes ranging in gas

input rates of 40,000 to 120,000 Bmh.

__D FURNACE

OOR

TRAP (INSIDE_ X[

TU% OOSO ETRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

FIELD--

DRAIN

CONN

/-- CONDENSATE

/TRA uRNAOE7

JS'DV

Y,--? /o

£_2% ......

26_/4 1_/2

SIDE VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

_1 FURNACE

OOR

FIELD --

DRAIN

CONN

-- FURNACE

SIDE

END VIEW FRONT VIEW

HORIZONTAL

APPLICATIONS

s'-°7'-%:°:U7

(OPTIONAL) /

Z W, ET,E

GUIDES

(WHEN USED)

71/8

COD

COLLECTOR BOX TO

TRAP RELIEF PORT

_OD

INDUCER HOUSING

DRAIN CONNECTION

'_OD

COLLECTOR BOX

DRAIN CONNECTION

SCREW HOLE FOR

UPFLOW OR DOWN-

FLOW APPLICATIONS

(OPTIONAL)

YnlN. PVC OR CPVC

FRONT VIEW SIDE VIEW

A93026

Fig. 8--Condensate Trap

MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor property

damage,

Local codes may reqnire a drain pan under entire _rnace and

condensate trap when a condensing furnace is used in an attic

application or over a finished ceiling.

APPLiCATiONS

Step l--General

Some assembly and modifications are required for fire, aces

installed in any of the 4 applications shown in Fig. 1. All &ain and

pressure robes are connected as shown in Fig 6 See appropriate

application instructions _br these procedures

Step 2--Upflow Applications

An upflow t'tmlace application is where fm'nace blower is located

below combustion and controls section of ffimace, and conditioned

air is discharged upwards

( ONDENSATE TRAP LO(ATION (FACTORY-SHIPPED

ORIENTATK)N)

The condensate tlap is _hctory installed in the blower shell:"and

fhctory connected for UPFLOW applications. A factory-supplied

tube is used to extend the condensate trap drain connection to the

desired furnace side %r field drain attachment See Condensate

Trap Tubing (FactoQ--Shipped Orientation) section *%r drain tube

extension details. (See Fig. 6.)

CONDENSATE TRAP TL BING (FACTORY-SHIPPED

ORIENTATION)

NOTE: See Fig. 6 or robe routing label on main furnace door to

confirm tocation of these tubes

l. ( ollector Box Drain, Inducer Housing Drain, Retief Port, and

Pressure Switch Tubes

These tubes are fhcto W attached to the condensate trap and

pressure switch ready _;oruse in UPFLOW applications. These

robes can be identified by their connection location and also

by a color label on each robe. These robes are identified as

£_llows: collector box &ain robe (blue label), inducer housing

&ain robe (violet label or molded), relief port robe (green

label), and pressure switch robe (pink label).

2. (ondensate Trap Drain Tube

The condensate trap drain connection must be extended for

field attachment by doing the *%llowing:

a. Detemine location of field drain connection. (See Fig. 2or

6.)

NOTE: If internal filter is used, drain robe should be located to

opposite side of casing from remm duct attachment to assist in

filter removal.

PLUG

CAP

COLLECTOR

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR

TUBE (PINK)

COLLECTOR BOX --_

TUBE (GREEN)

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

DRAIN TUBE (BLUE)

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLiED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

V_-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (RIGHT

DRAIN OPTION)

A94163

Fig. 6--Factory-SNpped Upflow Tube Configuration

(Shown With Blower Access Panel Removed}

b. Remove and discard casing drain hole plug button from

desired side.

c Install &ain tube coupling grommet (factor-supplied in

loose parts bag) in selected casing hole.

& Slide drain robe coupling di_ctok_'°supplied in loose parts

bag) through grommet ensuring tong end of coupling fi_ces

blower.

e. Cement 2 factory°supplied 1i2qn. stleet CPVC elbows to

the rigid drain tube connection on the condensate trap. (See

Fig. 6.) These elbows must be cemented together and

cemented to condensate trap drain connection.

NOTE: Failure to use CPV( elbows may allow &ain to kink and

prevent draining.

t_ Connect larger diameter drain tube and clamp (factory°

supplied in loose parts bag) to condensate trap and clamp

securely.

g. Route robe to coupling and cut to appropriate length.

h. Attach robe to coupling and clamp securely.

(ONDENSATE TRAP LOCATION (ALTERNATE UPFLOW

ORIENTATION)

An alternate location fbr the condensate tlap is the left-hand side

of casing. (See Fig 2and 7)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

TRAP

HOUSING

DRAIN TUBE

(VIOLET)

O O

A94164

Fig. 7--Alternate Upflow Tube Configuration and

Trap Location

--9

NOTE: If the alternate tef_-hand side of casing location is used_

the factory-connected drain and relief port robes must he discon-

nected and modified for attachment See Condensate Trap Tubing

(Alternate Upflow Orientation) section for tubing attachment

To relocate condensate trap to the te_t-hand side, perfbrm the

following:

1 Remove 3 tubes connected to condensate t_ap.

2 Remove trap from blower shelf by gently pushing tabs inward

and rotating trap.

3. Install casing hole filler cap (_i_ctory=supplied in loose parts

bag) into blower shelf hole where trap was removed.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning eoutd result in personal inju W

or death,

Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated.

4 Install condensate trap into left=hand side casing hole by

inserting tube cormection stubs through casing hole and

rotating until tabs snap into locking position.

5. Fill unused condensate tlap casing holes with plastic filler

caps (bactory=supplied in loose parts bag).

CONDENSATETRAPTUBING(ALTERNATEt PFL()W

ORIENTATION)

NOTE:SeeFig.7orroberoutinglabelonmainfhrnacedoorto

confirmlocationoftheserobes

1.(ollectorBoxDrainTube

(onnectcollectorboxdrainrobe(bluelabel)tocondensate

t_ap.

NOTE:On17-1/2-in.widetk_rnacesONLY,cuttubebetween

corrugatedsectionstopreventkinksfloraoccurring.

2. InducerHousingDrainTube

a.RemoveanddiscardLOWER(molded)inducerhousing

&Bintubewhichwaspreviouslyconnectedtocondensate

t_ap.

b. [seinducerhousing&Binextensiontube(violetlabeland

fhctow-suppliedinloosepartsbag)toconnectLOWER

inducerhousing&Binconnectiontothecondensatetrap

c.Determineappropriatelength,cut,andconnectrobe

d.Clamprobetopreventanycondensateleakage.

3.ReliefPortTube

a.(onnectreliefporttube(greenlabel)tocondensatetrap.

b. Usesmallerdiametertube(fitctory=suppliedinlooseparts

bag)toextendthistubeif required.

c.Determineappropriatelength,cut,andconnectrobe.

( ONDENSATETRAPFIELDDRAINATTACHMENT

Referto CondensateDrainsectionfor recommendationsand

procedures.

PRESStRESWIT(HTt BING

TheLOWER collector box pressure tube (pink 1abel) is facto W

connected to the pressure switch and should not require any

modificatiom

COLLECTOR

DRAIN TUBE (BLUE)

TUBE (GREEN)

EXTENSION TUBE

TUBE (PINK)

COLLECTOR

DRAIN TUBE (BLUE

& WHITE STRIPED)

EXTENSION TUBE

TRAP ©

INDUCER HOUSING

DRAIN TUBE(VIOLET)

Fig. 8--Downflow Tube Configuration

(Left-Hand Trap Installation)

A94165

NOTE: See Fig 6 or 7 or robe routing label on main furnace door

to check fbr proper connections.

UPPER COLLECTOR BOX AND INDUCER HOUSIN'G

(UNUSED) DRAIN" CONNE(TIONS

tipper (ollector Box Drain Connection

Attached to the tIPPER collector box drain connection is a

factory-installed corrugated, plugged tube (blue and white striped

label). This tube is plugged to prevent condensate leakage in this

application. Ensure this robe is plugged.

NOTE: See Fig. 6 or 7 or tube routing label on main furnace door

to check fbr proper connections.

tipper Inducer Housing Drain (onnection

Attached to the tIPPER (unused) inducer housing &Bin connection

is a cap and clamp. This cap is used to prevent condensate leakage

in this application Ensure this connection is capped.

NOTE: See Fig. 6 or 7 or tube routing label on main fhrnace door

to check fbr proper connections.

CONDENSATE TRAP FREEZE PROTECTION

RefBr to (ondensate Drain Protection section for recommenda-

tions and procedures.

Step 3--Oownflow Applications

A downflow ftn'nace application is where fitmace blower is located

above combustion and controls section of furnace, and conditioned

air is discharged downwards.

CONDENSATE TRAP LOCATION

The condensate trap must be removed from the fhctow-installed

blowe* shelf'location and relocated in selected application location

as shown in Fig 2, 8, or 9.

O O

LDRAIN TUBE "_

COUPLING

PLUG

CAP

_ COLLECTOR BOX

DRAIN TUBE (BLUE)

_ COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

INDUCER HOUSING

D RAIN TUBE

(VIOLET)

CONDENSATE

TRAP

_'- COLLECTOR BOX

EXTENSION

DRAIN TUBE

Fig. 9--Oownflow Tube Configuration

(Right-Hand Trap Insta{lation)

A94166

-->

To relocate condensate trap fi'om the blower shelf to desired

location, perfbrm the following:

1. Remove 3 tubes connected to condensate t_ap

2. Remove trap from blower shelf by gently pushing tabs inward

and rotating t_ap.

3. Install casing hole filler cap (*hctow-supplied in loose parts

bag) into blower shelf hole where trap was removed.

CARBON MONOXIDE POISONING HAZARD

Failure to fbllow this warning could result in personal in}ury

or death.

Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated.

4. Install condensate trap into desired casing hole by inserting

tube connection stubs through casing hole and rotating until

tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler

caps (*i_ctory=supplied in loose parts bag)

CONDENSATE TRAP TUBING

NOTE: See Fig 8 or 9 or robe routing label on main furnace door

to check fbr proper connections.

1. Collector Box Drain Tube

a Remove fimtory=installed plug fi'om LOWER collector box

drain robe (blue and white striped label).

b. Install removed clamp and plug into [PPER collector box

&ain robe (blue label) which was connected to condensate

tlap.

c. Connect LOWER collector box drain connection to con=

densate trap.

(1.) Condensate Trap Located on Left Side of Casing

Ca3 Connect LOWER collector box &ain robe (blue

and white striped label) to condensate tlap. Tube

does not need to be cut.

(b.) Clamp tube to prevent any condensate leakage.

(2.) Condensate Trap Located on Right Side of Casing

Ca3 Install drain robe coupling (fhctow-supplied in

loose parts bag) into collector box drain robe

(blue and white striped label) which was previ=

ously plugged.

(b.) Connect larger diameter &ain robe (_tctory°

supplied in loose parts bag) to &ain tube cou°

piing, extending collector box drain robe for

connection to condensate trap.

(c.) Route extended collector box drain robe between

gas valve and inlet housing as shown in Fig. 9.

(d.) Determine appropriate length and cut.

(e.) Connect to condensate trap.

(f.) Clamp robe to prevent any condensate leakage.

2. Inducer Housing Drain Tube

a Remove fhctoEyoinstalled cap and clamp from LOWER

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

&ain robe which was previously connected to condensate

t_ap.

c Install cap and clamp on UPPER inducer housing &ain

connection where molded &ain robe was removed.

d. l_se inducer housing &ain robe (violet label and factoQ-

supplied in loose parts bag) to connect LOWER inducer

housing drain connection to the condensate trap.

e. Connect inducer housing drain connection to condensate

trap.

(10 Condensate Trap Located on Left Side of Casing

Ca,) Determine appropriate length and cut,

(b.) Connect tube to condensate trap.

(c.) Clamp robe to prevent any condensate teakage

(20 Condensate Trap Located on Right Side of Casing

Ca.) Route inducer housing drain tube (violet 1abel)

between gas valve and inlet housing behind col-

lector box drain tube

(b) Determine appropriate length and cut

(c.) Connect robe to condensate trap.

(d) Clamp robe to prevent any condensate teakage.

3 Relief Port Tube

Refkr to Pressure Switch Tubing section fbr connection

procedure

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section fbr recommendations and

procedures,

PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to

the pressure switch fbr use when furnace is installed in UPFLOW

applications. This robe MUST be disconnected and used for the

condensate trap relief port robe. The other collector box pressure

robe (green label) which was f_ctory connected to the condensate

trap relief port connection MUST be connected to the pressure

switch in DOVv_TLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 8 or 9 or robe routing label on main fhrnace door

to check fbr proper connections

Relocate robes as described below.

1. Disconnect collector box pressure robe (pink label) attached to

pressure switch

2. Use smaller diameter robe (factor-supplied in loose parts

bag) to extend collector box pressure tube (green label) which

was previously connected to condensate t_ap relief port

connection.

3. Connect collector box pressure robe (green label) to pressure

switch connection labeled "collector box."

4. Use remaining smaller diameter robe (factmT-supplied in

loose parts bag) to extend collector box pressure robe (pink

label) which was previously connected to pressure switch.

5. Route this extended tube (pink label) to condensate trap relief

port connection.

6. Determine appropriate length, cut, and connect robe.

7. Clamp robe to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommenda-

tions and procedures

Step 4--Horizontal Left (Supply-Air Discharge)

Applications

A horizontal left fhrnace application is where fhrnace blower is

located to the right of combustion and controls section of' furnace,

and conditioned air is discharged to the left.

PLUG

AUXILIARY 'U" BOX COLLECTOR BOX

DRAIN TUBE

(BLUE AND WHITE STRIPED)

CONDENSATE

TRAP COLLECTOR BOX

TUBE (GREEN)

BOX EXTENSION

DRAtNTUBE

COLLECTOR BOX

EXTENSION TUBE

HOUSING

DRAIN TUBE (VIOLET)

BOX

DRAIN TUBE (BLUE)

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040,060, AND 080 HEATING INPUT FURNACES

Fig. 10--Horizontal Left Tube Configuration

A00215

CONDENSATE TRAP LOCATION

The condensate tlap must be removed from the factor-installed

blower shelf location and relocated in selected application location

as shown in Fig. 2or 10.

To relocate condensate trap from the blower shelf to desired

location, perform the Ibllowing:

1. Remove 3 robes connected to condensate trap.

2. Remove tlap flora blower shelf by gently pushing tabs inward

and rotating trap.

3. Install casing hole filler cap (factov-supplied in loose parts

bag) into blower shelf hole where tlap was removed.

-9 CARBON MONOXIDE POISONING HAZARD

Failure to _bllow this warning could result in personal injury

or death.

Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated.

4. Install condensate trap into casing hole by inserting tube

connection stubs through casing hole and rotating until tabs

snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler

caps (fi_ctory=supplied in loose parts bag)

CONDENSATE TRAP TUBING

NOTE: See Fig. 10 or tube routing label on main fl/rnace door to

check for proper connections.

1. Collector Box Drain Tube

a Install &ain tube coupling (factory-supplied in loose parts

bag) into collector box drain tube (blue label) which was

previously connected to condensate trap

b. Connect large diameter drain robe and clamp (factory-

supplied in loose parts bag) to drain robe coupling, extend-

ing collector box &ain robe

c Route extended robe (blue label) to condensate trap and cut

to appropriate length

d. (lamp robe to prevent any condensate leakage.

2. Inducer Housing Drain Tube

a. Remove and discard LOWER (molded) inducer housing

drain robe which was previously connected to condensate

trap.

b. Use inducer housing &ain extension robe (violet label and

factoryosupplied in loose parts bag) to connect LOWER

inducer housing &ain connection to the condensate trap.

c. Detem_ine appropriate length, cuL and connect robe.

d. (lamp robe to prevent any condensate leakage.

3. Relief Port Tube

a. Use smaller diameter robe (factov-supplied in loose parts

bag) to extend collector box tube (green label) which was

previously connected to the condensate trap.

b. Route extended collector box pressure robe to relief port

connection on the condensate trap.

c. Detem_ine appropriate length, cuL and connect robe.

d. (lamp robe to prevent any condensate leakage.

A 3-IN. MINIMUMCLEARANCE

TO COMBUSTION-AIRINTAKE _VENT

IS REQUIRED.

INTAKE

30-IN. MtN

, A 12-tN. MIN HORIZONTAL PIPE

SECTION tS RECOMMENDED WITH

SHORT (5 TO 8 FT) VENT SYSTEMS

TO REDUCE EXCESSIVE

CONDENSATE DROPLETS FROM

EXITING THE VENT PIPE.

SHUTOFF

GAS VALVE

SEDIMENT

TRAP CONDENSATE

TRAP

DRAIN

ACCESS OPENING

FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

FURNACE AND CONDENSATE TRAP WHEN A CONDENSING

FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.

Fig. 11--Attic Location and Working Platform

A96184

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section %r recommendations and

procedures

PRESSURE SWIT(H TUBING

The LOWER collector box pressure tube (pink label) is fhctory

connected to the pressure switch for use when [_urnace is installed

in UPFLOW applications. This tube MUST be disconnected,

extended, rerouted, and then reconnected to the pressure switch in

HORIZONTAL LEFT applications.

NOTE: See Fig. 10 or tube routing label on main Nmace door to

check for proper connections.

Modify robe as described below.

1. Disconnect collector box pressure tube (pink label) attached to

pressure switch.

2. Use smaller diameter tube (factory-supplied in loose parts

bag) to extend tube disconnected in item 1.

3. Route extended robe:

a. Behind inducer housing.

b. Between blower shelf and inducer housing.

c. Behind inducer motor bracket.

d. Between inducer motor and pressure switch.

4. Detem_ine appropriate length, cut, and reconnect robe to

pressure switch connection labeled COLLE(TOR BOX.

CONDENSATE TRAP FREEZE PROTECTR)N

Refkr to Condensate Drain Protection section for recommenda°

tions and procedures.

(ONSTRU(T A WORKING PLATFORM

(onstruct working plat%m_ where all required furnace clearances

are met (See Fig. 3 and 11)

INIT MAY NOT OPERATE

Failure to fbltow this caution may result in intem_ittent unit

operation.

The condensate trap MUST be installed below furnace See

Fig. 5 [br dimensions. The drain connection to condensate

nap must also be properly sloped to an open drain.

NOTE: Vent pipe length is restricted to a minimum of 5 It. (See

Table 8.)

NOTE: A 12-in. minimum horizontal pipe section is recom-

mended with short (5 to 8 f_) vent systems. This recommendation

is to reduce excessive condensate droplets fi'om exiting the vent

pipe. (See Fig. 11 or 38.)

Step 5--Horizontal Right (SupplyoAir Discharge)

Applications

A horizontal right furnace application is where furnace blower is

located to the tel} of combustion and controls section of fi/mace,

and conditioned air is discharged to the right.

MINOR PROPERTY DAMAGE

Failure to fbllow this caution may result in minor property

damage

Local codes may require a drain pan under entire furnace and

condensate trap when a condensing fi/rnace is used in attic

application or over a finished ceiling_

PLUG

CAP BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

BOX RELOCATED HERE

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE

TRAP

A00214

Fig. 12--Horizontal Right Tube Configuration

NOTE: In (anada, installations shall be in accordance with

current NSCNGPIC Installation Codes andor local codes.

NOTE: The auxilial_- junction box (J°Box) MUST be relocated to

opposite side of _/rnace casing. (See Fig. 12.) See Electrical

Connection section _br J-Box relocation.

CONDENSATE TRAP LOCATION

The condensate tlap must be removed from the factor-installed

blower shelf location and relocated in selected application location

as shown in Fig. 2or 12.

To relocate condensate trap from the blower shelf to desired

location, perform the fbllowing:

1. Remove 3 tubes connected to condensate trap.

2. Remove tlap fi'om blower shelf by gently pushing tabs inward

and rotating trap.

3. Install casing hole filler cap (factov-supplied in loose parts

bag) into blower shelf hole where tlap was remo_ ed.

--> (ARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal in3u D'

or death.

Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated.

4. Install condensate trap into casing hole by inserting tube

connection stubs through casing hole and rotating until tabs

snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler

caps (_Sctoryosupplied in loose parts bag)

(ONDENSATE TRAP TL BING

NOTE: See Fig 12 or robe routing label on main furnace door to

check for proper connections

1. Collector Box Drain Tube

a Remove _ctoryoinsta!led plug from LOWER collector box

drain robe (blue and white striped label).

b. Install removed clamp and plug into UPPER collector box

&ain tube (blue label) which was previously connected to

condensate tlap.

c. Connect LOWER collector box drain robe (blue and white

striped label) to condensate trap. Tube does not need to be

cut.

d. (lamp robe to prevent any condensate leakage.

2. Inducer Housing Drain Tube

a. Remove fhctoryoinstalled cap and clamp from LOWER

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

&ain robe which was previously connected to condensate

tlap.

c. Install cap and clamp on UPPER inducer housing &ain

connection where molded &ain robe was removed.

d. Use inducer housing &ain extension tube (violet label and

factory-supplied in loose parts bag) to connect LOWER

inducer housing &ain connection to condensate trap.

e. Detem?ine appropriate length, cuk and connect robe to

condensate trap.

_ Clamp robe to prevent any condensate leakage.

3. Relief Port Tube

Refer to Pressure Switch Tubing section _br connection

procedure.

(ONDENSATETRAP FIELD DRAIN ATTA(HMENT

Ref?r to Condensate Drain section %r recommendations and

procedures

PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is fhctory connected to

the pressure switch fbr use when furnace is installed in UPFLOW

applications. This robe MUST be disconnected and used for the

condensate trap relief port robe. The other collector box pressure

robe (green label) which was fhctory connected to the condensate

trap relief port connection MUST be connected to the pressure

switch in DOW2qFLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 12 or robe routing label on main furnace door to

check for proper connections.

Relocate tubes as described belom

1. Disconnect collector box pressure tube (pink label) attached to

pressure switch.

2. Use smaller diameter robe (factory-supplied in loose parts

bag) to extend collector box pressure robe (green label) which

was previously connected to condensate trap relief port

connection

3. Route extended collector box pressure robe behind inducer

motor bracket then between inducer motor and pressure

switch.

4. Connect collector box pressure tube (green label) to pressure

switch connection labeled COLLECTOR BOX.

5. Use remaining smaller diameter tube (g_ctoryosupplied in

loose parts bag) to extend collector box pressure tube (pink

label) which was previously connected to pressure switch.

6. Route this extended tube (pink label) to condensate trap relief

port connection.

7. Detem_ine appropriate length, cut, and connect robe.

8. (lamp robe to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendao

tiGriS and procedures.

CONSTRUCT A WORKING PLATFORM

Construct working platfbrm where all required Nrnace clearances

are met. (See Fig. 3 and 11.)

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intem_ittent unit

operation.

The condensate trap MUST be installed below fire, ace. See

Fig 5 £br dimensions. The drain connection to condensate

trap must also be properly sloped to an open &ain

NOTE: Vent pipe length is restricted to a n_ininmm of 5 ft. (See

Table 8.)

NOTE: A 12-in. minimum horizontal pipe section is recomo

mended with short (5 to 8 f0 vent systems. This recomn_endation

is to reduce excessive condensate droplets from exiting the vent

pipe (See Fig. 11 or 38)

UPFLOW OR DOWNFLOW

V2" MAX

HORIZONTAL

A02146

Fig. 13--Furnace Location for Proper Condensate

Drainage

LOCATION

Step l--General

This furnace must

* be installed so the electrical components are protected from

water.

not be installed directly on any combustible material other than

wood flooring (refkr to SAFETY CONSIDERATIONS).

* be located so combustion-air and vent pipe maximun_ lengths

are not exceeded. Refkr to Table 8

* be located where available eteca'ic power and gas supplies meet

specifications on the furnace rating plate

* be attached to an air distribution system and be located as close

to the center of the distribution system as possible Refer to Air

Ducts section

* be provided with ample space fi_r servicing and cleaning.

Always comply with mininmm fire protection clearances

shown on the Nrnace clearance4oocombustibles label.

NOTE: For upflowidownflow applications install fhrnace so that

it is level or pitched _bnvard within 1/2Gin. for proper hmaace

operation. For horizontal applications pitch 1/4-in. minimum to

li2oin, naaximum forward to ensure proper condensate &ainage

from secondaw heat exchangers. (See Fig. 13.)

When a furnace is installed so that supply ducts car_- air circulated

by the filmace to areas outside the space containing the fine, ace.

the return air shall also be handled by &lct(s) sealed to filmace

casing and terminating outside tl_e space containing the fitrnace to

ensure there will not be a negative pressure condition within

equipment room or space.

UNIT DAMAGE HAZARD

Failure to _bllow this caution may result in intermittent unit

operation.

Do not install furnace in a con'osive or contaminated atmoo

sphere Make sure all combustion and circulating air require°

nlents are met

BACK

A93043

Fig. 14_Prohibit Installation on Back

--€ UNIT DAMAGE HAZARD

This gas fire, ace may be used %r construction heat provided

that:

-The hu'nace is permanently installed with all electrical

wiring, piping, air filters, venting and ducting installed

according to these installation instructions. A return air duct

is provided, sealed to the furnace casing, and tem_inated

outside the space containing the Nrnace. This prevents a

negative pressure condition as created by the circulating air

blower, causing a flame rollout and/or &awing combustion

products into d-_estructure.

-The t\lmace is controlled by a thermostat. It may not be "hot

wired" to provide heat continuously to the structure without

thermostatic control.

-Clean omside air is provided for combustion. This is to

minimize the con'osive eff)cts of adhesives, sealers and other

constr_ction materials. It also prevents the entrainment of

dwwall dust into combustion air, which can cause fouling and

plugging of furnace components.

-The temperature of the retmn air to the fhrnace is maintained

between 55_T (13%) and 80°F (27%), with no evening

sethack or shutdown. The use of the filrnace while the

structure is under construction is deemed to be intem_ittent

operation per our installation instructions.

-The air temperature rise is within the rated rise range on the

fm'nace rating plate, and the firing rate has been set to the

nameplate value.

-The filters used to clean the circulating air during the

construction process nmst be either changed or thoroughly

cleaned prior to occupancy.

-The fi/rnace, ductwork and filters are cleaned as necessary to

remove &ywall dust and construction debris tiom all HVA(

system components after construction is completed.

-After construction is complete, verii}' fhmace operating

conditions including ignition, input rate, temperatt_re rise and

venting, according to the manufhcturer's instructions.

Step 2--Furnace Location Relative to Cooling

Equipment

_he cooling coil must be installed parallel with or on downstleam

side of furnace to avoid condensation in heat exchanger. When

installed parallel with a f:tmaace, dampers or other means used to

control flow of air shall be adequate to prevent chilled air tiom

entering filrnace. If dampers are manually operated, they must be

equipped with a means to prevent operation of either unit unless

damper is in fi/ll-heat or fi/tl=cool position.

_32°F MINIMUM INSTALLED

/AMBIENT OR FREEZE

_\\ _! PROTECTION REQUIRED

A93058

Fig. 15--Freeze Protection

FIRE, INJURY OR DEATH HAZARD

Failure to %llow this warning could result in fire, personal

iajury, or death

Do not install t'umace on its back. (See Fig. 14.) Safety

control operation will be adversely affected Never connect

return-air ducts to back of fi/rnace.

[N[T DAMAGE HAZARD

Failure to [bllow this caution may result in minor property or

unit damage.

If this f_/rnace is installed in an unconditioned space where

ambient temperatt_res may be 32_>For lower, fieeze protection

measures must be taken. (See Fig 15.)

Step 3--Hazardous Locations

[]

FIRE, EXPLOSION, INJURY OR DEATH HAZARD

Improper location or inadequate protection could result in fire

or explosion

When the 51mace is installed in a residential garage_ the

burners and ignition sources must be located at least 18 in.

above the floor. The filrnace must be located or protected to

avoid physical damage by vehicles. When the 141mace is

installed in a public garage, airplane hangar, or other building

having a hazardous atmosphere, the fi/rnace must be installed

in accordance with the NFG( or NSCNGPIC. (See Fig. 16.)

AIR FOR COMBUSTION AND VENTILATION

Provisions fbr adequate combustion, ventilation, and dilution air

must he provided in accordance with:

* U.S. Ins_alla{ions: Section 8.3 of the NFGC, Air for Combuso

tion and Ventilation and applicable provisions of the local

building codes

* (anadian Installations: Part 7 of the NS(NGPI(, Venting

Systems and Air Supply for Appliances and all authorities

having jurisdiction

18-IN. MINIMUM

TO BURNERS

Fig. 16--1nstNtation in a Garage

A93044

F[ RNA(E CORROSION HAZARD

Air _br con_bustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and

iodide. These elements could corrode heat exchangers and

shorten fhmace life. Air contaminants are found in aerosol

sprays, detergents, bleaches, cleaning solvents, salts, air

fresheners, and other household products.

The following types of fl_mace installations may require OUT°

DOOR AIR fbr combustion due to chemical exposures:

° Commercial buildings

° Buildings with indoor pools

° LaundQ- rooms

* Hobby or craft rooms, and

* Chemical storage areas

If air is exposed to the fbllowing substances, it should not be used

for combustion air, and outdoor air may be required _br eombus°

tion:

Permanent wave solutions

Chlorinated waxes and cleaners

Chlorine based swimming pool chemicals

Water sokening chemicals

Deqcing 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 _hbric softeners _br clothes dQ'ers

Masonry acid washing materials

All fuel=burning equipment must be supplied with air fbr Net

combustion. Sufficient air must be provided to avoid negative

pressure in the equipment room or space. A positive seal must be

made between the Nmace cabinet and the returnoair duct to

prevent pulling air fi'om the burner area and from &aft safeguard

opening.

CARBON MONOXIDE POISONING HAZARD

The operation of exhaust fans, kitchen ventilation _ms,

clothes &yers, attic exhaust fans or fireplaces could create a

NEGATIVE PRESSURE (ONDITION at the furnace.

Make-up air MUST be provided for the ventilation devices, in

addition to that required by the fl/rnace. Refer to the (arbon

Monoxide Poisoning Hazard warning in the venting section

of these instructions to determine if an adequate amount of

make=up air is available.

The requirements for combustion and ventilation air depend upon

whether or not the fl/mace is located in a space having a volmne

of at least 50 cubic feet per 1,000 Bmh input rating ibr all gas

appliances installed in the space.

Spaces having less d-_an 50 cubic feet per 1,000 Bmh require

the O[ TDOOR (OMB[ STION AIR METHOD.

Spaces having at least 50 cubic feet per 1,000 Btuh may use the

INDOOR ( OMBUSTION AIR, STANDARD or KNOWN-

AIR INFILTRATION METHOD.

Outdoor (ombustion Air Method

1. Provide the space with sufficient air %r proper congbustion,

ventilation, and dilution of flue gases using pem_anent hori-

zontal or vertical duct(s) or opening(s) directly comnmnicat-

ing with the outdoors or spaces that freely communicate with

the outdoors

2_ Fig. 17 illustrates how to provide TWO OUTDOOR OPEN-

INGS, one inlet and one outlet combustion and ventilation air

openings to the outdoors.

a. One opening MUST commence within 12" (300 mm) of

the ceiling and the second opening MUST commence

within 12" (300 mm) of the floor.

b. Size openings and ducts per Fig. 17 and Table 1.

c. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btuh (1,100 mm2ikW) of combined

input fi_r all gas appliances in the space per Fig. 17 and

Table 1.

d_ TWO OPEND._GS OR VERTI(AL DUCTS require 1

square inch of flee area per 4,000 Btuh (550 ram2 kW) _br

combined input of all gas appliances in the space per Fig.

17 and Table 1

3. ONE OUTDOOR OPENING requires:

a. 1 square inch of flee area per 3,000 Btnh (734 n'lnl2ikW)

for combined input of all gas appliances in the space per

Table 1 and

b. Not tess than the sum of the areas of all vent connectors in

the space

The opening shall commence within 12" (300 mm) of the

ceiling. Appliances in the space shall have clearances of at

least 1" (25 ram) from the sides and back and 6" (150 mm)

fiom the front. The opening shall directly communicate

with the outdoors or shall communicate through a vertical

or horizontal duct to the outdoors or spaces (crawl or attic)

that fl-eely communicate with the outdoors.

Indoor Combustion Air_) NFPA & AGA

Standard and Known-Air-InfiRration Rate Methods

Indoor air is permitted %r combustion, ventilation, and dilution,

if the Slandard or Known-Air-InfiRration Method is used

Table 1--Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OP_=N_NGS OR VI=RTICAL DUCTS

FURNACE

iNPUT

(BTUH)

44,000

66,000

88,000

110,000

132,000

154,000

{1 SQ. IN.I2,000 BTUH)

Free Area of

Opening and Duct

(sq. in.)

{t,100 SO. MMtKW)

Round Duct

(in. Dia)

(1 SQ. IN.t3,000 BTUH)

Free Area of

Opening and Duct

(sq In.)

14.7

29.3

36.7

51.3

(734 SO. MM/KW)

Round Duct

(in. Dia)

{1 SQ. IN.14,000 BTUH)

Free Area of

Opening and Duct

(Sq In.)

16.5

27.5

38.5

(550 SO. MMiKW)

Round Duct

(In. Dia)

EXANPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

t10,000 + 30,000 = (140,000 divided by 4,000) 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 = (t06,000 divided by 3,000) 35.3 Sq. In. for a Single Duct or Opening

88,000 + 30,000 = (t 18,000 divided by 2,000) 59.0 Sq. tn. for each of two Horizontal Ducts

Table 2--Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors

OTHER THAN FAN-ASSISTED TOTAL [ FAN-ASSISTED TOTAL

{1,000'S BTUH GAS INPUT RATE) / {1,000'S BTUH GAS INPUT RATE)

ACH 30 I 40 I 50 44 166 I 88 1110 1132 1154

Space Volume (fts)

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

0.50 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.t0 6,390 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

CARBON MONOXIDE POISONING HAZARD

Failure to supply outdoor air via grilles or dncts could result

in death and/or personal i11iury.

Many homes require air to be supplied flora outdoors for

ftlrnace combustion, ventilation, and dilution of flue gases.

The _b.mace combustion air supply must be provided in

accordance with this instruction manual.

The Standard Method:

1. The space has no less volume than 50 cubic f)et per 1,go0

Btuh of the n_axinmm 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 (A(H)

The Known 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

minimum required volume of tl_e space varies with the number of

ACH and shall be determined per Table 2or Equations 1 and 2.

Determine the mininmna required volume for each appliance in the

space and add the volumes together to get the total mininmm

required volume %r the space.

Table 2:Minimum Space Volumes were detem_ined by using the

following equations flora the Yationa/ F_el Gas Co&_ A:\%7

Z223.J-2002/YFP.t 54-2002,&3.2.2:

1. For ether than fan-assisted appliances, such as a draft

hoodoequipped water heater:

'Volume - 21ft3

ether ACH

A04002

2, For fan-assisted appliances such as this _hrnace:

- 15ft3f- If_,

Volume Fan AOH 00(_ B-_u/hr

A04003

Iom_ combined input of all other than fan-assisted appli-

ances in Bmihr

I_.,, combined input of all fan-assisted appliances in Bm&r

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.

OUTDOORS

1 SQ IN.

PER4000

BTUH*

12"MAX

1 SQ IN.

PER2000

BTUH*

DUCTS

OUTDOORS

1 SQ IN.

PER2000

BTUH T

12"*MAX

12"

MAX

1 SQ IN.

PER

4000

BTUH*

1 SQ IN.

PER

4000

BTUH*

12 "_

MAX

CIRCULATING AIR DUCTS

OUTDOORS

*Minimum dimensions of 3 in.

NOTE: Use any of the following

combinations of openings:

A&B C&D D&E F&G

1SQ IN

PER4000

BTUH*

A03174

Fig. 17--Air for Combustion, Ventilation, and Ditution

for Outdoors

1. Adjoining rooms can be considered part of a space ik

a There are no closable doors between rooms.

b. Combining spaces on same floor level Each opening shall

have free area of at least 1 in.2/1,000 Bmh (2,000 mm2&W)

of the total input rating of all gas appliances in the space,

but not less than 100 in. 2 (0.06 m 2) One opening shall

commence within 12" (300 nrm) of the ceiling and the

second opening shall commence within 12" (300 ram) of

the floor. The mininmm dimension of air openings shall be

at least 3 in. (80 ram). (See Fig. 18.)

c. Combining space on dif£)rent floor levels. The volumes of

spaces on different floor levels shall be considered as

communicating spaces if connected by one or more permao

nest openings in doors or floors having fi'ee area of at least

2in.S/l,000 Bmh (4,400 ramS&W) of total input rating of

all gas appliances.

2. An attic or crawlspace *nay be considered a space that freely

communicates wit}* the outdoors provided there are adequate

permanent ventilation openings directly to outdoors having

fi'ee area of at least 1-in.2/4,000 Bmh of total input rating for

all gas appliances in the space.

3. In spaces that use d_e Indoor Combustion Air Method,

infiltration should be adequate to provide air for combustiom

permanent ventilation and diludon 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.

_CIRCULATING[DUCTS AIR

I I

VENT THROUGH ROOF

INTERIOR

HEATED

SPACE

- l

CIRCULATING AIR DUCTS

F- _ 1 SQ IN.

co PER 1000

ca BTUH* IN DOOR

:_ ORWALL

mUNCONFINED

O SPACE

a: 6" MtN

m(FRONT)t

o 1 SQtN.

z PER 1000

a: BTUH* IN DOOR

<: S ORWALL

L12" MAX

* Minimum opening size is 100 sq in. with

minimum dimensions of 3 in.

'Minimum of 3 in when type-B1 vent is used

A03175

Fig. 18--Air for Combustion, Ventilation, and Dilution

from Indoors

Lnusually tight construction is defined as

( onstr_/ction with:

a. Walls and ceilings exposed to the outdoors have a continu_

ous, sealed vapor bare'let. 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 frames, between sole plates and

floors, between wall-ceiling joints, between wal! panels, at

penetrations fbr plumbing, electrical and gas lines, etc.

NOTE: In detem_ining the fi'ee area of an opening, the blocking

ef_kct of the louvers, grilles, and screens must be considered. If the

free area of a louver or grille design is unknown, it may be

assumed that wood louvers have a 20 percent fi'ee area, and metal

louvers or grilles have a 60 percent fi'ee area. Screens, when used,

must not be smaller than 1i4oin. mesh. Louvers and grilles must be

constructed so they cannot be closed.

When combustion air ducts are used, they nmst be of the same

cross sectional area as d-*eflee area of the openings to which they

connect. The minimum dimension of ducts must not be less than 3

in. (80mm).

Combination of Indoor and Outdoor Air

1. [ndoor openings shall compy with the Indoor Combustion

Air Method below and,

2. Outdoor openings shall be located as required in the Outdoor

Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as %llows:

a. (alculate the Ratio of all Indoor Space volume divided by

required volume fbr Indoor (ombustion Air Method

below.

b. Outdoor opening size rednction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combus{ion Air Method above

multiplied by reduction Factor in b. above. The mininlnnl

dimension of air openings shall be not tess than 3 in. (80

111111) 0

BNSTALLATION

Step l--Leveling Legs (If Desired)

When furnace is used in opflow position with side inlet(s), leveling

legs may be desired. (See Fig. 19.) Install field-supplied,

corrosion-resistant 5/16-im machine bolts and nuts.

NOTE: The nlaximmll length of bolt should not exceed 1- 1/2 in.

1. Position flmaace on its back. Locate and drill a 5/16=in.

diameter hole in each bottom corner of furnace. (See Fig. 19.)

Holes in bottom closure panel may be used as guide locations.

2. For each hole. 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 fl/mace base. (Install flat

washer if desired.)

4. Adjust outside nut to provide desired height, and tighten inside

nut to secure arrangement.

NOTE: Bottom closure must be used when leveling legs are used

See Bottom Closure Panel section

Step 2--_nstaHation in Upfiow and Downflow

Applications

NOTE: For downflow applications, this fhrnace is approved for

use on combustible flooring when special base (available fl'om

manufacturer) Part No. KGASB0201ALL is used. Special base in

not required when dlis fhmace is installed on manufacturer's (?oil

Assenlbly Part No. CD5 or CK5, or (;oil Box Part No. KCAKC is

used,

1. Determine application being installed from Table 3.

2. (onstruct hole in floor per dimensions specified in Table 3

and Fig. 20.

Fig, 19--Leve{ing Legs

A89014

3. (onstruct plenum to dimensions specified in Table 1 and Fig.

20.

4. If downflow subbase (KGASB) is used, install as shown in

Fig. 2!.

If (oil Assembly Part No. CD5 or CK5 or Coil Box Part No

KCAKC is used, install as shown in Fig. 22.

NOTE: Remove t:umace perR_rated, discharge duct flanges when

they interfere with mating flanges on coil on downflow subbase.

To remove fi/rnace perforated, discharge duct flange, use wide

duct pliers or dtlct flange tool to bend flange back and forth until

it breaks off_ Be carefld of sharp edges. (See Fig. 23.)

UNIT MAY NOT OPERATE

Failure to follow this caution could result in intermittent unit

operation.

Do not bend duct flanges inward as shown in Fig 23 This

will affect airflow across heat exchangers arid may cause limit

cycling or premature heat exchanger fifilure. Remove duct

flange completely or bend it inward a nlininlnm of 2!0 ° as

shown in Fig, 23

Step 3--hstaHation in Horizontal Applications

tNIT MAY NOT OPERATE

Failure to %llow tllis caution may result in intermittent unit

operation.

The entire length of flmlace MUST be supported when

furnace is used in a horizontal position to ensure proper

draining. When suspended, bottom brace supports sides and

center blower shelf When unit is supported fi'om file ground,

blocks or pad should support sides and center blower shelf

area.

These furnaces can be installed horizontally in either horizontal

left or right discharge position. In a crawlspace, fmnace can either

be hung from floor joist or installed on suitable blocks or pad.

Furnace can be suspended flora each corner by hanger bolts and

angle iron supports. (See Fig. 24.) (Jut hanger bolts (4 each 3i8=im

all=thread rod) to desired length. Use 1 X 3i8=im flat washers.

3/%in. lockwashers, and 3/8=in. nuts on hanger rods as shown in

Fig. 24. Dimples are provided for hole locations. (See Fig. 2.)

Step 4-==Air Ducts

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 arid

Air Conditioning ContIactors National Association (SMACNA) or

American Society- of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE) or consult The Ai_' 5)',slems DesNr_ Gzdde-

[i_ves refkrence tables available fi'om your local distributor. The

duct system should be sized to handle the required system design

CFM at the design static pressure.

When a furnace is installed so that the supply ducts caia T air

circulated by the furnace to areas outside _he space containing the

Nrnace, the remm air shall also be handled by a duct(s) sealed to

the furnace casing and temlinating outside the space containing the

furnace

Secure ductwork with proper fasteners for type of ductwork used.

Seal supply° and return-duct connections to furnace with code

approved tape or duct sealer.

A96283

Fig. 20--Floor and Plenum Opening Dimensions

SUBBASE

PLENUM

-- FLOOR --

OPENING

A96285

Fig. 21--Furnace_ Plenum, and Subbase

Installed on a Combustible Floor

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

FLOORING

SHEET METAL

PLENUM

__ FLOOR __

OPENING

A96284

Fig. 22--Furnace, Plenum, and CoN

Assembly or Coil Box Installed

on a Combustible Floor

FURNACE

CASING

WIDTH

Table 3--Opening Dimensions (In.)

APPLICATION C

Upflow Applications 16-5/8

Downflow Applications on Non-Combustible Flooring 16-1/2

t7ot/2 Downflow Applications on Combustible Ftooring Using KGASB Subbase 16-3/4

Furnace with or without CD5 or CK5 Coil Assembty or KCAKC Coil Box

Downflow Applications on Combustible Ftooring NOT Using KGASB Subbase 16-1/2

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

Upflow Applications 20-1/8

Downflow Applications on Non-Combustible Flooring 20

21 Downflow Applications on Combustible Ftooring Using KGASB Subbase 20-1/4

Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Ftooring NOT Using KGASB Subbase 20

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

Upflow Applications 23-5/8

Downflow Applications on Non-Combustible Flooring 23-1/2

24ott2 Downflow Applications on Combustible Ftooring Using KGASB Subbase 23-3/4

Furnace with or without CD5 or CK5 Coil Assembty or KCAKC Coil Box

Downflow Applications on Combustible Ftooring NOT Using KGASB Subbase 23-1/2

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

PLENUM OPENING

A B

16 24-1/8

15-7/8 19

15-1/8 19

15-1/2 19

19-1/2 24-1/8

19-3/8 19

18-5/8 19

19 19

23 24-1/8

22W/8 19

22-1/8 19

22-1/2 19

FLOOR OPENING

24-3/4

19-5/8

20-3/8

24-3/4

19-5/8

20-8/8

24-3/4

19-5/8

20-3/8

DISCHARGE DUCT

FLANGE

Horizontal Furnaces

(onnect supply-air &ct to supply air opening on ftm_ace The

supply-air duct attachment must ONLY be connected to ftmaace

supply/outlet or air conditioning coil casing (when used) DO NOT

cut main f_rnace casing to attach supply side air duct, humidifier,

or other accessories. All accessories MUST be connected external

to fhrnace main casing.

I I

210 ° .....................

MIN

Fig. 23--Duct Flanges

YES

A93029

Flexible connections should be used between ductwork and

_;,/rnace to prevent transmission of vibration Ductwork passing

through unconditioned space should be insulated to enhance

system perforn_ance. When air conditioning is use& a vapor

barrier is recommended.

Maintain a l-in. clearance fi'om comhustible materials to supply air

ductwork fbr a distance of 36 in. horizontally fiom the t_urnace. See

NFPA 90B or local code fbr _hrther requirements.

For a fhmace not equipped with a cooling coil, the outlet duct shall

be provided with a removable access panel. This opening shall be

accessible when the ft,.mace is installed and shall be of such a size

that the heat exchanger can be viewed %r possible openings using

light assistance or a probe can be inserted for sampling the air

stream. The cover attachment shall prevent leaks.

DU(TWORK ACOUSTICAL TREATMENT

Metal duct systems that do not have a 90 degree elbow and 10 fi

of main &ct to the first branch rake-off may require internal

acoustical lining As an ahernative, fibrous ductwork may be used

if constructed and installed in accordance with the latest edition of

SMACNA construction standard on fibrous glass ducts Both

acoustical lining and fibrous ductwork shall comply with NFPA

90B as tested by UL Standard 181%r (lass 1 Rigid air ducts.

SUPPLY AIR (ONNECTIONS

Lpflow Furnaces

Connect supply-air duct to 3/4-in flange on _hrnace supply-air

outlet. The supply-air duct attachment must ONLY be connected

to fbrnace supply-/outlet-air duct flanges or air conditioning coil

casing (when used) DO NOT cut main fhmace casing to attach

supply side air duct, humidifier, or other accessories. All accesso-

ries MUST be connected external to ft_rnace main casing

Downflow Furnaces

(onnect supply-air duct to supply-air opening on t_urnace. The

supply-air duct attachment must ONLY be connected to t'umace

supply/outlet or air conditioning coil casing (when used), when

installed on non-comhustible material. When installed on comhus-

tible material, supply-air duct attachment nmst ONLY be con-

nected to an accesso_- subbase or _i_ctory approved air condition-

ing coil casing. DO NOT cut main fhmace casing to attach supply

side air duct, humidifier, or other accessories. All accessories

MUST be connected external to fi/rnace main casing.

--9

RETETRN AIR (ONNECTIONS

The t:t_rnace and its remm air system shall be designed and

installed so that negative pressure created by the air circulating fan

cannot a£f_ct another appliance's air supply or act to mix products

of combustion with circulating air, and that the air circulating fan

of the fhrnace, if installed in an enclosure communicating with

another fhel-burning appliance not of the direct-vent type, shall be

operable only when any door or panel covering an opening in the

ft_rnace fan compartment or in a return air plenum on ducts is in

the closed position.

FIRE HAZARD

A failure to %11ow this warning could result in fire, personal

Jr{jury, or death

Never connect return-air ducts to the back of the t'umace

Return-air duct connections on ftm_ace side(s) pem_itted in

upflow applications only

Upflow 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 2 Bypass humidifier may be attached into

unused side remm air portion of the furnace casing. DO NOT

connect any portion of return-air duct to back of furnace casing.

Downflow and Horizontal Furnaces

The return-air duct must be connected to return-air opening

provided as shown in Fig. 2DO NOT cut into casing sides or back

to attach any portion of return-air duct Bypass humidifier connec-

tions should be made at ductwork or coil casing sides exterior to

ft_rnace

Step 5--FHter Arrangement

FIRE, CARBON MONOXIDE AND POISONING

HAZARD

Failure to %11ow this warning could result in fire, personal

injury, or death

Never operate unit without a filter or with blower access

panel removed.

Factory-supplied washable framed filters are shipped in blower

comparm_ent Determine location %r filter and relocate filter

retaining wire if necessaD- See Table 4 to determine correct filter

size %r desired filter location. Table 4 indicates filter size,

location, and quantity- shipped with this _hmace. See Fig. 2for

location and size of bottom and side return-air openings.

A3-1N MINIMUM

CLEARANCE TO INTAKE

IS REQUIRED

3/8-1N. ROD

ANGLE --_

IRON OR

EQUIVALENT "_

(B)

(A)

ALTERNATE SUPPORT

LOCATION 4-IN MIN

8-IN MAX

(A) ROD LOCATION

USING DIMPLE

LOCATORS

tSEE DIMENSIONAL

DWG FOR

LOCATIONS)

3/8-1N

& WASHER (4)

REQD PER ROD

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

13/16-1N.MAX

(B) ALTERNATE SUPPORT

LOCATION FROM BACK

NOTES: 1 A 1 In. clearance minimum between top of

furnace and combustibIe material.

2 The entire length of furnace must be

supported when furnace is used in

horizontal position to ensure proper

drainage.

3 Bottom side combustion-air entry cannot

be used when furnace is installed with

hangers as shown

Fig. 24_Crawlspace HorizontN Application

A96209

TaNe 4--Filter information

FURNACE FILTER SIZE (IN.l* FILTER TYPE

CASING

W{DTN (IN.} Side Return Bottom Return FRAMED

17-1t2 (1) 16 X 25 X 11- (1) 16 X 25 X 11- Cleanable

21 (1)16X25X1 (1)20 X 25 X It C_eanab_e

24_1/2 (1 or 2/ 16 X 25 X 1 (1/ 24 X 25 X 11- C_eanable

* Filters can be field modified by cutting to the desired size. Alternate sizes

can be ordered from your distributor or dealer

? Factory-provided with furnace.

(UT HAZARD

Failure to %llow this caution may result in minor personal

injury

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.

UNIT MAY NOT OPERATE

Failure to fk_llow this caution may result in intem_ittent unit

operation.

For airflow requirements above 1800 CFM, see Air Deliveo-

table in Product Data literature for specific use of single side

inlets. The use of both side inlets, a combination of 1 side and

the bottom, or the bottom only will ensm'e adequate remm air

openings for airflow requirements above 1800 CFM.

NOTE: Side returnoair openings can ONLY be used in 1_PFLOW

configurations, Install _ter(s) as shown in Fig, 25,

WASHABLE

FILTER \

RETAINER

SPRING

A00217

Fig. 25--Filter Installed for Side Inlet

Bottom return-air opening may be used with all 4 orientations.

Filter may need to be cut to fit some I:tmaace widths Install filter

as shown in Fig 26.

Step 6--Bottom Cmosure Panel

These _i/rnaces are shipped with bottom enclosure panel installed

in bottom return-air opening. This panel MUST be in place when

side return air is used.

To remove bottom closure panel, perfbm_ the following:

1. Tilt or raise furnace and remove 2screws holding fiont filler

panel. (See Fig. 27.)

2. Rotate fiont filler panel downward to release holding tabs.

3. Remove bottom closure panel.

171/2oIN.WIDE

CASINGS ONLY:

INSTALL FELD-SUPPLIED

FILTER FILLER STRIP

UNDER FILTER.

21-IN.WIDE

CASINGS ONLY:

SUPPORT RODS (3)

EXTEND 1/4" ON EACH

SIDE OF FILTER AND

REST ON CASING FLANGE

• WASHABLE

FILTER

SUPPORT

FILTER

RETAINER

Fig. 26--Bottom Filter Arrangement

4, Reinstall fiont filler panel and screws

A00290

Step 7--Gas Piping

Gas piping must be installed in accordance with national and local

codes Refer to current edition of NFGC in the United States

Canadian installations must be made in accordance with NSCNG°

BOTTOM

CLOSURE

PANEL

FRONT FILLER

PANEL

A93047

Fig. 2g--Removing Bottom Closure Pane{

PI( and all authorities having jurisdiction. Gas supply line should

be a separate line running directly fi'om meter to t:urnace, if

possible. Refer to Table 5 fbr recommended gas pipe sizing. Risers

mnst be used to connect to fhrnace and to meter. Support all gas

piping with appropriate stlaps, hangers, etc. l_se a minimum of 1

hanger ever?" 6 ft. Joint compound (pipe dope) should be applied

sparingly and only to male threads of joints. Pipe dope must be

resistant to propane gas.

FIRE OR EXPLOSION HAZARD

Failure to %llow this warning could result in fire, explosion,

personal ir!iury, or death

-Connect gas pipe to t:m'nace using a backup wrench to avoid

damaging gas controls

-Gas vah'e shutoff switch MUST be thcing _:bp,vard or tilted

upward.

-Never purge a gas line into a combustion chamber. Never

test tbr gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of

leaks to cheek all connections.

-Use proper length of pipe to avoid stress on gas control

manit'old,

-It" a flexible connector is required or allowed by authori w

having jurisdiction, black iron pipe shall be installed at

fl/rnace gas valve and extend a n_ininmm of 2 in outside

flul_ace casing.

Install a sediment trap in riser leading to flmaace Trap can be

installed by connecting a tee to riser leading to fimaace so

straight-through section of tee is vertical. Then connect a capped

nipple into lower end of tee Capped nipple should extend below

level of gas controls. Place a ground joint union between gas

control manifold and manual gas shutoff valve (See Fig. 28)

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.

FIRE OR EXPLOSION HAZARD

Failure to %llow the safety warnings exactly could result in

serious injury, death or property damage.

Never test £_r gas leaks with an open flame. Use a commer-

cially available soap solution made specifically £_r the

detection of leaks to check all connections. A fire or explo=

sion could result causing property damage, personal injury or

toss of lit).

An accessible manual shutoff valve MLST be installed external to

the flul_ace casing and within 6 fi of furnace A 1iS=in NPT

plugged tapping, accessible tbr test gauge connection, MUST be

Table 5--Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE

SIZE

(BN.)

tl2

314

1-114

1-tl2

INTERNAL

DIAMETER

{BN.)

0.622

0.824

1.049

1.380

1.610

LENGTH OF PiPE (F7)

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 fl of gas per hr for gas pressures of 05 psig (14-in. wc) or less, and

a pressure drop of 05qn. wc (based on a 060 specific gravity gas).

Ref: Table 12-2 NFPA 54-2002.

GAS A

SUPPLY

MANUAL JII

V A" J

A93324

Fig, 28--Typical Gas Pipe Arrangement

installed immediately upstream of gas supply connection to

ftm_ace and downstleam of manual shutoff valve.

NOTE: The gas valve inlet pressure tap connection is suitable to

use as test gauge connection providing test pressure DOES NOT

exceed maxin_um 0.5 psig (14-in. wc) stated on gas valve. (See

Fig. 460

Piping should be pressure and leak tested in accordance with

NFGC in the United States or NSCNGPI( in Canada, local, and

national plumbing and gas codes bei:ore the t_urnace has been

connected. After all connections have been made, purge lines and

check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14oin. wc), gas supply pipe nmst be

disconnected fiom _i_rnace and capped be_bre pressure test. If test

pressure is equal to or less than 0.5 psig (14=in. wc), turn off

electric shutoff switch located on furnace gas valve and accessible

manual shutoff valve before test.

The gas supply pressure shall be within the n_axinmm and

minimum inlet supply pressures marked on the rating plate with

the f£maace burners ON and OFF.

Step 8--Electrical Connections

See Fig 30 £;orfield wiring diagram showing typical field 115=v

and 24-v wiring Check all _hctory and field electrical connections

for tighmess

Field=supplied wiring shall conform with the limitations of 63_T

(35°C) rise

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in serious injury or

death.

Blower access panel door switch opens l l5-v power to

control center. No component operation can occur Do not

bypass or close switch with panel removed.

F[ RNACE MAY NOT OPERATE

Failure to _bllow this caution may result in furnace operation

stopping and water pipes fi'eezing during cold weather

Furnace control must be grounded _br proper operation or

contlol will lock out (ontrol is grounded through

green yellow wire routed to gas valve and burner box screw

115°V WIRING

Befbre proceeding with electrical connections, make certain that

voltage, fi'equency, and phase correspond to that specified on unit

rating plate Also, check to be sure that service provided by power

supply is sufficient to handle toad imposed by this equipment.

Refkr to rating plate or Table 6 for equipment electrical specifi-

cations

Make all electrical connections in accordance with National

Electrical Code (NEC) ANSI NFPA 70°2002 and any local codes

or ordinances that might apply For (anadian installations, all

electrical connections must be made in accordance with Canadian

Electrical (7ode CSA C22.1 or authorities having jurisdiction.

Use a separate, filsed branch electrical circuit containing a properly

sized Nse or circuit breaker [br this furnace. See Table 6 for wire

size and fuse specifications. A disconnecting means must be

located within sight fiom and readily accessible to Nmace.

UNIT

SIZE

040-08

040-12

060-08

06042

08048

08042

08048

080-20

10048

tOO-20

120-20

VOLTS--

HERTZ--

PHASE

115--60--1

OPERATING

VOLTAGE RANGE[

Max* Min*

127 104

Table 6--ElectricN Data

MAX

UNIT

AMPS

6.1

7.3

6.1

7.1

9.5

7.6

10.0

14.1

10.2

14.8

14.6

MBN

UNiT MAX WRRE

WIRE

AMPACBTY? SRZE LENGTH {FT)_

8.4 14 44

10.0 14 37

8.4 14 44

9.8 14 38

12.8 14 29

10.4 14 36

13.4 14 28

18.4 12 31

13.5 14 27

19.3 12 30

19.1 12 30

MAX FUSE OR

CKT BKR AMPS**

* Permissible limits of voltage range at which unit will operate satisfactorily.

t Unit ampacity = 125 percent of largest operating component's fu{I load amps plus 100 percent of all other potential operating components' (EAC, humidifier, etc.) full

load amps

$ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

** Time-delay type is recommended.

Table 7--Approved

ASTM SPECBFJOATION

(MARKED ON MATER_AL)

D1527

D1788

D2235

D2241

D2466

D2468

D2564

D2881

D2665

Combustion-Air and Vent Pipe, Fitting and Cement Materials

MATERIAL PiPE FITTINGS

ABS Pipe --

PVC Pipe --

For ABS -- --

PVC Pipe --

PVC -- Fittings

ABS -- Fittings

For PVC -- --

ABS Pipe Fittings

PVC Pipe Fittings

SOLVENT CEMENT AND PRBMI=RS

Solvent

Cement

Solvent

Cement

DESCRIPTBON

Schedule-40

For ABS

SDR-21 & SDR-26

Schedule-40

For PVC

DWV at Schedule-40 tPS sizes

DWV

F438

F441

F442

F493

F628

F656

F891

CPVC -- Fittings

CPVC Pipe --

For CPVC -- --

ABS Pipe --

For PVC -- --

PVC Pipe --

Solvent

Cement

Primer

Schedule-40

SDR

For CPVC

Cellular Core DWV at Schedule-40 IPS sizes

For PVC

Cettular Core Schedule-40 & DWV

NOTE: Proper polarity must be maintained for 115-v wiring If

polarity is incorrect, control center fault code indicator light will

flash rapidly and Alrnace will NOT operate.

FIRE HAZARD

Failure to %11ow this warning could result in serious injury,

death, or property damage.

Do not connect aluminum wire between disconnect switch

and furnace. Use only copper wire. (See Fig. 29.)

ELECTRIC

DISCONNECT

SWITCH

A93033

Fig. 29--Disconnect Switch and Furnace

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to fbllow this warning could result in serious inju W,

death, or property damage.

The cabinet MUST have an unintemlpted or unbroken ground

according to NEC ANSI NFPA 70-2002 and Canadian Elec=

trical (7ode CSA C22.1 or local codes to minimize personal

injury if an electrical fimlt should occur. This may consist of

electrical wire or conduit approved for electrical ground when

installed in accordance with existing electrical codes. Do not

use gas piping as an electrical ground.

J-Box Relocation

1. Remove 2 screws holding auxiliaQ' J-box. (See Fig 31.)

2. Rotate J=box 180° and attach box to leit side, using holes

provided.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning may result in serious inju W,

death, or property damage,

If manual disconnect switch is to be mounted on furnace,

select a location where a drill or fhstener will not contact

electrical or gas components.

24-V WIRING

Make field 24-v thermostat connections at 24-v terminal block on

fm'nace control For proper cooling operation, Y wire from

thermostat MUST be connected to ¥ terminal on filrnace connol,

as shown in Fig. 30. The 24=v terminal block is marked fbr easy

connection of field wiring. (See Fig. 320 The 24=vcircuit contains

a 3=amp, automotive4ype fuse located on fi/mace control. (See

Fig. 33.) Any electrical shorts of 24-v wiring during installation,

service, or maintenance may cause lime to blow. If filse replace-

merit is required, use only a time of identical size (3 amp) and type.

The control will flash code 24 when fuse needs replacement.

NOTE: Use AWG No. 18 color-coded copper thermostat wire fbr

lengths up to 100 it. For wire lengths over 100 ft, use AWG No.

16 wire.

A( CESSORIES

l. Electronic Air Cleaner (EAC)

Two quick-connect terminals marked EAC-I and EAC°2 are

provided for EAC connection. (See Fig 33) These terminals

are energized with 115v (1 0-amp maximum) during blower

motor operation.

NOTE: DO NOT connect f:urnace control HI_M tem_inal to HUM

(humidifier) terminal on Thermidistat-f_L Zone Controller or simi-

tar device See Thermidistat TM, Zone Controller, thermostat, or

controller manufi_cturer's instructions fbr proper connection.

-+ Table 8--Maximum Allowable Vent Pipe Length (Ft)

ALTITUDE

0to 2000

ALTITUDE

2001 to 3000

ALTITUDE

3001 to 4000

ALTITUDE

4001 to 5000t

UNiT SRZE

040-08

040-12

060-08

036060

060-16

080-12

080-16

080-20

100-16

100-20

120-20

UNiT SBZE

040-08

040-12

060-08

036060

060-16

080-12

080-16

080-20

100-16

100-20

120-20

UNiT SRZE

040-08

040-12

060-08

036060

060-16

080-12

080-16

080-20

100-16

100-20

120-20

UNiT SBZE

040-08

040-12

060-08

036060

060-16

080-I2

080-16

080-20

100-16

100-20

120-20

VENT PIPE

DIAMETER (IN.)

1-1/2

2-1/2

VENT PIP_=

DIAMETER (iN.)

1-1/2

2-1/2

VENT PIPE

DIAMETER (iN.)

1-1/2

2-1/2

VENT PIPE

DIAMETER (iN.)

1-1/2

2-1/2

NUMBER

1 2 3

5 NA NA

70 70 65

70 70 70

20 15 10

70 70 70

10 NA NA

55 50 35

70 70 70

5 NA NA

40 30 20

70 70 70

10 NA NA

70 70 70

NUMBER

1 2 3

67 62 57

70 70 70

17 12 7

70 67 66

49 44 30

70 70 70

35 26 16

70 70 70

63 62 62

NUMBER

I 2 3

64 59 54

70 70 70

16 11 6

68 63 62

46 41 28

70 70 70

33 24 15

70 70 70

59 59 58

NUMBER

I 2 3

60 55 50

70 70 70

15 10 5

64 59 58

44 39 26

70 70 70

31 22 13

70 70 67

56 55 54

OF 90 ° ELBOWS

4 5

NA NA

60 60

70 70

5 NA

70 70

NA NA

30 30

70 70

NA NA

20 10

70 70

NA NA

70 70

OF 00 ° ELBOWS

4 5

52 52

70 70

NA NA

61 61

25 25

70 70

16 6

70 66

61 61

OF 00° ELBOWS

4 5

49 48

70 70

NA NA

57 57

23 22

70 70

14 5

66 61

57 57

OF 00° ELBOWS

4 5

45 44

70 70

NA NA

53 52

21 20

70 70

12 NA

62 57

53 52

* Wide radius elbow

? Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction.

NA--Not Allowed; pressure switch will not make

NOTES:

1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.

2. Assume two 45 ° elbows equal one 90 ° elbow Long radius elbows are desirable and may be required in some cases

3. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.

4. The minimum pipe length is 5 fl for all applications

-+ Table8--1VlaxirnumAllowableVentPipeLength(Ft) Continued

ALTITUDE

500t to 6000t

ALTITUDE

600t to 7000t

ALTITUDE

700t to 800Ot

ALTITUDE

800t to 9000?

UNiT SiZE

040-08

040-12

060-08

036060

060-16

080-12

080-16

080-20

100-16

100-20

120-20

UNiT SIZE

040-08

040-12

060-08

036060

060-16

080-12

080-16

080-20

100-16

100-20

120-20

UNIT SiZE

040-08

040-12

060-08

036060

060-16

080-12

080-16

080-20

100-16

100-20

120-20

UNIT SIZE

040-08

040-12

060-08

036060

060-16

080-12

080-16

080-20

100-16

100-20

120-20

VENT PIPE

DIAIVIETER (IN.)

1-1/2

2-1/2

VENT PIPE

OIAIVIETER (IN.)

1-1/2

2-1/2

VENT P_PE

OIAMETER (IN.)

1-1/2

2-1/2

VENT PIPE

DIAIVIETER (IN.)

1-1/2

2-1/2

NUMBER OF 90 °

NUMBER OF 90°

ELBOWS

Wide radius elbow

i- Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction.

NA--Not Allowed pressure switch will not make

NOTES:

1 Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur

2 Assume two 45 ° elbows equal one 90 ° e@ow Long radius elbows are desirable and may be required in some cases. 3 Elbows and pipe sections within the furnace

casing and at the vent termination should not be included in vent length or elbow count.

4 The minimum pipe length is 5 ft for all applications

-_ Tab{e8--MaximumAllowableVentPipeLength(Ft) Continued

ALTITUDE UNiT S_ZE VENT PIPE

DIAMETER (BN.)

1-1/2

040-08

040-12

060-08

036060

060-I6

080-12

080-16

080-20

100-16

100-20

120-20

NUMBER OF 90 ° ELBOWS

3 4

32 27

53 51

38 33

14 9

53 51

5 NA

44 39

35 33

2 45 40 31 29

9001 to 10,000t 2 30 25 7 NA

2-1/2 57 55 49 47

2-1/2 21 13 NA NA

3 54 49 34 29

3* 39 37 31 29

* Wide radius elbow

? Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction.

NA--Not Allowed; pressure switch will not make

NOTES:

1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.

2. Assume two 45 ° elbows equal one 90 ° elbow Long radius elbows are desirable and may be required in some cases

3. Elbows and pipe sections within the furnace casing and at the vent termination should not be induded in vent length or elbow count.

4. The minimum pipe length is 5 fl for all applications

.... FIELD 24-V WIRING

.... FIELD 115-, 208/230-, 460-V WIRING

-- FACTORY 24-V WiRiNG

-- FACTORY 115-V WIRING

24-V

TERMINAl

BLOCK

FURNACE

WiRE

NOTES: 1. Connect YZterminal in furnace as shown for proper blower operation.

2. Some thermostats require a "C" terminal connection as shown.

3. if any of the original wire, as supplied, must be replaced, use

same type or equivalent wire.

Fig. 30--Typical Heating and Cooling Application Wiring Diagram

A02174

2. Humidifier (HUM)

A quick-connect terminal (HErM) and screw terminal ((oM

24°v) are provided for 24-v humidifier connection (See Fig

33) HUM terminal is energized with 24v (0.5-amp maximum)

when gas valve is energized

NOTE: A field=supplied, 115-v controlled relay connected to

EAC tem_inals may be added if humidifier operation is desired

dttring blower operation

Step 9--Venting

The 5SMSA Furnaces require a dedicated, (one 58MSA t\mlace

only) sealed vent system. All air for combustion is taken t'rom the

area adjacent to t\_rnace, and all flue gases are discharged to

outdoor atmosphere. The venting system shall be installed in

accordance to these inst_,_ctions.

REMOVAL OF EXISTING EL RNACES FROM

(OMMON VENT SYSTEMS

When an existing < ategory I furnace is removed or replace& the

original venting system may no longer be sized to properly vent

the remaining attached appliances An improperly sized (ategory

I venting system could cause the formation of condensate in the

£t_rnace and vent, leakage of condensate and combustion products,

spillage of combustion products into the living space, etc.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below fbr each appliance

connected to the venting system being placed into operation

could result in carbon rnonoxide poisoning or death

The following steps shall be fbllowed for each appliance

connected to the venting system being placed into operation,

while all other appliances connected to the venting system are

not in operation:

1. Seal any unused openings in venting system.

2. Inspect t!-_eventing system for proper size and horizontal

pitch, as required in the National Fuel Gas Code, ANSI

Z223A=2002NFPA 54°2002 or the CSA B149.1, Natural

Gas and Propane Installation (?ode and these instructions.

Determine that there is no blockage or restriction, leakage,

corrosion and other deficiencies, which could cause an

unsafe condition.

3. As far as 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. (?lose fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to

the venting system. Turn on any exhaust fans, such as

range hoods and bathroom exhausts, so they are operating

at maximum speed. Do not operate a summer exhaust tim.

6 Follow t!-_etighting instructions Ptace the appliance being

inspected into operation. Adjust the thermostat so appli=

ance is operating continuously

7 Test for spillage flora drak hood equipped appliances 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 con'ected in accordance

with the National Fuel Gas (ode, ANSI Z223.1=

2002 NFPA 54-2002 and/or (SA B 149.1, Natural Gas and

Propane Installation Code.

9 After it has been deternrined that each appliance connected

to the venting system properly vents when tested as

outlined above, remm doors, windows, exhaust fans,

fireplace dampers and any other gas-fired appliance to their

previous conditions of use.

Vent system or vent connectors rnay need to be resizcd. For any

other appliances when resizing vent systems or vent connectors,

system or connector must be sized to approach mininmm size as

determined using appropriate table fbund in the NFGC or NSC=

NGPIC.

COMBUSTION=AIR AND VENT PIPING

General

FIRE AND EXPLOSION HAZARD

Failure to %llow this warning could result in fire, property

damage, personal injuw, or death

Solvent cements are combustible. Keep away fiom heat,

sparks, and open flame. Use only in well°ventilated areas.

Avoid breathing in vapor or allowing contact with skin or

eyes.

( ombustion°air and vent pipe, fittings, printers, and solvents must

conform to American National Standards Institute (ANSI) stan=

dards and American Society for Testing and Materials (ASTM)

standards See Table 7 for approved rnaterials %r use in the U.S.A.

See Table 8 fPr nlaxinmm pipe lengths and Fig 39, 40, and 41 fbr

exterior piping arrangements

In Canada, construct all cornhustion-air and vent pipes [br this unit

of CSA or UL( listed schedule-40 PVC, PV(-DWV or ABS=

DWV pipe and pipe cement. SDR pipe is NOT approved in

Canada

Vent pipe re*ruination must be installed with adequate clearances

to building openings and equipment to comply with national and

tocal codes,

Combustion Air Pipe

UNIT CORROSION HAZARD

Excessive exposure to contaminated congt_ustion air may

result in safety and perfbrmance related problems.

Combustion air must not be taken front inside a structme that

is fi'equently contaminated by halogens, which include fluo=

rides, chlorides, bromides, and iodides These elements are

found in aerosols, detergents, bleaches, cleaning solvents,

salts, air fresheners, adhesives, paint, and other household

products. Locate combustion-air inlet as fbr as possible fi'om

swimming pool and swimming pool pump house

NOTE: Furnace combustion°air connections are sized fPr 2°in.

pipe. The combustion=air pipe will be 2=in. diameter in all

installations.

See Table 10 fbr required clearances,

Furnace combustion°air connection must be attached as shown in

Fig 34 Combustion-air intake housing plug may need to be

relocated in some applications,

Combustion-air pipe must terminate outside of f:urnace casing with

1 elbow Orient elbow so that opening faces down fbr upflow or

downf]ow applications Orient elbow so that it faces sideways (left

or right) for horizontal left or horizontal right applications (See

Fig 34,) Maintain a 3-in. mininmnt clearance between the opening

of' the comhustion-air inlet pipe and any object,

NOTE: All pipe joints must be cemented except attachment of

comhustion-air inlet pipe to inlet housing connection, since it may

be necessary to remove pipe for servicing.

Install combustion air inlet pipe as fbllows:

1. Assemble combustion-air inlet pipe.

a. Permanently install perforated disk assembly (factory-

supplied in loose parts bag) in combustion°air elbow using

RTV or by cementing. (See Fig. 35.)

For 120,990 Btuh size unRs only: Separate the 2 halves of

perfPrated disk assembly and use only the shouldered disk

half,

b. Determine length of straight portion of combustion°air inlet

pipe fi'om table in Fig. 35.

c. (ut field°supplied 2-in diameter PVC pipe to detem_ined

length.

d, Permanently attach elbowiperfbrated disk assembly to

straight portion of' pipe using RTV or by cementing. (See

Fig. 35)

2, Attach con-{bustion-air inlet pipe

a Detem_ine tocation of combustion-air intake pipe connec°

tion to combustion-air intake housing as shown in Fig 34

fbr application.

b. Reposition combustion°air intake housing plug fitting in

appropriate unused intake housing connection.

TaNe 9--Maximum Allowable Exposed Vent Pipe Length {ft) With and Without Insulation in Winter Design

Temperature Ambient*

WINTER DESIGN MAX PBPE

FURNACE WITHOUT W_TH 3t8=lN. OR

TEMPERATURE DIAMETER

SRZE (°F) (BN.} INSULATION THICKER INSULATIONt

20 1.5 51 70

0 1.5 28 70

-20 1.5 16 70

040 20 2 45 70

0 2 22 70

-20 2 10 58

20 2 65 70

060 0 2 35 70

-20 2 20 70

20 2 55 55

0 2 48 55

-20 2 30 55

080 20 2.5 70 70

0 2.5 47 70

-20 2.5 28 70

20 2.5 40 40

0 2.5 40 40

-20 2.5 38 40

100 20 3 70 70

0 3 50 70

-20 3 28 70

20 3 70 70

0 3 61 70

-20 3 37 70

120 20 4 70 70

0 4 48 70

-20 4 23 70

* Pipe length (fi) specified for maximum pipe lengths located Jn unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length

as specified in Table 9.

? Insulation thickness based on R value of 35 per in.

FIELD

LOCATION =FACTORY

INSTALLED

LOCATION

A00212

Fig. 31--Relocating &Box

c Install pipe support (_ilctow-supplied in loose parts bag)

into selected fimaace casing combustion-air pipe hole. Pipe

support should be positioned at bottom of casing hole.

d. Insert assembled combustion-air inlet pipe into intake

housing.

e. Make sure elbow is oriented in an acceptable direction and

that the minimum clearance of 3 in is observed. (See Fig.

34.)

LDrill a 1/8-in. hole in 2=in. combustion=air inlet pipe using

hole in intake housing as a guide

g. Install a field-supplied No. 6 or No. 8 sheet metal screw

into combustion-air pipe

h Install casing hole filler cap (factow-supplied) in loose

parts bag) in unused combustion-air pipe casing hole

NOTE: Do not attach combustion-air intake pipe permanently to

combustion-air intake honsing since it may be necessaw to remove

pipe for service of igniter or flame sensor.

(OMBUSTION=AIR INTAKE HOUSING PLUG

FITTING

The combustion-air intake plug fitting must be installed in

unused combustion-air intake housing This fitting must be

attached by using RTV sealant, or by &illing a 1i%im hole in

fitting, using hole in intake housing as a guide. Install a

field-supplied No. 6 or No. 8 sheet metal screw.

NOTE: DO NOT OVERTIGHT]EN SCREW. Breakage of intake

housing or fitting may cause air leakage to occur.

E_ VENT TERMINAL (_AIR SUPPLY INLET

25-24-65-2

E_ AREAWHERE TERMINAL IS NOT PERMITED

Item Clearance Descriptions Canadian fastaHaflon (1) U.S fastallation (2)

A Clearance above grade, veranda, porch, deck, bafaony, or 12 (3Ocm) # 12" (36 cm)

anticipated snow level

E Clearancetoawindowordoorthatmaybeopened 6" (15cm)forapplia_ices 10,OOOBTUH(3kW),12 (30 4"(12m)belowortothesideoftheopenfag'l(3Ocm)

cm) for appliances > 10,OOOStut'd3 kW) and 100,OOOBtuh above the opening

(36 kW)j'36 (91 cm)for appliances > 100.000 Btuh (30 kW)

C Clearance to a permanently dosed window

D Vertical clearance to a ventilated soffit located above the

termina_ within a horizontal distance of 2'(61 cm) from the

centedine of the terminal

E Clearance to an unventilated soffit

F Clearance to an outside cornet

G Clearance to an inside corner

H Clearance to each side ofthe centedine extended above _ (91 cm) within 15"(4.5 m) above the meter/regulator 3" (91 cm) withih 15 (45 m) above the meter/regulator

electrical meter or gas service regulator assembly assembly assembly

Clearance to service regulator vent outlet _ (91 cm)

J Clearancetonon-mechanicalairsupplyin_ettobuildfagor 6" (15cm)forapplia_ces 10,OOOBTUH(3kW),12 (30 4" (12m)belowortothesideofdpening:1 (3Ocm)above

the combustion air inlet to any other appliance cm) for appliances > 1O,OOOBtuh_3 kW) and 1OO,6OOEtuh opening

(36 kW)j'36 (91 cm) for appliances > 100,660 Etuh (30 kW)

K Clearance to a mechanical air supply inlet 6 (1 83 m) 3(91 cm) above if withfa 10'(3m horizontally)

L Clearance under a verand& porch, deck, or balcony 12" (30 cm) +

7' (2.13m)

Clearance to each side of the centedine extended above or

below vent terminal of the furnace to a dryer or water heater

vent, or other appliance's direct vent intake or exhaust

N Clearance to the vent terminal of a dryer vent, water heater

vent, or other appliances direct vent intake or exhaust

O Clearance from a plumbing vent stack

p Clearance above paved sidewalk or paved 7' (2 13m)**

driveway located on public property

(1) In accordance with the current CSA B149.1, Natural Gas and Propane fastallaflon Code

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

# 18" (46 cm) above roof surface

+ 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 t/NFPA 54 or CSA E149.1, clearances shall be in accordance with Iocat installation codes and the requirements of the gas supplier and the

Manufacturer's installation instructions

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

Notes:

1 The vent for this appliance shall not terminate

a Over public walkways: or

b Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nusiance or hazard or property damage; or

c Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

2 When locating vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recirculafion of the combus6ob products of adjacent vents

Recircuiation can cause poor combustion, inlet condensate problems, and accelerated corrosion of the heat exchangers

3 Avoid venting under a deck or large overhang Recirculafion could occur and cause performance or system problems

A05013

-_ Table 10--Other than Direct Vent Termination Clearance

PCB

PL1

SPARE 2 EAC-1

_HT CAP-

PL4 V_ff BRN BRN

CRN/YEI,, ]DM

BLK

NOTE #10

RED (LO)

BLU

(MED LOJ

¢THT (OOM)

BLK

_SCONNECT S/._ITCH (lAdEN REQ'D}

JB ___NOTE_#2

I PU2 I

BLK ---- BLK---_OI" I -- L1

........ I

I ILK G_D 1 I

ILK--

BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT

BLWR BLOWER MOTOR RELAY, SPST-(N O)

BLWM BLOWER MOTOR¸ PERMANENTSPUTCAPACITOR PCB

CAP 1,2 CAPACITOR PL1

CPU MICROPROCESSOR AND CIRCUITRy PL2

EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1 0 AMP MAX¸) PL3

EAC_ ELECTRONIC AIR CLEANER CONNECTION (COMMON) PL4

FRS FLAME ROLLOUT SW -MANUAL RESET SPST-(N C ) PRS

FSE FLAME-PROVING ELECTRODE TE SPPRA/IN

FU 1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED TRAM

FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

(FIELD INSTALLED & SUPPUED)

GND EOUIPMENT GROUND Q

GV GAS MALVE_REDUN DANT m

GMR 1 2 GAS VALVE RELAY, DPS_-(N O ) m

HSI HOT SURFACE IGNITER (115 VAC)

HSIR HOT SURFACE IGNITER RELAY SPS_, (N O)

HUM 24VAC HUMIDIFIER CONNECTION (0 5 AMP MAX¸) -- -- --

IDM INDUCED DRAFT MOTOR¸ PSC ....

IDR INDUCED DRAFT MOTOR RELAY, SPST (NO)

ILK BLOVlJER ACCESS PANEL IN]ERLOCK SWITCH, SPST (N O)

J1 BLOWER - OFF DELAY JUMPER SELECTOR Q

J2 COOLING -OFF DELAY JUMPER

JB JUNCTION BOX

LED LIGH*PEMITTING DIODE FOR STATUS CODES - RED

LGPS LOWGAS PRESSURE SM/ITCH, SPS]:(N O)

LS LIMIT SWITCH, AUTO-RESET SPST (NC) _ )_

AUTO RESET INTERNAL MOTOR OVERLOAD

[EMPERATURE SWITCH (NC)

PRINTED CIRCUIT BOARD CONTROL

11_31RCUIT PCB CONNECTOR

2_CIRCUIT CONNECTOR

2_IRCUIT HSI, CONNECTOR

3dSIRCUIT IDM EXTENSION CONNECTOR

PRESSURE SWITCH, SPST-(N O )

COMPONENT TEST & _RMN TERMIRAL

TRANSFORMER-115VAC!24_,AC

JUNCTION

UNMARKED TERMINAL

PCB CONTROL TERMINAL

FACTORY tMRING (115VAC)

FACTORY WIRING (24VAC)

FIELD WIRING (115VAC)

FIELD WIRING (24MAC)

CONDUCTOR ON CONTROL PCB

FIELD WIRING SCREW TERMINAL

FIELD EARTH GROUND

EQUIPMENT GROUND

FIELD SPLICE

PLUG RECEPTACLE

TO 115VAC FIELD DISCONNECT SCHEMATIC DIAGRAM

NOTE #2 IL 2 GNDi_ 7 EQUI[t%IBXq GROUND (NATURALGAS & PROPANE)

SPARE-2 -" M[DLO CAP-1

HEAT ..

L1D@R_ H}ILO SPAREq L2 I

COOL NOTE #10 EAC_

R® /: I .E.osJ

w®/t/ 1

IM1 i Li,_{_#11_ I

_JM PRS I

NOTES:

1 If ar_y of the onginal eq_ #_leqt '_'_re is iet:Jaced use '_re lated for 105 C

2 Use only copper '_re bet_,een the disconr_ct s,_tde and the fun'ace jul_ction box (JB)

3 This _._.4remust de cor_ected to furnace sheet met_ for control to prove flame

Syrdeols are elec_]cal repiesenta_on onl

Solid lines ir_ide PCB are printed circ_t _oard conductors apd are not ir_,luded in legend

6 Replace ctly with a 3 amp f_se

7 Inducer (IDM) a_d blower (BL_M) motc_s centaln intem_ ad_o-reset therm_ overlead S',Mtches (OL)

8 Neutral connections _ e interchangeaNe _thin the NEUTRAL conr_cto_ block

9 BloweI" moto_ speed selec_or_ ale for avetage condtions see ii_st_lation instrucqons for details on

optimum speed selection

10 YELLOWlead i'_€ on all r_'oto_ s

11 Fantol 3, connected whel LGPS is not used

12 lgnitiol_-Iockout w_ll OCCUr after four consecutive unsuccessful trials-for4gn_tion Control w_ll

auto4-eset alter _ree houis

13 Blower-ct_ delay: gas dealsng 60 seconds, cooling c{ hea_ pt,rnp 2 seconds

14 Blower-off delay: gas dealing selections are 90 120,150 or 180 seconds, coding or heat p_rrlp

90 see_nds Or 5 seconds when J2 is cut

328150-101 RE1L A ./

A02271

Fig. 32--Wiring Diagram

BLOWER OFF-DELAY

J2 JUMPER

TWINNING AND/OR

COMPONENT TEST

TERMINAL

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)

CONNECTIONS

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLTAGE MAIN

HARNESS CONNECTOR

A02100

A plugged drain connection has been provided on this fitting

fbr use when moisture is fbund in combustion-air intake pipe

and combustion box If use of this drain connection is desired,

&ill out fitting's tap plug with a 3/16-in. &ill and connect a

field-supplied 3/8-in. robe. This tube should be routed to open

condensate &ain for furnace and AiC (if used), and should be

tIapped. (See Fig. 36.)

Vent Pipe

NOTE: Furnace vent pipe connections are sized for 2-in. pipe.

Any vent pipe size change should be made outside furnace casing

in vertical pipe. (See Fig. 37.) This allows proper &ainage of vent

condensate.

Detem_ine vent pipe diameter and maximm_a pipe lengths using

Table 8

Furnace vent pipe connection must be attached as shown in Fig.

34. Inducer housing alternate vent cap may need to be relocated in

some applications.

NOTE: Starting at furnace, slope vent pipe a minimum of 1/4 in

per linear ft upward to termination(s) with no sags between

hangers.

UNIT MAY NOT OPERATE

Failure to %ltow this caution may result in intem_ittent unit

operation.

When vent pipe is exposed to temperatures below fi'eezing,

such as when it passes through an unheated space or when a

chimney is used as a raceway, pipe must be insulated as

described in Table 9 with Am_aflex-type insulation

An abandoned masonry chimney may be used as a raceway %r

properly insulated and supported vent pipe Each furnace must

have its own vent pipe and be terminated individually, as shown in

Fig. 41.

Other gas appliances wit}* their own venting system may also use

the abandoned chimney as a raceway providing it is permitted by

local code, the curt'out edition of d_e National Fuel Gas (7ode and

the vent or liner manufi_cmrer's installation instl-uctions. Care must

be taken to prevent the exhaust gases fi'om one appliance from

contaminating the combustion air of other gas appliances.

NOTE: Select 1 vent pipe connection and

I combustion-air pipe connection.

AIR

AIRCOMBUSTION- _ COMBUSTION-AIR

VENT _]_

_ _2 72227

UPFLOW

COMBUSTION-

AIR

VENT

HORIZONTAl-LEFT DISCHARGE

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

V_NT j_[ VENT

AIR AIR AIR

FLOW

DOWNFLOW

COMBUSTION-

AiR VENT

HORIZONTAL-RIGHT DISCHARGE

A96188

[NIT MAY NOT OPERATE

Failu*e to follow this caution may result m intemlittent unit

operation.

Make sure there is adequate clearance (3°in. minhmma) to any

fixed or toose objects in orde* to ensure an adequate

combustion-air supply

Fig. 34_Combustion-Air and Vent Pipe

Connections

HHHH,_, t: IIII

CARBON MONOXIDE POISONING AND PROPERTY

DAMAGE HAZARD

Failure to fbltow this warning could result in property

damage, personal ir_juW, or death.

Vent pipes must be airtight and watertight

NOTE: The mh_imum vent pipe length for these fm'naces is 5 f_

Short pipe lengths (5=8 ft) may discharge water droplets These

droplets may be undesirable, and a 12=in mininmn_ of_get pipe

section is recommended to reduce excessive droplets flora exiting

vent pipe outtet. (See Fig 3g.)

NOTE: Do not count elbows or pipe sections in tem_inations or

within t:umace. See shaded areas in Fig. 40,

FIELD-SUPPLIED

2-IN. DIAMETER ,,--- F ELD-SUPPL ED

PVC 90" ELBOW/ 2-IN. DIAMETER

/_" PVC PIPE

_ _1

t II A I,

_LCOMBUSTION-AIR DISC

(FACTORY-SUPPLIED IN

LOOSE PARTS BAG)

A96211

Length of Straight Pipe Portion of

Combustion-Air 1Net Pipe Assembly (In.)

CASBNGWIDTH A

17-112 8-112+ 112

21 10-1/2 + 1/2

24-112 12+ 1/2

Fig. 38--Combustion-Air Inlet Pipe AssemNy

HOUSING

PLUG INTAKE HOUSING BURNER

BOX

E_COMBUSTION-

AIR PIPE

A96190

Fig. 36--Air Intake Housing Plug Fitting Drain

NOT IN

HORIZONTAL

SECTION

• FURNACE •£j_

TRANSITION iN

VERTICAL SECTION

A93034

Fig. 37--Vent Pipe Diameter Transition Location

and Elbow Configuration

i.,,,,_t_ 12" MIN

VENT PIPE VENT PIPE

HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL

F VENT PIPE

12" MIN

VENT PIPE

VERTICALTO ROOF VERTICAL TO SIDEWALL

NOTE: A 12-1n. minimum offset pipe section is recommended with

short (5 to 8 ft) vent systems. This recommendation is to reduce

excessive condensate droplets from exiting the vent pipe.

Fig. 38--Short Vent (8 to 8 Ft) System

A96189

EXAMPLE:

An 080-12 size furnace located in Indianapolis, elevation

650 ft above sea level, could be installed in an application

requiring 3 elbows and 32 ft of vent pipe Table 8 indicates

this application would allow a 2-in. diameter vent pipe. At

0°2000 k elevation, 2-in. pipe is good fbr up to 35 ft with

3 elbows. If same installation were in Albuquerque, eleva-

tion 5250 ft above sea level installation would require 2° 1/2

in. vent pipe. At 500I- to 6000-_ elevation, 2-in. pipe is

allowed for up to 23 f_ with 3 elbows, but 2-!/2 in. pipe can

be used for up to 70 ft with 3 elbows

Install vent pipe as _bllows:

l. Determine location of vent pipe connection to inducer housing

as shown in Fig 34 fbr application

2. Reposition elastomeric (rubber) inducer housing oudet cap

and clamp to appropriate unused inducer housing connection

Tighten clamp.

--€

___>

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component

damage.

Inducer housing outlet cap must be installed and thlly seated

against inducer housing. Clamp must be tightened to prevent

any condensate leakage.

3, Install pipe support (factowosupplied in loose parts bag) into

selected furnace casing vent pipe hole, Pipe support shoutd be

positioned at bottom of casing hole

(ARBON MONOXIDE POISONING AND [NIT

DAMAGE HAZARD

Failure to fPllow this warning could result in personal injury

or death and unit damage

Vent pipe must be installed and fully seated against inducer

housing internal stop. Clamp must be tightened to prevent any

condensate leakage.

NOTE: A 2=in. diameter pipe must be used within the furnace

casing Make all pipe diameter transitions outside [:urnace casing.

4. Be certain that mating surfaces of inducer housing connection

elastomeric coupling, and 2-in diameter vent pipe are clean

and&y.Assembletheelastomeric(rllbber)ventcoupling

(with2looseclamps)ontoinducerhousingconnection.Insert

the2-in.diameterventpipethroughtheelastomeric(rllbber)

couplingand_hllyintoinducerhousingconnectionuntilit

bottomsontheinternalstop.Tighten both clamps to secure the

pipe to inducer housing. Tighten the clamp screws to 15 inMb.

of torque.

5. Install casing hole filler cap (fhctolT-supplied in loose parts

bag) in unused vent pipe casing hole.

VENT EXTENSION PIPE

Some filrnaces are supplied with a PVC vent extension pipe

(2-in. diameter by 12=in. tong). This pipe has a built-in

channel to assist vent condensate disposal. When this vent

extension pipe is supplied, it must be used to connect the field

vent pipe to filrnace inducer housing on ALL upflow and

downflow applications.

NOTE: See label on vent extension pipe for proper installation

This pipe may be shortened if an elbow is used to connect vent

extension robe to field-installed vent pipe.

5. Working fiom fi/rnace to outside, cut pipe to required

length(s).

7. Deburr inside and outside of pipe.

8. Chamfer outside edge of pipe for better distribution of primer

and cement.

9. Clean and d_ all surfitces to be joined.

10. Check &y fit of pipe and mark insertion depth on pipe.

NOTE: It is recommended that all pipes be cut, prepared, and

preassembled before pem?anently cementing any joint.

11. After pipes have been cut and preassembled, apply generous

layer of cement primer to pipe fitting socket and end of pipe

to insertion mark. Quickly apply approved cement to end of

pipe and fitdng socket Cover primer). Apply cement in a light,

uni[bm_ coat on inside of socket to prevent buildup of excess

cement. Apply second coat.

12. While cement is still wet, twist pipe into socket with 1/4 turn.

Be sure pipe is [:ully inserted into fitting socket.

13. Wipe excess cement fiom joint. A continuous bead of cement

will be visible around perimeter of a properly made joint.

14. Handle pipe joints carefidly until cement sets.

15. Support vent piping a minimum of every 5 ft (3 ft for SDR=2!

or -26 PVC) using perforated metal hanging shap.

16. Slope vent pipe downward toward Nrnace a minimum of 1/4

in. per linear ft with no sags between hangers.

17. Use appropriate methods to seal openings where vent pipe

passes through roof or sidewall.

Extended Exposed Sidewall Pipes

Sidewall vent pipe tem?ination may be extended beyond area

shown in Fig. 40 in outside ambient by insulating pipe as indicated

in Table 9.

1. Detemline vent pipe diameter, as stated above, using total pipe

length and number of elbows.

2. Find appropriate temperature fPr your application and furnace

model using winter design temperature (used in load calcula=

tions).

3. Detem_ine required insulation thickness fbr exposed pipe

lengths.

NOTE: Pipe length (ft) specified l\)r maximum pipe lengths

located in unconditioned spaces cannot exceed total allowable pipe

length as specified in Table 8.

VENT TERMINATION

Vent pipe must terminate either through roof or sidewall. See

Table 10 _br required clearances. See Fig 39, 40, and 41 _br

exterior piping an'angements

Consideration of the _Pllowing should be made when determining

an appropriate location for tem_ination:

1. (omply with all clearance requirements stated in Table 10.

2. Termination should be positioned where vent vapors will not

damage plants/shrubs or air conditioning equipment.

3. Tem_ination should be positioned where it will not be dan>

aged by or subjected to foreign objects such as stones, balls,

etc.

4. Termination should be positioned where vent vapors are not

objectionable.

MULTIVENTING

When 2 or more 58MSA Furnaces are vented near each other, each

fitmace must be individually vented NEVER common vent or

breach vent 58MSA fiu_aces

Step lO--Condensate Drain

GENERAL

Condensate trap is shipped installed in the blower shelf and [itctory

connected _br UPFLOW applications. Condensate trap must be

RELOCATED _br use in DOVv_TLOW and HORIZONTAL

applications.

(ondensate trap MUST be used for all applications.

An external trap is not required when connecting the field drain to

this condensate trap.

The field drain connection (condensate flap or drain robe coupling)

is sized fPr 1i2=im CPV(, 1/2-in. PVC, or 5/8=in. ID robe

connection.

Drain pipe and fitdngs must conform to ANSI standards and

ASTM D1785, D2466 or D2846. CPVC or PV( cement must

conform to ASTM D2564 or F493. Primer must conform to ASTM

F656. In Canada, use CSA or ULC listed schedule 40 CPV( or

PVC drain pipe, fittings, and cement.

When a condensate pump is required, select a pump which is

approved tbr condensing furnace applications. To avoid conden-

sate spillage, select a pump with an overflow switch.

UNIT MAY NOT OPERATE

Failure to _bllow this caution may result in intem_ittent unit

operation.

Unit must not be installed, operated, and then mined off and

left in an unconditioned structure doting cold weather when

temperature &ops to 32°F and below unless drain trap and

&ain line have adequate [i'eeze protection. See Service and

Maintenance Instructions _Br winterizing procedures. (See

Fig. 15.)

Furnace condensate is mildly acidic, typically in the pH range of

32 to 4.5 Due to cotl'osive nature of unneutralized condensate, a

condensate pH neutralizing filter may be desired. Check with local

authorities to determine if a pH neutralizer is required

APPLICATION

The f_lrnace, A/C, and humidifier drains may be combined and

drained together. The Ai( drain retest have an external, field-

supplied trap prior to the fi/rnace drain connection. Al! drain

connections (furnace, A/C, or humidifier) must be tem_inated into

ROOF

12-1N.

CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL OR GRADE,

WHICHEVER IS

GREATER.

PIPE.

10-1N.MAXIMUM PIPE LENGTH

12-IN.

CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL OR GRADE,

WHICHEVER IS

GREATER.

A96210

Fig. 41--Sidewall Termination with Straight Pipe

OPEN STAND --7

PiPE FOR /

A/COR/

HUMIDIFIER _[

DRAIN

A94054

Fig. 42--Example of Field Drain Attachment

an open or vented drain as close to the respective equipment as

possible to prevent siphoning of the equipment's drain,

See Fig 42 for example of possible field drain attachment using

li2-in (PVC or PV( tee for vent and AiC or humidifie* &ain

connection,

Outdoor draining of the ihmace is permissible if allowed by local

codes. Caution should be taken Freezing ambient may fieeze drain

pipe and prohibit draining

PERSONAL IN J[ RY HAZARD

Caunon should be taken to prevent draining where slippew

conditions could cause personal injuries

Excessive condensate draining may cause saturated soil

conditions which could result in damage to plants.

CONDENSATE DRAIN PROTECTION

Freezing condensate left in condensate trap and drain line may

cause cracks, and possible water damage may occur. If fieeze

protection is required, use condensate freeze protection accessow

or equivalent 3 to 6 watt per ft at 120v and 40°F sel[:regutating,

shielded, and waterproof heat tape. See Installation Instructions

supplied with accessory or heat tape manufhcmrer's recommenda-

tions

1. Fold heat tape in half and wrap on itself 3 times.

2. Locate heat tape between sides of condensate trap back. (See

Fig. 43)

3. Use wire ties to secure heat tape in place. Wire ties can be

positioned in notches of condensate trap sides. (See Fig. 43j

4. Wrap field drain pipe with remaining heat tape, approximately

1 wrap per ft.

5. When using field=supplied heat rope, fbllow heat rope manu=

_Scturer's instractions for all other installation guidelines.

CONDENSATE

WIRE TIE

HEAT

(3 WRAPS MINIMUM)

A93036

Fig. 43--Condensate Trap Heat Tape

START-UP, ADJUSTMENTS AND SAFETY CHECK

Step l--General

1. Furnace mast have a 115-v power supply properly connected

and grounded. Proper polarity must be maintained fbr con'ect

operation.

NOTE: Proper polarity must be maintained for l15-v wiring. If

polarity is incorrect, ft/rnace control fault indicator light will flash

rapidly and furnace will not operate.

2. Them_ostat wire connections at terminals R, W, G, and Y

must be made at 24-v terminal block on thmace control center.

3. Natural gas service pressure must not exceed 0.5 psig (14oin.

we), but must be no tess than 0.16 psig (4.5-in. wc).

4. Blower access panel must be in place to complete l15-v

electrical circuit to furnace.

FIRE HAZARD

Failure to follow this caution may result in intermittent unit

operation.

These thrnaces are equipped with a manual reset limit switch

in burner box. This switch will open and shut offpower to gas

control vah'e if an overheat condition (flame rollout) occurs

in burner enclosure. Correct inadequate combustion-air sup°

ply or improper venting condition and reset switch DO NOT

jumper this switch

Befbre operating f_/mace, check flame rollout manual reset switch

for continuity. If necessa_, press button to reset switch

Step 2--Prime Condensate Trap with Water

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit

operation.

Condensate trap must be PRIMED or proper draining may not

occur The condensate trap has 2internal charnbers which can

ONLY be primed by pouring water into the inducer drain side

of condensate trap.

1, Remove upper inducer housing drain connection cap (See

Fig. 44)

2, (onnect field-supplied 1i2oin ID robe to upper inducer

housing &ain connection,

......7

A99118

Fig. 44_[nducer Housing Drain Tube Cap

A99119

Fig. 45--FHffng Condensate Trap

3 Insert field-supplied fhnnel into tube

4. Pour 1 quart of water into funnel/robe. Water should run

through inducer housing, overfill condensate tIap, and flow

into open field drain. (See Fig. 45.)

5. Remove funnel and robe fiom inducer housing and replace

drain connection cap and clamp.

Step 3--Purge Gas Lines

FIRE AND EXPLOSION HAZARD

Failure to %llow this warning could result in a fire, explosion,

personal injury, or death

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.

[f not previously done, purge lines after all connections have been

made and check for leaks.

Step 4--Sequence of Operation

FURNA(E MAY NOT OPERATE

Failure to %llow this caution may result in t:urnace operation

stopping and water pipes freezing during cold weather.

Furnace control must be grounded for proper operation, or

control will lock out. Control is grounded through

green/yellow wire routed to gas valve and burner box screw

[sing the schematic diagram in Fig. 32, fbllow the sequence of

operation through the diffkrent modes Read and fbltow the wiring

diagram very- carefully.

NOTE: If a power interalpfion occurs during a call for heat (W),

the control will start a 90-second blower-only ON period two

seconds after power is restored, if the thermostat is still calling for

gas heating. The red LED light will flash code 12 during the

90-second period, after which the LED will be ON continuous, as

long as no faults are detected. Afier the 90-second period, the

flul_ace will respond to the thermostat normally

The blower door must be installed for power to be condtlcted

through the blower door interlock switch ILK to the furnace

control (PU, transl\_rmer TRAN, inducer motor IDM, blower

motor BLWM, hot-surface igniter HSI, and gas valve GV.

1. Heating

(See Fig 30 fbr thermostat connections.)

The wall thermostat "calls for heat", closing the R to W

circuit. The fl/mace contlol perfbm_s a self-check, verifies the

pressure switch contacts PRS are open, and starts the inducer

motor IDM.

a. Inducer Prepurge Period- As the inducer motor IDM

comes up to speed, the pressure switch contacts PRS close,

24 vac power is supplied fbr a field installed humidifier at

the HUM terminal and the control begins a 15-second

prepurge period.

b. Igniter Warm-Up- At tl-_eend of the prepurge period, the

Hot-Surfi_ce Igniter HSI is energized fbr a 17-second

igniter warm-up period.

c. Trial-Nr-Ignition Sequence- When the igniter warm-up

period is completed, the main gas valve relay contacts GVR

close to energize the gas valve GV, the gas valve opens.

The gas valve GV pemaits gas flow to the burners where it

is ignited by the Hot Surfhce Igniter HSL Five seconds after

the GVR closes, a 2-second flame period begins. The HSI

igniter will remain energized until d-_e flame is sensed or

until the 2-second flame proving period begins.

d. Flame-Proving- When the burner flame is proved at the

flame-proving sensor electrode FSE, the fl/mace contlol

CPU begins the blower-ON delay period and continues to

hold the gas valve GV open. If the burner flame is not

proved within two seconds, the control CPU will close the

gas valve GV, and the control CPU will repeat the ignition

sequence fbr up to three more Trials-For-Ignition befbre

going to Ignition-Lockout. Lockout will be reset auto-

matically after three hours, by momentarily interrupting

115 vac power to the furnace, or by interrupting 24 vac

power at SEC1 or SE(2 to the [:urnace control CPU (not at

W, G, R, etc.)

If flame is proved when flame should not be present, the

fhmace control CPU will lock out of Gas-Heating mode

and operate the inducer motor IDM until flame is no longer

proved.

e. Blower-On Delay- If the burner flame is proven, the

blower motor is energized on HEAT speed 66 seconds after

the gas valve GV is energized.

Simultaneously, the electronic air cleaner terminal EAC-!

is energized and remains energized as tong as the blower

motor BLWM is energized.

f_ Blower-Off Delay- When the thermostat is satisfied, the

R-to-W circuit is opened, de-energizing the gas valve GV,

stopping gas flow to the burclers, and de-energizing the

humidifier terminal HLM. The inducer motor IDM will

remain energized for a 15-second post=purge period. The

blower motor BLWM and air cleaner terminal EAC-I wilt

remain energized fbr 90, 120, 150, or 180 seconds (depend-

ing on the blower-OFF delay selection). The flu'hate

control CPU is fitctory-set for a 120-second blower-OFF

delay.

Cooliug Mode

(See Fig. 30 fbr them_ostat connections)

The thermostat closes the R-to-G-and-Y circuits. The R-to-Y

circuit starts the outdoor unit, and the R-to-G and Y circuits

start the t\lrnace blower motor BLWM on COOL speed.

The electronic air cleaner terminal EAC-1 is energized with

115 vac when the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y circuits are

opened. The outdoor unit will stop, and the t\trnace blower

motor BLWM will continue operating on the COOL speed fbr

an additional 90 seconds. Cut jumper J2 to reduce the cooling

off'delay to 5 seconds. (See Fig. 33.)

Continuous Blower Mode

When the R-to-G circuit is closed by the themlostat, the

blower motor BLWM will operate on continuous-blower

speed (same as HEAT speed) Terminal EAC-! is energized as

long as ff*e blower motor BLWM is energized

During % call for heat(' the blower BLWM will stop during

igniter wam_-up (17 seconds), ignition (7 seconds), and

blower-ON delay (65 seconds), allowing the fhmace heat

exchangers to heat up more quickly, then restarts at the end of

the blower-ON delay period at HEAT speed

In heating, the furnace control CPU will continue running the

blower motor BLWM at HEAT speed after the selected

blower-OFF delay period is completed.

When the thermostat "calls fbr cooling", the blower motor

BLWM will operate at (OOL speed. When the d_em_ostat is

satisfied, the blower motor BLWM will operate an additional

90 seconds on COOL speed befbre reverting back to HEAT

speed. Jumper J2 can be can be cut to reduce the cooling

offtdelay to 5 seconds. (See Fig. 33.)

When the R-to-G circuit is opened, the blower motor BLWM

will continue operating for an additional 5 seconds, if no other

flmction requires blower motor BLWM operation.

4. HeatPumpMode

Wheninstalledwithaheatpump,thefl/macecontrolauto-

maticallychangesthetimingsequencetoavoidlongblower

offtimesduringdemanddefrostcycles.WhentheR-to-W-

and-Yor R-to=W-and-Y-and-Gcircuitsareenergizedthe

NmacecontrolCPUwillcontinuetoturnontheblowermotor

BLWMat HEATspeed,andbegina heatingcycle.The

blower motor BLWM will remain on until the end of the

prepurge period, then shut off %r 24 seconds then come back

on at HEAT speed. When the W input signal disappears, the

Nrnace control begins a normal inducer post-purge period and

the blower switches to (OOL speed after a 3 second delay. If

the R=to-W-and-Y-and=G signals disappear at the same time,

the blower motor BLWM will remain on for d-_e selected

blower-OFF delay period. If the R=to-W-and=Y signals disap-

pear, leaving the G signal, the blower motor BLWM will

continue running the blower motor BLWM at HEAT speed

after the selected blower-OFF delay period is completed.

( OMPONENT TEST

NOTE: The furnace control component test allows all compo=

nents to run for a short time; except the gas valve and humidifier

terminal HUM are not energized for safety reasons. The EAC-1

terminal is energized when the blower is energized. This feature

helps diagnose a system problem in case of a component f_ilure.

The component test fcatu, e will not operate if any thermostat

signal is present at the control and not until all time delays are

completed.

To Begin Component Self=Test:

ELECTRICAL SHOCK HAZARD

Failure to %ltow d_is warning could result in electrical shocL

personal injury, or death.

Blower access panel door switch opens l15=v power to

control center No component operation can occur. Caution

must be taken when manually closing this switch for service

purposes.

1. Remove blower access door.

2. Disconnect the fl-_ermostat R lead from furnace control.

3. Manually close blower door switch.

4. For approximately 2sec, short 0umper) the COM-24V terminal

on control to the TEST/TWIN 3/16=inch quick-connect termi=

hal on control until the LED goes out. Remover jumper from

terminals. (See Fig. 33.)

NOTE: If TEST/TWIN and (o_,>24v terminals are jumpered

longer than 2sec, LED will flash rapidly and ignore component

test request

Component test sequence is as fbllows:

a. LED will display previous status code 4 dines.

b. Inducer motor starts and continues to run until Step g of

component test sequence

c. After 7 seconds the hot surfSce igniter is energized for 15

sec_ then off'.

d. Blower motor operates on HEAT speed for 10 sec.

e. Blower motor operates on (OOL speed for 10 sec.

£ Inducer motor stops.

5. iReconnect R lead to furnace contiot, remove tape from blower

door switch, and re=install blower door.

6. Operate thmace per instruction on outer door.

7 Verify flmaace shut down by lowering thermostat setting

below room temperature

8 Verify that flmaace restarts by raising thermostat setting above

room temperature.

Step 5--Adjustments

SET GAS INPUT RATE

Furnace gas input rate on rating plate is %r installations at ahimdes

up to 2000 It,

In the [,SA, the input ratings fbr ahitudes above 2000 ft must be

reduced by 2 pc*cent %* each 1000 ft above sea tevel,

In Canada, the input ratings must be de*ated by 5 percent fbr

ahimdes of" 2000 ft to 4500 ft above sea level,

Furnace input rate must be within 2 percent of input on furnace

rating plate adjusted fbr altitode.

1 Determine natural gas orifice size and manifold pressure fbr

correct input

a Obtain average gas heat value (at installed altitude) from

local gas supplier

b Obtain average gas specific gravity flora local gas supplier.

c Verif) furnace model. Table 11 can only be used fbr model

58MSA furnaces

d Find installation ahimde in Table 11

NOTE: For Canadian altitudes of 2001 to 4500 It, use USA,

altitudes of"2001 to 3000 ft in Table 11,

e Find closest natural gas heat value and specific gravity on

Table 11

£ Follow heat value and specific gravity lines to point of

intersection to find orifice size and mani%ld pressure

settings for proper operation

REGULATOR

_SEAL CAP

REGULATOR

/_ADJUSTMENT

SCREW

INLET

PRESSURE TAP

REGULATOR SPRING

(PROPANE -WHITE, 6 TURNS

NATURAL - SILVER 10 TURNS)

GAS PRESSURE

REGULATOR

ADJUSTMENT

A03142

Fig. 4g--Redundant Automatic Gas VNve

Table11--Mode{g8MSA Orifice Size and Manifold Pressure for Correct input

(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)*

ALTITUDE

RANGE

(FT)

20OO

derate

ALTITUDE

RANGE

(FT)

U.S.A.

Altitudes

200i to

3000

Canada

Altitudes

2001 to

4500

derate

ALTITUDE

RANGE

(FT)

300i

4000

derate

AVG GAS

NEAT VALUE

AT ALTITUDE

(BTUICU FT)

85O

875

9OO

925

95O

975

1000

1025

1050

1075

1t00

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTUICU FT)

775

8O0

825

850

875

90O

925

950

975

1000

1025

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTUICU FT)

750

775

80O

825

85O

875

9OO

925

950

975

iO00

0.58

Orifice Manifotd

No. Pressure

43 3.7

43 3.5

44 3.7

44 3.5

44 3.4

44 3.2

45 3.7

45 3.5

45 3.3

45 3.2

47 3.6

SPECIFIC GRAVITY OF NATURAL GAS

0.50 0.82

Orifice Manifotd Orifice Manifold

No. Pressure No. Pressure

43 3.8 42 3.2

43 3.6 43 3.7

43 3.4 43 3.5

44 3.7 44 3.8

44 3.5 44 3.6

44 3.3 44 3.4

45 3.8 44 3.2

45 3.5 45 3.7

45 3.4 45 3.5

45 3.3 45 3.4

47 3.7 45 3.2

0.64 0.55

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.3 42 3.4

43 3.8 42 3.2

43 3.6 43 3.7

43 3.4 43 3.5

44 3.7 44 3.8

44 3.5 44 3.6

44 3.4 44 3.5

44 3.2 44 3.3

45 3.7 45 3.8

45 3.5 45 3.5

45 3.4 45 3.5

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.50 0.52

Orifice Manifotd Orifice Manifold Orifice Manifotd

No. Pressure No. Pressure No. Pressure

43 3.8 42 3.2 42 3.3

43 3.5 43 3.7 43 3.8

44 3.8 43 3.4 43 3.6

44 3.6 44 3.7 44 3.8

44 3.4 44 3.5 44 3.6

44 3.2 44 3.3 44 3.4

45 3.7 45 3.8 44 3.2

45 3.5 45 3.5 45 3.7

45 3.3 45 3.4 45 3.5

45 3.1 45 3.2 45 3.4

45 3.0 45 3.t 45 3.2

0.64 0.55

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.4 42 3.5

42 3.2 42 3.3

43 3.7 43 3.8

43 3.5 43 3.6

44 3.7 43 3.4

44 3.5 44 3.6

44 3.3 44 3.4

48 3.8 44 3.3

45 3.5 45 3.8

45 3.5 45 3.5

45 3.3 45 3.4

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.50 0.52

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

43 3.7 43 3.8 42 3.3

43 3.5 43 3.6 43 3.7

44 3.7 43 3.4 43 3.5

44 3.5 44 3.6 44 3.8

44 3.3 44 3.4 44 3.5

45 3.8 44 3.2 44 3.3

45 3.5 45 3.7 45 3.8

45 3.4 45 3.5 45 3.5

45 3.2 45 3.3 45 3.4

45 3.0 45 3.2 45 3.3

45 2.9 45 3.0 45 3.t

0.64 0.55

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.4 42 3.5

43 3.8 42 3.2

43 3.6 43 3.7

43 3.4 43 3.5

44 3.7 44 3.8

44 3.5 44 3.6

44 3.3 44 3.4

45 3.7 44 3.2

45 3.5 45 3.7

45 3.4 45 3.5

45 3.2 45 3.3

_Odfice numbers 45 are factory installed.

Percents of derate are based on midpoints of U.S. altitude ranges.

Table 11--Model 58MSA Orifice Size and Manifold Pressure for Correct Input Continued

(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Levem)*

ALTITUDE

RANGE

(FT)

4001

<." to

5000

derate

ALTBTUDE

RANGE

(FT)

500t

_ to

D 6000

11%

derate

ALTITUDE

RANGE

(FT)

6001

_ to

7000

t3%

derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTUiCU FT)

725

750

775

800

825

850

875

900

925

950

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTUiCU FT)

700

725

750

775

800

825

850

875

900

925

950

975

iO00

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTUICU FT)

650

675

700

725

750

775

800

825

850

875

0.58

Orifice Manifold

No. Pressure

43 3.7

43 3.4

44 3.7

44 3.5

44 3.2

45 3.7

45 3.5

45 3.3

45 3.1

45 3.0

0.58

Orifice Manifold

No. Pressure

43 3.6

43 3.4

44 3.6

44 3.4

44 3.2

45 3.8

48 3.4

48 3.2

48 3.0

48 2.9

48 2.7

48 2.8

48 2.5

0.58

Orifice Manifold

No. Pressure

42 3.2

43 3.6

44 3.8

44 3.6

44 3.3

48 3.8

48 3.5

48 3.3

45 3.1

48 3.8

SPECIFIC GRAVITY OF NATURAL GAS

0.80

Orifice Manifold

No. Pressure

43 3.8

43 3.5

44 3.8

44 3.6

44 3.4

48 3.8

45 3.4

48 3.2

45 3.t

0.82 8.84 8.85

Orifice Manifotd Orifice Manifotd Orifice Manifold

No. Pressure No. Pressure No. Pressure

42 3.2 42 3.3 42 3.4

43 3.7 43 3.8 42 3.2

43 3.4 43 3.5 43 3.7

44 3.7 44 3.8 43 3.4

44 3.5 44 3.6 44 3.7

44 3.3 44 3.4 44 3.5

48 3.7 44 3.2 44 3.3

48 3.5 48 3.8 45 3.8

48 3.3 45 3.4 45 3.8

48 3.2 45 3.3 45 3.4

SPECIFIC GRAVITY OF NATURAL GAS

0.80

Orifice Manifold

No. Pressure

43 3.7

43 3.5

44 3.7

44 3.5

44 3.3

48 3.7

48 3.8

48 3.3

48 3.1

48 3.8

48 2.8

45 2.7

48 2.8

0.82 8.84 8.88

Orifice Manifold Orifice Manifotd Orifice Manifotd

No. Pressure No. Pressure No. Pressure

42 3.2 42 3.3 42 3.4

43 3.6 43 3.7 43 3.8

43 3.4 43 3.5 43 3.6

44 3.6 44 3.7 43 3.4

44 3.4 44 3.5 44 3.6

44 3.2 44 3.3 44 3.4

48 3.8 48 3.8 44 3.2

48 3.4 48 3.8 45 3.7

48 3.3 48 3.4 45 3.8

48 3.1 48 3.2 45 3.3

45 2.9 48 3.0 45 3.t

45 2.8 45 2.9 45 2.9

45 2.8 48 2.7 45 2.8

SPECIFIC GRAVITY OF NATURAL GAS

0.88 0.82 8.84 0.85

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure No. Pressure

42 3.3 42 3.4 42 3.5 42 3.6

43 3.7 43 3.8 42 3.2 42 3.3

43 3.4 43 3.6 43 3.7 43 3.8

44 3.7 44 3.8 43 3.4 43 3.5

44 3.4 44 3.6 44 3.7 44 3.8

44 3.2 44 3.3 44 3.4 44 3.5

45 3.7 48 3.8 44 3.2 44 3.3

48 3.4 48 3.8 48 3.7 45 3.8

48 3.2 48 3.4 48 3.8 45 3.6

48 3.t 45 3.2 48 3.3 45 3.4

*Orifice numbers 45 are factory installed

Percents of derate are based on midpoints of U.S. altitude ranges

Table 11--Model 58MSA Orifice Size and Manifold Pressure for Correct Input Continued

(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Levem)*

ALTITUDE

RANGE

(FT)

700t

8000

19%

derate

ALTITUDE

RANGE

(FT)

800t

9000

17%

derate

ALTITUDE

RANGE

(FT)

900t

t0,000

19%

derate

AVG GAS

NEAT VALUE

AT ALTITUDE

(BTUICU FT)

929

990

975

700

799

750

775

800

895

890

AVG GAS

NEAT VALUE

AT ALTITUDE

(BTUiCU FT)

900

929

990

975

700

799

750

779

8OO

AVG GAS

NEAT VALUE

AT ALTITUDE

(BTUICU FT)

979

900

929

950

975

700

795

750

779

0.58

Orifice Manifold

No. Pressure

43 3.8

43 3.5

44 3.8

44 3.5

44 3.3

49 9.7

49 9.9

49 3.3

49 3.t

49 2.9

0.58

Orifice Manifold

No. Pressure

43 3.8

43 3.5

44 3.7

44 3.5

44 3.2

49 9.9

49 9.4

49 9.2

49 3.0

0.58

Orifice Manifold

No. Pressure

43 3.8

43 3.5

44 3.7

44 3.4

45 9.8

45 3.9

45 3.3

49 3.1

49 2.9

SPI=CIFIC GRAVITY OF NATURAL GAS

0.90 0.92

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.3 42 3.4

43 3.7 43 3.8

43 3.4 43 3.5

44 3.6 44 3.8

44 3.4 44 3.5

45 3.8 44 3.3

45 9.9 49 9.7

49 9.4 49 9.5

45 3.2 45 3.3

49 3.0 45 3.1

0.5.4 0.99

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.5 42 3.6

42 3.2 42 3.3

43 3.6 43 3.7

43 3.4 43 3.5

44 3.6 44 3.7

44 3.4 44 3.5

45 9.8 44 3.3

49 9.9 49 3.7

49 9.4 49 3.5

49 9.2 49 3.9

SPECIFIC GRAVITY OF NATURAL GAS

0.90 0.92

Orifice Manifotd Orifice Manifold

No. Pressure No. Pressure

42 3.3 42 3.4

43 3.6 43 3.8

43 3.4 43 3.5

44 3.6 44 3.7

44 3.3 44 3.4

45 3.8 44 3.2

49 9.5 45 9.9

45 3.3 45 3.4

49 9.t 49 3.2

0.64 0.69

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.5 42 3.6

42 3.2 42 3.3

43 3.6 43 3.7

44 3.8 43 3.4

44 3.6 44 3.7

44 3.3 44 3.4

49 3.8 44 3.2

45 9.9 49 3.9

49 9.9 49 3.4

SPECIFIC GRAWTY OF NATURAL GAS

0.90 0.92

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.2 42 3.3

43 3.6 43 3.7

44 3.8 43 3.5

44 3.5 44 3.7

44 3.3 44 3.4

45 9.7 45 9.8

45 3.4 45 3.9

45 3.2 45 3.3

49 3.0 49 9.1

0.54 0.99

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.5 42 3.6

42 3.2 42 3.3

43 3.6 43 3.7

44 3.8 43 3.4

44 3.5 44 3.6

44 3.3 44 3.4

49 9.7 49 3.8

49 3.4 49 3.5

49 3.2 49 3.9

*Orifice numbers 45 are factory installed.

Percents of derate are based on U.S. altitude ranges.

-->

EXAMPLE: (0 2000 altitude)

Heating value 1050 Bmicu ft

Specific gravity 062

Therefore: Orifice No. 45

Manifold pressure 3 6=in wc

* Furnace is shipped with No. 45 orifices. In this example

all main burner orifices are the correct size and do not need

to be changed to obtain the proper input rate.

Check and verify7 burner orifice size in fhnaace. NEVER ASSUME

ORIFI(E SIZE; ALWAYS CHECK AND VERIFY

2. Adjust maniibld pressure to obtain input rate

NOTE: Manifold pressure must always be measured with burner

enclosure fiont REMOVED Gas meter must always be clocked

with burner enclosure front INSTALLED.

a Remove burner enclosure flout.

b. Remove cap that conceals adjustment screw fk_r gas valve

regulator. (See Fig 46.)

c Jumper R and W thermostat connections on control to start

f_/rnace operation.

d. Turn adjusting screw, counterclockwise (out) to decrease

manifold pressure or clockwise (in) to increase manifbld

pressure

NOTE: This furnace has been approved for a manifold pressure

of 32 in. wc to 3.8 in. wc when installed at ahimdes up to 2000 ft.

For ahimdes above 2000 ft, the manil:bld pressure can be adjusted

from 22 in. wc to 3.8 in. wc. If manifold pressure is outside this

range, change burner orifices to obtain pressure in this range.

tNIT DAMAGE HAZARD

Failure to ibllow this caution may result in reduced furnace

tifc

DO NOT bottom out gas valve regulator adjusting screw

This can result in unregulated manit\_ld pressure and result in

excess overfire and heat exchanger failures.

NOTE: If orifice hole appears damaged or it is suspected to have

been re&illed, check orifice hole with a numbered &ill bit of

correct size. Never re&ill an orifice. A burr=fi'ee and squarely

aligned orifice hole is essential for proper flame characteristics.

e. Replace gas valve regulator adjustment screw cap.

i\ Replace burner enclosure fi'ont and veri/_ adjusted gas

input rate using method outlined in item 3.

[TNTT DAMAGE HAZARD

Failure to follow t_is caution may result in component

damage due to flame impingement of burners and heat

exchangers.

DO NOT re&ill orifices. Improper &illing (burrs. out=of =

round holes, etc.) can cause excessive burner noise and

misdirection of burner flames. (See Fig. 47.)

g. Look through sight glass in burner enclosure and check

burner flame. Burner flame should be clear blue, ahnost

tlansparent. (See Fig. 480

h. Remove jumper fiom R and W.

3. Verii}- natural gas input rate by clocking gas meter.

NOTE: Be sure all pressure robing, cornbustion=air and vent

pipes, and bunaer enclosure front are in place when checking input

by clocking gas meter.

BURNER

---- ORIFICE

Fig. 47--Burner Orifice

A93059

a. Calculate high-altitude adjustment (if required).

United States

At altitudes above 2000 R, this Nrnace has been approved for a 2%

&rate for each 1000 R above sea level. See Table 12 ibr &rate

multiplier ihctor.

EXAMPLE: 100,000 Btuh input furnace installed at 4300 ft.

Furnace input Rate Derate Furnace Input Rate

at Sea Level X Multiplier = at Installation

Factor Altitude

100,000 X 0.91 = 91,000

Canada

At installation altitudes fiom 200! to 4500 it, this _:_/macemust be

&rated 5% by an aud_orized Gas (;onve*sion Station. To deter-

mine con'ect input rate for ahimd< see example above and use

095 as derate multiplier fhctor.

b Reinstall burner box cover.

c. Gas valve regulator seal cap MUST be installed

d Turn off all other gas appliances and pilots.

e Start furnace and let operate for 3 minutes

i_ Measure time (in sec) ibr gas meter test dial to complete 1

revolution

g. Reibr to Table 13 %r cuft of gas per hr.

h. Multiply gas rate (cu flihr) X heating value (Bmicu it)

using natural gas heating value from local gas

utility/supplier

Table 12--Ntitude Derate MuNplier for U.S.A.

ALTITUDE

{FT}

0--2000

2001--3000

3001--4000

4001--5000

8001--6000

6001--7000

7001--8000

8001--9000

9001--10,000

* Derate multiplierfactoris

% OF DI=RATE MULTiPLiER

BERATE FACTOR FOR U.S.A*

0 1.00

4--6 0.95

6--8 0.93

8--10 0.91

10--12 0.89

12--14 0.87

14--16 0.85

16--18 0.83

18--20 0.81

based on midpoint altitude for altitude range.

BURNER FLAME'-_ _ BURNER

MANIFOLD J

Fig. 48--Burner Flame

Table 13--Gas Rate {Cu Ft/Hr)

SECONDS SIZE OF TEST DIAL SECONDS

FOR 1 I 2 5 FOR 1

REVOLUTION cuff cu fl cu fl REVOLUTION

10 360 720 1800 50

11 327 655 1636 51

12 300 600 1500 52

13 277 555 1385 53

14 257 514 1286 54

15 240 480 1200 55

16 225 450 1125 56

17 212 424 1059 57

18 200 400 1000 58

19 189 379 947 59

20 180 360 900 60

21 171 343 857 62

22 164 327 818 64

23 157 313 783 66

24 150 300 750 68

25 144 288 720 70

26 138 277 692 72

A89020

27 133 267 667 74

28 129 257 643 76

29 124 248 621 78

30 120 240 600 80

31 116 232 581 82

32 113 225 563 84

33 109 218 545 86

34 106 212 529 88

35 103 206 514 90

36 100 200 500 92

37 97 195 486 94

38 95 189 474 96

39 92 185 462 98

40 90 180 450 100

41 88 176 439 102

42 86 172 429 104

43 84 167 419 106

44 82 164 409 108

45 80 160 400 110

46 78 157 391 112

47 76 153 383 116

48 75 150 375 120

49 73 147 367 124

SIZE OF TEST DIAL

125

cu fl cu fl cu fl

72 144 360

71 141 355

69 138 346

68 136 340

67 133 333

65 131 327

64 129 321

63 126 316

62 124 310

61 122 305

60 120 300

58 116 290

56 112 281

54 109 273

53 106 265

51 103 257

50 100 250

48 97 243

47 95 237

46 92 231

45 90 225

44 88 220

43 86 214

42 84 209

41 82 205

40 80 200

39 78 196

38 76 192

38 75 188

37 74 184

36 72 180

35 71 178

35 69 173

34 68 170

33 67 167

33 65 164

32 64 161

31 62 155

30 60 150

29 58 145

EXAMPLE: (0 2000 fi altitude)

Furnace input fi'om rating plate is 100,000 Bmh.

Bm heating input Bmicu ft X cu ftihr

Heating value of gas 975 Btuicu 1:i

Time for 1 revolution of 2-cu fl dial 70 sec

Gas rate 103 cu ftihr (f?om Table 11)

Bm heating input 103 X 975 100,425 Btuh

In this example, the orifice size and manifbld pressure

adjustment is within !2 percent of the fl/mace input rate.

SET TEMPERATURE RISE

[NIT DAMAGE HAZARD

Failure to fbllow this caudon may result in overheating d-xe

heat exchangers or condensing flue gases in heat exchanger

areas not designed for condensate.

Temperature rise must be within limits specified on hlmace

rating plate. Recommended operation is at mi@oint of rise

range or slightly above.

Determine and ac[iust air temperature rise as fbllows:

1. Place thermometers in return and supply ducts as close to

fi/rnace as possible Be sure thermon_eters do not see heat

exchanger so that radiant heat does not affect readings This

practice is particularly important with stlaight-run ducts.

2. When tlaern_ometer readings stabilize, subtract return-air tern:

perature fl'om supply-air temperature to detemaine air tem-

perature rise.

3. Acliust temperature rise by adjusting blower speed. Increase

blower speed to redtlce temperature rise. Decrease blower

speed to increase temperature rise.

ELECTRICAL SHOCK HAZARD

Failure to %llow this warning could result in personal injury

or death.

Disconnect 115-v electrical power before changing speed tap

4. To change blower motor speed selections for heating mode,

remove blower motor lead J:'rom control center HEAT termi-

nal. (See Fig 33) Select desired blower motor speed lead

fi'om 1 of the other motor leads and relocate it to HEAT

terminal See Table 14 for lead color identification. Reconnect

original lead on SPARE terminal

Follow this same procedure %r proper selection of (OOL

speed selection

BLOWER OFF DELAY (HEAT MODE)

The blower offdelay has 4 adjustable settings h'om 90 sec to 180

sec. (See Table 15.) The blower off delay jumpers are located on

the fl/rnace control board (See Fig. 33) To change the blower off

Table 14--Speed Selector

FACTORY-

COLOR SPEED SHIPPED

CONNECTION

Black High Cool

Yellow (When Present) Medium High Spare

Blue Medium Low Heat

Red Low Spare

White Common Corn

Table18--BlowerOff DelaySetupPosition

PiNS 1 AND 2 2AND 3 3 AND 4 4 AND 8

Time (in sec) 90 120 150 180

delay setting, move the jumper flora one set of pins on the conhol

board to the pins used for the desired blower off delay. Factoiw

blower off delay setting is 120 sec.

SET THERMOSTAT HEAT ANTI(IPATOR

When using a nonelectronic them_ostat, the them_ostat heat

anticipator must be set to match amp draw of components in R-W

circuit. Accurate amp draw measurements can be obtained at

thermostat subbase terminals R and W. Fig. 49 illustrates an easy

method of obtaining these measurements. The anap reading should

be taken after blower motor has started and furnace is heating.

Connect ammeter wires as shown in Fig. 49. The thermostat

anticipator should NOT be in the circuit while measuring current.

If them_ostat has no subbase, the them?ostat must be disconnected

from R and W wires during cun'ent measurement. See thermostat

manufacturer's instructions for adjusting heat anticipator and for

raving heating cycle tengd_.

For an electronic thermostat, set cycle rate for 3 cycles per hour.

CHECK SAFETY CONTROLS

This section covers the safety controls that must be checked be_bre

the installation is complete. The flame sensor, gas valve, and

pressure switch were all checked in the Start=up procedure section

as part of nom_al operation.

Step l--Check Primary Limit Control

This control shuts off gas control system and energizes air-

circulating blower motor it" fm'nace overheats Recommended

method of checking this limit control is to gradually block off

return air aker furnace has been operating for a period of at least

5 minutes. As soon as limit control has shut offburners, return-air

opening should be unblocked to pem_it nora?HI air circulation. By

using this method to check limit control, it can be established that

limit is t\mctioning properly and operates if there is a restricted

return-air duct or motor _i_ilure. If limit control does not [hnction

during this test, cause must be determined and con'ected.

Step 2--Check Pressure Switch

This control pIoves opeiation of draf_ inducer (heel< switch

operation as fbllows:

1. Turn off 115-v power to furnace.

TERMINALS WITH

THERMOSTAT REMOVED

2 Remove main fi/rnace door and disconnect inducer motor lead

wires flora wire harness.

3. Turn on 115-v power to furnace.

4 Set them_ostat to "call for heat" and wait 1 minute When

pressure switch is _imctioning properly, hot surface igniter

should NOT glow, and control status code LED flashes status

code 31 _imlt. [f hot sur_itce igniter g!ows when inducer motor

is disconnected, shut furnace down immediately. Determine

reason pressure switch did not function properly and correct

condition.

5. Turn off 115=v power to _i/rnace.

6. Reconnect inducer motor leads, reinstall main furnace door,

and mm on 115=v power supply.

CHECKUST

1 Put away tools and instruments. (lean up debris.

2 Verify flame rollout manual reset switch has continuity.

3. Verify that blower and main access doors are properly

installed.

4. Cycle test fi_rnace with room them_ostat.

5. Check operation of accessories per manufacturer's instl_ac-

lions.

6 Review User's Guide with owner

7. Leave literature packet near furnace.

FROM UNIT 24-VOLT

TERMINAL BLOCK

EXAMPLE: 5 0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT SETTING

10 TURNS AROUND JAWS

A80201

Fig. 49--Amp Draw Check w{th Ammeter

CH ECKL[ST--BNSTALLAT[ON

LOAD CALCULATION

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

VENT PIPING

Termination Location

Roof or Sidewall

Vent Pipe Length

Vent Pipe Elbow Quantity

Pipe Diameter Determined from Sizing Table

Pipe Sloped To Furnace

Pipe Insulation

Over Ceitings

Low-Ambient Exposed Pipes

Condensate Drain

Unit Level or Pitched Forward

Internal Tubing Connections Free of Kinks

and Traps

External Drain Connection Leak Tight and

Sloped

Condensate Trap Primed before Start-Up

Heat Tape Installed if Required

CHECKLIST--START-UP

Gas Input Rate (Set Within 2 percent of

Rating Plate)

Temperature Rise Adjusted

Thermostat Anticipator

Anticipator Setting Adjusted or

Cycte Rate (3 Cyctes per Hr) Setected

Safety Controls Check Operation

Primary Limit

Pressure Switch

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations,

Book 1 4

Tab 6a 8a PC 101 Catalog No 535-80154 Printed in U.S.A. Form 58MSA-11SI Pg 48 2-05 Replaces: 58MSA-10SI

CARRIER Furnace/Heater, Gas Manual L0503144

Navigation menu

Versions of this User Manual:

Views

Navigation