CARRIER Furnace/Heater, Gas Manual L0503146

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

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58NXA

DeMuxe 4-Way NuRipoise Fixed-Capacity

Direct Vent Condensing Gas Furnace

\isit _ v_w carrier.corn

tnstammation, Start-Up, and Operating

Sizes 040o140, Series 170

NEATUNG & COOUNG

A93040

NOTE: Read the entire instruction nmnua] before starting the

installation.

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

TABLE OF CONTENTS

SAFETY CONSIDERATIONS 2

INTRODL CTION 4

CODES AND STANDARDS 4

ELECTROSTATI( DISCHARGE (ESD) PRECAUTIONS .... 5

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

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

Lpflow Applications ............................... 6

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

Horizontal Lek (Supply-Air Discharge)

Applications ........................................ 10

Horizontal Right (Supply-Air Discharge)

Applications .................................... 11

LOCATION ......................................... ! 3

General ......................................... 13

Furnace Location Relative to Cooling

Equipment ...................................... ] 4

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

INSTALLATION ........................................ 14

Leveling Legs (If"Desired) ............................ 14

Installation in Upfiow and Downflow

Applications ....................................... 15

Installation in Horizontal Applications .................. 16

Air Ducts ........................................ ] 7

General Requirements ............................ 17

Ductwork Acoustical Treatment ................... 17

Supply Ai* ( onnections ......................... 17

Return Air Connections .......................... 17

Filter Arrangement ................................ 1S

Bottom Closure Panel ............................ 19

Gas Piping ....................................... ] 9

Electrical Connections ............................ 20

115 v Wiring ................................. 20

24 v Wiring .................................. 22

Accessories ........................................................................ 22

Direct Venting ...................................... 22

Removal of Existing Furnaces t)om Common

Vent Systems .................................... 22

Combustion-Air and Vent Piping .................... 22

Vent Extension Pipe ............................ 27

Concentric Vent and Combustion-Air

Termination Kit Installation .............................................. 29

Multiventing and Vent Terminations .................. 33

Condensate Drain .................................. 34

General ....................................... 34

Application ....................................... 34

Condensation Drain Protection ..................... 35

START-UP, ADJL STMENTS AND SAFETY (HECK ........... 35

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

Prime Condensate Trap With Water .................... 36

Purge Gas Lines ................................... 37

Sequence of Operation ............................. 37

Heating Mode ................................. 37

Cooling Mode ................................ 40

Thermidistat Mode ............................. 40

Continuous Blower Mode ........................ 41

Heat Pump Mode .............................. 41

Component Test ............................... 41

Adjustments ........................................ 42

Set Gas Input Rate ............................. 42

Set Temperature Rise ............................ 48

Adjust Blowe* Off Delay (Heat Mode) ................ 49

Set Thermostat Heat Anticipator .................... 49

(hock Safe w Controls ............................... 49

Check Primmy Limit Control ...................... 49

Check Pressure Switch .......................... 49

( hecklist .......................................... 50

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 101 Catalog No. 535-80157 Printed in U.S.A. Form 58MXA-18SI Pg 1 2-05 Replaces: 58MXA-17SI

AIRFLOW

_ HORIZONTAL ]

LEFT

AIRFLOW hAIRFLOW

AIRFLOW

A93041

Fig. 1--MuRipoise Orientations

SAFETY CONSIDERATIONS

/NIT RELIABILITY HAZARD

Improper installation or misapplication of ihmace may re-

quire excessive servicing or cause premature component

failure

Application of this lhrnace should be indoors with special

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

temperature rise, unit leveling, and unit sizing

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

(ARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in electrical shock,

fire_ personal ir!inry_ or death.

Improper installation, adjustment, alteration, service, mainteo

nance, or use can cause carbon monoxide poisoning, exploo

sion, fire, electrical shock, or other conditions which may

cause personal injury or property damage. Consuh a qualified

installer, service agency, local gas supplier, or your distribuo

tot or branch ibr information or assistance. The qualified

installer or agency must use only [hctoryoauthorized and

listed kits or accessories when modi_)ing this prodact.

Installing and servicing heating equipment can be hazardous due to

gas arid electrical components. Only trained and qualified

personnel s][muld install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance f_anctions

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 minimmn requirements arid conform

to existing national standards and safety codes. In some instances,

these instructions exceed certain local codes and ordinances,

especially those that *nay not have kept up with changing resideno

tial construction practices. We require these instl-t,ctions as a

minimum fbr a saf_ installation.

Wear safety glasses and work gloves. Have a fire extinguisher

available during startoup and adjustment procedures and service

calls.

--€

-->

--€

(IT HAZARD

Failure to %11ow this caution *nay result in personal Jr!jury.

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

wear appropriate protective clothing and gloves when hano

dling parts.

Recognize sa_kty infornlation. This is the safety-alert symbol Z_ "

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

manuals, be alert to the potential ibr personal injury.

Understand these signal words: DANGER, WARNING, and

CAUTION. These words are used with the safctyoalert symbol.

DANGER identifies the most serious hazards which will result in

severe personal injm7 or death. WARNING signifies hazards

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

to identii}" unsafe practices which may result in minor personal

injuw or product and property damage. NOTE is used to highlight

suggestions which will result in enhanced installation, reliability,

or operation.

The 58MXA Multipoise Condensing Gas-Fired Furnaces are CSA

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

gases (see fimaace rating plate) and _br installation in alcoves,

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

The ihmace is factoryoshipped ibr use with natural gas. A CSA

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

propane gas.

See Fig. 3 for required clearances to combustibles.

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

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

See NFPA 90B or local code ibr further requirements.

These ftunaces SHALL NOT be installed directly on carpeting,

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

downflow installations, factory accesso_' floor base MUST be

used when installed on combustible materials and wood flooring.

Special base is not required when this _iulaace is installed on

manufacturer's (?oil Assembly Part No. CD5 or CK5, or when (Toil

Box Part No. KCAKC is used.

The 58MXA 040 through 120 size units are (SA design-certified

for use in manufactured (mobile) homes when ihctory accessou

conversion kit is used The 140 size unit is NOT design-certified

for use in manufactured (mobile) homes. These thrnaces are

suitable for installation in a structure built on site or a manufac-

tured building completed at final site. The design of this thmace

line is NOT CSA design-certified for installation in recreation

vehicles or outdoors.

This fl*rnace is designed %r continuous return=air n_ininmm

temperature of 60_T 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 d_ese

remm air limits may affect reliability of heat exchangers, motors

and controls. (See Fig 4.)

These ihrnaces 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 fku_ace only in a location and position as specified in

LO(ATION and INSTALLATION sections of these instructions.

Combustion products must be discharged outdoors. Connect this

fm'nace to an approved vent system only, as specified in the

(ombustion Air and Vent piping sections of these instructions

14 9'

TYP

26 £"

SIDE INLET

_ +_ .................. _

11"_ _ 23 :_"TYP

SIDE iNLET

26 %i6" TYP

CONDENSATE DRAIN

TRAP LOC,RHON

(DOWNFLOW &

HORIZONTAL LEFT)

_%-- /:-IN D{A

ACCESSORY

POWER ENTRY

CONDENSATE

DRAIN TRAP

LOCATION

(AJTERNATE

UPFLOW)

17 M_"

AIRFLOW

_A_

TLET

DRAIN LOC#<T_O N

(UPFLO_M)

30 /z"

FOR HORIZONTAL

HANGING

THERMOSTAT ENTRY

80 [10M iNLEt

39 %'

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

see flex duct manufacturers recommendations for equivalent diameters

2 Minimum return-air opening at furnace:

a For 800 CFM-16qn round or t4/: x 124n, rectangle

b, For 1200 CFM-20qn, round or 14/, x 19/:din rectangle,

c, For 1600 CFM-224n, round or 14/: x 23/Mm rectangle

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

literature for specific use of single side inlets, Tbe 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 05 WC ESP

UNIT S_ZE

040-08

040-12

080-08

060-12

060-10

080-12

080-16

080-20

100-16

100-20

120-20

140-20

Dimensions (in.)

17-I/2

17-1/2

24-1/2

15-7/8

19-3/8

22-7/8

19-1/2

A02149

Fig. 2--Dimensional Drawing

--> Never test %r gas leaks with an open flame. [se a commercially

available soap solution made specifically fbr detection of leaks to

check all connections as specified in the GAS PIPING section of

these instructions

--> Always install the Nmace to operate within the t_omace'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 fi/rnace is installed so that supply ducts carry air circulated

by the Nmace to areas outside the space containing the furnace,

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

casing and tem?inating outside the space containing the Nrnace.

--> A gas-fired Nrnace for installation in a residential garage must be

installed as specified in the Hazardous Locations section of these

insm_ctions,

---> The t:urnace is not to be used for tempma W heating of buildings o1"

strt/ctures under construction unless the furnace installation and

operation complies with the first (AUTION in the LO(ATION

section of these instructions.

This thmace must be installed with a direct-vent (combustion air

and flue gas) system and a factory accessory tei_nination kit. In a

direct-vent system, all air for combustion is taken directly from the

outdoor atmosphere and flue gases are discharged to the outside

atmosphere. See Nmace and factory accesso_ vent-air intake

termination kit instructions for proper installation.

These fimaaces are shipped with the following 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

l/2qn CPVC street elbow 2

Drain tube coupling 1

Drain tube coupling grommet 1

Vent and combustion-air pipe support 2

Condensate trap hole filler plug 3

Vent and combustion-air intake hole filler plug 2

Combustion-air pipe perforated disk assembly 1

Vent Pipe Extension 1"

ONLY supplied with some furnaces.

For accessory installation details, refer to accessory installation

instl_._ctions.

_NTRODUCTmON

The model 58MXA 4=way multipoise, Gas=Fired, Category IV,

direct-vent condensing fitrnace is available in model sizes ranging

in input capacities of 40,000 to 138,000 Bmh

CODES AND STANDARDS

FMIow all nationM and locM codes and standards in addition to

these instructions° The installation must comply with regulations

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

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

comply with die national codes listed below and all authorities

having jurisdiction.

In the United States and Canada, %llow all codes and standards %r

the fbllowing:

Step l--Safety

• US: National Fuel Gas (7ode (NFGC) NFPA 54-2002/ANSI

Z223.1-2002 and the Installation Standards, Warm Air Heating

and Air Conditioning Systems ANSI NFPA 90B

• (ANADA: National Standard of Canada, Natural Gas and

Propane Installation (ode (NSCNGPIC) CANiCGA -B149,1

=and2 M=00

Step 2--General Installation

• US: NFGC and the NFPA 90B. For copies, contact the National

Fire Protection Association Inc, Battewmarch Park, Quincy,

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

Association, 400 N. (apitol, N.W., Washington DC 20001

--> * A manufhctured (Mobile) home installation must confbrm with

the Manzt_bctured _12)me Construction and 5"qfi._0' Standard,

Tide 24 (_FR, Part 3280, or when this standard is not

applicable, the Standard fbr :l,Ian@mtzcred Home in.stgd/ation

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

A_ifZ,.VCS' A225. I, an_or (it_\-_ (WA-Z240, MN Serie,s Mofile

• (ANADA: NSCNGPI(L For a copy_ contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke (Tot=

onto), Ontario, MPW 1R3, Canada.

Step a--Combustion and Ventilation Air

• US: Section 53 of the NFG(, Air for (ombnstion and

Ventilation

• CANADA: Part 7 of the NSCNGPIC, Venting Systems and Air

Supply for Appliances

Step 4--Duct Systems

• US and CANADA: Air (onditioning (ontractors Association

(ACCA) Manual D, Sheet Metal and Ai* Conditioning Con=

tractors National Association (SMACNA), or American Soci-

ety of Heating, Refrigeration, and Air Conditioning Engineers

(ASHRAE) 200I Fundamentals Handbook Chapter 34

Step g--Acoustical Lining and Fibrous Glass Duct

• Ers and CANADA: cmTent edition of' SMACNA, NFPA 90B as

tested by EL Standard 18! for Class I Rigid Air Ducts

Step g--Gas Piping and Gas Pipe Pressure Testing

• US: NFGC chapters 2, 3, 4_ and 9 and national plumbing codes

--> In the state of Massachusetts:

* This product must be installed by a licensed plun_her or gas

fitter

* When flexible connectors are used, the maximum length shall

not exceed 36 inches

* When lever type gas shutoff?4 are used they shall not exceed 36

inches

*CANADA: NSCNGPI( Parts 3, 4, 5, A, B, E, and H.

Step 7--Electrical Connections

* US: National Electrical Code (NEC) ANSIiNFPA 70=2002

* (ANADA: Canadian Electrical Code CSA (22 1

This forced air furnace is equipped for use with natural gas at altitudes 0 -10,000 ft (0 -3,050m), except 14,0 size furnaces are only approved for altitudes 0 -7,000 ft.

(0 -2 135m).

An accessory kit supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications.

This furnace is for indoor installation in a building cy,_nstructed on site. This furnace may be installed in a manufactured (mobile) home when stated on rating plate and

using factory authorized kit..

This furnace may be installed on combustible floedng in alcove or closet at Minimum inches Clearance To Combustible Construction as described below.

This fumace requires a special venting system. Refer to the installation instructions for parts list and method of installation. This fumace is for use with schedula40 PVC,

PVC-DWV CPVC or ABS-DWV pipe and must not be vented in common with other gas-fired appliances. Construction through whiclq vent/air intake pipes may be

installed is maximum 24 inches (600 nlm), minimum 3/4 inches (19 mm) thickness (including roofing n_qteriala).

Cette foumaise _ air pula_ est d,quip_e pour utillaation avec gaz naturel et altitudes comprises 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).

Utiliser une trausse de conversion fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz natarel.

Cette foumaise A air pula6 est pour installation & Hnt6rlaur dans un bAtiment construit sur place. Cette foumalae & air pulse paut 6tre installd, e dens une maison

pr6fabriqu6e (malaon mobile) si prescrit par la plaque signal6tique et si I_on utilise une trousse speclfi6e par la fabrlaant.

Cette foumaise peut 6tre installd, e sur un plancher combustible dens un enfoncement ou un placard en observant les D_gagement Minimum En Pouces Avec

Elements De Construction Combustibles.

Cette fournalae n@cessite un systeme d'6vacuation sp6cial. La n_thede d'installation et la Ilata des pieces nd,cessaires flgurent dens les instructions d'installation. Cette

fournaise doit s'utiliser avec la tayautede des nomenclatures 40 PVC, PVC-DWV, CPVC ou ABS-DWV et ella ne peut pas 6tre ventil_e conjolatment avec d'autres

appareila & gaz. Epaisseur de la construction au travers de laquelle il est possible de faire passer les tuyaux d'a6ration (admlaslan/6vacuation); 24 po (600 mm)

maximum, 3/4 po (19mm) minimum (y compris la toiture).

For upflc_w and cDwnflow applications, furnace must be installed level, or pitched within 1/2" of level. For a M IN 1/4" TO 1/2" MAX

horizontal application, the furnace must be pitahed minimum 1/4" to maximum of 1/Z' forward for propar

drainage. See Installation Manual for IMPORTANT unit support details on horizontal applications.

Pour des applications de flux ascendant et descendant, la fournalae doit (}tre installg_e de niveau ou laclla6e _ T

pas plas de 1/Z' du niveau. Pour une application hodzontale, la fournaise deit (}tre inclin6e entra n-tinimum UPFLOW OR

1/4" et maximum 1/2" du niveau pour le drainage approprid,. En cas d'installatlan en position horizontak_, DOWNFLOW

consulter les renseignementa JMPORTANTS sur le support dens le manuel d'ind_allation. HORIZONTAL

NININUN INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSITIONS:

Minimum front clearance for sep,zice 24 inches (610ram).

1 1" 140 size furnaces require 1 inch back clearance to combustible materials.

DOWNFLOW POSITIONS:

1" For installa/Jon on cornbustible 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 POUCES AVEC ELEMENTS DE CONSTRUCTION COMBUSTIBLES

POUR TOtJS LES POSITIONS:

Degagement avant minimum de 610mm (24 po) pour I'entrelien.

1" 1" Pourles foumaises de 140taille, 1 po(25mm)degagement des mat6riaux combustiblesest

requis au_arriere.

POUR LA POSITION COURANT DESCENDANT:

1" Pour Hnstallalion sur le plancher combustible seulement quand on utilise la base spedale, piece

n ° KGASB0201ALL I'ensernble serpaniin, pi6ce n° CD5 ou CKS, ou le carter de serpentin,

piece n ° KCAKC.

POUR LA POSITION HORIZONTALE:

Le contact n'est permis qOen_-e les lignes formees par les intersectioes du dessus et des

deuxc6tgs de la d:_emise de la foumaise, et des solives, des montanta ou de la d:rarpente du

batirnent

§ La distance indiquee concerne I'extr@mite du tuyau d'arfivee d'air et I'extrernit6 du tuyau de sortie

d'air.

O Pour les fournaises de 120 et 140 taille, 1 po (25mm) degagement des materiaux combusitbles

est requis au dessous.

This furnace is approved for UPFLOW, DOW_q FLOW and

HORIZONTAL ins'talla_ns.

Cette fournaise est approuv@e paur Hns[allation HORIZONTALE

et la drculatlan d'air VERS LE HAUT et VERS LE BAS.

Cl_aranoa at-raws

do not change with ne cl]ange pas avec

furnace orlantation, I'otientation de la

g6n6rateur d'ak chaud.

Vent clearance to

combustibles 0".

Clearance in inches 0 (1::o)Dg%Jagement

D_gagement (po). d'@vent avec combustibles.

328066-201 REV. B LIT TOP

Fig. 3--Clearances to Combustibles

ELECTROSTAT{C DISCHARGE {ESD} PRECAUT{ONS 2 Firmly [ouch the clean, unpaiute& metal surface of the _.m_ace

UNIT DAMAGE HAZARD

Failure to follow this caution may damage furnace compo=

nents,

Electrostatic discharge can affect electronic components

Take precautions during [_urnace installation and servicing to

protect the f_m_ace electronic control. Precautions will pre=

vent electrostatic discharges fi'om personnel and hand tools

which are held during the procedure. These precautions will

help to avoid exposing the control to electrostatic discharge

by putting the furnace, the control, and the person at the same

electrostatic potential.

l, Disconuect all power to the [_urnace Multiple disconnects may

be required DO NOT TOUCH THE CONTROL OR ANY

WIRE CONNECTED TO THE CONTROL PRIOR TO DIS=

CHARGING YOUR BODY' S ELE(TROSTATIC ( HARGE

TO GROUND

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

haud during grounding will be satisfactorily discharged.

After touching the chassis, you may proceed to service the

control or connecting wires as tong as you do nothing to

recharge your body with static electricity (for example; DO

NOT move or shuffle your feet, do not touch ungrouuded

objects, etc)

If you touch uugrounded ohjects (and recharge your body with

static electricity), firmly touch a clean, uupainted metal

surface of the f_,_mace again befbre touching control or wires.

Use this procedure for installed and uninstalled (ungrounded)

_/fnaces

Betbre removing a new control flora its container, discharge

your body's electrostatic charge to grouud to protect d'*e

control f?om damage If [!_e control is to be installed iu a

f_,u_ace, follow items 1 through 4 bef_._re bringing the control

or yourself in contact with the furnace Put all used and new

FRONT

MAX 80°F

M[N 60°F

-->

A05004

Fig, 4_Retum-Air Temperature

controls into containers be%re touching ungrounded objects

7. An ESD service kit (available fiom commercial sources) may

also be used to prevent ESD damage.

PROPERTY DAMAGE

Failure to follow this caution may result in minor property

damage.

Local codes may require a drain pan under entire filmace 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 %r furnaces

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 instla/ctions fbr d-lese procedures

Step 2--Upf[ow Applications

An upflow furnace application is where t_mnace blowei is located

below combustion and controls section of f_./rnace, and conditioned

air is discharged upwards.

CONDENSATE TRAP LOCATION (FACTORY-SHIPPED

ORIENTATION)

The condensate tlap is flactol-y installed in the blower shelf and

fhctory connected for UPFLOW applications A factoo-supplied

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

desired t'urnace side for field drain attachment. See (ondensate

Trap Tubing (Factory=Shipped Orientation) section fbr drain tube

extension details. (See Fig. 5.)

CONDENSATE TRAP TUBING (FACTORY-SHIPPED

ORIENTATION)

NOTE: See Fig. 6 or robe routing label on main fi/mace door to

confirm location of these tubes.

1. Collector Box Drain, Inducer Housing Drain, Relief Port, and

Pressure Switch Tubes.

These robes should be factory attached to condensate trap and

pressure switch ready for use 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 hmMng

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

label), and pressure switch robe (pink label)

2, Condensate Trap Drain Tube

The condensate trap drain connection must be extended for

field attachment by doing the fbllowing:

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

6.)

NOTE: If internal filter or side Filter/Media (abinet is used, &ain

robe should be located to opposite side of casing fiom return duct

attachment to assist in filter removal.

b. Remove and discard casing drain hole plug button Ii"om

desired side.

c. Install &ain robe coupling grommet (factow-supplied in

loose parts bag) in selected casing hole.

d. Slide &ain robe coupling (fbctory=supplied in loose parts

bag) through grommet ensuring tong end of coupling fitces

blower.

e. Cement 2 factory=supplied 1/2-in. street CPVC elbows to

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

Fig. 5.) 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.

£ 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.

CONDENSATE TRAP LO(ATION (ALTERNATE LPFLOW

ORIENTATION)

An alternate tocation fbr d-le condensate t_ap is the left=hand side

of casing. (See Fig 2 and 7)

NOTE: If the alternate left°hand side of casing location is used.

the fimtolT°connected &ain and relief port tubes must be discon-

nected and modified for attachment. See Condensate Trap Tubing

(Alternate Upflow Orientation) section for tubing attachment.

To relocate condensate tlap to the left-hand side, perfbm_ the

following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap ti"om blower shelf by gently pushing tabs inward

and rotating trap.

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

bag) into blower shelf hole where trap was removed.

CARBON MONOXIDE POISONING HAZARD

Failure to £dlow this warning could result in personal inju W

or death.

Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated to prevent combustion

products being drawn in ti'om appliances in the equipment

1"OO111.

4. Install condensate trap into teftohand side casing hole by

inserting robe 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)

r--- BLOWER SHELF _ FURNACE

/X DOOR /_ CONDENSATE

Jf r-- CONDENSATE \/TRAP

/ / TRAP (INSIDE) X/FURNACE

X]s'w

FIELD2 '4 1 '2

/_ \ DRAIN

X---ALTERNATE DRAIN \ CONN

TUBE LOCATION \

CONDENSATE TRAP _ SIDE VIEW FRONT VIEW

DRAIN TUBE LOCATION DOWNFLOW AND ALTERNATE

UPFLOW APPLICATIONS EXTERNAL UPFLOW APPLICATIONS

FURNACE

OOR ! FURNACE

IDE

DRAIN

CONN

END VIEW FRONT VIEW

HORIZONTAL

APPLICATIONS

(OPTIONAL) /

._111/2 /

GUIDES

(WHEN USED)

FRONT VIEW

71/8

7/8Z :

SIDE VIEW

Fig. 5--Condensate Trap

/40D

COLLECTOR BOX TO

TRAP RELIEF PORT

%OD

INDUCER HOUSING

DRAIN CONNECTION

/80D

COLLECTOR BOX

DRAIN CONNECTION

SCREW HOLE FOR

UPFLOW OR DOWN-

FLOW APPLICATIONS

(OPTIONAL)

V2-1N PVC OR CPVC

CONDENSATE TRAP TUBING (ALTERNATE UPFLOW

ORIENTATION)

NOTE: See Fig 7 or robe routing label on nmin I_urnace door to

confim_ location of these tubes

1, (ollector Box Drain Tube

(onnect collector box &ain robe (blue label) to condensate

trap,

NOTE: On 17=1/2 in wide k'urnaces ONLY, cut tube between

corrugated sections to prevent kinks from occurring,

2, Inducer Housing Drain Tube

a, Remove and discard LOWER (molded) inducer housing

drain tube which was previously connected to condensate

trap,

b, Use inducer housing &ain extension tube (violet label and

factory-supplied in loose parts bag) to connect LOWER

inducer housing drain connection to the condensate trap,

c Detem_ine appropriate length, cut, and connect robe,

d, (lamp robe to prevent any condensate leakage,

3, Relief Port Tube

a (onnect relief port tube (green label) to condensate trap,

b, Extend this robe (if required) by splicing to snmll diameter

robe (factory=supplied in loose parts bag),

c Detem_ine appropriate length, cut, and connect robe,

A93026

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and

procedures,

PRESSURE SWITCH TL BING

The LOWER collector box pressure robe (pink label) is facto U

connected to the pressure switch and should not require any

modification,

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

to check for proper connections,

UPPER (OLLECTOR BOX AND INDU(ER HOUSING

(L NUSED) DRAIN CONNECTIONS

Erpper Collector Box Drain Connection

Attached to the UPPER collector box drain connection is a

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

1abel), This tube is plugged to prevent condensate teakage in this

application Ensure this robe is plugged,

NOTE: See Fig 6 or 7 or robe routing label on nmin f_ulmce door

to check for proper connections

Upper Inducer Housing Drain Connection

Attached to the [?PPER (unused) inducer housing &ain 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 robe routing label on nmin fi/rnace door

to check for proper connections,

PLUG

COLLECTOR

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR

TUBE (PINK)

COLLECTOR BOX "-_

TUBE (GREEN)

INDUCER

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

DRAIN TUBE (BLUE)

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX --

TUBE (GREEN)

COLLECTOR BOX --

DRAIN TUBE (BLUE)

CONDENSATE _

TRAP EL

INDUCER J

HOUSING

DRAIN TUBE

(VIOLET)

O O

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

_i2-1N CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (RIGHT

DRAIN OPTION)

A94163

Fig. 6--Factory-Shipped Upflow Tube

Configuration (Shown w{th BNower Access Panel

Removed}

CONDENSATE TRAP FREEZE PROTECTION

Ref?r to Condensate Drain Protection section %r recommenda°

lions and procedures.

Step 3--Downfiow Applications

A downflow _/mace application is where :_trnace blower is located

above congbustion and controls section of fi_rnace, and conditioned

air is discharged downwards

( ONDENSATE TRAP LO(ATION

The condensate tlap mttst be removed from the factow-installed

blower shelf location and relocated in selected application location

as shown in Fig. 2, 8, or 9

To relocate condensate trap from the blower shelf to desired

location, perform the following:

1. Remove 3 robes connected to condensate trap

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

and rotating trap

3. Remove casing hole filler cap from casing hole. (See Fig. 2, 8,

or 9.)

4. [nstall casing hole filler cap into blower shelf hole where trap

was removed

-->

A94164

Fig. 7--ARernate Upflow Configuration and Trap

Location

CARBON MONOXIDE POISONING HAZARD

Failm'e to follow this warning could result in personal inju W

or death,

Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated to prevent combustion

products being drawn in from appliances in the equipment

roonl.

5. [nstall condensate trap into desired casing hole by inserting

robe connection stubs through casing hole and rotating until

tabs snap into locking position,

CONDENSATE TRAP TUBING

NOTE: See Fig 8 or 9 or tube routing label on main f:umace door

to check for proper connections,

Relocate robes as described below,

1. Collector Box Drain Tube

a. Remove factory=installed plug from LOWER collector box

drain robe (blue and white striped label),

b. Install removed clamp and plug into UPPER collector box

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

t_ap.

c (onnect LOWER collector box drain connection to con=

densate trap.

(i) (ondensate Trap Located on Left Side of (asing

(a) (onnect LOWER collector box &ain robe (blue

and white striped 1abel) to condensate trap. Tube

does not need to be cut.

(b) Clamp tube to prevent any condensate leakage.

COLLECTOR BOX -'_

DRAIN TUBE (BLUE)

TUBE (GREEN)

EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

TRAP ©

iNDUCER HOUSING

DRAIN TUBE (VIOLET) /

A94165

Fig. 8--Downflow Tube Configuration (Left-Hand

Trap Instatlat{on)

(2) Condensate Trap Located on Right Side of (asing

(a) Install drain tube coupling d5ctow-supplied in

loose parts bag) into collector box drain robe

(blue and white striped label) which was previo

ously plugged.

(b) Connect larger diameter &ain robe (gmtoryo

supplied in loose parts bag) to &ain tube couo

piing, extending collector box drain robe for

connection to condensate trap

(c.) Route extended collector box &ain tube directly

from collector box &ain to condensate trap as

shown in Fig. 9.

(d) Determine appropriate length and cut

(e) (onnect to condensate trap

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

2. Inducer Housing Drain Tube

a. Remove fi_ctoL-y-installed 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. Use inducer housing &ain robe (violet label and factory°

supplied in loose parts bag) to connect LOWER inducer

housing &ain connection to the condensate trap.

e. Connect inducer housing drain connection to condensate

trap.

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

(a.) Detemline appropriate length and cut.

O O

,DRAIN TUBE _1_

COUPLING

Fig.

_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

; RAIN TUBE

(VIOLET)

CONDENSATE

TRAP

b F'_'-COLLECTOR BOX

EXTENSION

DRAIN TUBE

A94166

g--Downflow Tube Configuration (Right-Hand

Trap Installation)

(b.) Connect tube to condensate trap,

(c,) Clamp robe to prevent any condensate leakage

(20 (ondensate Trap Located on Right Side of Casing

(a.) Route inducer housing drain tube (violet label)

directly from inducer housing to condensate trap

as shown in Fig. 9.

(b) Determine appropriate length and cut

(c.) Connect robe to condensate trap.

(d) (lamp robe to prevent any condensate leakage.

3. Relief Port Tube

Re_r to Pressure Switch Tubing section _br connection procedure.

CONDENSATE TRAP FIELD DRAIN ATTA(HMENT

Refkr to Condensate Drain section for recommendations and

procedures.

PRESSURE SWITCH TUBING

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

the pressure switch _br 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 i:i_ctory connected to the condensate

trap relief port connection MUST be connected to the pressure

switch in DOVvL\TLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 8 or 9 or robe routing label on main fi/mace door

to check for proper connections.

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

pressure switch.

2. Extend collector box pressure robe (green label) which was

previously connected to condensate trap relief port connection

by splicing to small diameter robe d;actou-supptied in loose

parts bag).

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

A00215

Fig. 10--Horizontal Left Tube Configuration

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

switch connection labeled COLLECTOR BOX

4. Extend collector box pressure tube (pink label) which was

previously connected to pressure switch by splicing to remain°

lug small diameter robe (factoQ'-supplied in loose parts bag).

5. Route this extended robe (pink label) to condensate t_ap relief

port connection.

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

7. Clamp robe to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION

Refkr to Condensate Drain Protection section for recommenda°

tions and procedures.

Step 4--Horizontal Left {Supply-Ak Discharge)

Applications

A horizontal lef[ _mlace application is where furnace blower is

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

and conditioned air is discharged to the le_L

( ONDENSATE TRAP LO(ATION

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, perfom_ the fbllowing:

1. Remove 3 robes connected to condensate trap

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

and rotating trap

3. Instal! casing hole tiller cap (factory-supplied in loose parts

bag) into blower shelf hole where trap was removed.

-->

CARBON MONOXIDE POISONING HAZARD

Failure to follow 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 to prevent combustion

products being drawn in from appliances in the equipment

roonl.

4. [nstall condensate trap into left-hand side casing hole by

inserting robe connection stubs through casing hole and

rotating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler

caps di_ctory-supplied in loose parts bag).

CONDEXSATE TRAP TUBING

NOTI::: See Fig. 10 or tube routing label on main furnace door to

check for proper connections.

1. Collector Box Drain Tube

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

bag) into collector box drain robe (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 tube (blue label) to condensate trap and cut

to appropriate length.

d. Clamp robe to prevent any condensate leakage.

2. InducerHousingDrainTube

a RemoveanddiscardLOWER(molded)inducerhousing

draintubewhichwaspreviouslyconnectedtocondensate

trap.

b.Useinducerhousing&ainextensiontube(violetlabeland

fhctoD--suppliedinloosepartsbag)toconnectLOWER

inducerhousing&ainconnectiontothecondensatetrap

c.Determineappropriatelength,cut,andconnectrobe.

d.(lamprobetopreventanycondensateleakage.

3.ReliefPortTube

a.Extendcollectorboxrobe(greenlabel)whichwasprevi=

ouslyconnectedtothecondensatetrapbysplicingtosmall

diameterrobe(fhctory=suppliedinloosepartsbag).

b.Routeextendedcollectorboxpressurerobetoreliefport

connectiononthecondensatetrap.

c.Determineappropriatelength,cut,andconnectrobe.

d.Clamprobetopreventanycondensateleakage.

CONDENSATETRAPFIELDDRAINATTACHMENTS

Referto CondensateDrainsectionfbr recommendationsand

procedures.

PRESSURESWIT(HTUBING

TheLOWERcollectorboxpressuretube(pinklabel)isfhctory

connectedtothepressure switch for use when Ihrnace is installed

in UPFLOW applications. This robe 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 Nrnace door to

check for proper connections.

Modif}" robe as described below.

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

pressure switch.

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

bag) to extend robe disconnected in item 1.

3. Route extended robe:

a. Behind inducer housing,

b. Between blowe* 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 COLLECTOR BOX.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommenda°

tions and procedures.

CONSTRU(T A WORKING PLATFORM

Construct working platfbrm where all required Ihrnace clearances

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

[TNIT MAY NOT OPERATE

Failure to %llow this caution may result in intem_ittent unit

operation.

The condensate trap MUST be installed below furnace See

Fig 5 ibr dimensions. The drain connection to condensate

trap must also be properly sloped to an open &ain.

NOTE: Combustion-air and vent pipes are restricted to a mini°

mum length of 5 it. (See Table 7.)

--€

NOTE: A 12-in mininmm of_ket pipe section is recommended

with short (5 to 8 It) vent systems. This recommendation is to

reduce excessive condensate droplets fiom exiting the vent pipe,

(See Fig 11 or 34)

Step 5--Horizontal Right {Supply-Air Discharge)

Applications

A horizontal right furnace application is where furnace blowei is

located to the left of combustion and contlols section of ihmace,

and conditioned air is discharged to the right.

PROPERTY DAMAGE

Failure to ibllow this caution may result in minor property

damage

Local codes may require a drain pan under entire Ihrnace and

condensate trap when a condensing fhrnace is used in attic

application or over a finished ceiling.

NOTE: In Canada, installations shall be in accordance with

cun'ent NS(NGPI( Installation Codes and/or local codes

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

side of furnace casing. (See Fig. 12.) See Electrical Connection

section for J-Box relocation.

CONDENSATE TRAP LOCATION

The condensate trap must be removed fi'om the fi_ctory°installed

blower shelf location and relocated in selected application location

as shown in Fig. 2 or 12,

To relocate condensate trap fiom the blowei shelf to desired

location, perfbnn the following:

1 Remove 3 tubes connected to condensate nap.

2. Remove trap from blower shetfby gently pushing tabs inward

and rotating trap.

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

bag) into blower shelf hole where trap was removed.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning coutd result in personal inju W

or death.

Casing hole filler cap must be installed in blower shelf" hole

when condensate trap is relocated to prevent combustion

products being drawn in from appliances in the equipment

roonl.

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

inserting tube connection stubs through casing hole and

rotating until tabs snap into locking position.

5 Fill unused condensate tlap casing holes with plastic filler

caps (Pactory=supplied in loose parts bag).

CONDENSATE TRAP TUBING

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

check for proper connections

1 Collector Box Drain Tube

a Remove factory-installed plug from LOWER collector box

drain robe (blue and white striped label).

b Install removed clamp and plug into UPPER collector box

drain tube (blue label) which was previously connected to

condensate trap.

c Connect LOWER collector box drain tube (blue and white

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

cut,

COMBUSTIONINTAKE

VENT

12-1N. MIN HORIZONTAL PIPE

SECTION iS RECOMMENDED WITH

SHORT (5 TO 8 FT) VENT SYSTEMS

TO REDUCE EXCESSIVE

CONDENSATE DROPLETS FROM

EXITING THE VENT PIPE.

SHUTOFF

GAS VALVE ACCESS OPENING

FOR TRAP

SEDIMENT

TRAP CONDENSATE

TRAP

DRAIN

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

BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

RELOCATED HERE

A93031

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHFE STRIPED)

CONDENSATE

TRAP

INDUCER

DRAINTUBE(VIOLET)

COLLECTOR BOX i'/

EXTENSION TUBE

Fig. 12--Horizonta{ Right Tube Configuration

A00214

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

drain robe which was previously connected to condensate

trap.

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, cuL and connect robe to

condensate trap.

f\ Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection

procedure.

(ONDENSATE TRAP FIELD DRAIN ATTA(HMENT

Refer to Condensate Drain section %r recommendations and

procedures

PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is f'_ctory connected to

the pressnre switch fbr use when furnace is installed in UPFLOW

applications This tube MUST be disconnected and used for the

condensate trap relief port robe. The other collector box pressnre

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

trap relief port connection MUST be connected to the pressure

switch in DOWNFLOW or HORIZONTAL RIGHT applications

NOTE: See Fig. 12 or tube routing label on main filrnace door to

check for proper connections Relocate tubes as described below

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

pressure switch.

2. Extend collector box pressure tube (green label) which was

previously connected to condensate trap relief porq_connection

by splicing to small diameter robe (factov-supptied in loose

parts bag).

3. Route extended collector box pressure robe behind inducer

motor bracket then between inducer motor and pressure

switch,

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

switch connection labeled COLLE(TOR BOX.

5. Use remaining smaller diameter tube (gtctoryosupplied in

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

label) which was previously connected to pressure switch.

d. Route this extended robe (pink label) to condensate trap relief

port connection.

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

8. Clamp robe to relief port connection.

(ONDENSATE TRAP FREEZE PROTECTION

Re[kr to (ondensate Drain Protection section %r recommendao

tions and procedt/res.

(ONSTRUCT A WORKING PLATFORM

Construct working platfbm_ where all required furnace clearances

are met. (See Fig 3 and 11)

UPFLOW OR DOWNFLOW

V2" MAX

HORIZONTAL

A02146

Fig. 13--Furnace Location for Proper Condensate

Drainage

UNIT MAY NOT OPERATE

Failure to [bllow this caution may result in intem_ittent unit

operation.

The condensate trap MUST be installed below furnace See

Fig. 5 for dimensions. The drain connection to condensate

trap must also be properly sloped to an open drain.

NOTE: (ombustionoair and vent pipes are restricted to a mini-

mun_ length of 5 ft. (See Table 7.)

NOTE: A 12oin. mininmm of_;et pipe section is recommended

with short (5 to 8 ft) vent systems. This recomn_endation is to

reduce excessive condensate droplets fi'om exiting the vent pipe.

(See Fig. 11 or 34.)

LOCATION

Step t--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 (refer to SAFETY CONSIDERATIONS).

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

are not exceeded. Re[_r to Table 7.

* be located where available electric 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. Re['cr to Air

Ducts section.

* be provided with ample space fbr servicing and cleaning.

Always comply with nainimun_ fire protection clearances

shown on the furnace clearance-toocombustibles label.

This fi_rnace may be located in a confined space without special

provisions fbr dilution or ventilation air.

When a fm'nace is installed so that supply/lucts caro- air circulated

by d_e ftm_ace to areas outside the space containing the f'umace.

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

casing. The &lcts terminate outside the space containing the

ft_rnace to ensure there will not be a negative pressure condition

within equipment room or space.

NOTE: For upflowidownflow applications install furnace so that

it is level or pitched [brward within 1i2oin. for proper furnace

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

1i2oin. maxinmnl forward to ensure proper condensate &ainage

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

---5

BACK

A93043

Fig. 14--Prohibit Installation on Back

FIRE HAZARD

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

damage, personal injury or death.

Do not install furnace on its back. Safety control operation

will be adversely affected. Never connect return=air ducts to

back of Nmace. (See Fig. 140

[TNIT DAMAGE HAZARD

This gas fire, ace may be used fbr construction heat provided

that:

-The ftm_ace is permanently installed with all electrical

wiring, piping, air filters, venting and ducting installed

according to these installation instructions. A retnrn air duct

is provided, sealed to the furnace casing, and terminated

outside the space containing the fkmlace. This prevents a

negative pressure condition as created by the circulating air

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

products into the stl_acture.

-The furnace is controlled by a thermostat. It may not be "hot

wired" to provide heat continuously to the strt/cture without

thermostatic control.

-(lean outside air is provided for combustion. This is to

minimize the corrosive effects of adhesives, sealers and other

construction materials. It also prevents the entrainment of

dwwall dust into cornbusfion air, which can cause %uling and

plugging of Nmace components.

-The temperature of the return air to the fhmace is maintained

between 55cT (13c>() and 80°F (27_>(), with no evening

setback or shutdown. The use of the Nmace while the

stl_acture is under construction is deemed to be intermittent

operation per our installation instructions.

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

furnace 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 Nmace, ductwork and filters are cleaned as necessary to

remove &ywall dust and construction debris t)om all HVAC

system components after construction is completed.

-After construction is complete, verify Nmace operating

conditions including ignition, input rate, temperature rise and

venting, according to the manufi_cmrer's instluctions.

A93058

Fig. 15--Freeze Protection

[NIT DAMAGE HAZARD

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

unit damage.

If Nrnace is installed in an unconditioned space where the

arnbient temperatures may be 3UT or lower, fi'eeze protection

measures must be taken. (See Fig. 15.)

Step 2--Furnace Location Relative to Cooting

Equipment

)"he cooling coil must be installed parallel with or oll downstream

side of t:urnace to avoid condensation in heat exchanger. When

installed parallel with a fi/mace, dampers or other means used to

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

entering t:urnace. If dampers are manually operated, they must be

equipped with a means to prevent operation of either unit, unless

damper is in fgll=heat or full-cool position.

Step a--Hazardous Locations

FIRE, EXPLOSION, IN J[ RY OR DEATH HAZARD

Improper location or inadequate protection could result in fire

or explosion

When fhmace is installed in a residential garage, it must be

installed so that burners and ignition sources are located a

mininmn_ of 18 in. above floor. The fi/mace must be located

or protected to avoid physical damage by vehicles. When

ft_rnace is installed in a public garage, airplane hangar, or

other building having a hazardous atmosphere, the t'umace

must be installed in accordance with NFGC or NS(NGPIC.

(See Fig. 16.)

mNSTALLATION

Step l--Leveling Legs {ff Desired)

When f_/rnace is nsed in upftow position with side inlet(s), leveling

legs may be desired. (See Fig. I7.) Install field-supplied,

corrosion-resistant 5/16°in machine bolts and nuts.

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

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

diameter hole in each bottom corner of furnace. (See Fig. 17.)

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

4 If downflow subbase (KGASB) is use& install as shown in

Fig. 19

If (?oil Assembly Part No, (D5 or CK5 or (?oil Box Part No,

K(AK( is use& install as shown in Fig 20_

18-IN. MINIMUM

TO BURNERS

Fig. 16--Installation in a Garage

A93044

A89014

Fig. 17--Leveling Legs

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 fi/rnace 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--Installation in Upflow and Downflow

Applications

NOTE: For downt'tow applications_ this fllmace is approved for

use on combustible flooring when special base (available from

manu_acmrer) Part No. KGASB0201ALL is used. Special base is

not required when this :[ilmace is installed on manu_hcmrer's (?oil

Assembly Part No. CD5 or CK5, or (?oil Box Part No. KCAKC is

used.

1. Detemaine application being installed t'rom Table 1.

2. Construct hole in floor per dimensions specified in Table 1

and Fig. 18.

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

18.

A96283

Fig. 18--Floor and Plenum Opening Dimensions

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING "_

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

-- FLOOR --

OPENING

A96285

Fig. 1g--Furnace, Plenum, and Subbase Installed

on a Combustib{e Floor

NOTE: Remove furnace per_brated, discharge duct flanges when

they inter['_re with mating flanges on coil on downflow subbase.

To remove fl/mace perforate& discharge duct flange, use wide

duct pliers or duct flange tool or hand seamers to bend flange back

and forth until it breaks off. Be carefl/t of sharp edges. (See Fig.

21)

FURNACE

CASBNG

WIDTH

Table 1--OpeNng Dimensions (in.)

APPLICATION FLOOR OPENING

24-3/4

19-5/8

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

22-7/8 19

22-1/8 19

22-1/2 19

Upflow Applications 16-5/8

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

Downflow Applications on Combustible Flooring Using

KGASB Subbase 16-3/4 20-3/8

17-112 Furnace with or without CD5 or CK5 Coil Assembly or

KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using

KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or 16-1/2 20

KCAKC Coil Box

Upflow Applications 20-1/8 24-3/4

Downflow AppIications on Non-Combustible Flooring 20 1%5/8

Downflow Applications on Combustible Flooring Using

KGASB Subbase 20-1/4 20-3/8

21 Furnace with or without CD5 or CK5 Coil Assembly or

KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using

KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or 20 20

KCAKC Coil Box

Upflow Applications 23-5/8 24-3/4

Downflow Applications on Non-Combustible Flooring 23-1/2 1%5/8

Downflow Applications on Combustible Flooring Using

KGASB Subbase 23-3/4 20-3/8

24-112 Furnace with or without CD5 or CK5 Coil Assembly or

KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using

KGASB Subbase

Furnace with or without CD5 or CK5 Coil Assembly or 23-1/2 20

KCAKC Coil Box

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

/_ COMBUSTIBLE

FLOORING "k

SHEET METAL ._,.

PLENUM

__ FLOOR __

OPENING

A96284

Fig. 20--Furnace, Plenum, and Coil AssemNy or

Coil Box Installed on a Combustib{e Floor

[TNIT MAY NOT OPERATE

Failure to %ltow this caution may result in intem_ittent unit

operation.

Do not bend duct flanges inward as shown in Fig 2! This

will affect airflow across heat exchangers and may cause limit

cycling or premature heat exchanger _itilure, Remove duct

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

shown in Fig, 21

NOTE: For 140 size unit when installed in downflow orientation,

cut the white jumper wire offbetween terminals PL]-7 and PLI=9.

Do not cut white jumper between tem_inals PLI=7 and PLI-11.

Refer to Fig. 30 _br location of jumper (ut jumper close to

connector and remove wire to avoid a short circuit

Step a--installation in Horizontal Applications

UNIT MAY NOT OPERATE

Failure to _bltow this caution may result in intem_ittent unit

operation.

The entire length of _i/rnace 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 the ground,

blocks or pad should support sides and center blower shelf

area.

These fmnaces can be installed horizontally in either horizontal

te_ or right discharge position. In a crawlspace, t'm'nace 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 s_/pports (See Fig. 22.) Cut hanger bolts (4 each 3/8=in.

all=thread rod) to desired tength. Use 1 X 3/8=in flat washers,

3/8-in. tock washers, and 3/8=in nuts on hanger rods as shown in

Fig 22. Dimples are provided fbr hole locations. (See Fig 2)

if constructed and installed in accordance with the latest edition of

SMAENA construction 18 standard on fibrous glass ducts. Both

acoustical lining and fibrous ductwork shall comply with NFPA

90B as tested by EL Standard 18! for (?lass 1 Rigid air ducts.

DISCHARGE DUCT

FLANGE

210°

MIN

YES

A93029

Fig. 21--Duct Flanges

Step 4--Air Duets

GENERAL REQUIREMENTS

The duct system should be designed and sized according to

accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning ContIactors National Association (SMACNA) or

American Society of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE) or consult Fhe Air 51v,ste_sDesiglv G_ide-

trees rel:_rence rabies available fiom 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 catty- air

circulated by the t:urnace to areas outside the space containing the

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

the furnace casing and tem_inating outside the space containing the

furp, ace

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.

Flexible connections should be used between ductwork and

furnace to prevent tlansmission of vibration. Ductwork passing

through unconditioned space should be insulated to enhance

system performance. When air conditioning is used, a vapor

battier is recommended.

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

ductwork for a distance of 36=in. horizontally fiom the furnace.

See NFPA 90B or local code fbr further 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 t:urnace is installed and shall be of such a size

that the heat exchanger can be viewed fbr possible openings using

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

stream. The cover attachment shall prevent leaks.

DUCTWORK ACOUSTIE AL TREATMENT

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

of main duct to the first branch take-off may require internal

acoustical lining. As an aheraative, fibrous ductwmk may be used

SUPPLY AIR CONNECTIONS

Upflow Furnaces

Connect supply=air duct to 3/4-in. flange on furnace supply-air

outlet. The supply=air duct attachment must be connected to

ONLY fhmace 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

accessories MUST be connected external to furnace main casing.

Downflow Furnaces

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

supply-air duct attachment must be connected to ONLY fhrnace

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

installed on non=combustible material. When installed on combus-

tible material, supply=air duct attachment must be connected to

ONLY an accessory subbase or Pactory approved air conditioning

coil casing. D() NOT cut main furnace casing to attach supply side

air duct, humidifier, or other accessories. All accessories MUST be

connected external to furnace main casing. Supply air opening duct

flanges must be modified per Fig. 21.

Horizontal Furnaces

Connect supply=air duct to supply air opening on furnace. The

supply-air duct attachment must be connected to ONLY fhmace

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

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

or other accessories. All accessories MUST be connected external

to fhrnace main casing.

RETURN AIR CONNECTIONS

The furnace and its return air system shall be designed and

installed so that negative pressure created by the air circulating fan

cannot affect another appliance's combustion air supply or act to

mix products of combustion with circulating air. The air circulat-

ing fhn of the furnace, if installed in an enclosure communicating

with another filel=buming appliance not of the direct=vent type,

shall be operable only when any door or panel covering an opening

in the fhmace fhn compartment or in a return air plenum on ducts

is in the closed position.

FIRE HAZARD

A failure to _bltow this warning could result in fire, personal

injury, or death.

Never connect return=air ducts to d_e back of the _hmace.

Return=air duct connections on furnace side{s) peimitted in

upflow applications only

Upflow Furnaces

The return-air duct mttst be connected to bottom, sides (le_:_ or

right), or a congbination of bottom and side(s) of main furnace

casing as shown in Fig. 2. Bypass humidifier may be attached into

unused side return 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 end inlet opening

provided as shown in Fig. 2. DO 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

furnace

ANGLE

IRON OR

EQUIVALENT

3/8-1N.ROD

ALTERNATE SUPPORT

LOCATION 4-IN. MIN

8-IN. MAX

(B)

(A) ROD LOCATION

USING DIMPLE

LOCATORS

(SEE DIMENSIONAL

DWG FOR

LOCATIONS)

3/8-1N.HEX

& WASHER (4)

REQD PER ROD

(B) ALTERNATE SUPPORT

LOCATION FROM BACK

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

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

furnace and combustible material.

2. The entire length of furnace must be

supported when furnace is used in horizontal

position to ensure proper drainage.

Fig. 22--Crawlspace Horizonta{ ApNication

A93304

Step 5--Filter Arrangement

FIRE, CARBON MONOXIDE AND POISONING

HAZARD

Failure to %llow this warning co_dd result in fire_ personal

injur?% or death

Never operate fi/rnace without a filter or with filter access

door removed.

The air filter an'angement will va N" due to application, furnace

orientation, and filter type. The filter may be installed in an

external Filter/Media cabinet (if provided) or the t'umace blower

compartment. Facto_ supplied washable filters are shipped in the

blower compartment.

If a factoryosupplied external Filter Media cabinet is provided,

instructions for its application, assembly, and installation are

packaged with the cabinet. The Filter/Media cabinet can be used

with the fitctoryosupplied washable filter or a factor'-specified

highoefficiency disposable filter (see cabinet instructions)

If installing the filter in the t_urnace blower compartment, deter-

mine location %r filter and relocate filter retaining wire, if

necessary. See Table 2 to determine correct filter size for desired

filter location. Table 2indicates filter size, location, and quantity

shipped with this filrnace. See Fig. 2 %r location and size of

bottom and side returnoair openings.

(IT HAZARD

Failure to %llow this caution may result in minor personal

ir!iury

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.

[TNIT MAY NOT OPERATE

Failure to fc4tow this caution may result in intem_ittent unit

operation.

For airflow requirements above 1800 CFM, see Air Deliver-

table in Prodnct Data literature %r 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.

NOTE: Side remrnoair openings can ONLY be used in UPFLOW

configurations. Install filter(s) as shown in Fig 23 Bottom

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

need to be cut to fit some furnace widths. Install filter as shown in

Fig. 24.

NOTE: Remove and discard bottom closure panel when bottom

inlet is used.

Table 2--FHter Information

AmR FBLTER LOCATED }N BLOWER COMPARTMENT

FURNACE FILTER SIZE (IN.) FILTER

CASBNG

WIDTH {IN.) Side Return Bottom Return TYPE

17=112 (1) 16 X 25X 11. (1) 16 X 25 X 11- CleanaNe

21 (1) 16X25X 1" (1) 20X25X 11- Cleanabte

24=112 (1 or 2) 16X25X1* (1) 24X25X 11- Cleanabie

* Filters may be field modified by cutting filter matedal and support rods (3) in

filters Alternate sizes and additional filters may be ordered from your dealer

? Factory-provided with furnace.

17_-IN.WIDE

CASINGS ONLY:

INSTALL FELD-SUPPLIED

FILTER FILLER STRIP

UNDER FILTER.

FILTER

RETAINER

Fig. 23--FiRer Installed for Side INet

A93045

Step 6--Bottom Closure PaneJ

These f_tmaces 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_ _bllowing:

l, Tilt or raise tin'hate and remove 2 screws holding flont filler

panel, (See Fig 25,)

2, Rotate front filler pane1 downward to release holding tabs

3, Remove bottom closure pane1

4, Reinstall fi'ont _lle* panel and screws,

Step 7--Gas Piping

Gas piping must be installed in accordance with national and local

codes. Refer to cmTent edition of NFG( iu the United States.

(anadian iustallations must be made iu accordance with NSCNG=

PIC and all authorities having jurisdiction.

Gas supply line should be a separate line rurming directly t'rom

meter to furnace, if possible. RefEr to Table 3 _br recommended

gas pipe sizing Risers must be used to cormect to _i/rnace aud to

meter. Support all gas piping with appropriate straps, hangers, etc

Use a minimum of I hanger ever?" 6 t't. Joint con_pound (pipe dope)

should be applied sparingly and only to male threads of joints. Pipe

dope must be resistant to propane gas.

=WASHABLE

FILTER

SUPPORT

FILTER

RETAINER

Fig. 24_Bottom FHter Arrangement

A00213

}

BOTTOM

CLOSURE

PANEL

FRONT FILLER

PANEL

A93047

Fig. 2g--Removing Bottom Closure Panel

TaNe 3--Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE

SmZE

ON.)

I/2

3/4

1-1/4

1-1t2

iNTERNAL

DIAMETER

(IN.)

0.622

0.824

1.049

1.380

1.610

LENGTH OF PIPE (FT}

10 20 30 40 50

175 120 97 82 73

360 250 200 170 151

680 465 375 320 285

1400 950 770 660 580

2100 1460 1180 990 900

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in wc) or less and a

pressure drop of 0.5-in wc (based on a 060 specific gravity gas).

Ref: Table 9.2 NFGC.

FIRE OR EXPLOSION HAZARD

Failm'e to %llow this wa*ning could result in fire, explosion,

personal inju W, or death

-(onnect gas pipe to 5n'nace using a backup wrench to avoid

damaging gas controls.

-Gas valve shutoff switch MUST be fhcing fbrward or tilted

upward.

-Never pu*ge 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.

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

manifbld.

-If a /'lexible connector is required or allowed by attthori w

having jurisdiction, black iron pipe shall be installed at

fimaace gas valve and extend a mininmm of 2 in outside

furnace casing.

Install a sediment trap in riser leading to fl/mace. Trap can be

installed by connecting a tee to riser leading to t\u'nace so

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

nipple into lower end of tee. (apped nipple should extend below

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

control manifold and manual gas shutoff valve. (See Fig 26.)

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 f\fllow the safkty warnings exactly could result in

serious injury, death or property damage

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

cially available soap solution made specifically for the

detection of leaks to check all connections A fire or explo°

sion could result causing property damage, personal ir!iury or

toss of life

An accessible manual shutoff valve MUST be installed external to

fl/mace casing and within 6 ft of filmace. A li8°in. NPT plugged

tapping, accessible for test gage connection, MLST be installed

immediately upstream of gas supply connection to furnace and

downstIeam 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 maximum 0.5 psig (14-in. wc) stated on gas control valve

(See Fig. 57)

GAS

SUPPLY

MANUAL _/ II

A93324

Fig. 26--Typical Gas Pipe Arrangement

Piping should be pressure and leak tested in accordance with

NFG( in the United States or NSCNGPI( in Canada. local, and

national plumbing and gas codes be_;ore the t'urnace has been

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

check for leakage at furnace prior to operating t:urnace.

If pressure exceeds 0.5 psig (14=in. wc), gas supply pipe must be

disconnected from ftlrnace and capped be_bre pressure test If test

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

electIic shutoff switch located on _hrnace gas control valve and

accessible manual shutoff valve before test After all connections

have been made, purge lines and check fbr leakage.

The gas supply pressure shall be within the maximum and

minimum inlet supply pressures marked on the rating plate with

the fl/rnace burners ON and OFF.

Step 8--Electrical Connections

See Fig 27 for field wiring diagram showing typical field 115-v

and 24-v wiring (hock all fhctoo" and field electrical connections

for tightness

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

(33°(7) rise.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in serious injury or

death

Blower access door switch opens 115-v power to control. No

component operation can occur Do not bypass or close

switch with panel removed

FURNACE MAY NOT OPERATE/PROPERTY

DAMAGE

Failure to %llow this caution may result in fhraace operation

stopping and water pipes freezing during cold weather.

Furnace control must be grounded for proper operation or

control will lock out. (ontrol is grounded through

green yellow wire connected to gas valve and burner box

SCrew,

115 V WIRING

Be_bre proceeding with electrical connections, make certain that

voltage, fi'equency, and phase con'espond to that specified on

furnace rating plate. Also, check to be sure that service provided

.... FIELD 24-V WIRtNG

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

-- FACTORY 24-V WIRING

-- FACTORY 115-VWtRtNG

NOTE 2 I

FIVEW RE-- I

THREE-WIRE _

HEATING-ONLY _

7¿ :

115-V FIELD- AUXILIARY O F.

SUPPLIED J-BOX h_

DISCONNECT @

24-V

TERMINAL

BLOCK

FURNACE NOTES: 1. Connect Y-terminal 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 suppled, must be replaced, use

same type or equivalent wire. A99440

Fig. 27--Typical Heating and Cooling Application Wiring Diagram

ELECTRIC _C

DISCONNECT

SWITCH

OPPER

WIRE ONLY

®A93033

National Electlical (:ode (NEC) ANSIiNFPA 70-2002 and any

local codes or ordinances that might apply For Canadian instal-

tations, all electrical connections must be made in accordance with

Canadian Electrical (?ode CSA (722,1 or authorities having juris-

diction, Use a separate, branch electrical circuit containing a

properly sized _ase or circuit breaker _br this fl/mace, See Table 4

for wire size and t:ime specifications. A disconnecting means must

be located within sight fiom and readily accessible to Nrnace,

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

polarity is incon'ect, control LED stares indicator will flash rapidly

and _arnace will NOT operate,

Fig. 28--Disconnect Switch and Furnace

ALTERNATE --

FIELD

LOCATION

S ACTORY

INSTALLED

LOCATION

A00212

Fig. 29--Relocating J-Box

by power supply is sufficient to handle load imposed by this

equipment Refer to rating plate or Table 4 for equipment electrical

specifications Make all electrical connections in accordance with

FIRE HAZARD

Failure to fd!ow this warning could result in serious inju U,

death, or property damage

Do not connect alun_inun_ wire between disconnect switch

and _i/rnace, Use only copper wire (See Fig, 28)

ELECTRICAL SHOCK AND FIRE HAZARD

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

death, or property damage,

The cabinet MUST have an unintetTupted or unbroken ground

according to NEC ANSI NFPA 70-2002 and ( anadian Elec-

trical (ode (SA (22i or local codes to minimize personal

injm'y if an electrical limit should occur, This may consist of

electrical wire or condtdt approved _Pr 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. 29,)

2Rotate J-box 180 ° and attach box to left side, using holes

provided

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to billow this warning could result in serious injury,

death, or property damage.

If manual disconnect switch is to be mounted on furnace,

select a location where a drill or ihstener will not contact

electrical or gas components

24 V WIRING

(onnect 24-v thermostat leads to 24ov terminal block on t:urnace

control. For proper cooling operation, Y wire from thermostat

MUST be connected Go YY2 tem_inal on fhmace control, as

shown in Fig. 27 The 24=v terminal block is marked l\_r easy

connection of field wiring. (See Fig 30) The 24ov circuit contains

a 3-amp, automotive-type fuse located on flul_ace control. (See

Fig. 31.) Any electrical shorts of 24-v wiring during installation,

service, or n_aintenance may cause t:use to blow If fuse replace°

ment is required, use only a ihse 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 them_ostat wire

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

15 wire.

AC( ESSORIES

1. Electronic Air (leaner (EAC)

Two quick-connect terminals marked EAC-1 and EACo2 are

provided for EAC connection. (See Fig 3 I.) These terminals

are energized with 115-v (i 0oamp rnaxinmm) during blower

motor operation.

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent

operation or performance satisfa_ction

DO NOT connect _hmace contlol HUM terminal to HUM

(humidifier) terminal on ThermidistaV M, Zone Cormoller or

similar device. See Thermidistat TM, Zone Controller, them_oo

star, or controller manufacturer's insm_ctions ibr proper

connection

2. Humidifier (HUM)

A quick-connect terminal (HI_M) and screw terminal ((o\*

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

30) HUM tem_inal is energized with 24-v (0 5=amp maxi=

mum) when gas valve is energized

NOTE: A field-supplied, ll5ov controlled relay connected to

EA( tem_inals may be added if humidifier operation is desired

during all blower operation.

Step 9--Direct Venting

The 58MXA furnaces require a dedicated (one 58MXA furnace

only) directovent system In a direct-vent system, all air for

combustion is taken directly fi'om outdoor atmosphere, and all flue

gases are discharged to outdoor atmosphere. The venting system

shall be installed in accordance to these instructions

REMOVAL OF EXISTING FURNACES FROM (OMMON

VENT SYSTEMS

When an existing Categow I fire, ace is removed or replaced, the

original venting system may no longer be sized to properly vent

the remaining attached appliances. An improperly sized Categow

I venting system could cause the ibm_afion of condensate in the

fl/mace and vent, leakage of condensate and combustion products,

and spillage of combustion products into the living space, etc.

(ARBON MONOXIDE POISONING HAZARD

Failure to fbllow the steps outlined below %r each appliance

connected to the venting system being placed into operation

could result in cmbon monoxide 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 the venting system ibr proper size and horizontal

pitch, as required in the National Fuel Gas (;ode, ANSI

Z223.1=2002NFPA 54°2002 or the CSA B149.1. Natu=

ral Gas and Propane Installation (ode and these instruco

tions. Determine that there is no blockage or restlicfion,

leakage, con'osion 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 applio

ance(s) connected to the venting system are located and

other spaces of the building.

4. (?lose fireplace dampers.

5. Turn on clothes dD'ers and any appliance not connected

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

range hoods and bathroom exhausts, so they are operato

ing at maximum speed. Do not operate a summer

exhaust fan.

6. Fol!ow the lighting instructions. Place the appliance

being inspected into operation. Adjust the them?ostat so

appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at

the &ak hood relief opening aker 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 cotxected in accordance

with the National Fuel Gas (ode. ANSI Z223.1o

2002 NFPA 54-2002 and/or CSA B149.1. Natural Gas

and Propane Installation (;odes.

9. After it has been determined that each appliance con°

nected to the venting system properly vents when tested

as outlined above, return doors, windows, exhaust ihns,

fireplace dampers and any other gas-fired burning applio

ance to their previous conditions of use.

Vent system or vent connectors may need to be resized. For any

other appliances when resizing vent systems or vent connectors,

system or connector mnst be sized to approach n_ininmm size as

determined using appropriate table ibtmd in the NFGC or NSCo

NGPIC.

COMBUSTION°AIR AND VENT PIPING

General

(ombustion-air and vent pipe, fittings, primers, and solvents must

conform to American National Standards Institute (ANSI) stan-

dards and American Society fbr Testing and Materials (ASTM)

standards. See Table 6 for approved materials for use in the USA.

In Canada constrnct all cornbustionoair and vent pipes fbr this

furnace of CSA or UL( listed scheduleo40 PVC, PV(oDWV or

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

Canada.

See Table 7for maximum pipe lengths and Fig. 36, 37, 38, 39, and

40 ibr exterior piping an'angements

NOTE: Furnace cornbustionoair and vent pipe connections are

sized for 2-in pipe Any pipe size change should be made outside

CAP 2

PL4

FS£

(cc_).

1 BIA'_R CON INLOLS [AN SEIEC RE[,£ S_sE}

B!i_,CI R BLOWERMOTORSPEEDCHANGERE[,_<SPDT

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G BIWM BIOWER_40_OR PERMANEN_Sr'Ll_CA_V_CI_OR

NE C/_' 1 2 CA_V_CI_OR!_r_ MICROPROCESSOR AND CIRCUITRY

EAC I _[ EC_RONIC AIR CI EAN_r_CONN_C_I( N_ I _ ',AC / (//:_,_ MAX i

rAC2 _[ EC_RONIC AIR CI EANERCONNECTION _COMMON_

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FU 2 [USE OR CIRCUI_BREAKERCURREN_ IN_ERRUP_0 P,'IC_

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GV GAS '_I_,'E REDUN_AN_

G'¢R 1 2 GAS '_1_, E RE[,_ DPS_ _N O }

I ql HO_ SUR[AC_IGNITER_115 ',AC_

I _IR HO_ SURFACEIGNITERREI,_ SPS__N O }

HUM 24',AC HU_,,II_I[IERCONNECqON {05 AMP [_V_ i

IDR INDUC_O D_V_[_ [V_)_OR RE[,_< SPS__N O _

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tl BLOWER O[ [ DE[,_d ;UMPERSE[ EC_OR

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01 AUO RESEIN E_NAI ',,0 Oq O',ER[OAD

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PCB PRIN_8 CIRCUI_BOARD CONtROl

P[1 /1 CIRCUI_PCBCONNECTOR

P[2 2 CIRCUI_CONNECTOR

Pb_ :_ CIRCUI_IDr,,,lEXTENSIONCONNECX)R

PRS PRESSURES',_Ci L SPS__N 0

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[AC_ORY'A_RING_115'_C_

Em [IEL_ WIRING_I 1pd_C_

CONDUCX)R ON CONtROl PCB

__ HEL_'/q_ING SCRE'_ _ERMINAI

_ [IEL_D_R_HGROUND

_- EQUIPMEN_GROUND

_ _ PLUGRECEP_C[ E

[O 115VAC fIELD DISCCqNECT SCHEMATIC DIAGRAM

#2 _2 (NATURAL GAS & PROPANE)

LGNO_ £QU 'MLN1 GRO JND

_aOTES:

i arly o_th_ ong n _ equ pr_ nt wire is repac_:d use vqre r 1_d for 105 C

tJs_ onN copp{_zw re L_4w_n the, d s{x)nn_-ctsv_itch _nd _he_rn _cv urlct on box {J8)

3 ]-is VqR,n_lst be connected to urn _c_ sh_-_4t=_¢ for mt_roi to prov_ hm_

, Synt_os ree_ectr{dreprus{t_tonon[y

Solid inr_s ins&*PCB ire prnted circuit bord conductors _nd re not [nciuded n [egerld

Replace only !'_th in/p use

71 IrldUC_:r(IDV? lnd bio/'_tr (BL\_@')motors corlt in [t_vrrl [ auto res/4 thern_ i ow_ro d s/'_it/:h_s (OL)

11 F ctory corlne{:[ed "_hen LGPS is riot used

12 Iqn_tion _ockoL__1[ Occur _@erfour consecutive urlsuccessf u[ tr_4[s for igrlition Corl_ro__q!i

_[_o res_ 4"t_ _hree hours¸

326795101 REV B

Fig. 30--Wiring Diagram

A03229

TWINNING AND/OR

BLOWER OFF-DELAY COMPONENT TEST

TERMINAL

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)

CONNECTIONS

HUMIDIFIER TERMINAL

(24-VAC 05 AMP MAX)

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLTAGE MAIN

HARNESS CONNECTOR

Fig. 31--Furnace Control

A02142

FURNACE

SIZE

040-08

040-12

080-08

060-12

080-16

080-t2

080-16

080-20

100-16

100-20

120-20

140-20

VOLTS--

HERTZ--

PHASE

115-60-1

TaNe 4--Electrical Data

OPERATING

VOLTAGE RANGE

Max* Min*

127 104

MAX UNIT

UNIT

AMPS AMPACBTYt

6.1 8.4

7.3 10.0

6.1 8.4

7.1 9.8

9.5 12.8

7.6 10.4

10.0 13.4

14.1 18.4

10.2 13.5

14.8 19.3

14.6 19.1

14.3 18.8

NIN

WiRE

SIZE

MAX WiRE

LENGTH

(FT)_;

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

MAX FUSE

OR CKT BKR

AMPS**

i- Unit ampacity = 125 percent of largest operating component's full load amps plus 100 percent of all other potential operating components' (EAC, humidifier, etc ) full

load amps

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

** Time-delay type is recommended

_lrnace casing in vertical pipe. (See Fig 320 This allows proper

drainage of vent condensate

Combustionoair and vent pipes must terminate together in same

atmospheric pressure zone, either through roof or sidewall (roof

termination preferred), using accessoI 7 termination kit.

See Table 5 tbr required clearances.

Furnace combustion-air and xent pipe connections must be at-

tached as shown in Fig. 33. Combustion-air intake plug fitdng and

inducer housing alternate _ent cap may need to be relocated in

some applications.

NOTE: Slope combustionoair and xent pipes down\\ared toward

furnace a minimum of 14 in per linear ft with no sags between

hangers.

(

NOT IN

HORIZONTAL

SECTION

FURNACE

TRANSITION IN

VERTICAL SECTION

A93034

Fig. 32--CombustionoAir and Vent Pipe Diameter

Transition Location and Elbow Configuration

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in fire, property

damage, personal injury, or death.

Solvent cements are combustible. Keep away h'om heat,

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

Avoid breathing in vapor or allowing contact with skin or

eyes.

CARBON MONOXIDE/PROPERTY DAMAGE

Failure to follow this warning could result in property

damage, personal injury, or death.

All combustion-air and vent pipes must be airtight and

watertight Pipes must also tem_inate exactly as shown in Fig.

36, 37, 38, 39, or 40.

PROPERTY DAMAGE

Failure to %llow this caution may result in dripping condeno

sate and potential property damage.

When combustion-air pipe is installed above a suspended

ceiling, pipe must be insulated with 3/8oin. thick Armaflexo

type insulation. ( ombustionoair pipe should also be insulated

when it passes through wam_, humid space

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

properly insulated and supported combustionoair and vent pipes.

Eacia fhrnace must have its own set of combustion-air and vent

pipes and be terminated individually, as shown in Fig. 42.

Other gas appliances with their own venting system may also use

the abandoned chimney as a raceway providing it is permitted by

local code, the NFGC or NSCNGPIC, and the vent or liner

manufacturer's installation instn/ctions (?are must be taken to

prevent the exhaust gases ti'om one appliance fiom contaminating

the combustion air of other gas appliances.

UNIT MAY NOT OPERATE

Failure to follow 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

shown in Table 8 with Armaflexotype insulation

UNIT CORROSION HAZARD

Excessive exposure to contaminated comhustion air may

result in sa_bty and perfbrrnance related problems.

Combustion air must not be taken fiom inside structure

because inside air is frequently contaminated by halogens,

which include fluorides, chlorides, bromides, and iodides.

These elements are found in aerosols, detergents, bleaches,

cleaning solvents, salts, air fi'esheners, adhesives, paint, and

other household products. Locate combustionoair inlet as _r

as possible fi'om swimming pool and swimming pool pump

hol.lSe,

NOTE: The minimum combustionoair and vent pipe length (each)

for d-_ese hlmaces is 5 ft. Short pipe lengths (5°8 ft) may discharge

water droplets These &oplets may be undesirable, and a 12-in.

minimum off'set pipe section is recommended, as shown in Fig. 34,

to reduce excessive droplets f_'om exiting vent pipe outlet.

Combustion-Air and Vent Pipe Diameter

Determine combustion-air and vent pipe diameter.

1. Using Table 7, individually determine the smallest

combustionoair and vent pipe diameters permitted for each

pipe. Pick the larger of these 2pipe diameters and use this

diameter for both combustionoair and vent pipes.

2. When installing vent systems of short pipe length, use the

smallest allowable pipe diameter. Do not use pipe size greater

than required becuase incomplete combustion, flame distur-

bance, or flame sense lockout may occur.

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

within h_mace. See shaded areas in Fig. 36, 37, 38, 39, and 40.

EXAMPLE: An 080-12 size _hrnace located in Indianapo-

lis, elevation 650 ft above sea level, could be installed in an

application requiring 3 elbows and 32 ft of vent pipe, along

with 5 elbows and 34 ft of cornhustionoair pipe Table 7

indicates this application wo_dd allow a 2oin. diameter vent

pipe, but require a 2ol/2 in diameter combustion air pipe

(2oin. pipe is good fbr 35 ft with 3 elbows, but only 30 ft

with 5 elbows). Therelbre, 2-1/2 in diameter pipe must be

used for both vent and combustion-air pipes since larger

required diameter must always be used for both pipes. If

same installation were in Albuquerque, elevation 5250 _

above sea level, installation would require 2ol/2 in. vent

pipe and combustion-air pipe. At 5001o to 6000o_t eleva-

tion, 2-in. pipe is only good for 17 R with 5 elbows, and

2-1/2 in. pipe is good fbr 70 R with 5 elbows.

(ombustion-Air and Vent Pipe Attachment

NOTE: All pipe joints must be cemented except attachment of

combustion-air pipe to inlet housing connection, since it may be

necessary to remove pipe _br servicing.

1. Attach combustion=air pipe as follows:

a. Determine location of combustion-air intake pipe connec-

tion to combustion-air intake housing as shown in Fig. 33

for application.

b. Reposition combustionoair intake housing plug fitting in

appropriate unused intake housing connection.

i_>

VENTTERMINAL (_) AIR SUPPLY iNLET AREA WHERE TERMINAL IS NOT PERMITED

Item Clearance Description

A Clearance above grade, veranda, porch, deck, balcony, or

anticipated snow level

B Clearance to a window or door that may be opened

C Clearance to a permanently closed window

D Ver ficaI clearance to a ventilated soffit located above the

terminal within a horizontal distance of 2 (61bm) from the

centedine of the terminal

E Clearance to an unventilated soffit

F Clearance 1oan outside corner

G Clearance to an inside corner

H Clearance to each side of the centedine extended above

electrical meter or gas service regulator assembly

I Clearance to service regulator vent outlet

J Clearance to non-mechanical air supply inlet to building or

the combustion air inlet to any other appliance

K Clearance to a mechanical air supply inlet

L Clearance under a veranda, porch, deck, or balcony

M Clearance to each side of the centeriine 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

driveway located on public property

(I) In accordance with the current CSA B149 1. Natural Gas and Pro

Canadian Installation (1)

12" (30cm) #

12 "(30 cm) for appliances > 10,OO0Btuh (3 kW)

and < 100,000 Btuh(30 kW), 36"

(91 cm) for appliances > 100.000 Btuh (30 kW)

3" (91 cm) within 15 (4:5 m) above the meter/regulator

assembly

3" (91 cm)

9" (23 cm)_r appliances > 10,000 Btuh (3 kW) and

< 100,000 Btuh (30kW) and <50.000 Btuh (15 kW), 12"

(30 cm) for appliances > 50,000 Btuh (15 kW)

6" (I 83m)

12" (30 cm) +

12" (30 cm)

3" (91 cm)

T(2 13m)**

,ane Installafion Code

US Installation (2)

12" (30 cm)

9" (23 cmyor appliances > 10,000 Btuh (3 kW)

and < 50,000 Btuh (15kW), 12 "

(30 cm) for appJiances > 50,000 Btuh (15 kW)

3' (91 cm) within 15"(45 m) above the meter/regulator

assembly

9"(23 cm) for appliances > 10,000 Btuh (3 kW)

and < 50.000 Btuh (15kW), 12 "

(30 cm) for appliances > 50,000 Btuh (15 kW)

3' (91 cm) above ifvwthin 10 (3rh)horizontally

12" (30 cm)

3' (91 cm)

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

# 18" (46cm)aboveroofsurface

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

For clearances not specified in ANSI Z223.1/N FPA 54or CSA B 149 1, clearances shall be in accordance with local instailafion 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 nusaince 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 combustion products of adjacent vents

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

3 Avoid venting under a deck or large overhang Recircula0on could occur and cause performance or system problems

A05009

Table 5--Direct Vent Termination Clearance

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

AIR

COMBUSTION-AIR _ COMBUSTION-AIR

UPFLOW

COMBUSTION-

AIR VENT

HORIZONTAL-LEFT DISCHARGE

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

COMBUSTION- _ COMBUSTION-

AIR AIR

AIR

FLOW

DOWNFLOW

COMBUSTION-

AiR

VENT

HORIZONTAL-RIGHT DISCHARGE

A96187

Fig. 33--Combustion-Air and Vent Pipe

Connections

c. If required per Table 7, insert per%rated disk assembly

(factow_supplied in loose parts bag) in intake housing

where combustion-air intake pipe wilt be connected If half

disk set is require& install with shoulder of disk against

stop in combustionoair inlet

d. Install pipe support (fi_ctoryosupplied in loose parts bag)

into selected fi/mace casing combustion-air pipe hole. Pipe

support should be positioned at bottom of casing hole.

e. Insert 2-in. diameter pipe into intake housing.

NOTE: A 2oin. diameter pipe rmtst be used within the Nmace

casing. Make all pipe diameter transitions outside I:mnace casing.

_ Instal! casing hole tiller plug ([i_ctow-supplied in loose

parts bag) in unused congbustionoair pipe casing hole.

g. Drill a 1/8-in. hole in 2-in. combustion-air pipe using hole

in intake housing as a guide.

h. Install a fieldosupplied No. 6 or No. g sheet metal screw

into combustionoair pipe.

NOTE: DO NOT OVERTIGHTEN SCREW. Breakage of intake

housing or fitting may cause air leakage to occur.

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

combustionoair intake housing since it may be necessary- to remove

pipe for service of ignitor or flame sensor.

COMBUSTIONoAIR 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 l/g-in, hole in fitting, using

hole in intake housing as a guide. Install a _ield-supplied No. 6 or

No. 8 sheet metal screw.

NOTE: DO NOT OVERTIGHTEN SCREW. Breakage of intake

housing or fitting may cause air leakage to occur

A plugged drain connection has been provided on this fitting for

use _hen moisture is found in combustion-air intake pipe and

combustion box.

NOTE: Moisture in cornbustionoair intake may be result of

improper termination. Ensure combustion-air intake pipe termina-

tion is similar to that shown in Fig. 36, 37, 38, 39, and 40 so it will

not be susceptible to areas where light snow or other sources of

moisture could be pulled in.

If use of this drain connection is desire& drill out fitting's tap plug

with a 3/16-in. &ill and connect a field-supplied 3/8-in. tube. This

robe should be routed to open condensate drain for ft_rnace and

AiC (if used), and should be trapped. (See Fig. 35.)

2. Attach vent pipe to ft_rnace as follows:

a. Determine location of vent pipe connection to inducer

housing as shown in Fig. 33 for application.

b. Reposition elastomeric (robber) inducer housing outlet cap

and clamp to appropriate unused inducer housing connec_

don. Tighten clamp.

INIT DAMAGE HAZARD

Failure to follow this caution may result in unit component

damage

Inducer housing outle_ cap must be installed and fktlly

seated against inducer housing. (lamp must be tightened to

prevent any condensate leakage.

c Install pipe support (_i_ctoryosupplied in loose parts bag)

into selected ftmaace casing vent pipe hole. Pipe support

should be positioned at bottom of casing hole

_:l 0-_ '_

INleT DAMAGE HAZARD

Failure to %llow this caution may result in unit component

damage

Vent pipe must be installed and fi/lly 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 [:tmaace casing.

d Be certain that mating surfaces of inducer housing connec-

tion, elastomeric coupling, and 2oin diameter vent pipe are

clean and dw Assemble the elastomeric (l_./bber) vent

coupling (with 2loose clamps) onto inducer housing

connection Insert the 2oin diameter vent pipe through the

elastomeric (rubber) coupling and _ally into inducer hous-

ing connection until it bottoms on the internal stop Tighten

both clamps to secure the pipe to inducer housing Tighten

the clamp screws to 15 in olb. of torque.

e Install casing hole filler plug di_ctoryosupplied in loose

parts bag) in unused combustion-air pipe casing hole.

VENT EXTENSION PIPE

Furnaces with 100,000 Btuh and larger inputs are supplied with a

PVC vent extension pipe (2oin. diameter by 12oin long). 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 _arnace inducer housing on ALL upflow and down-

flow applications

NOTE: See label on vent extension pipe *;or proper installation.

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

extension robe to fieldoinstalled vent pipe.

HORIZONTAL TO ROOF

--,,I.-- 12" MIN---,,-- I

I 4

VENTP,PE--

l_lt/'-- CO MBUSTION-AIR PIPE

HORIZONTALTO SIDEWALL

COMBUSTION-AIR PIPE --""_"I

MIN ,_m,,-

COMBUSTION-AIR PiPE

/-- VENT PiPE

VERTICAL TO ROOF VERTICAL TO SIDEWALL

NOTE: A 12 In. 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. 34--Short Vent {5 to 8 Ft) System

A96230

TaNe 6--Approved Combustion-Air and Vent Pipe,Fitting and Cement Materials

ASTM SPECIFICATION

(MARKED ON MATER_AL)

D1527

D1785

D2235

D2241

D2488

D2564

D2661

D2885

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 PRBMERS

Solvent

Cement

Sotvent

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

F856

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

Ceitular Core Schedule-40 & DWV

3_ Working fiom ft_rnace to outside, cut pipe to required

length(s)_

4. Deburr inside and outside of pipe

5. (hamlet outside edge of pipe for better distribution of primer

and cement

6. (lean and d_ all sur_i_ces to be joined.

7. (beck &y fit of pipe and mark insertion depth on pipe

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

preassembled be_bre pem_anently cementing any joint.

8. ARer 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 fitting socket (over primer). Apply cement in a light,

COMBUSTION - AIR

INTAKE HOUSING

BURNER

BOX

DRILL

TO OPEN

DRAIN

L_COMBUSTION -

AIR PIPE

A93035

Fig. 35--Air intake Housing Plug Fitting Drain

unifbrm coat on inside of socket to prevent buildup of excess

cement Apply second coat.

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

Be s-are pipe is/_ully inserted into fitting socket

10. Wipe excess cement fi'om joint. A continuous bead of cement

will be visible around perimeter of a properly made joint.

11. Handle pipe joints careNlly until cement sets.

12. Support combustion-air and vent piping a minimum of eve_

5 fi (3 ft for SDR-21 or -26 PVC) using perforated metal

hanging stlap.

13. Slope combustion-air and vent pipes downward toward Nr-

nace a n_inimum of 1/4 in. per linear ft with no sags between

hangers.

14. Use appropriate methods to seal openings where vent and

combustion-air pipes pass through roof or side wall.

(ONCENTRIC VENT AND (OMBUSTION-AIR

TERMINATION KIT INSTALLATION

NOTE: If these instructions differ fi'om those packaged with

termination kit, follow kit instructions

Combustion-air and vent pipes must terminate outside structure A

factory accessory termination kit must be installed in 1 of the

installations shown in Fig 36, 37, 38, 39, and 40. Four termination

kits are available:

See Table 5 fPr additional termination inf'ormation.

1. The 2-in. [ermination bracket kit is fbr 1-in, 1-1/2 in. and

2-in. diameter 2-pipe termination systems.

2. The 3-in. termination bracket kit is fbr 2ol/2 in., 3-in., and

4-in. diameter 2-pipe termination systems.

3. The 2-in. concentric vent/air termination kit is for l-in. 1-1/2

in., 2-in., and 2-1/2 in. diameter pipe systems when single

penetration of wall or roof is desired.

4. The 3-in. concenkic vent/air tei_nination kit is for 2-1/2 in.,

3-in. and 4-in. diameter pipe systems when single penet*ation

of wall or roof is desired.

NOTE: Shaded parts in Fig. 36, 37, 38, 39, and 40 are considered

to be tem_ination. These components should NOT be counted

when determining pipe diameter Roof termination is prefen'ed

since it is less susceptible to damage, has reduced chances to take

in contaminants, and has tess visible vent vapors (See Fig. 36 or

37.) Sidewall termination may require sealing or shielding of

building surfaces with a con'osive resistance material due to

corrosive combustion products of vent system.

Extended Exposed Sidewall Pipes

Sidewall congbustion°air and vent pipe tem_inations may be

extended beyond area shown in Fig 39 or 40 in outside ambient by

insulating pipes as indicated in Table 8

1 Determine combustion-air and vent pipe diameters, as stated

above, using total pipe length and number of elbows.

2 [sing winter design temperatme (used in load calculations),

find appropriate temperature for your application and furaace

model

3 Detem_ine required insulation thickness for exposed pipe

lengths

NOTE: Pipe length (k) specified _br maximum pipe lengths

tocated in unconditioned spaces Pipes located in unconditioned

space cannot exceed total allowable pipe length as specified in

Table 7.

Two-Pipe Tem_ination Kit

1 Determine location _br tem_ination.

(onside* the following when determining an appropriate

location _br tem_ination kit

a Compty with all clearance requirements as stated in Table

b Termination kit should be positioned where vent vapors

wil! not damage plants/shrubs or air conditioning equip-

ment.

c. Teimination kit should be positioned so that it will not be

affected by wind eddy (such as inside building corners) or

allow recirculation of flue gases, airborne leaves, or light

snow

d Tem_ination kit should be positioned where it will not be

damaged by or subjected to foreign objects_ such as stones,

balls, etc.

e. Teimination kit should be positioned where vent vapors are

not objectionable.

2. Cut 2holes, 1 for each pipe, of appropriate size for pipe size

being used.

3. Loosely install elbow in bracket and place assembly on

combustion=air pipe.

Roof terminations Loosely install pipe coupling on prop-

erly cut vent pipe. Coupling must be positioned so bracket will

mount as shown in Fig. 36.

For applications using comhustion-air pipe option, indicated

by dashed lines in Fig. 36, install 90 ° street elbow into 90 °

elbow, making U-fitting. A 180 _>U-fitting may be used.

Sidewall terminations Install bracket as shown in Fig. 39 or

40.

For applications using vent pipe option indicated by dashed

lines in Fig. 39, rotate vent elbow 90 _ from position shown in

Fig. 39.

4. Disassemble loose pipe fittings. Clean and cement using same

procedures as used fPr system piping.

5. (heck required dimensions as shown in Fig. 36, 39, or 40.

Concentric Vent/Air Termination Kit

1. Determine location fbr termination.

(onsideration of the following should be made when deter-

mining an appropriate location fbr tem_ination kit.

a. Comply with all clearance requirements as stated in Table

b. Tem_ination kit should be positioned where vent vapors

will not damage ptantsishrnbs or air conditioning equip-

nlent,

ALTITUDE (FT)

0 to 2000

ALTITUDE (FT)

2001 to 3000

ALTITUDE (FT)

3001 to 4000

See notes at end of tame

Tab{e 7--Maximum Allowable Pipe Length (ft)

UNIT SBZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

140-20

UNIT SIZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

140-20

UNIT SIZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

140-20

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

PIPE OmA

{IN,)*

1-1/2

2-1/2

2-1/2 one disk

3t no disk

2-1/2 one disk

3t one disk

3? no disk

41-no disk

PIPE DIA

(IN.)*

1-1/2

2-1/2

3? no disk

41-no disk

3? one disk

3? no disk

4? no disk

PIPE DtA

(IN.)*

1-1/2

2-1/2

3? no disk

41-no disk

3? one disk

3? no disk

4t no disk

NUMBER OF 90 ° ELBOWS

1 2 3 4 5 6

5 NA NA NA NA NA

70 70 65 60 60 55

70 70 70 70 70 70

20 15 10 5 NA NA

70 70 70 70 70 70

10 NA NA NA NA NA

55 50 35 30 30 20

70 70 70 70 70 70

5 NA NA NA NA NA

40 30 20 20 10 NA

70 70 70 70 70 70

10 NA NA NA NA NA

45 40 35 30 25 20

70 70 70 70 70 70

5 NA NA NA NA NA

40 35 30 25 20 15

60 56 52 48 44 40

70 70 70 70 70 70

NUMBER OF 90 ° ELBOWS

1 2 3 4 5 6

67 62 57 52 52 47

70 70 70 70 70 70

17 12 7 NA NA NA

70 67 66 61 61 61

1 2

64 59

70 70

16 11

68 63

46 41

70 70

33 24

70 70

65 58

70 70

11 6

30 26

70 70

NUMBER

25 25 15

70 70 70

16 6 NA

70 66 61

NA NA NA

56 50 43

70 70 70

5 NA NA

27 23 19

70 70 70

OF 90 ° ELBOWS

4 5 6

49 48 43

70 70 70

NA NA NA

57 57 56

28 23 22 13

70 70 70 70

15 14 5 NA

70 66 61 56

51 44 38 31

70 70 70 70

NA NA NA NA

22 18 14 10

70 70 70 70

c, Tem_ination kit should be positioned so it will not be

a_:_cted by wind eddy (such as inside building comers) or

that may allow recirculation of flue gases, airborne leaves,

or light snow,

d, Tem_ination kit should be positioned where it will not be

damaged by or subjected to foreign objects, such as stones,

balls, etc,

ALTITUDE (FT)

4001 to 5000_

ALTITUDE (FT)

5001 to 6000_

ALTITUDE (FT)

8001 to 7000_

ALTITUDE (FT)

7001 to 8000_

See notes at end of table

Table 7--Maximum AHowable Pipe Length (ft) (Continued)

UNIT SiZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

140-20

UNIT SiZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

140-20

UNIT SiZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

140-20

UNIT SiZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

140-20

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3dn.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3dn.

Concentric

TERMiNATiON

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3dn.

Concentric

2 Pipe or 3dn.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

PIPE DmA

(IN,)*

1-1/2

2-1/2

3t no disk

41 no disk

3t no disk

4t no disk

PIPE DtA

dN.)*

1-1/2

2-1/2

3t no disk

41 no disk

3t no disk

4t no disk

PIPE DtA

dN.)*

1-1/2

2-1/2

3t no disk

4t no disk

PIPE DIA

(IN.)*

1-1/2

2-1/2

3t no disk

4t no disk

NUMBER OF g0 ° ELBOWS

1 2 3 4 5

60 55 50 45 44

70 70 70 70 70

15 10 5 NA NA

64 59 58 53 52

44 39 26 21 20

70 70 70 70 70

31 22 13 12 NA

70 70 67 62 57

53 46 40 33 26

70 70 70 70 70

21 17 13 9 5

69 64 59 54 49

NUMBER OF 90 ° ELBOWS

1 2 3 4 5

57 52 47 42 40

70 70 70 70 70

14 9 NA NA NA

60 55 54 49 48

41 36 23 18 17

70 70 70 70 70

29 21 12 11 NA

70 67 62 57 52

42 35 29 22 15

70 70 70 70 70

12 8 NA NA NA

42 37 32 27 22

NUMBER OF 90 ° ELBOWS

1 2 3 4 5

53 48 43 38 37

70 70 68 67 66

13 8 NA NA NA

57 52 50 45 44

38 33 21 16 15

70 70 68 67 66

27 19 10 9 NA

68 63 58 53 48

31 24 18 11 NA

70 70 70 70 67

17 12 7 NA NA

NUMBER OF 90 ° ELBOWS

1 2 3 4 5

49 44 39 34 33

66 65 63 62 60

12 7 NA NA NA

53 48 46 41 40

36 31 19 14 12

66 65 63 62 60

25 17 8 7 NA

63 58 53 48 43

20 13 7 NA NA

61 56 51 46 41

TaNe7--Maximum Allowable Pipe Length (ft) (Continued)

ALTITUDE (FT}

800t to 9000@

ALTITUDE (FT)

9001 to I0,000_

UNiT SBZE

040-08

040-I2

060-08

060-12

060-16

080-I2

080-16

080-20

100-16

100-20

120-20

140-20

UNIT SIZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

140-20

TERMINATBON

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

PIPE DmA NUMBER OF 90 ° ELBOWS

(IN.)* 1 2 3 4 5 6

1-1/2 46 41 36 31 29 24

2 62 60 58 56 55 53

1-1/2 11 6 NA NA NA NA

2 49 44 42 37 35 34

2 33 28 17 12 10 NA

2-1/2 62 60 58 56 55 53

2-1/2 23 15 7 5 NA NA

3 59 54 49 44 39 34

31- no disk 10 NA NA NA NA NA

41- no disk 35 30 25 20 15 10

PiPE DtA NUMBER OF 90 ° ELBOWS

(IN.)* 1 2 3 4 5

1-1/2 42 37 32 27 25

2 57 55 53 51 49

45 40 38 33 31 29

2 30 25 14 9 7 NA

2-1/2 57 55 53 51 49 47

2-1/2 21 13 5 NA NA NA

3 54 49 44 39 34 29

4t no disk 10 5 NA NA NA NA

Disk usage-Unless otherwise specified, use perforated disk assembly (factory-supplied in loose parts bag). If one disk is stated, separate 2 halves of perforated disk

assembly and use shouldered disk half When using shouldered disk half, install screen side toward iNet box.

tWide radius elbow

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

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 Size both the combustion-air and vent pipe independently, then use the larger diameter for both pipes

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

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

5 The minimum pipe length is 5 ft for all applications

6 Use 3-in. diameter vent termination kit for instNlations requiring 4-in diameter pipe.

AIR AND VENT

8 314" FOR 3" KIT

6 314" FOR 2" KIT

MAINTAIN 12 IN.

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL.

MAXIMUM OF 24 IN. ABOVE ROOF.

A87224

Fig. 36--Roof Termination (Preferred)

e, Termination kit should be positioned where vent vapors are 3, Loosely assemble concentric vent air termination components

not objectionable together using instructions in kit

2, Cut one 4-in, diameter hole for 2-in, kit, or one 5-in, diameter 4, Slide assembled kit with rain shield REMOVED through hole,

hole for 3-in, kit, 32

Fig. 37--Concentric Vent and Combustion=Air Roof

Termination (Preferred}

12 IN.

CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL OR GRADE,

WHICHEVER IS

GREATER.

A93055

Fig. 38--Concentric Vent and Combustion-Air Side

Termination

NOTE: Do not allow insulation or other materials to accumulate

inside of pipe assembly when installing it through hole

Roof ternfi.adons Locate assembly through roof to appropriate

height as shown in Fig. 37,

Sidewall terminations Locate assembly through sidewall with

rain shield positioned no more than l=in fi'om wall as shown in

Fig 38,

5, Disassemble loose pipe fittings. Clean and cement using same

procedures as used for system piping.

6, Check required dimensions as shown in Fig 37 or 38,

IN. SEPARATION

BOTTOM OF

COMBUSTION AIR AND

OF VENT

12 IN.

CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL OR GRADE,

COMBUSTION-AIR WHICHEVER IS

GREATER.

A87225

Fig. 39--Sidewall Termination of 12 in. or More

OVERHANG OR ROOF /_,-----_/"

VENT-""* / /_

_ 90 °

BRACKET

COUPLING

/" I It l_-->< ! x-12 iN.SEPARATION

/" _ _d _ [-/_/BETWEEN BOTTOM OF

_a_/l_--- I .COMBUSTIONAIR AND

J_ ,,7__r_/_" . 1_71BOTTOM OF VENT

/_?- 77 J,_ /f""'--'MAINTAIN 12 IN.

•/ /_ _/ cLEARANCE

_k!g ---¢-'- _/ _ _ABOVE HIGHEST

-" _ '--ANTICIPATED SNOW

"-COMBUSTION-AIR LEVEL OR GRADE,

(ELBOW PARALLEL WHICHEVER IS

TO WALL) GREATER.

A87226

Fig. 40--Sidewall Termination When Wall Penetra-

tion is Less than 12 in Above Snow or Grade.

MULTIVENTING AND VENT TERMINATIONS

When 2 or more 58MXA Furnaces are vented near each other,

each f_lrnace must be individually vented. NEVER common vent

or breach vent 58MXA furnaces. When 2 or more 58MXA

furnaces are vented near each other, 2 vent tem_inations may be

installed as shown in Fig. 41, 42, 43, 44, and 45, but next vent

termination must be at least 36 in. away fi'om first 2terminations.

It is important that vent terminations be made as shown to avoid

recirculation of flue gases. Dimension "A" in Fig. 41, 42, 43, 44,

and 45 represents distance between pipes or rain shields, as

touching or 2=in. maximum separation.

TaNe 8--Maximum AItowaNe Exposed Vent Pipe Length (ft) With and Without Insulation in Winter Design

Temperature Ambient*

WINTER DESIGN MAX PIPE

FURNACE W_THOUT W_TH 3/8-1N. OR

TEMPERATURE DIAMETER

SRZE (OF) (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

20 3 60 60

0 3 60 60

-20 3 44 60

140 20 4 70 70

0 4 57 70

-20 4 30 70

* Pipe length (if) specified _r maximum pipe lengths located unconditioned

as specified in Table 7.

tInsulation thickness based on R vNue of 35 per in

spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length

[?NIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit

operation

Unit must not be installed, operated, and then mined off and

left in an unoccupied structure during cold weather when

temperature drops to 32cT and below unless &ain trap and

drain line have adequate t'reeze protection. See Service and

Maintenance Instructions for winterizing procedure (See Fig

15.)

Step 10--Condensate Drain

GENERAL

( ondensate trap is shipped installed in the blower shelf and factow

connected for UPFLOW applications (ondensate trap must be

RELOCATED for use in DOWNFLOW and HORIZONTAL

applications.

(ondensate trap MUST be used for all applications.

An external trap isnot required when connecting the field drain to

this condensate trap.

The field drain connection (condensate trap or drain robe coupling)

is sized for ti2=in. CPV(, li2-in PV(, or 5/g-in. ID robe

connection.

Drain pipe and fittings must confbm_ to ANSI standards and

ASTM D1785, D2466 or D2846. CPVC or PVC cement must

confc_rm to ASTM D2564 or F493. Primer must conform to ASTM

F656. In Canada, use CSA or ULC listed schedule 40 (PVC or

PVC drain pipe, fittings, and cement.

When a condensate pump is required, select a pump which is

approved fbr condensing Nmace applications. To avoid conden=

sate spillage, select a pump with an overflow switch.

Furnace condensate is mildly acidic, typically in the pH range of

3.2 to 4.5. Due to corrosive nature of this condensate, a condensate

pH neutralizing filter may be desired. Check with local authorities

to determine if a pH neutralizer is required.

APPLICATION

The furnace, A/C, and humidifier drains may be combined and

drained together. The AiC &ain must have an external, field=

supplied trap prior to the _ilrnace &ain connection. All &ain

connections (t:urnace, Ai(, or humidifier) must be temlinated into

an open or vented drain as close to the respective equipment as

possible to prevent siphoning of the equipment's drain.

A96128

Fig. 41--Rooftop Termination (Dimension "A" is Touching or 2=in. Maximum Separation)

See Fig 46 %r example of possible t_eld drain attachment using

1/2-in CPV( or PVC tee fbr vent and Ai( or humidifier &ain

connection.

Outdoor draining of the ii/mace is permissible if allowed by local

codes. Caution should be taken when fi'eezing ambient may fieeze

drain pipe and prohibit draining.

PERSONAL INJ[ R¥ HAZARD

Caution should be taken to prevent draining where slippeQ'

conditions could cause personal injuries.

Excessive condensate draining may cause saturated soil

conditions which conld result in damage to plants

COMBUSTION

AIR

(ONDENSATE DRAIN PROTE(TION

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 accesso_

or equivalent 3 to 6 watt per ft at 120 v and 40°F self-regulating,

shielded, and waterproof heat tape. See Installation Instructions

supplied with accessory or heat tape manuihcmrer's recomrnenda°

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. 47.)

3. Use wire ties to secure heat tape in place. Wire ties can be

positioned in notches of condensate trap sides. (See Fig. 47.)

4. Wrap field &ain pipe with remaining heat tape, approximately

1 wrap per k.

5. When using field=supplied heat tape, _bllow heat tape manu=

_hcmrer's instructions for all other installation guidelines.

A93056

Fig. 42--Concentric Vent and Combustion-Air Roof

Termination (Dimension "A" is Touching or

2-in. Maximum Separation)

START-UP, ADJUSTMENTS, AND SAFETY CHECK

Step l--General

l. Furnace m_/st have a 115-v power supply properly connected

and gronnded

NOTE: Proper polarity must be maintained for l15-v wiring. If

polarity is incmTect, control LED status indicator will flash rapidly

and furnace will not operate.

2. Thermostat wire connections at terminals R, W, G, and Y/Y2

must be made at 24-v terminal block on t:urnace control.

3. Natural gas service pressure must not exceed 0.5 psig (14=in.

wc), and 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 filrnace.

VENT

A93057

Fig. 43--Concentric Vent and Combustion-Air Side

Termination (Dimension "A" is Touching or

2-in. Maximum Separation)

_/// _1t/_

COMBUSTION

JAIR

A96129

Fig. 44_Raised SidewNl Termination When Wail

Penetration is 12 in. or Less Above Snow or Grade

(Dimension "A" is Touching or 2=in. Maximum

Separation}

OPEN STAND -'7

PIPE FOR /

A/COR/

HUMIDIFIER d

DRAIN

TEE U_

A94054

Fig. 46--Example of Field Drain Attachment

CONDENSATE

COMBUSTION AIR

A96130

Fig. 45--Sidewall Termination of More than 12 in.

(Dimension "A" is Touching or 2-in. Maximum

Separation}

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit

operation

These furnaces are equipped with a manual reset limit switch

in burner box. This switch wil! open and shut offpower to gas

valve if an overheat condition (flame rollout) occurs in burner

enclosure. Correct inadequate combustion=air supply or ira=

proper venting condition and reset switch. DO NOT jumper

this switch_

Befbre operating fumacQ check flanre roll=out manual reset switch

for continuity_ If necessaD', press button to reset sx_itch

WIRE TIEq

HEAT

(3 WRAPS MINIMUM)

A93036

Fig. 47--Condensate Trap Heat Tape

Step 2--Prime Condensate Trap With Water

UNIT MAY NOT OPERATE

Failure to _bltow this caution may result in intem_ittent unit

operatiom

Condensate trap must be PRIMED or proper draining may not

occur The condensate trap has 2internal chambers which can

ONLY be primed by pouring water into the inducer drain side

of condensate trap_

1_ Remove upper inducer housing &ain connection caD (See

Fig. 48.)

Z (onnect fiel&supplied 1i2=in_ ID robe to upper inducer

housing &ain connection.

A99118

Fig. 48--Inducer Housing Drain Tube Cap

3. Insert field=supplied flmnel into tube.

4. Pour 1 quart of water into funnel/robe. Water sho_fld run

through inducer housing, overfill condensate trap, and flow

into open field drain. (See Fig 49.)

5. Remove flmnel and robe from inducer housing and replace

&ain connection cap and clamp.

A99119

Fig. 49--Filling Condensate Trap

Step 3--Purge Gas Lines

If not previously done, purge lines after all connections have been

made and check tbr leaks.

iiiii_, 1,_: iiiiiil,.

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in a fire, explosion,

personal it!ire'y, or death.

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

_br gas leaks with an open flame Use a commercially

available soap solution made specifically _br the detection of

leaks to check all connections.

Step 4--Sequence of Operation

F! RNACE MAY NOT OPERATE

Failure to _bllow this caution may result in flu'nace operation

stopping and water pipes fi'eezing during cold weather

Furnace control must be grounded _br proper operation, or

control will lock out Control is grounded d_rough

green yellow wire connected to gas valve and burner box

screw.

Using schematic diagram, follow sequence of operation through

di_:_krent modes. (See Fig. 30.) Read and follow wiring diagram

carefully.

NOTE: Ifa power interruption occurs during a call [br 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 _br

gas heating. The Amber status code LED light will flash code 12

during the 90=second period, after which the LED will be ON

continuous, as tong as no faults are detected After the 90=second

period, the fl/mace will respond to the thermostat normally.

The blower door must be installed _br power to be conducted

through the blower door interlock switch ILK to the furnace

contloi CPU, transformer TRAN, inducer motor IDM, blower

motor BLWM, hot=surfitce igniter HSI, and gas valve GV.

HEATING MODE

(See Fig. 27 for thermostat connections.)

The wall thermostat "calls for heat," closing the R to W

circuit. The furnace control performs 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

to begin a 15-second prepurge period.

b. Igniter '_¥arm-[ p- At the end of the prepurge period, the

Hot-Surface igniter HSI is energized for 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-I and -2 close to energize the gas valve GV, the gas

valve opens, and 24 vac power is supplied for a field-

installed humidifier at the HUM terminal. The gas valve

GV permits gas flow to the burners where it is ignited by

the Hot Surfhce Igniter HSI. Five seconds after the GVR=I

closes, a 2-second flame period begins. The HSI igniter

will remain energized until the flame is sensed or until the

2-second flame proving period begins.

THERMIDISTAT SINGLE-STAGE SINGLE-SPEED THERMIDISTAT SINGLE-STAGE SiNGLE-SPEED

FURNACE AIR CONDITIONER FURNACE HEAT PUMP

N_A

NIA

HEAT STAGE 1

COOL STAGE 1 [_

FAN _-

24 VAC HOT [_

DEHGM}D}FY

24 VAC COMM

HUMIDIFY

N/A [_

OUTDOORF_

c&E"&OT,%Q[2_

HUM

z_ E HUMIDIFIER

(24 VAC)

OUTDOOR

SENSOR

See notes 2, 5, 7, and 10

A00268

Fig. 50-Single-Stage Furnace with Single-Speed

Air Conditioner

RVS COOLING

N/A

HEAT STAGE 2

(FURNACE)

HEAT/COOL STAGE 1

(COMPRESSOR)

FAN [_

24 VAC HOT [_

DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY

N/A

[_ HUM

_[2_ OUTDOOR

OUTDOOR SENSOR

SENSOR

CONNECTION _ _ __ i

See notes 1, 2, 4, 6, 7, 9, 10 and 12

A00270

Fig. 52-Single-Stage Furnace with Single-Speed

Heat Pump (Dua! Fuel)

THERM;D;STAT SINGLE-STAGE TWO-SPEED

FURNACE HEATPUMP

THERMIDISTAT SINGLE-STAGE TWO-SPEED

FURNACE AIR CONDITIONER

COOLSTAGEI_

dEATSTAGEI_

COOLSTAGE2_

FAN_

24 MAC HOT

DEHUMIDIFY

24 VAC COMM [_

HUMIDIFY [_

N/A

O0TDOO*_

_HUMI'"-

J_'WJ HUMIDIFIER

(24 VAC }

LSENSOR

See notes 2, 5, 8, and 10

A00269

Fig. 51-Single Stage Furnace with Two-Speed

Air Conditioner

RVS COOLING

HEA(rc/COOFLSTAG LEc1)_ ............... _ ............ _ _

H EAIFSuTAGcEE: [_ _ l _]_

........

FAN_ .............._ []

_,MACHOT_......... _ 2_

DEHOM'D'FY

_4MACCOMM_ ....... \ ...... []

HUMIDIFIER

HUMIDIFY _ (24 VAC)

N/A

CONNECT'ON

See notes 1, 2, 3, 4, 6, 8, 9,10 and 12

A00271

Fig. 53-Single-Stage Furnace with Two-Speed

Heat Pump (Dual Fuel)

DUAL FUEL SINGLE-STAGE SINGLE-SPEED DUAL FUEL SINGLE-STAGE TWO-SPEED

THERMOSTAT FURNACE HEAT PUMP THERMOSTAT FURNACE HEAT PUMP

RVS COOLING

NfA [_

HEATSTAGE2

(FURNACE) [_

HEAT/COOLSTAGE1

(COMPRESSOR)_

FAN[_

24 VAC HOT[_

24 VAC COMM [_

N/A [_

RVS SENSING [_

DONNECT,ON

] I]_____[_

See netes1, 2, 4 ,11,12, and13

A02102

Fig. 54-Dua{ Fuel Thermostat with Single-Stage

Furnace and Single-Speed Heat Pump

RVS COOLING

HEAT/COOL STAGE 1

(COMPRESSOR LO)

HEAT/COOL STAGE 2

(COMPRESSOR HI)

FAN

24 VAC HOT [_

24 VAC COMM [_

RVS SENSING [_

OUTDOOR _[_

co_c°,_o_[_

'] F []

i iii ¸¸

See notes 1, 2, 3, 4 11,12, and 14

A02103

Fig. 55-Dua{ Fuel Thermostat with Single-Stage

Furnace and Two-Speed Heat Pump

TWO-STAGE SINGLE-STAGE TWO-SPEED

THERMOSTAT FURNACE AIR CONDITIONER

ED -pq

mI1 HUM

See note 2 ', HUMIDFIER _..

(24VAC)

A02161

Fig. 56-Two-Stage Thermostat with Single-Stage

Furnace and Two-Speed Air Conditioner

Notes For Figure 50°56

1. Heat pump M_ST have a high pressm'e switch l\_r dual f_lel applications.

2. Refer to outdoor equipment Installation Instructions _br additional in*bm_ation and setup procedure.

3. Select the "ZONE" position on the two=speed heat pump control.

4. Outdoor Air Temperature Sensor must be attached in all dual fuel applications

5. Dip switch No 1 on Thermidistat should be set in OFF position _br air conditioner installations This is _ctory dePault.

6. Dip switch No 1 on Thermidistat should be set in ON position for heat pump installations.

7. Dip switch No 2 on Thenr_idistat should be set in OFF position t:br single-speed compressor operation. This is _cto W default

8. Dip switch No 2 on Thermidistat should be set in ON position for two-speed compressor operation.

9. (or*figuration Option No 10 "Dual Fuel Selection" must be mined ON in all daal _hel applications.

10. NO connection should be made to the furnace HI_M terminal when using a Thermidistat

11. The RVS Sensing terminal "L" should not be connected This is internally used m sense def_'ost operation

12. DO NOT SELECT the "FUPC\'A( E INTERFACE" or "BALAN(E POINT" option on the two=speed heat pump control board. This is

controlled internally by the ThermidistatiDual Fuel Them_ostat.

13. Dip switch D on Dual Fuel Thermostat shoutd be set in OFF position tbr single-speed compressor operation This is i:actoW default.

14. Dip switch D on Dual Fuel Thermostat shoutd be set in ON position for two-speed compressor operation.

d. Flame-Proving- When the burner flame is proved at the

flame-proving sensor electrode FSE, fl-_efhmace control

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 ctose the

gas valve GV, and the control CPU will repeat the ignition

sequence _br up to three more Trials=For-Ignition before

going to Ignition=Lockout. Lockout will be reset auto-

matically af'te, three hou*s, or by momentarily interrupting

115 vac power to tl_e _k/rnace, or by interrupting 24 vac

powe* at SEC 1 or SEC2 to the fro'hate control CPU (not at

W, G, R, etc.).

If flame is proved when flame should not be present, the

furnace control CP[ will lock out of Gas-Heating mode

and operate the in&cer motor IDM until flame is no tonger

proved.

e. Blower-On Delay- If the burner flame is proven, the

blower motor is energized on HEAT speed 66 seconds (040

through 120 sizes) or 45 seconds (140 size) aker the gas

valve GV is energized.

Simultaneously, the electronic air cleaner tem_inai EAC-1

is energized and remains energized as long as the blower

motor BLWM is energized.

E Blower-Off Delay- When the the*mostat is satisfied, the

R=to-W circuit is opened, de=energizing the gas valve GV,

stopping gas 13ow to the burners, and de-energizing the

humidifier terminal HUM The inducer motor IDM will

remain energized for a 15=second (040 through 120 sizes)

or 5=second (I40 size) post=purge pe*iod. The blower motor

BLWM and air cleaner terminal EAC-I will remain ener-

gized fbr 90, 120, 150, or 180 seconds (depending on the

blower-OFF delay selection). The finlaace colmol CP[ is

factow-set for a 120-second blower-OFF delay.

( OOLING MODE

The them_ostat "calls for cooling."

a, Single-Speed Cooling

(See Fig. 27, 50, 52, and 54 for thermostat connections)

The d'*ermostat closes the R to G-and=Y circuits. The R to

Y circuit starts the outdoor unit, and the R to G-and-Y/Y2

circuits start the furnace blower motor BLWM on (OOL

speed.

The etect*onic air cleaner tem_inal EAC= 1is 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 furnace

blower motor BLWM wi!l continue operating on the

COOL speed fbr an additional 90 seconds. Jumper Y/Y2 to

DHUM to reduce the cooling off-delay to 5 seconds (See

Fig. 3!)

b, Two-Speed (ooling

(See Fig. 27, 51, 53, 55, and 56 for thermostat connec-

tions.)

The thermostat closes the R to G-and-Y1 circuits fbr

low-cooling or closes the R to G-and-Yl-and-Y2 circuits

_br high-cooling The Rto YI circuit starts the outdoor unit

on low-cooling speed, and the R to G-and-Y1 el*cult starts

the furnace blower motor BLWM on low-coot speed (same

speed as FAN) The Rto Yl-and-Y2 circuits start the

outdoor unit on high-cooling speed, and the R to G-and-

Y/Y2 circuits start the fi/rnace blower motor BLWM on

COOL speed.

The electronic air cleaner terminal EAC-1 is energized

with 115 vac whenever the blower motor BLWM is

operating.

When the thermostat is satisfied, the R to G and-Y1 or R to

G and-Y1 and-Y2 circuits a*e opened. The outdoor unit

stops, and the furnace blower BLWM and electronic air

cleaner te*minal EAC-1 will remain energized for an

additional 90 seconds. Jumper Y1 to DHUM to reduce the

cooling off'delay to 5 seconds (See Fig. 3i)

THERMIDISTAT MODE

(See Fig. 50, 51, 52, and 53 fbr Them_idistat connections.)

The dehumidification output, DHI_M on the Them_idistat

should be connected to the furnace control thermostat terminal

DHUM. When there is a dehumidify demand, the DHI_M

input is activated, which means 24 vac signal is removed ['rom

the DHUM input terminal. In other words, the DHUM input

logic is reversed. The DHUM input is turned ON when no

dehumidif) demand exists. When 24 vac is initially detected

by the fine, ace control on the DHUM input, the flmaace control

operates in Themaidistat mode. If the DHUM input is tow or

OFF for more than 48 hours, the [:umace control reverts back

to non=Thermidistat mode.

The cooling operation described in item 2above also applies

to operation with a Tl"_ermidistat The exceptions are listed

below:

a. When the R to G-and-Y1 circuit is closed and there is a

demand fbr dehumidification, the furnace blower motor

BLWM will continue running at low-cool speed (same

speed as FAN).

b. When the R to G-and Y/Y2 circuit is closed and there is a

demand for dehumidification, the furnace blower motor

BLWM will drop the blower speed flora COOL to HEAT

fbr a maximum of i0 minutes before reverting back to

(OOL speed. If there is still a demand h_r dehumidification

after 20 minutes, the furnace control CPI_ will drop tl-_e

blower speed back to HEAT speed. This alternating 10-

minute cycle will continue as tong as there is a call for

cooling.

c. When the "call for cooling" is satisfied while there is a

demand for dehumidification, the cooling blower-off delay

is decreased fi'om 90 seconds to 5 seconds,

CONTIN/OUS BLOWER MODE

When the R to G circuit is closed by the thermostat, the blower

motor BLWM will operate on continuous-blower speed (can

be adjusted to FAN, HEAT, or COOL speed) at the tl",ermo-

star. Factory- default is FAN" speed. Tem_inal EAC-1 is

energized as long as the blower motor BLWM is energized

During a call fbr heat, the blower BLWM will stop during

igniter warn>up (17 seconds), ignition (7 seconds), and

blower-ON delay (66 or 45 seconds for 040 through 120 sizes

or fbr 140 size), allowing the fiu'nace heat exchangers to heat

up more quickly, then restarts at the end of the blower-ON

delay period at HEAT speed.

In heating, the filmace control CPU will hold the blower

motor BLWM at HEAT speed during the selected blower-OFF

delay period before reverting to continuous-blower speed.

When the thermostat "calls h_r tow-cooling", the blower motor

BLWM will switch to operate at tow-cool speed (same speed

as FAN) When the them_ostat is satisfied, the blower motor

BLWM will operate an additional 90 seconds on lmv-coot

speed (same speed as FAN) befbre reve*ting back to

continuous-blower speed

When the thermostat "calls for high-cooling", the blowe*

motor BLWM will operate at COOL speed. When the the*-

mostat is satisfied, the blower motor BLWM will operate an

additional 90 seconds on (OOL speed before reverting back

to continuous-blower speed

When the Rto G circuit is opened, the blower motor BLWM

will continue operating for an additional 5 seconds, if'no other

fhnction requires blower motor BLWM operation

Continuous Blower Speed Selection from Thermostat -To

select different continuous-blower speeds from the room

thermostat, momentarily trim off the FAN' switch or push-

button on the room thermostat for 1-3 seconds are*"the blower

motor BLWM is operating. The fhmace control CPU will shift

the continuous=blower speed fi'om the fi_ctoW setting of FAN

to HEAT speed. Momentarily turning off the FAN" switch

again at the thermostat will shik the continuous-blower speed

fi'om HEAT to COOL. Repeating the procedure will shift the

continuous-blower speed fi'om COOL back to FAN" speed.

The selection can be changed as many times as desired and is

stored in the memoD" to be automatically used following a

power inten'uption.

HEAT PUMP MODE

(See Fig. 52, 53, 54, and 55 %r them_ostat connections)

When installed with a heat pump, the furnace control auto-

matically changes the blower timing sequence to avoid long

blower ofttimes during demand defrost cycles When the R to

W-and-Y 1 or R to W-and-Y l-and-G circuits are energized the

fhmace control (PU will switch to or mrn on the blower

motor BLWM at HEAT speed, and begin a heating cycle The

blower motor BLWM wilt remain on until the end of the

prepurge period, then shut off for 24 seconds _hen come back

on at HEAT speed When tl_e W input signal disappears, the

fimaace control begins a normal inducer post-purge period and

the blower remains rmming at HEAT speed fPr the selected

blower-OFF delay period then switches to low-cool speed

(same speed as FAN) If the R to W-and-Yl-and-G signals

disappear at tl-_e same time, the blower motor BLWM will

remain on fbr the selected blower-OFF delay period. If the R

to W-and-Y1 signals disappear, leaving the G signal, the

blower motor BLWM will remain on for the selected blower-

OFF delay period then switch to continuous-blower speed.

When the R to W-and-Y/Y2, R to W-and-Y Y2-and-G, R to

W-and-Yl-and-YY2, or R to W-and-Yl-and-YiY2-and-G

circuits are energized the hm_ace control (PU will switch to

or mm on the blower motor BLWM at HEAT speed, and

begin a heating cycle The blower motor BLWM will remain

on until the end of the prepurge period, then shut off for 24

seconds then come back on at HEAT speed. When the W input

signal disappears, the fi/mace contIol begins a normal inducer

post-purge period and the blower switches to COOL speed

after a 3-second delay. If the R to W-and-YiY2-and-G or R to

W-and-Yl-and-YY2-and-G signals disappear at the same

time, the blower motor BLWM will remain on fbr the selected

blower-OFF delay period. If the R to W-and-YY2 or R to

W-and-Yl-and-Y Y2 signals disappear, leaving the G signal,

the blower motor BLWM will remain on for the selected

blower-OFF delay period then switch to continuous-blower

speed.

COMPONENT TEST

NOTE: The furnace contlol component test allows all compo-

nents to run fbr a short time; except the gas valve and humidifier

terminal HUM are not energized fbr safety reasons. The EA(-I

terminal is energized when the blower is energized. This fkature

helps diagnose a system problem in case of a component fitilure.

The component test feature will not operate if any thermostat

signal is present ant the control and not until all time delays are

completed.

To Begin Component Self=Test:

ELECTRICAL SHOCK HAZARD

Failure to fbllow this warning could result in electrical shock,

personal i_.imy,or death.

Blower access panel door switch opens l15-v power to

control. No component operation can occur. Caution must be

taken when manually closing this switch fPr service purposes.

1. Remove blower access door.

2. Disconnect the thermostat R lead f?om furnace control.

3. Manually close blower door switch.

4. For approximately 2sec, short (lumper) the Cox_-24v tem_inal

on contlol to the TEST/TWIN 3/16-inch quick-connect termi-

nal on control until the LED goes oftl Remover jumper from

terminals. (See Fig. 3!.)

NOTE:If TEST/TWINandCOM-24Vterminalsarejm_apered

longerthan2sec, LED will flash rapidly and ignore component

test request

Component test sequence is as ibllows:

a. LED will display previous stares code 4 times.

b. Inducer motor starts and continues to run until Step g of

component test sequence.

c. After 7 seconds the hot surface igniter is energized for 15

see., then of£

d. Blower motor operates on (ontinuous=FAN speed for 10

see.

e. Blower motor operates on HEAT speed £_r 10 sec.

£ Blower motor operates on COOL speed _br 10 sec.

g. Inducer motor stops.

5. Reconnect R lead to furnace contlol, remove tape fiom blower

door switch, and re=install blower door.

6. Operate furnace per instruction on outer door.

7. Verii}" ihmace shut down by lowering thermostat setting

below room temperature.

8. Verify7 that filrnace restarts by raising them_ostat setting above

roonl temperature

Step 5--Adjustments

SET GAS INPUT RATE

Furnace gas input rate on rating plate is %r installations at altitudes

up to 2000 ft.

In the U.S.A., the input ratings for altitudes above 2000 ft must be

reduced by 2 percent fbr each 1000 ft above sea level.

In Canada, the input ratings must be derated by 5 percent for

altitudes between 2001 ft to 4500 ft above sea level.

Furnace input rate must be within ÷ 2 percent of input on [_urnace

rating plate adjusted for altitude

1. Determine natural gas orifice size and manifPld pressure for

correct input

a. Obtain average gas heat value (at installed altitude) fi'om

local gas supplier.

b. Obtain average gas specific gravity fiom local gas supplier

c. Verii}' f_m'nace model and size. Table 9 can only be used for

model 5gMXA fhmaces with rating plate heating inputs

(1000's Btuh) of 040 through 120. Table 10 can only be

used fbr model 58MXA fhmaces with a heating size of 140.

d. Find installation altitude in Table 9 or 10.

NOTE: For Canadian altitudes of 2001 to 4500 It, use L.SA

altitudes of 200! to 3000 ft in Table 9 or 10.

e. Find closest natural gas heat value and specific gravity in

Table 9 or 10.

£ Follow heat value and specific gravity lines to point of

intersection to find orifice size and manifbld pressure

settings fbr proper operation.

--€

EXAMPLE: (0-2000 fi altitude using Table 9)

Heating value 1050 Btuicu ft

Specific gravity 0.62

TherefPre: Orifice No 45 and

Manifold pressure 3 6-in. wc

* Furnace is shipped with No. 45 orifices In this

example all main burner orifices are the cmTect size

and do not need to be changed to obtain the proper

input rate.

Check and verify7 burner orifice size in fEmace. NEVER ASSL ME

ORIFI(E SIZE; ALWAYS CHECK AND VERIFY

2. Adjust mani_bld 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 flout INSTALLED.

a Remove burner enclosure fi'ont

b. Remove seal cap that conceals adjustment screw for gas

valve regulator. (See Fig. 57.)

c Jumper R and W thermostat connections on control to start

_/rnace,

d. Turn adjusting screw, cmmterclockwise (out) to decrease

manifold pressure or clockwise (in) to increase manifbld

pressure

NOTE: This furnace has been approved for a manifold pressure

of 3.2 in. wc to 3.S in. wc when installed at altitudes up to 2000 ft.

For altitudes above 2000 It, the manifold pressure can be adjusted

from 2.0 in. wc to 3.S in. we. If manifold pressure is outside this

range, change burner orifices to obtain pressure in this range.

UNIT DAMAGE HAZARD

Failm'e to fbllow this caution may result in reduced furnace

1ilk

DO NOT bottom-out gas valve regulator adjusting screw

This can result in unregulated manifold pressure and result in

excess overfire and heat exchanger failures.

NOTE: If orifice hole appears damaged or it is suspected to have

been redrilled, check orifice hole with a mm_bered &ill bit of

con'ect size. Never re&i!l art orifice A bun'-flee and squarely

aligned orifice hole is essential for proper flame characteristics.

._ . ® u

UNIT DAMAGE HAZARD

Failure to %tlow this caution may result in component

damage due to flame impingement of burners and heat

exchangers.

DO NOT re&ill orifices. Improper &illing (burrs, out-o_=

round holes, etc.) can cause excessive burner noise and

misdirection of burner flames. (See Fig. 58.)

e. Replace gas valve regulator adjustment screw seal cap.

£ Replace burner enclosure fiont and verify adjusted gas

input rate using method outlined in item 3

g. Look through sight glass in bmner enclosure and check

burner flame Burner flame should be clear blue, almost

tlanspareat. (See Fig 590

h. Remove jumper fiom R and W

Verify natural gas input rate by clocking gas meter.

Table 9--Model 58MXA Orifice Size and Manifold Pressure for Correct Input

For Use with 040 through 120 Size Furnaces Only

(Tabulated Data is Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

"13 0

2000

derate

ALTITUDE

RANGE

(Ft)

U.S.A.

Altitudes

200i to

=_ 3000

_3 or

Canada

r_ Altitudes

2001 to

D 4500

derate

ALTITUDE

RANGE

(Ft)

>, 300t

<.. to

D 4000

derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTUiCU FT)

850

875

900

925

950

075

i000

i025

i050

i075

II00

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btuicu ft)

775

800

825

850

875

000

925

950

075

i000

i025

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btuicu ft)

750

775

800

825

850

875

900

025

050

075

i000

0.58

"_rifice Manifold

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

0.58

Orifice Manifold

No. Pressure

43 3.8

43 3.5

44 3.8

44 3.6

44 3.4

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 3.7

43 3.5

44 3.7

44 3.5

44 3.3

45 3.8

45 3.6

45 3.4

45 3.2

45 3.0

45 2.9

SPECIFIC GRAVITY OF NATURAL GAS

0.50

Orifice Manifold

No. Pressure

43 3.8

43 3.6

43 3.4

44 3.7

44 3.5

44 3.3

45 3.8

45 3.6

45 3.4

45 3.3

47 3.7

0.52 0.54 0.65

Orifice Manifold Orifice Manifold 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 3.5 43 3.6 43 3.7

44 3.8 43 3.4 43 3.5

44 3.6 44 3.7 44 3.8

44 3.4 44 3.5 44 3.6

44 3.2 44 3.4 44 3.5

45 3.7 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 3.4 45 3.5

SPECIFIC GRAVITY OF NATURAL GAS

0.50 0.52 0.54 0.65

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure No. Pressure

42 3.2 42 3.3 42 3.4 42 3.5

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 3.5 43 3.6

44 3.5 44 3.6 44 3.7 43 3.4

44 3.3 44 3.4 44 3.5 44 3.6

45 3.8 44 3.2 44 3.3 44 3.4

45 3.6 45 3.7 45 3.8 44 3.3

45 3.4 45 3.5 45 3.6 45 3.8

45 3.2 45 3.4 45 3.5 45 3.5

45 3.t 45 3.2 45 3.3 45 3.4

SPECIFIC GRAVITY OF NATURAL GAS

0.50

Orifice Manifold

No. Pressure

43 3.8

43 3.6

43 3.4

44 3.6

44 3.4

44 3.2

45 3.7

45 3.5

45 3.3

45 3.2

45 3.0

0.52 0.54 0.55

Orifice Manifotd Orifice Manifotd Orifice Manifotd

No. Pressure No. Pressure No. Pressure

42 3.3 42 3.4 42 3.5

43 3.7 43 3.8 42 3.2

43 3.5 43 3.6 43 3.7

44 3.8 43 3.4 43 3.5

44 3.5 44 3.7 44 3.8

44 3.3 44 3.5 44 3.6

45 3.8 44 3.3 44 3.4

45 3.6 45 3.7 44 3.2

45 3.4 45 3.5 45 3.7

45 3.3 45 3.4 45 3.5

45 3.1 45 3.2 45 3.3

* Orifice numbers 45 shown in BOLD are factory installed

Percents of derate are based on midpoints of U.S. altitude ranges

TABLE 9--Model 58MXA Orifice Size and Manifold Pressure for Correct Input (Continued)

for Use W{th 040 Through 120 Size Furnaces Only

(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2 Percent for Each 1000 ft Above Sea Levem)*

ALTITUDE

RANGE

(FT)

4001

5000

derate

ALTITUDE

RANGE

(Ft)

500t

8000

11%

derate

ALTITUDE

RANGE

(Ft)

600t

7000

13%

derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725

750

775

800

825

850

875

900

925

950

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btuteu ft)

700

725

750

775

800

825

850

875

900

925

950

975

1000

Avg GAS

HEAT VALUE

AT ALTITUDE

(Etuteu ft)

050

075

700

725

750

775

800

825

850

875

SPECIFIC GRAVITY OF NATURAL GAg

0.58 0.60 0.62

Orifice Manifotd Orifice Manifotd Orifice Manifold

No. Pressure No. Pressure No. Pressure

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 3.2 44 3.4 44 3.5

45 3.7 45 3.8 44 3.3

45 3.5 45 3.0 45 3.7

45 3.3 45 3.4 45 3.5

45 3.1 45 3.2 45 3.3

45 3.0 45 3.t 45 3.2

0.58

Orifice Manifotd

No. Pressure

43 3.6

43 3.4

44 3.6

44 3.4

44 3.2

45 3.6

45 3.4

45 3.2

45 3.0

45 2.9

45 2.7

45 2.0

45 2.5

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.3 42 3.4

43 3.8 42 3.2

43 3.5 43 3.7

44 3.8 43 3.4

44 3.6 44 3.7

44 3.4 44 3.5

44 3.2 44 3.3

48 3.0 45 3.8

45 3.4 48 3.0

45 3.3 45 3.4

SPECIFIC GRAVITY OF NATURAL GAS

0.58

Orifice Manifold

No. Pressure

42 3.2

43 3.6

44 3.8

44 3.6

44 3.3

45 3.8

45 3.5

45 3.3

45 3.1

45 3.0

0.60 0.62

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

43 3.7 42 3.2

43 3.5 43 3.6

44 3.7 43 3.4

44 3.5 44 3.6

44 3.3 44 3.4

45 3.7 44 3.2

45 3.5 45 3.0

45 3.3 45 3.4

45 3.t 45 3.3

45 3.0 45 3.t

45 2.8 45 2.9

45 2.7 48 2.8

45 2.5 45 2.0

0.84 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.3 42 3.4

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

45 3.8 44 3.2

45 3.0 45 3.7

45 3.4 45 3.5

45 3.2 45 3.3

45 3.0 45 3.1

45 2,9 45 2.9

45 2,7 45 2.8

SPECIFIC GRAVITY OF NATURAL GAS

0.00 0.62

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.3 42 3.4

43 3.7 43 3.8

43 3.4 43 3.6

44 3.7 44 3.8

44 3.4 44 3.6

44 3.2 44 3.3

45 3.7 45 3.8

45 3.4 45 3.6

45 3.2 45 3.4

45 3.t 45 3.2

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.5 42 3.6

42 3.2 42 3.3

43 3.7 43 3.8

43 3.4 43 3.5

44 3.7 44 3.8

44 3.4 44 3.5

44 3.2 44 3.3

45 3.7 45 3.8

45 3.5 45 3.0

45 3.3 45 3.4

Orifice numbers 45 shown in BOLD are factory installed.

Percents of derate are based on midpoints of U.S. Altitude ranges.

Table 9--Model 58MXA Orifice Size and Manifold Pressure for Correct Input (Continued)

For Use with 040 through 120 Size Furnaces Only

(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

700t

_ to

8000

15%

derate

ALTITUDE

RANGE

(Ft)

800t

_ to

D 9000

t7%

derate

ALTITUDE

RANGE

(ft)

900t

<.. to

D 10,000

t9%

derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTUiCU FT)

825

650

875

7O0

725

750

775

8O0

825

850

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

800

625

850

675

700

725

750

775

800

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

575

600

625

650

675

700

725

750

775

0.58

Orifice Manifold

No. Pressure

43 3.8

43 3.5

44 3.8

44 3.5

44 3.3

45 3.7

45 3.5

45 3.3

45 3.1

45 2.9

0.58

Orifice Manifold

No. Pressure

43 3.8

43 3.5

44 3.7

44 3.5

44 3.2

45 3.6

45 3.4

45 3.2

45 3.0

0.58

Orifice Manifold

No. Pressure

43 3.8

43 3.5

44 3.7

44 3.4

45 3.8

45 3.6

45 3.3

45 3.1

45 2.9

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice Manifold

No. Pressure

42 3.3

43 3.7

43 3.4

44 3.6

44 3.4

45 3.8

45 3.4

45 3.2

45 3.0

0.62 0.64 0.66

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

42 3.4 42 3.5 42 3.6

43 3.8 42 3.2 42 3.3

43 3.5 43 3.6 43 3.7

44 3.8 43 3.4 43 3.5

44 3.5 44 3.6 44 3.7

44 3.3 44 3.4 44 3.5

45 3.7 45 3.8 44 3.3

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 3.3

SPECIFIC GRAVITY OF NATURAL GAS

0.50

Orifice Manifold

No. Pressure

42 3.3

43 3.6

43 3.4

44 3.6

44 3.3

45 3.8

45 3.5

45 3.3

45 3.1

0.62 0.64 0.65

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

42 3.4 42 3.5 42 3.6

43 3.8 42 3.2 42 3.3

43 3.5 43 3.6 43 3.7

44 3.7 44 3.8 43 3.4

44 3.4 44 3.6 44 3.7

44 3.2 44 3.3 44 3.4

45 3.5 45 3.8 44 3.2

45 3.4 45 3.5 45 3.5

45 3.2 45 3.3 45 3.4

SPECIFIC GRAVITY OF NATURAL GAS

0.50

Orifice Manifold

No. Pressure

42 3.2

43 3.6

44 3.8

44 3.5

44 3.3

45 3.7

45 3.4

45 3.2

45 3.0

0.62 0.64 0.55

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

42 3.3 42 3.5 42 3.6

43 3.7 42 3.2 42 3.3

43 3.5 43 3.6 43 3.7

44 3.7 44 3.8 43 3.4

44 3.4 44 3.5 44 3.6

45 3.8 44 3.3 44 3.4

45 3.5 45 3.7 45 3.8

45 3.3 45 3.4 45 3.5

45 3.t 45 3.2 45 3.3

Orifice numbers 45 shown in BOLD are factory installed.

Percents of derate are based on midpoints of U.S. altitude ranges

Table10--Model58tVlXAOrificeSizeand Manifold Pressure for Correct Input

For Use with 140 Size Furnaces Only

(Tabulated Data Based on 23,000 Btuh pet Burner, Detated 2"/. for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

2000

derate

ALTITUDE

RANGE

(ft)

U.S.A.

Altitudes

2001 to

3000 or

Canada

Altitudes

2001 to

4500

derate

ALTITUDE

RANGE

(ft)

300t

4000

derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTUiCU FT)

850

875

9O0

925

950

975

iO00

i025

i050

i075

iiO0

AVG GAS

HEAT VALUE

AT ALTITUDE

(Btutcu _)

775

800

825

850

875

900

925

950

975

iO00

i025

AVG GAS

HEAT VALUE

AT ALTITUDE

(Btulca_)

750

775

8O0

825

850

875

9O0

925

950

975

iO00

0.58

Orifice Manifold

No. Pressure

41 3.6

42 3.8

42 3.5

42 3.4

42 3.2

43 3.7

43 3.5

43 3.3

43 3.2

44 3.5

44 3.3

0.58

Orifice Manifold

No. Pressure

41 3.7

42 3.8

42 3.6

42 3.4

42 3.2

43 3.7

43 3.5

43 3.3

43 3.i

43 3.0

43 2.8

SPECIFIC GRAVITY OF NATURAL GAS

0.50 0.82

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

41 3.7 41 3.8

41 3.5 41 3.6

42 3.7 42 3.8

42 3.5 42 3.6

42 3.3 42 3.4

43 3.8 42 3.2

43 3.5 43 3.7

43 3.4 43 3.5

43 3.3 43 3.4

44 3.5 43 3.2

44 3.4 44 3.5

0.64 0.65

Orifice Mani_Id Orifice Manifold

No. Pressure No. Pressure

40 3.6 40 3.8

41 3.7 41 3.8

41 3.5 41 3.6

42 3.7 42 3.8

42 3.5 42 3.6

42 3.3 42 3.4

42 3.2 42 3.3

43 3.7 43 3.8

43 3.5 43 3.5

43 3.3 43 3.4

43 3.2 43 3.3

SPECIFIC GRAVtTY OF NATURAL GAS

0.50 0.52

Orifice Manifotd Orifice Manifold

No. Pressure No. Pressure

41 3.8 40 3.6

41 3.6 41 3.7

42 3.7 41 3.5

42 3.5 42 3.6

42 3.3 42 3.4

43 3,8 42 3.2

43 3.5 43 3.7

43 3.4 43 3.5

43 3.3 43 3.4

43 3.1 43 3.2

43 2.9 43 3.0

0.54 0.65

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

40 3.7 39 3.6

41 3.8 40 3.6

41 3.6 41 3.7

42 3.7 41 3.5

42 3.5 42 3.6

42 3.3 42 3.4

42 3.2 42 3.3

43 3.7 43 3.8

43 3.5 43 3.5

43 3.3 43 3.4

43 3.1 43 3.2

SPECIFIC GRAVtTY OF NATURAL GAS

0.58 0.50 0.52

Orifice Manifold Orifice Manifotd Orifice Manifotd

No. Pressure No. Pressure No. Pressure

41 3.6 41 3.8 40 3.6

42 3.8 41 3.5 41 3.6

42 3.5 42 3.7 42 3.8

42 3.3 42 3.4 42 3.6

43 3.8 42 3.2 42 3.4

43 3.5 43 3.7 42 3.2

43 3.4 43 3.5 43 3.5

43 3.2 43 3.3 43 3.5

43 3.t 43 3.2 43 3.3

43 2.9 43 3.0 43 3.1

43 2.8 43 2.9 43 3.0

0.64 0.55

Orifice Mani_Id Orifice Mani_Id

No. Pressure No. Pressure

40 3.7 40 3.8

41 3.7 40 3.6

41 3.5 41 3.6

42 3.7 42 3.8

42 3.5 42 3.6

42 3.3 42 3.4

43 3.8 42 3.2

43 3.5 45 3.7

43 3.4 43 3.5

43 3.2 43 3.3

43 3.0 43 3.1

Orifice numbers 43 shown in BOLD are factory installed.

Percents of derate are based on midpoints of U.S. altitude ranges.

Table 10--Model 58M×A Orifice Size and NaNfold Pressure for Correct input (Continued)

for Use With 140 Size Furnaces Only

(Tabulated Data Based on 23,000 Btuh per Burner, Derated 2"/. for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

4001

o to

:5 5000

derate

ALTITUDE

RANGE

(ft)

500t

D$000

11%

derate

ALTITUDE

RANGE

(ft)

6001

o to

d} 7000

13%

derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725

750

775

800

825

850

875

900

925

950

AVG GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

700

725

750

775

800

825

850

875

900

925

950

975

1000

AVG GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

850

675

700

725

750

775

800

825

850

875

0.58

'_rifice Manifold

No. Pressure

41 3.6

42 3.7

42 3.5

42 3.3

43 3,7

43 3.5

43 3.3

43 3.1

43 3.0

43 2.8

0.58

Orifice Manifold

No. Pressure

41 3.5

42 3.7

42 3.4

42 3.2

43 3,7

43 3.5

43 3,3

43 3.1

43 2.9

43 2.7

43 2.6

43 2.8

43 2.3

0.58

Orifice Manifold

No. Pressure

4I 3.8

41 3.5

42 3.6

42 3.4

43 3.8

43 3.6

43 3.4

43 3.2

43 3.0

43 2.8

SPECIFIC GRAVITY OF NATURAL GAS

0.00

Orifice Manifold

No. Pressure

41 3.7

42 3.8

42 3.6

42 3.4

42 3.2

43 3.6

43 3.4

43 3.3

43 3.1

43 2.9

0.62 0.64 0.66

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

4I 3.8 40 3.6 40 3.8

41 3.6 41 3.7 41 3.8

42 3.7 42 3.8 41 3.6

42 3.5 42 3.6 42 3.7

42 3.3 42 3.4 42 3.5

43 3,8 42 3.2 42 3.3

43 3.$ 43 3.7 43 3.8

43 3.4 43 3.5 43 3.6

43 3.2 43 3.3 43 3.4

43 3.0 43 3.t 43 3.2

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64 0.66

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure No. Pressure

41 3.7 41 3.8 40 3.6 40 3.7

42 3.8 41 3.5 41 3.6 41 3.8

42 3.5 42 3.7 42 3.8 41 3.5

42 3.3 42 3.4 42 3.5 42 3.7

43 3,8 42 3.2 42 3.3 42 3.4

43 3.0 43 3,7 43 3,8 42 3.2

43 3.4 43 3.5 43 3.8 43 3.7

43 3.2 43 3.3 43 3.4 43 3.5

43 3.0 43 3.t 43 3.2 43 3.3

43 2.8 43 2.9 43 3.0 43 3.t

43 2.7 43 2.8 43 2.9 43 3.0

43 2.6 43 2.6 43 2.7 43 2.8

43 2.4 43 2.5 43 2.0 43 2.7

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice Manifold

No. Pressure

40 3.6

41 3.6

42 3.7

42 3.5

42 3.3

43 3.7

43 3.5

43 3.3

43 3.t

43 2.9

0.62 0.64 0.66

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

40 3.7 40 3.8 39 3.7

41 3.7 40 3.6 40 3.7

41 3.5 41 3.6 41 3.7

42 3.6 42 3.7 42 3.8

42 3.4 42 3.5 42 3.6

43 3.8 42 3.3 42 3.4

43 3.6 43 3.7 43 3.8

43 3.4 43 3.5 43 3.6

43 3.2 43 3.3 43 3.4

43 3.0 43 3.t 43 3.2

* Orifice numbers 43 shown in BOLD are factory installed

Percents of derate are based on midpoints of U.S. altitude ranges

NOTE: Be sure all pressure robing, con_bustion-air and vent

pipes, and burner box cover flont are in place when checking input

by clocking gas meter.

EXAMPLE:

100,000 Btuh input furnace installed at 4300 ft.

Derate Furnace input Rate

Furnace Input Rate X Multiplier at Installation

at Sea Level Factor Altitude

100,000 X 0.91 91,000

a. Calcnlate high-altitude adjustment (if required).

UNITED STATES

At altitudes above 2000 fk this _hmace has been approved

for a 2percent derate for each 1000 f_ above sea level See

Table 11 for derate multiplier _ctor.

CANADA

At installation altitudes between 2001 to 4500 ft, this

furnace must be derated 5 percent by an authorized Gas

Conversion Station or Dealer. To determine correct input

rate for altimdQ see example above and use 0.95 as derate

multiplier _hctor.

b. Reinstall burner box cover.

REGULATOR Tab{e 11-ARRude Derate MuRipler for U.S.A.

ON/OFF SWITCH

INLET

PRESSURE TAP

REGULATOR

ADJUSTMENT

SCREW

REGULATOR SPRING

(PROPANE - WHITE 6 TURNS

NATURAL -SILVER, 10 TURNS)

GAS PRESSURE

REGULATOR

ADJUSTMENT

ALTITUDE PERCENT

(FT} OF DERATE

0=2000 0

2001=3000 4-6

3001 =4000 6-8

4001=8000 8-10

8001=6000 10-12

6001=7000 12-14

7001=8000 14-16

8001=9000 16-18

9001=t0,000 18-20

* Derate multiplier factors are based on midpoint altitude

BERATE MULTIPUER

FACTOR*

1.00

0.95

0.93

0.91

0.89

0.87

0.85

0.83

0.81

for altitude range

MANIFOLD

PRESSURE TAP

A03142

Fig. 87--Redundant Automatic Gas Control Valve

--BURNER J

ORIFICE

Fig. 88--Orifice Holes

BURNER FLAME J_

f_ FBURNER

MANIFOLD J

Fig. 59--Burner Flame

A93059

A89020

c. Gas valve regulator seal cap MIST be on

d. Turn off all other gas applications and pilots

e. Start fi/rnace and let operate _br 3 minutes.

£ Measure time (in sec) for gas meter to dial to complete 1

revolution,

g. Refer to Table 12 %r cu ft of gas per hr.

h. Multiply gas rate (cu fl&r) X heating value (Bmicu ft)

using natural gas heating value fiom local gas

utility/supplier.

EXAMPLE: (0=2000 ft altitude)

Furnace input t)om rating plate is 100,000 Btuh.

Bm heating input Bmicu ft X cu fthr

Heating value of gas 975 Btuicu _l

Time _br 1 revolution of 2=cu ft dial 70 sec

Gas rate 103 cu ft&r (from Table 12)

Btu heating input 103 X 975 100,425 Bmh.

In this example, the orifice size and manifbld

pressure adjustment is within ÷2 percent of the

_;arnace input rate

SET TEMPERATURE RISE

UNIT DAMAGE HAZARD

Failure to fbllow d_is caudon may result in overheating the

heat exchangers or condensing flue gases in heat exchanger

areas not designed for condensate.

Temperature rise must be within limits specified on t:urnace

rating plate. Recommended operation is at mi@oint of rise

range or slightly above.

Determine and adjust air temperature rise as _bllows:

1. Place them_ometers in return and supply ducts as close to

f_ultace as possible Be sure thermometers do not see heat

exchangers so that radiant heat does not affect readings This

practice is particularly important with straight=run ducts.

2. When thermometer readings stabilize, subtract return-air tem-

perature from supply=air temperature to detemaine air tem-

perature rise.

3. Adjust temperature rise by adjusting blower speed. Increase

blower speed to reduce temperature rise. Decrease blower

speed to increase temperature rise.

ELECTRICAL SHOCK HAZARD

Failm'e to _Bllow this warning could result in personal in3u W

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 fiom control HEAT terminal. (See

Fig. 31.) Select desired blower motor speed lead fi'om 1 of the

Table 12--Gas Rate (cu ft/hr}

SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL

FOR 1 1 2 5 FOR 1 1 2 5

REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION Cu Ft Cu Ft Cu Ft

10 360 720 1800 50 72 144 360

11 327 655 1636 51 71 141 355

12 300 600 1500 52 69 138 346

13 277 555 1385 53 68 136 340

14 257 514 1286 54 67 133 333

15 240 480 1200 55 65 131 327

16 225 450 1125 56 64 129 321

17 212 424 1059 57 63 126 316

18 200 400 1000 58 62 124 310

19 189 379 947 59 61 122 305

20 180 360 900 60 60 120 300

21 171 343 857 62 58 116 290

22 164 327 818 64 56 112 281

23 157 313 783 66 54 109 273

24 150 300 750 68 53 106 265

25 144 288 720 70 51 103 257

26 138 277 692 72 50 100 250

27 133 267 667 74 48 97 243

28 129 257 643 76 47 95 237

29 124 248 621 78 46 92 231

30 120 240 600 80 45 90 225

31 116 232 581 82 44 88 220

32 113 225 563 84 43 86 214

33 109 218 545 86 42 84 209

34 106 212 529 88 41 82 205

35 103 206 514 80 40 80 200

38 100 200 500 82 39 78 196

37 97 195 486 84 38 76 192

88 95 189 474 96 38 75 188

36 92 185 462 98 37 74 184

40 90 180 450 108 36 72 180

41 88 176 439 102 35 71 178

42 86 172 429 104 35 69 173

43 84 167 419 106 34 68 170

44 82 164 409 108 33 67 167

45 80 160 400 110 33 65 164

48 78 157 391 112 32 64 161

47 76 153 383 116 31 62 155

48 75 150 375 120 30 60 150

49 73 147 367 124 29 58 145

other motor leads and relocate it to HEAT tem_inaL See Table

13 for lead color identification. Reconnect original lead on

SPARE tem_inal.

Follow this same procedure fbr proper selection of COOL

speed selection.

ADJUST BLOWER OFF DELAY (HEAT MODE)

The blower off delay has 4 adjustable settings tkem 90 sec to 180

sec (See Table 14.) The blower off delay jumpers are located on

the ft/mace control (See Fig 31). To change the blower off delay

setdng, move the jumper fi'om one set of pins on the control to the

pins used [br the desired blower off delay. Factory blower off

delay setting is 120 sec.

SET THERMOSTAT HEAT ANTICIPATOR

When using a nonelectronic them_ostat, the them_ostat heat

anticipator must be set to match the amp &aw of the electrical

components in R-W circuit. Accurate amp draw readings can be

obtained at them_ostat subbase terminals R and W. Fig 60

illustrates the easy method of obtaining actual amp &aw. The amp

reading should be taken after blower motor has started and furnace

Table 13--Speed Selector

FACTORY-

COLOR SPEED SH_PPED

CONNECTION

B_ack High Cool

Yellow (When Present} Medium High Spare

B_ue Medium Low Heat

Red Low Fan

White Common COM

Table 14_Biower Off Delay Jumper Positions

PINS ,AND2 12AND3 I 3AND4 [ 4AND5

Time (in sec) 90 120 150 180

is heating. (onnect ammeter wires as shown in Fig. 60 The

thermostat anticipator should NOT be in the curcuit while mea=

suring current. If them_ostat has no subbase, the thermostat must

be disconnected flora R and W wires during CUITent measurement.

See them_ostat manufi_cturer's instrnctions t'or adjusting heat

anticipator and for yawing heating cycle length.

For an electronic thermostat_ set cycle rate for 3 cycles per hour.

Step 6--Check Safety Controls

This section covers the safety controls that must be checked befbre

the installation is complete. The flame sensor, gas valve, and

pressure switch were all checked in the Start-up procedure section

as part of normal operation.

CHE(K PRIMARY LIMIT CONTROL

This control shuts off gas control system and energizes alp

circulating blower motor if furnace overheats. Recommended

method of checking this limit control is to gradually block off

return air after ftlmace has been operating fc_r a period of at least

5 minutes. As soon as limit control has shut offbumers, return=air

opening should be unblocked to pem_it normal air circulation. By

using this method to check limit control, it can be established that

limit is functioning properly and operates if there is a restricted

return=air duct or motor _hilure. If limit control does not function

during this test, cause must be determined and corrected.

CHECK PRESSURE SWITCH

This control proves operation of draft inducer. Check switch

operation as fbllows:

1. Turn off l15=v power to fi/mace.

2. Remove outer _arnace door and disconnect inducer motor

fi'om wire harness.

3. Turn on 115=v power to furnace.

4. Set d-_ennostat to "call for heat" and wait 1 minute. When

pressure switch is ftmctioning properly, hot surface igniter

should NOT glow, and control status code LED flashes a

Status Code 31. If hot surface igniter glows when inducer

motor is disconnected, shut ft/mace down immediately. De-

termine reason pressure switch did not flmction properly and

correct condition.

5. Tufa off l15=v power to fi/mace.

(5. Reconnect inducer motor leads, reinstall main furnace door,

and tara on 115=v power supply.

TERMINALS WiTH

THERMOSTAT REMOVED

FROM UNIT 24-VOLT

TERMINAL BLOCK

EXAMPLE 5 0 AMPS ON AMMETER = 0 5 AMPS FOR THERMOSTAT SETTING

l0 TURNS AROUND JAWS

A80201

Fig. 60--Amp Draw Check wRh Ammeter

Step 7--Checklist

l, Pot away tools and instruments Clean up debris

2, Verify flame=roliout manual reset s_itch has continuity

3, Ve*it}- that blower and main outer access doors are properly

installed.

4. (ycle test furnace x_ith room thermostat.

5. (heck operation of accessories per manui:acturer's inst,/c=

tions,

6. Review Users Guide _ith owner.

7. Leave literature packet near fhrnace.

LOAD CALCULATION

CH ECKMST--INSTALLATION

Condensate Drain

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace ModeJ Selection

COMBUSTION AiR AND VENT PIPING

Termination Location

Roof or Sidewall

Termination Kit -- 2 Pipe or Concentric

Combustion-Air Pipe Length

Combustion-Air Pipe Elbow Quantity

Vent Pipe Length

Vent Pipe Elbow Quantity

Pipe Diameter Determined from Sizing Table

Pipe Sloped To Furnace

Pipe insulation

Over CeiJings

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

Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Cheek Operation

Primary Limit

Pressure Switch

Low-Ambient Exposed Pipes

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations,

B°°kLL_. PC 101 Catalog No 535-80157 Pd_ted in U.S.A. Form 58MXA-18SI Pg 52 2-05 Replaces: 58MXA-17SI

Tab 16al 8a

CARRIER Furnace/Heater, Gas Manual L0503146

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