CARRIER Furnace/Heater, Gas Manual L0902516

58MVC080-F-10114 58MVC080-F-10114 CARRIER GAS FURNACE - Manuals and Guides L0902516 View the owners manual for your CARRIER GAS FURNACE #58MVC080F10114. Home:Heating & Cooling Parts:Carrier Parts:Carrier GAS FURNACE Manual

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Installation Instructions

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NOTE: Read the entire instruction manual before starting

the installation.

Please retain these instructions with the furnace after installation

for future reference.

NOTE: This furnace can be installed as a (2-pipe) direct vent

or (1-pipe) non-direct vent condensing gas furnace.

ISO 9001:2000

11

Special Venting Requirements for Installations in Canada

Installation in Canada must conform to the requirements of CSA

B149 code. Vent systems must be composed of pipe, fittings,

cements, and primers listed to ULC $636. The special vent

fittings and accessory concentric vent termination kits and

accessory external drain trap have been certified to ULC $636 for

use with those IPEX PVC vent components which have been

certified to this standard. In Canada, the primer and cement must

be of the same manufacturer as the vent system - IPEX System

636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and

IPEX System 636(1) TM , PVC Cement for Flue Gas Venting, rated

Class IIA, 65 deg C. must be used with this venting system - do

not mix primers and cements from one manufacturer with a vent

system from a different manufacturer. Follow the manufacturer's

instructions in the use of primer and cement and never use primer

or cement beyond its expiration date.

The safe operation, as defined by ULC $636, of the vent system

is based on following these installation instructions, the vent

system manufacturer's installation instructions, and proper use of

primer and cement. All fire stop and roof flashing used with this

system must be UL listed material. Acceptability under Canadian

standard CSA B149 is dependent upon full compliance with all

installation instructions. Under this standard, it is recommended

that the vent system be checked once a year by qualified service

personnel.

The authority having jurisdiction (gas inspection authority,

municipal building department, fire department, etc) should be

consulted before installation to determine the need to obtain a

permit.

Consignes sp_ciales pour l'installation de ventillation au Canada

L'installation faite au Canada doit se conformer aux exigences du

code CSA B149. Ce syst_me de ventillation doit se composer de

tuyaux, raccords, ciments et appr_ts conformes au ULC $636. La

tuyauterie de ventillation des gaz, ses accessoires, le terminal

concentrique mural ainsi que l'ensemble du drain de condensat

ext_rieur ont _t_ certifies ULCS 636 pour l'application des

composantes IPEX PVC qui sont certifi_es 5. ce standard. Au

Canada l'appr_t et le ciment doivent _tre du m_me manufacturier

que le syst_me de ventillation - IPEX Syst_me 636, Appr_t

PVC/CPVC. Mauve Violette pour conduit en _vacuation des gaz

et IPEX Syst_me 636(1) TM, ciment pour PVC pour conduit en

_vacuation des gaz, _valu_ CLASSE IIA, 65 deg. C. doit _tre

utilis_ avec ce syst_eme d'_vacuation - ne pas m_langer l'appr_t

et le ciment d'un manufacturier avec le syst_me de ventillation

d'un autre manufacturier. Bien suivre les indications du

manufacturier lors de l'utilisation de l'appr_t et du ciment et ne

pas utiliser ceux-ci si la date d'expiration est atteinte.

L'op_ration s_curitaire, tel que d_finit par ULC $636, du syst_me

de ventilation est bass sur les instructions d'installation suivantes,

ainsi que l'usage appropri_ de l'appr_t et ciment. Tout arr_t feu et

solin de toit utilis_s avec ce syst_me doivent _tre des mat_riaux

list,s UL L'acceptation du standard Canadien CSA B419 est

directement reli_ 5. l'installation conforme aux instructions ci-

haut mentionn_es. Le standard Canadien recommande 1'

inspection par un personel qualifi_ et ce, une fois par annie.

Les autorit_es ayant juridiction (inspecteurs de gas, inspecteurs en

bfitiments, d@artement des incendies, etc) devraient _tre

consult_es avant l'installation afin de d_terminer si un permis est

requis.

(1) System 636 is a trademark of IPEX Inc.

Required Notice for Massachusetts Installations

IMPORTANT

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:

5.08: Modifications to NFPA-54, Chapter 10

2) Revise 10.8.3 by adding the following additional requirements:

(a.)For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in

whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the

side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,

including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented

gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an

alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing

plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on

each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It

shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of

hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in acrawl space or an attic, the hard wired

carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall

have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day

period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the

above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum

height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled

heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT

DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the

installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance

with the provisions of 248 CMR 5.08(2)(a)1 through 4.

5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

(1 .) The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA

54 as adopted by the Board; and

(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the

dwelling, building or structure used in whole or in part for residential purposes.

(c.) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or

venting system components with the equipment, the instructions provided by the manufacturer for installation of the

equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d.)MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the

manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts

for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by

the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation

instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a

parts list and detailed installation instructions.

(e.)A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,

all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with

the appliance or equipment at the completion of the installation.

For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers and

Gas Fitters, 239 Causeway Street, Boston, MA 02114. 617-727-9952.

TABLE OF CONTENTS

PAGE

IMPORTANT INFORMATION ........................ 2

SAFETY CONSIDERATIONS ........................ 3

CODES AND STANDARDS .......................... 7

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .. 7

INTRODUCTION .................................. 7

APPLICATIONS ................................... 8

Upflow ........................................ 8

Downflow ..................................... 11

Horizontal Left .................................. 12

Horizontal Right ................................ 15

LOCATION ...................................... 16

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

Air Ducts ....................................... 21

Air for Combustion and Ventilation .................. 28

Combustion Air Pipe .............................. 34

Vent Pipe ...................................... 36

Vent Termination ................................ 39

Condensate Drain ................................ 43

START-UP, ADJUSTMENTS, AND SAFETY CHECK ... 44

CHECKLIST ..................................... 60

AIRFLOW

d>

"i

©

AIRFLOW

Fig. l -Furnace Orientation

A93041

SAFETY CONSIDERATIONS

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit damage.

Improper installation or misapplication of furnace may

require excessive servicing or cause premature component

failure. This furnace can be vented as either a direct vent

(2-pipe) furnace or as an optional ventilated combustion air

application.

A direct vent system shall be installed in accordance with

the direct vent (2-pipe) procedures in the Combustion Air

and Vent Pipe Systems section within this instruction. For

optional ventilated combustion air applications, refer to the

ventilated combustion air option procedures in the same

section.

Application of this furnace should be indoors with special

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

air temperature rise, unit leveling, and unit sizing.

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury, death, or property damage.

Improper installation, adjustment, alteration, service,

maintenance, or use can cause carbon monoxide poisoning,

explosion, fire, electrical shock, or other conditions which

may cause personal iniury or property damage. Consult a

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

distributor or branch for information or assistance. The

qualified installer or agency must use only

factory-authorized and listed kits or accessories when

modifying this product.

CUT HAZARD

Failure to follow this caution may result in personal iniury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing and gloves when

handling parts.

Improper installation, adjustment, alteration, service,

maintenance, or use can cause explosion, fire, electrical shock, or

other conditions which may cause death, personal iniury, or

property damage. Consult a qualified installer, service agency, or

your distributor or branch for information or assistance. The

qualified installer or agency must use factory-authorized kits or

accessories when modifying this product. Refer to the individual

instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions

include in literature and attached to the unit. Consult local

building codes, the current editions of the National Fuel Gas

Code (NFGC) NFPA 54/ANSI Z223.1 and the National

Electrical Code (NEC) NFPA 70.

g

1

664 ram)

2 IN (51 mm) COMBUSTION

!_lN(13mm)

GAS CONN

2IN

VENTCONN

]_INDIA(13mm)

(684 ram)

TRAP LOCATION

(DOWNFLOW &

HORIZONTAL LEFT)

;a IN D]A (22ram)

--POWER CONN

ACCESSORY

POWER ENTRY

DRAIN TRAP ]

LOCATION

(ALTERNATE

UPFLOW)

9_s" 17 _16"

TYP (439

(240 ram)

(21 ram)

TYP

(829 ram)

©

AIRFLOW

A_ (14 ram)

D-- 'l:,r,, "{POUTLET

CONDENSATE DRAIN

(DOWNFLOW &

HORIZONTAL RIGHT) "_

OR ALTERNATE

!_z IN D]A GAS CONN

1

_NLET

_E_

DRAIN LOCATION 11'!6"_ _ 1'16"

(UPFLOW) (17 ram) (17 ram)

26 i¢,, (724 mm)

_26 %6" (664 mm)

2614" (667 mm)

22 5i_" (567 mm)_

_19"(463 ram) _ _!3fl6" (21 ram)

I/COMBUSTION AIR OONN b6"|

GAS OONN

........ /

17......

T_4 E R M O S+_,]r_'T Ry /

3O 1< /+-. 2 N _/T,r,l_5 39 7S"

(......... ) f_ _'_"- _/ENTSONN (......... )

SIDE INLET ,

1

b <1

..........

DRAIN LOCATION /_ 22 11"TYP ------'_'_1 _g_6" (11 ram)

(UPFLOW) (a65 ram)

.............. J --------_OT_;_1r'47----II...... "1 ........ )

FOR HORIZONTAL

HANGING (614 ram)

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

see flex duct manufactureris recommendations for equivalent diameters.

2. Minimum return-air opening at furnace:

a. For 800 OFM 16-in. (408mm) round or 141A (388 mm)x 12-in. (305 mm) rectangle

b. For !200 CFM 20-in. (508mm) round or 141# (368mm)x 197Mn. (495mm).rectangle

c. For !600 CFM 22-in. (558mm) round or 141# (368mm)x 231/4-in,(591mm) [ectangle

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

literature for specific use of single side inlets. The use of both side inlets, a

combination of 1 side and the bottom, or the bottom only will ensure adequate

return air openings for airflow requirements above 1800 CFM.

A05124

Dimensions (In. /mm)

UNIT SIZE A D E

080-14 /042080 17-1/2 /445 15-7/8 /403 16 /406

080-14 /042080 21 /533 19-3/8 /492 19-1/2 /495

080-20 /080080 21 /533 19-3/8 /492 19-1/2 /495

100-20 /080100 21 /533 19-3/8 /492 19-1/2 /495

120-20 /080120 24-1/2 /822 22-7/8 /581 23 /584

Fig. 2 -Dimensional Drawing

In Canada, refer to the current editions of the National Standards

of Canada CAN/CSA-BI49.1 and .2 Natural Gas and Propane

Installation Codes, and Canadian Electrical Code CSA C22.1

Recognize safety information. This is the safety-alert symbol/_.

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

manuals, be alert to the potential for personal iniury.

Understand the signal words DANGER, WARNING, and

CAUTION. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in

severe personal iniury or death. WARNING signifies hazards

which could result in personal iniury or death. CAUTION is

used to identify unsafe practices which may result in nfinor

personal iniury or product and property damage. NOTE is used

to highlight suggestions which will result in enhanced

installation, reliability, or operation.

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental

polution.

Remove and recycle all components or materials (i.e., oil,

refrigerant, control boards, etc.) before unit final disposal.

The 58MVC Condensing Gas-Fired Furnaces are CSA (formerly

AGA and CGA) design-certified for natural and propane gases

(see furnace rating plate) and for installation in alcoves, attics,

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

furnace is factory-shipped for use with natural gas. A CSA listed

gas conversion kit is required to convert furnace for use with

propane gas.

See Fig. 3 for required clearances to combustibles.

Maintain a 1-in. (25 ram) clearance from combustible materials

to supply air ductwork for a distance of 36 inches (914 ram)

horizontally from the furnace. See NFPA 90B or local code for

further requirements.

These furnaces SHALL NOT be installed directly on carpeting,

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

These furnaces are suitable for installation in a structure built on

site or a manufactured building completed at final site. The

design of this furnace line is NOT CSA design-certified for

installation in recreation vehicles, manufactured (mobile) homes

or outdoors.

This furnace is designed for continuous return-air minimum

temperature of 60 °F (16 °C) db or internfittent operation down to

55°F (13°C) db such as when used with a night setback

thermostat. Return-air temperature nmst not exceed 80°F (27 °C)

db. Failure to follow these return air linfits may affect reliability

of heat exchangers, motors and controls. (See Fig. 4.)

These furnaces are shipped with the drain and pressure tubes

connected for UPFLOW applications. Minor modifications are

required when used in DOWNFLOW, HORIZONTAL RIGHT,

or HORIZONTAL LEFT (supply-air discharge direction)

applications as shown in Fig. 1. See details in Applications

section.

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

LOCATION and INSTALLATION sections of these instructions.

Combustion products must be discharged outdoors. Connect this

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

Combustion Air and Vent piping sections of these instructions.

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

available soap solution made specifically for detection of leaks to

check all connections as specified in the GAS PIPING section of

these instructions.

Always install the furnace to operate within the furnace's

intended rise range with a duct system which has an external

static pressure within the allowable range as specified in the SET

TEMPERATURE RISE section of these instructions.

When a furnace is installed so that supply ducts carry air

circulated by the furnace to areas outside the space containing the

furnace, the return air shall also be handled by ducts sealed to the

furnace casing and terminating outside the space containing the

furnace.

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

installed as specified in the Hazardous Locations section of these

instructions and Fig. 5.

The furnace may be used for construction heat provided that the

furnace installation and operation complies with the first

CAUTION in the LOCATION section of these instructions.

This gas furnace may be used for construction heat provided that:

• The furnace is permanently installed with all electrical

wiring, piping, air filters, venting and ducting installed

according to these installation instructions. A return air

duct is provided, sealed to the furnace casing, and ter-

minated outside the space containing the furnace. This

prevents a negative pressure condition as created by the

circulating air blower, causing a flame rollout and/or

drawing combustion products into the structure.

• The furnace is controlled by a thermostat. It may not be

"hot wired" to provide heat continuously to the struc-

ture without thermostatic control.

• Clean outside air is provided for combustion. This is to

minimize the corrosive effects of adhesives, sealers and

other construction materials. It also prevents the en-

trainment of drywall dust into combustion air, which

can cause fouling and plugging of furnace components.

• The temperature of the return air to the furnace is main-

tained between 55°F (13°C) and 80°F (27°C), with no

evening setback or shutdown. The use of the furnace

while the structure is under construction is deemed to

be intermittent operation per our installation instruc-

tions.

• 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 must be either changed or thor-

oughly cleaned prior to occupancy.

• The furnace, ductwork and filters are cleaned as neces-

sary to remove drywall dust and construction debris

from all HVAC system components after construction

is completed.

• After construction is complete, verify furnace operating

conditions including ignition, input rate, temperature

rise and venting, according to the manufacturer's in-

structions.

If this furnace is installed with a direct-vent (combustion air and

flue) system, a factory accessory termination kit must be installed.

In a direct-vent system, all air for combustion is taken directly

from the outside atmosphere and all flue products are discharged

to the outside atmosphere. See furnace and factory accessory

termination kit instructions for proper installation.

These furnaces 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, Start-up, and Operating Instructions

Service and Maintenance Instructions

User's Information Manual

Warranty Certificate

Loose Parts Bag includes: Quantity

Collector Box or Condensate trap extension tube 1

Inducer housing drain tube 1

1/2-in CPVC street elbow 2

Drain tube coupling 1

Drain tube coupling grommet 1

Gas line grommet 1

Vent pipe grommet 1

Combustion-air pipe grommet 1

Gas line entry hole filler plug 1

Power entry hole filler plug 2

Condensate trap hole filler plug 3

Vent and combustion-air intake hole filler plug 2

Combustion-air pipe perforated disk assembly 1

g

INSTALLATION

e This forced air fumace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 fL

(0 - 2,135m).

• An accessory kit, supplied by the manufacturer, shah be used to convert to propane gas use or may be Pequired for some natural gas applicetions.

• This famace is for indoor installation in a building constructed on site. This furnace may be instated in a manufactured (mobile) home when stated on rating plate and

using factory authorized kit..

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

eThis _mace requires a special venting system. Refer to the installation instructions for parts list and method of installation. In the US this furnace is for use with

schedule=40 PVC, PVC-DWV, CPVC, or AB,S-DWV pipe, and must not be vented in common with other gas-fired appliances. In Canada, refer to installation instructions

for vent materials. Construction through which vent/air intake pipes may be installed is maximum 24 inches (610 ram), minimum 3/4 inches (19 mm) thickness (including

roofing materials).

e Cette foumaise _ air puis6 est 6quip6e pour utilisation avec gaz naturem et altitudes comprises entre 0 - 3,050m (0 - 10,000 pi),except6 queles foumaises de 140 taifle

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

® Utiiiser une trousse de conversion, foumie par le fabdcant, pour passer au gaz propane ou pour certaines installations au gaz natureL

e Cette foumaise & air pulse est pour installation a I'intedeur dans un b_timent construit sur place. Cette foumaise a air pulse peut 6tre install6e dans une maison

prCfabdqu6e (maison mobile) si prescrit par la plaque signal6tique et si'l on utilise une trousse specifi6e par le fabrleant.

•C.ette foumaise pout 6tre install6e sur un plancher combustible dans un enfoncement ou un placerd en observant les D6gagernent Minimum En Pouces Avec

EI6ments De Construction Combustibles.

• Cette foumaise n6cessite un syst_me d'6vacuation sp6cial. La m6thode d'instaliation et la iiste des pi_ces n6cessaires figurent dana les instructions d"installation. Aux

Etats-Unis, cette foumaise dolt s'utiliser avec la tuyautede des nomenclatures 40 PVC, PVC-DWV, CPVC, ou ,ABS-DWV et elle ne peut pas _tre ventil6e conjointment

avec d'autres appareils & gaz. Au Canada, referer aux instructions d'installation pour lax matedaux a ventiler. Epaisseur de la construction au travers de laquene il est

possible de faire passer les tuyaux d'aeration (admission/evacuation): 24 po (610 mm) maximum, 3/4 pc (19mm) minimum (y compds la toiture).

For up&3w and downflow applications, furnace must be installed level, or pitched within 1/2" (12.7ram) of level. For a LEVEL 0" ( 0 ) TO _,. MINI 14" (6.35mm) TO

horizonfal application, the furnace must be pitched minimum 1/4" (6.35mm) to maximum of 1/Z' (12.7mm) forward for 1/2" (12.7mm) MAXj ¢_L-_-_ 1/2" (12.7mm)MAX

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

Pour des applications de flux ascendant et descendant, la foumaise doit ¢¢e install6e de niveau ou indin6e _ T ............. !

pas plus de 1/2" (12.7mm) du niveau. Pour une application hodzontale, la fOumaise dOlt &'Ire inclle_-_eenli'e minimum UPFLOW OR F_ORON_ )

1/4" (6.35mm) et maximum 1/2" (12.7ram) du niveau pour le drainage appropn& En cas d'installation en position DOWN FLOW

hodzootale, consulter les renseignements mMPORTANTS sur le support dans le manuel d'instaHation. HORIZONTAL

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSiTiONS:

*Minimum front clearance for service 24 inches (610mm).

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

DOWNFLOW POSITIONS:

t For installation on combustible 11oors only when instated on special base No. KGASB0201ALL or

NAHA01101SB, CoilAssembly, Part No. CAR, CAP, CNPV, CNRV or Coil Casing, Part No. KCAKC,

or WENC or WTNC.

HORIZONTAL POSITIONSi

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 ou_et ends.

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

DEGAGEMENT MINfl_UIVIEN POUCESAVEC I_LleMENTSDE CONSTRUCTION COMBUSTIBLES

POUR TOUS LES POSITIONS:

D@jagement avant minimum de 24 po (610mm ) pour l'entretien.

1- t Pour les foumaises de 140 taifle, 1 pc (25mm) d6gagement des mat6riaux combustibles est

requis au-arriere.

POUR LA POSITION COURANT DESCENDANT:

1 Pour Ilnstaflation sur le plancher combustible seulement quand on utilise la base sp_ciale, piece

n° KGASB0201ALL ou NAHA01101SB, I'ensemble serpentin, pi_:e n ° CAR, CAP, CNPV, CNRV, ou

le carter de serpentin, piece n ° KCAKC ou WENC ou WTNC.

POUR LA POSmON HORIZONTALE:

Le contact n'est permis qQentre les lignes form6es par les intersec_ons du dessus et des

deuxottes de la chemise de la foumaise, et des solives, des montants ou de la charpente du

batiment.

§ La distance indiqu_e conceme I'extr_mit6 du tuyau d'ardv_e d'air et I'extr_mit_ du tuyau de sortie

d'aic

Pour les foumaises de 120 et 140 taifie, 1 pc (25mm) d6gagement des materiaux combustibles

est requis au-dessous.

This furnace is approved for UPFLOW, DOWNFLOW and

HORIZONTAL installations.

Cette foumaise est approuv_e pour I'installation HORIZONTALE

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

Clearance arrows Les _hes de degagement

do not change with ne change pas avec

I'orientation de la

furnace orientation, gen#rateur d'air chaud.

Vent dearance to

combustibles 0".

Clearancein inches 0 (pc)D_Jagement

D6gagement(pc). d'_vent aveccombustibles.

A08435

Fig. 3 - Clearances to Combustibles

FRONT o

! MAX80°F/27C

_ MIN60°F /16 C

Fig. 4 - Return-Air Temperature

A06745

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 5- Installation in a Garage

Thefurnaceshallbeinstalledsothat the electrical components are

protected from water.

For accessory installation details, refer to applicable installation

literature.

CODES AND STANDARDS

Follow all national and local codes and standards in addition

to these instructions. The installation must comply with

regulations of the serving gas supplier, local building, heating,

plumbing, and other codes. In absence of local codes, the

installation must comply with the national codes listed below and

all authorities having jurisdiction in Canada.

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

for the following:

General

US: National Fuel Gas Code (NFGC) NFPA

54-2006/ANSI Z223.1-2006 and the Installation

Standards, Warm Air Heating and Air Conditioning

Systems ANSI/NFPA 90B

CANADA: National Standard of Canada, Natural Gas

and Propane Installation Code (CAN/CSA-

B149.1-05) CSA B149.1-05

Installation

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

National Fire Protection Association Inc., Batterymarch

Park, Quincy, MA 02269; or for only the NFGC con-

tact the American Gas Association, 400 N. Capitol,

N.W, Washington DC 20001.

• A manufactured (Mobile) home installation nmst con-

form with the Manufactured Home Construction and

Safi, ty Standard, Title 24 CFR, Part 3280, or when this

standard is not applicable, the Standard for Manufac-

tured Home Installation (Manufactured Home Suites,

Communities, and Set-Ups), ANSI/NCS A225.1, and/

or CAN/CSA-z240, MH Series Mobile Homes.

• CANADA: CAN/CSA-B149.1-05. For a copy, con-

tact Standard Sales, CSA International, 178 Rexdale

Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3,

Canada.

Combustion and Ventilation Air

• US: Section 9.3 NFPA 54/ANSI Z223.1-2006, Air for

Combustion and Ventilation.

• CANADA: Part 8 of the CAN/CSA-B149.1-05, Vent-

ing Systems and Air Supply for Appliances.

Duct Systems

• US and CANADA: Air Conditioning Contractors As-

sociation (ACCA) Manual D, Sheet Metal and Air

Conditioning Contractors National Association

(SMACNA), or American Society of Heating, Refriger-

ation, and Air Conditioning Engineers (ASHRAE)

2005 Fundamentals Handbook Chapter 35.

Acoustical Lining and Fibrous Glass Duct

•US and CANADA: current edition of SMACNA,

NFPA 90B as tested by UL Standard 181 for Class I

Rigid Air Ducts.

Gas Piping and Gas Pipe Pressure Testing

• US: Section 9.3 NFPA 54/ANSI Z223A-2006 NFGC;

chapters 5, 6, 7, and 8 and national plumbing codes.

• CANADA: CAN/CSA-BI49.1-05 Parts 4, 5, 6, and 9.

In the state of Massachusetts:

• This product must be installed by a licensed plumber or

gas fitter.

• When flexible connectors are used, the maximum

length shall not exceed 36 inches (914 ram).

• When lever type gas shutoffs are used they shall be

T-handle type.

• The use of copper tubing for gas piping is not approved

by the state of Massachusetts.

Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA

70-2008.

• CANADA: Canadian Electrical Code CSA C22.1.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unit

components.

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing

to protect the furnace electronic control. Precautions will

prevent electrostatic discharges from 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.

3. Disconnect all power to the furnace. Multiple disconnects

may be required. DO NOT TOUCH THE CONTROL OR

ANY WIRE CONNECTED TO THE CONTROL PRIOR

TO DISCHARGING YOUR BODY'S

ELECTROSTATIC CHARGE TO GROUND.

4. Firmly touch a clean, unpainted, metal surface of the fur-

nace chassis which is close to the control. Tools held in a

person's hand during grounding will be satisfactorily dis-

charged.

5. After touching the chassis, you may proceed to service the

control or connecting wires as long as you do nothing that

recharges your body with static electricity (for example;

DO NOT move or shuffle your feet, DO NOT touch un-

grounded objects, etc.).

6. If you touch ungrounded objects (recharge your body with

static electricity), firmly touch furnace again before touch-

ing control or wires.

7. Use this procedure for installed and uninstalled (ungroun-

ded) furnaces.

8. Before removing a new control from its container, dis-

charge your body's electrostatic charge to ground to pro-

tect the control from damage. If the control is to be in-

stalled in a furnace, follow items 1 through 5 before

bringing the control or yourself into contact with the fur-

nace. Put all used AND new controls into containers be-

fore touching ungrounded objects.

9. An ESD service kit (available from commercial sources)

may also be used to prevent ESD damage.

INTRODUCTION

The model 58MVC Direct Vent, Upflow, Gas-Fired, Category

IV, condensing furnace is available in model sizes ranging in

input capacities of 60,000 to 120,000 Btuh.

g

APPLICATIONS

General

Some assembly and modifications are required for furnaces

installed in any of the four applications shown in Fig. 1. All

drain and pressure tubes are connected as shown in Fig. 7. See

appropriate application instructions for these procedures.

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property

damage.

Local codes may require a drain pan under entire furnace

and condensate trap when a condensing furnace is used in

an attic application or over a finished ceiling.

NOTE: In Canada, installations shall be in accordance with

current CAN/CSA-B149.1-05 and/or local codes.

UPFLOW APPLICATION

An upflow furnace application is where furnace blower is located

below combustion and controls section of furnace, and

conditioned air is discharged upwards.

Condensate Trap (Factory-Shipped Orientation)

The condensate trap is factory installed in the blower shelf and

factory connected for UPFLOW applications, A factory-supplied

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

desired furnace side for field drain attachment. See Condensate

Trap Tubing section for drain tube extension details, (See Fig. 6.)

Condensate Trap Tubing (Factory-Shipped Orientation)

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

confirm location of these tubes.

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

and Pressure Switch Tubes.

These tubes should be factory attached to condensate trap

and pressure switch ready for use in UPFLOW applica-

tions. These tubes can be identified by their connection

location and also by a color label on each tube. These

tubes are identified as follows: collector box drain tube

(blue label), inducer housing drain tube (violet label or

molded), relief port tube (green label), and pressure switch

tube (pink label).

2, Condensate Trap Drain Tube

The condensate trap drain connection must be extended

for field attachment by doing the following:

f. Determine location of field drain connection, (See Fig.

2 or 7.)

NOTE: If internal filter or side filter/media cabinet is used, drain

tube should be located to opposite side of casing from return duct

attachment to assist in filter removal.

g. Remove and discard casing drain hole plug button from

desired side.

h. Install drain tube coupling grommet (factory-supplied in

loose parts bag) in selected casing hole.

i. Slide drain tube coupling (factory-supplied in loose parts

bag) through grommet so long end of coupling faces

blower.

j. Cement 2 factory-supplied 1/2-in. (13 mm) street CPVC

elbows to rigid drain tube connection on condensate trap.

(See Fig. 7.) These elbows must be cemented together

and cemented to condensate trap drain connection.

/_ _TERNATE DRAIN

TUBE LOCATION

CONDENSATE TRAP --

DRAIN TUBE LOCATION

m BLOWER SHELF &-- FURNACE

\DOOR

FIELD ,..._

DRAIN

CONN

UPFLOW APPLICATIONS

f_ CONDENSATE

/TRA;uRNACE -7

jSIDe,,,"

,:_3 ......

_'/ /I 47/8(124mm)

21 J l iie

261/4 /2

(667mm) (38mm)

SIDE VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

FURNACE

DOOR

4

(102mm)

%2972 /4

FIELD (667mm)

DRAIN

CONN

END VIEW

FURNACE

SIDE

!

4(146mm)

(102ram'

3/4

(19ram)

FRONT Vl EW

HORIZONTAL

APPLICATIONS

SLOT FOR SCREW --j

HORIZONTAL /

APPLICATION

(OPTIONAL) /

11/2 (88mm)]

Uq --- ;

GUIDES -- _1 ,!

(WHEN USED) (57mm)

FRONT VIEW SIDE VIEW

1/40D

COLLECTOR BOX TO

TRAP RELIEF PORT

1/20D

INDUCER HOUSING

DRAIN CONNECTION

5/80D

COLLECTOR BOX

DRAIN CONNECTION

SCREW HOLE FOR

UPFLOW OR DOWN-

FLOW APPLICATIONS

(OPTIONAL)

1/2 IN. PVC OR CPVC

Fig. 6 - Condensate Trap

A07459

NOTE: Failure to use CPVC elbows may allow drain to kink,

preventing draining.

k. Connect larger diameter drain tube and clamp (factory-

supplied in loose parts bag) to condensate trap and clamp

securely.

1. Route tube to coupling and cut to appropriate length.

m. Attach tube to coupling and clamp securely.

Condensate Trap (Alternate Upflow Orientation)

An alternate location for the condensate trap is the left-hand side

of casing. (See Fig. 2 and 8.)

NOTE: If the alternate left-hand side of casing location is used,

the factory-connected drain and relief port tubes must be

disconnected and modified for attachment. See Condensate Trap

Tubing (Alternate Upflow Orientation) section for tubing

attachment.

To relocate condensate trap to the left-hand side, perform the

following:

1. Remove three tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs in-

ward 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 follow this warning could result in personal

iniury 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 room.

4. Install condensate trap into left-hand casing hole by in-

serting tube connection stubs through casing hole and ro-

tating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler

caps (factory-supplied in loose parts bag).

Condensate Trap 3klbing (Alternate Uptlow Orientation)

NOTE: See Fig. 8 or tube routing label on main furnace door to

confirm location of these tubes.

PLUG

COLLECTOR BOX

DRAIN TUBE (BLUE &

WHITE STRIPED)

CAP

COLLECTOR BOX

TUBE (PINK)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (GREEN

ROUTES BEHIND

INDUCER)

CONDENSATE

TRAP

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FIELD-INSTALLED FACTORY-SUPPLIED

FACTORY-SUPPLIED DRAIN TUBE

1/2- IN. CPVC STREET COUPLING (LEFT

ELBOWS (2) FOR DRAIN OPTION)

LEFT DRAIN OPTION

Fig. 7 -Factory-Shipped Trap Location

(Shown with Blower Access Panel Removed)

A07274

1. Collector Box Drain Tube

Connect collector box drain tube (blue label) to condens-

ate trap.

NOTE: On 17-1/2-in. (445 ram) wide furnaces ONLY, cut tube

between corrugated sections to prevent kinks.

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 drain extension tube (violet label

and factory-supplied in loose parts bag) to connect

LOWER inducer housing drain connection to condens-

ate trap.

c. Deternfine appropriate length, then cut and connect tube.

d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

a. Connect relief port tube (green label) to condensate trap.

b. Extend this tube (if required) by splicing to small diamet-

er tube (factory-supplied in loose parts bag).

c. Deternfine appropriate length, then cut and connect tube.

Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and

procedures.

PLUG

COLLECTOR BOX

DRAIN TUBE (BLUE &

WHITE STRIPED)

CAP

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (GREEN) _

CONDENSATE

TRAP

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (VIOLET)

A07281

Fig. 8 -Alternate Trap Location

Pressure Switch Tubing

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

connected to the pressure switch and should not require any

modification.

NOTE: See Fig. 7 or 8 or tube routing label on main furnace

door to check for proper connections.

Upper Collector Box and Inducer Housing (Unused) Drain

Connections

Upper Collector Box Drain Connection

Attached to the UPPER collector box drain connection is a

factory-installed corrugated, plugged tube (blue and white

striped label). This tube is plugged to prevent condensate leakage

in this application. Ensure this tube is plugged.

NOTE: See Fig. 7 or 8 or tube routing label on main furnace

door to check for proper connections.

Upper Inducer Housing Drain Connection

Attached to the UPPER (unused) inducer housing drain

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. 7 or 8 or tube routing label on main furnace

door to check for proper connections.

Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for

recommendations and procedures.

10

COLLECTORBOX =

DRAIN TUBE(BLUE)

PLUG

CAP

COLLECTORBOX

TUBE(GREEN)

COLLECTORBOX

TUBE(PINK)

COLLECTORBOX _

DRAIN TUBE(BLUE&

WHITESTRIPED)

COLLECTORBOX

TUBE EXTENS,ON _i i_ _

CONDENSATETRAP __q •

INDUCERHOUSING . _ •

(MOLDED)DRAIN

TUBE(VIOLET)

Fig. 9 -Downflow Tube Configuration

(Left-hand Trap Installation)

A07276

DOWNFLOW APPLICATIONS

Adownflow furnace application is where furnace blower is

located above combustion and controls section of furnace, and

conditioned air is discharged downwards.

Condensate Trap Location

The condensate trap must be removed from the factory-installed

blower shelf location and relocated in selected application

location as shown in Fig. 2, 9, or 10.

To relocate condensate trap from the blower shelf to desired

location, perform the following:

1. Remove three tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs in-

ward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig.

2 and 10.)

4. 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 follow this warning could result in personal

iniury 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

room.

5. 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.

6. Fill unused condensate trap casing holes with plastic filler

caps (factory-supplied in loose parts bag).

11

/

Z DRAIN TUBE

COUPLING

COLLECTOR BOX

TUBE (GREEN)

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

S TUBE (PINK)

PLUG

F COLLECTOR BOX

DRAIN TUBE (BLUE &

WHITE STRIPED)

COLLECTOR BOX

TUBE EXTENSION

INDUCER HOUSING

-- (MOLDED) DRAIN

TUBE (VIOLET)

CONDENSATE

TRAP

COLLECTOR BOX

EXTENSION

DRAIN TUBE

A07277

Fig. 10 - Downflow Tube Configuration

(Right-Hand Trap Configuration)

Condensate Trap Tubing

NOTE: See Fig. 9 or 10 or tube routing label on main furnace

door to check for proper connections.

1. Collector Box Drain Tube

a. Remove factory-installed plug from LOWER collector

box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector

box drain tube (blue label) which was connected to con-

densate trap.

c. Connect LOWER collector box drain connection to con-

densate trap.

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

(a.)Connect LOWER collector box drain tube (blue

and white striped label) to condensate trap.

Tube does not need to be cut.

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

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

(a.)Install drain tube coupling (factory-supplied in

loose parts bag) into collector box drain tube

(blue and white striped label) which was previ-

ously plugged.

(b.) Connect larger diameter drain tube (factory-sup-

plied in loose parts bag) to drain tube coupling,

extending collector box drain tube for connec-

tion to condensate trap.

(c.)Route extended collector box drain tube

between gas valve and inlet housing as shown in

Fig. 10.

(d.)Determine appropriate length and cut.

(e.)Connect to condensate trap.

2. Inducer Housing Drain Tube

a. Remove factory-installed cap and clamp from LOWER

inducer housing drain connection.

AUXILIARY "J" BOX

PLUG

CAP COLLECTOR BOX

DRAIN TUBE (BLUE &

WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR BOX

TUBE EXTENSION

COLLECTOR BOX

EXTENSION

DRAIN TUBE

DRAIN TUBE

COUPLING

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (VIOLET)

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (PINK)

Fig. 11 - Horizontal Left Tube Configuration

A07278

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate

trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

d. Use inducer housing drain tube (violet label and factory-

supplied in loose parts bag) to connect LOWER inducer

housing drain connection to the condensate trap,

e. Connect inducer housing drain connection to condensate

trap.

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

(a.)Determine appropriate length and cut.

(b.)connect tube to condensate trap.

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

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

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

directly from inducer housing to condensate

trap.

(b.)Determine appropriate length and cut.

(c.)Connect tube to condensate trap.

(d.)Clamp tube to prevent any condensate leakage,

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection

procedure,

Condensate Trap Field Drain Attachment

Refer 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 for use when furnace is installed in

UPFLOW or HORIZONTAL LEFT applications. The tube

MUST be disconnected and used or the condensate trap relief

port tube, The other collector box pressure tube (green label)

which was factory connected to the condensate trap relief port

connection MUST be connected to the pressure switch in

DOWNFLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 9 or 10 or tube routing label on man furnace

door to check for proper connections.

Relocate tubes as described below.

1. Disconnect collector box pressure tube (pink label) at-

tached to pressure switch.

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

was previously connected to condensate trap relief port

connection by splicing to small diameter tube (factory-

supplied in loose parts bag).

3. Connect collector box pressure tube (green label) to pres-

sure switch connection labeled COLLECTOR BOX.

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

previously connected to pressure switch by splicing to re-

maining small diameter tube (factory-supplied in loose

parts bag).

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

relief port connection.

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

7. Clamp tube to relief port connection.

Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for

recommendations and procedures.

HORIZONTAL LEFT (SUPPLY-AIR DISCHARGE)

APPLICATIONS

A horizontal left furnace application is where furnace blower is

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

and conditioned air is discharged to the left,

12

COMBUSTION -

INTAKE

MAN1

SHUTOFF

GAS VALVE

(I46 mm)

A 12qN. (305 mm) MIN HORIZONTAL PIPE

SECTION IS RECOMMENDED WITH

(5 TO 8 FT/1.5 TO 2.4 M) VENT

SYSTEMS TO REDUCE EXCESSIVE

CONDENSATE DROPLETS FROM

EXITING THE VENT PIPE.

30" (762 mm)MIN

)RK AREA

SEDIMENT

TRAP CONDENSATE

TRAP

DRAIN

ACCESS OPENING

FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

FURNACE AND CONDENSATE TRAP WHEN A CONDENSING

FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.

Fig. 12 -Attic Location and Working Platform for Direct Vent (2-Pipe) Application

A93031

g

A 3-IN (76mm) MINIMUM CLEARANCE

TO COMBUSTION-AIR INTAKE

IS REQUIRED.

COMBUSTI{

INTAKE

(146mm)

A 12-IN. (305mm) MIN HORIZONTAL PIPE

SECTION IS RECOMMENDED WITH

SHORT (5 TO 8 FT /1.5 TQ 2AM) VENT

SYSTEMS TO REDUCE EXCESSIVE

CONDENSATE DROPLETS FROM

EXITING THE VENT PIPE.

30qN. (762mm) MIN

WORK AREA

MAN[

SHUTOFF

GAS VALVE

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. 13 -Attic Location and Working Platform for

Ventilated Combustion Air Applications

ACCESS OPENING

FOR TRAP

A96184

13

g

PROPERTY DAMAGE

Failure to follow this caution may result in property

damage.

Local codes may require a drain pan under entire furnace

and condensate trap when a condensing furnace is used in

an attic application or over a finished ceiling.

NOTE: In Canada, installations shall be in accordance with

current NSCNGPIC and/or local codes.

Condensate Trap Location

The condensate trap nmst be removed from the factory-installed

blower shelf location and relocated in selected application

location as shown in Fig. 2 or 11.

To relocate condensate trap from the blower shelf to desired

location, perform the following:

1. Remove three tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs in-

ward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig.

2 or 11.)

4. 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 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

room.

5, 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.

6. Fill unused condensate trap casing holes with plastic filler

caps (factory-supplied in loose parts bag).

Condensate Trap _bing

NOTE: See Fig. 11 or tube routing label on main furnace door

to check for proper connections.

1. Collector Box Drain Tube

a. Install drain tube coupling (factory-supplied in loose

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

was previously connected to condensate trap.

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

supplied in loose parts bag) to drain tube coupling, ex-

tending collector box drain tube.

c. Route extended tube (blue label) to condensate trap and

cut to appropriate length.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube

(a.)Remove and discard LOWER (molded) inducer

housing drain tube which was previously con-

nected to condensate trap.

(b.)Use inducer housing drain extension tube (violet

label and factory-supplied in loose parts bag) to

connect LOWER inducer housing drain connec-

tion to condensate trap.

(c.)Deternfine appropriate length, cut and connect

tube.

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

3. Relief Port Tube

a. Extend collector box tube (green label) which was previ-

ously connected to condensate trap by splicing to small

diameter tube (factory-supplied in loose parts bag).

b. Route extended collector box pressure tube to relief port

connection on condensate trap.

c. Deternfine appropriate length, cut, and connect tube.

d. Clamp tube to prevent any condensate leakage.

Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and

procedures.

Pressure Switch Tubing

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

connected to the High Pressure Switch for use when furnace is

installed in UPFLOW applications. This tube MUST be

disconnected, extended rerouted, and then reconnected to the

pressure switch in HORIZONTAL LEFT applications for 060

and 080 heating input furnaces.

NOTE: See Fig. 11 or tube routing label on main furnace door

to check for proper connections.

Modify tube as described below.

1. Disconnect collector box pressure tube (pink label) at-

tached to High Pressure Switch.

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

bag) to extend tube disconnected in Item 1.

3. Route extended tube:

a. Behind inducer housing.

b. Between blower shelf and inducer housing.

4. Deternfine appropriate length, cut, and reconnect tube to

High Pressure Switch connections labeled COLLECTOR

BOX.

Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for

recommendations and procedures.

Construct aWorking Platform

Construct working platform where all required furnace clearances

are met, (See Fig. 3 and 12 or 130

[]NIT OPERATION HAZARD

Failure to follow this caution may result in internfittent unit

operation.

The condensate trap MUST be installed below furnace. See

Fig. 6 for dimensions. The drain connection to condensate

trap must also be properly sloped to an open drain.

NOTE: A 12-in. (305 ram) nfininmm offset pipe section is

recommended with short (5 to 8 ft. or 1.5M to 2.4M) vent

systems. This recommendation is to reduce excessive condensate

droplets from exiting the vent pipe. (See Fig. 12, 13, or 44.)

14

HORIZONTALRIGHT

(SUPPLY-AIR DISCHARGE) APPLICATIONS

A horizontal right furnace application is where furnace blower is

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

and conditioned air is discharged to the right.

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property

damage.

Local codes may require a drain pan under entire furnace

and condensate trap when a condensing furnace is used in

an attic application or over a finished ceiling.

NOTE: In Canada, installations shall be in accordance with

current NSCNGPIC and/or local codes.

NOTE: The auxiliary junction box (J-box) MUST be relocated

to opposite side of furnace casing. (See Fig. 14.) See Electrical

Connection section for J-box relocation.

Condensate Trap Location

PLUG

COLLECTOR BOX COLLECTOR BOX

DRAIN TUBE (BLUE) TUBE (GREEN)

CAP

COLLECTOR BOX TUBE (PINK)

AUXILIARY "J" BOX RELOCATED HERE

COLLECTOR BOX [J _ CONDENSATE

DRAIN TUBE (BLUE & t]_]3 TRAP

WHITE STRIPED)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 14 -Horizontal Right 1hbe Configuration

A07279

The condensate trap must be removed from the factory-installed

blower shelf location and relocated in selected application

location as shown in Fig. 2 or 14.

To relocate condensate trap from the blower shelf to desired

location, perform the following:

1. Remove three tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs in-

ward and rotating trap.

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

room.

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

parts bag) into blower shelf hole where trap was removed.

4. Install condensate trap into right-hand side casing hole by

inserting tube connection tabs through casing hole and ro-

tating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler

caps (factory-supplied in loose parts bag).

UPFLOW OR DOWNFLOW

MIN I/4" (7[l_Lm _

TO 1/2" (13mm)

MAX HORIZONTAL

A02146

Fig. 15 -Proper Condensate Drainage

Condensate Trap Tubing

NOTE: See Fig. 14 or tube routing label on main furnace door

to check for proper connections.

1. Collector Box Drain Tube

a. Remove factory-installed plug from LOWER collector

box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector

box drain tube (blue label) which was previously connec-

ted 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.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube

(a.)Remove factory-installed cap and clamp from

LOWER inducer housing drain connection.

(b.)Remove and discard UPPER (molded) inducer

housing drain tube which was previously con-

nected to condensate trap.

(c.)Install cap and clamp on UPPER inducer hous-

ing drain connection where molded drain tube

was removed.

(d.)Use inducer housing drain extension tube (violet

label and factory-supplied in loose parts bag) to

connect LOWER inducer housing drain connec-

tion to condensate trap.

(e.)Deternfine appropriate length, cut, and connect

tube to condensate trap.

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

3. Relief Port Tube

Refer to Pressure Switch Tubing section for recommenda-

tions and procedures.

Condenste Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and

procedures.

Pressure Switch 1hbing

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

to the pressure switch for use when furnace is installed in

UPFLOW or HORIZONTAL LEFT applications. This tube

MUST be disconnected and used for the condensate trap relief

port tube, The other collector box pressure tube (green label)

which was factory connected to the condensate trap relief port

connection MUST be connect to the pressure switch in

DOWNFLOW or HORIZONTAL RIGHT applications,

15

NOTE:SeeFig.14ortuberoutinglabelonmainfurnacedoor

tocheckforproperconnections.

Relocatetubesasdescribedbelow.

1.Disconnectcollectorboxpressuretube(pinklabel)at-

tachedtopressureswitch.

2.Extendcollectorboxpressuretube(greenlabel)which

waspreviouslyconnectedtocondensatetrapreliefport

connectionbysplicingtosmalldiametertube(factory-

suppliedinloosepartsbag.)

3.Connectcollectorboxpressuretube(greenlabel)topres-

sureswitchconnectionlabeledCOLLECTORBOX.

4.Useremainingsmalldiametertube(factory-suppliedin

loosepartsbag)toextendcollectorboxpressuretube

(pinklabel)whichwaspreviouslyconnectedtopressure

switch.

5.Routethisextendedtube(pinklabel)tocondensatetrap

reliefportconnection.

6.DetermineappropriateLength,cut,andconnecttube.

7.Clamptubetoreliefportconnection.

Condensate Trap Freeze Protection

Refer to condensate Drain Protection section for

recommendations and procedures.

Construct aWorking Platform

Construct working platform where all required furnace clearances

are met. (See Fig. 3 and 12 or 13.)

UNIT OPERATION HAZARD

Failure to follow this caution may result in intermittent unit

operation.

The condensate trap MUST be installed below furnace. See

Fig. 6 for dimensions. The drain connection to condensate

trap must also be properly sloped to an open drain.

NOTE: A 12-in. (305 ram) n_ininmm offset pipe section is

recommended with short (5 to 8 ft. or 1.5M to 2.4M) vent

systems. This recommendation is to reduce excessive condensate

droplets from exiting the vent pipe. (See Fig. 12, 13, or 44.)

LOCATION

General

This furnace nmst

• 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 maximum

lengths are not exceeded. Refer to Table 7.

• be located where available electric power and gas sup-

plies 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 pos-

sible. Refer to Air Ducts section.

• be provided with ample space for servicing and clean-

ing. Always comply with minimum fire protection

clearances shown on the furnace clearance-to-com-

bustibles label. (See Fig. 3.)

This furnace may be located in a confined space without special

provisions for dilution or ventilation air.

NOTE: For upflow/downflow applications install furnace so that

it is level or pitched and forward within 1/2-in. (13 ram) for

proper furnace operation. For horizontal applications pitch

1/4-in. (6 mm) n_ininmm to 1/2-in. (13 mm) n_axinmm forward

to ensure proper condensate drainage from secondary heat

exchangers. (See Fig. 15.)

When a furnace is installed so that supply ducts carry air

circulated by the furnace to areas outside the space containing the

furnace, the return air shall also be handled by ducts sealed to

furnace casing. The ducts terminate outside the space containing

the furnace to ensure there will not be a negative pressure

condition within equipment room or space.

BACK

Fig. 16 - Prohibit Installation on Back

A93043

16

[]NIT DAMAGE HAZARD

This gas furnace may be used for construction heat

provided that:

-The furnace is permanently installed with all electrical

wiring, piping, air filters, venting and ducting installed

according to these installation instructions. A return air duct

is provided, sealed to the furnace casing, and ternfinated

outside the space containing the furnace. This prevents a

negative pressure condition as created by the circulating air

blower, causing a flame rollout and/or drawing combustion

products into the structure.

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

"hot wired" to provide heat continuously to the structure

without thermostatic control.

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

nfininfize the corrosive effects of adhesives, sealers and

other construction materials. It also prevents the

entrainment of drywall dust into combustion air, which can

cause fouling and plugging of furnace components.

-The temperature of the return air to the furnace is

maintained between 55°F (13°C) and 80°F (27°C), with

no evening setback or shutdown. The use of the furnace

while the structure is under construction is deemed to be

internfittent 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 furnace, ductwork and filters are cleaned as necessary

to remove drywall dust and construction debris from all

HVAC system components after construction is completed.

-After construction is complete, verify furnace operating

conditions including ignition, input rate, temperature rise

and venting, according to the manufacturer's instructions.

FIRE OR DEATH HAZARD

Failure to follow this warning could result in property

damage, personal injury, or death.

Do not install furnace on its back. (See Fig. 16.) Safety

control operation will be adversely affected. Never connect

return-air ducts to back of furnace.

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 nfix products of combustion with circulating air, and that the

air circulating fan of the furnace, if installed in an enclosure

communicating with another fuel-burning appliance not of the

direct-vent type, shall be operable only when any door or panel

covering an opening in the furnace fan compartment or in a return

air plenum on ducts is in the closed position.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in nfinor property

or unit damage.

If these furnaces are installed in an unconditioned space

where ambient temperatures may be 32°F (0°C) or lower,

freeze protection measures must be taken. See Condensate

Drain Protection section and Fig. 17.

_3/ff/ 2MFfONCg4NFIMgMZI#STALLED

_ PROTECTION REQUIRED

Fig. 17 -Freeze Protection

/

A07911

Furnace Location Relative to Cooling Equipment

The cooling coil must be installed parallel with or on downstream

side of furnace to avoid condensation in heat exchanger. When

installed parallel with a furnace, dampers or other means used to

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

entering furnace. If dampers are manually operated, they nmst be

equipped with a means to prevent operation of either unit unless

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

Hazardous Locations

FIRE, EXPLOSION, INJURY OR DEATH

HAZARD

Improper location or inadequate protection could result in

fire or explosion,

When furnace is installed in a residential garage, it nmst be

installed so that burners and ignition sources are located a

nfininmm of 18 in. (457 ram) above floor. The furnace nmst

be located or protected to avoid physical damage by

vehicles. When furnace is installed in a public garage,

airplane hangar, or other building having a hazardous

atmosphere, unit must be installed in accordance with

requirements of National Fire Protection Association, Inc.

(See Fig. 5.)

g

17

(8ram)

and forth until it breaks off. Be careful of sharp edges. (See Fig.

22.)

g

13/4

(44ram)

(8ram)

5/16"

1 3/4"

(44ram)

(8mm)

(44mm) 1 3/4"

(44mm) 1

A89014

Fig. 18 -Leveling Legs

INSTALLATION

Levelin_ Le_s (If Desired)

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

leveling legs may be desired. (See Fig. 18.) Install field-supplied,

corrosion-resistant 5/16-in. (8 ram) machine bolts and nuts.

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

in. (38 mm).

1. Position furnace on its back. Locate and drill a 5/16-in. (8

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

Fig. 18.) Holes in bottom closure panel may be used as

guide locations.

2. For each hole, install nut on bolt and then install bolt and

nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install

flat washer if desired.)

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

inside nut to secure arrangement.

NOTE: Bottom closure nmst be used when leveling legs are

used. See Bottom Closure Panel section.

Installation in Upflow or Downflow Applications

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when special base (available from

Manufacturer) Part No. KGB is used. Special base is not required

when this furnace is installed on Manufacturer's Cased Coil

Assembly or when Manufacturer's Coil Box is used.

1. Determine application being installed from Table 1.

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

and Fig. 19.

3. Construct plenum to dimensions specified in Table 2 and

Fig. 19.

4. If special base (KGASB) is used, install as shown in Fig.

20.

5. If Manufacturer's Cased Coil Assembly or Manufacturer's

Coil Box is used, install as shown in Fig. 21.

NOTE: Remove furnace perforated discharge duct flanges when

they interfere with mating flanges on coil on downflow subbase.

To remove furnace perforated discharge duct flange, use hand

scanners, wide duct pliers or duct flange tool to bend flange back

[]NIT MAY NOT OPERATE HAZARD

Failure to follow this caution may result in intermittent unit

operation or performance satisfaction.

Do not bend duct flanges inward as shown in Fig. 22. This

will affect airflow across heat exchangers and may cause

limit cycling or premature heat exchanger failure. Remove

duct flange completely or bend it inward a minimum of

210°F (99°C) as shown in Fig. 22.

Installation in Horizontal Applications

These furnaces can be installed in either horizontal left or right

discharge position. In a crawlspace, furnace can either be hung

from floor joist or installed on suitable blocks or pad. Furnace

can be suspended from each corner by hanger bolts and angle

iron supports. (See Fig. 23.) Cut hanger bolts (4 each 3/8-in.

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

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

in Fig. 23. Dimples are provided for hole locations. (See Fig. 2.)

[]NIT MAY NOT OPERATE HAZARD

Failure to follow this caution may result in intermittent unit

operation or performance satisfaction.

The entire length of furnace 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 from the

ground, blocks or pad should support sides and center

blower shelf area.

A96283

Fig. 19 - Floor and Plenum Opening Dimensions

18

FURNACE

(OR OTHER MANUFACTURER'S

COIL CASING WHEN USED)

COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

FURNACE

FACTORY SUPPLIED

CASED COIL OR COIL BOX

/_ COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR -_

OPENING

A07585

Fig. 20 -Furnace, Plenum, and Subbase Installed on a

Combustible Floor

A07586

Fig. 21 -Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

DISCHARGE DUCT

FLANGE

210 DEG.

MIN

NO

YES

YES

Fig. 22 -Duct Flanges

A93029

19

COMBUSTION-AIRINTAKE

(NON-DIRECTVENT/1

ICATION)

_3-1N. MINIMUM CLEARANCE TO ' '

COMBUSTION-AIR INTAKE IS REQUIRED _'_

_ (NON-DIRECT VENT/1-PIPE

APPLICATION,) ill

:II

COMBUSTION-AIR PIPE

DIRECT VENT/2-PIPE

ALL SIZES)

3/8-1N. (10mm) ROD

ANGLE

IRON OR

EQU

(B)

(A) ROD LOCATION

USING DIMPLE

LOCATORS

(SEE DIMENSIONAL

DWG FOR

LOCATIONS)

3/8-1N.HEX

& WASHER (4)

REQD PER ROD

5 3/4' (146mm)

) (B) J

13/16-1N.(21mm) MAX

(B) ALTERNATE SUPPORT

LOCATION FROM BACK

ALTERNATE SUPPORT

LOCATION 4-IN. (102mm) MIN

8-IN. (203mm) MAX

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

NOTES: 1. A 1 In. (25mm) 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.

3. For non-direct vent/1 -pipe application,

bottom side combustion-air entry cannot be

used when furnace is installed with hangers

as shown.

A93304

Fig. 23 - Crawlspace Horizontal Application for Direct Vent /2-Pipe Installation and for Ventilated Combustion Air Installation

20

FURNACE

CASING

WIDTH

In. (mm)

PLENUM OPENING FLOOR OPENING

Table 1 - Opening Dimensions

APPLICATION

(APPROVED FACTORY SUPPLIED CASED COILS AND

COiL BOX: CD5, CKR, CAPVP, CARVP, CAPMR CARMR

CNPVR CNRVR AND KCAKC)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with Factory

supplied cased coil or Factory supplied coil box (KGASB

subbase not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with Factory

supplied cased coil or Factory supplied coil box (KGASB

subbase not required)

Upflow Applications on Combustible or Noncombustible

Flooring (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on Combustible flooring (KGASB

subbase required)

Downflow Applications on Combustible Flooring with Factory

supplied cased coil or Factory supplied coil box (KGASB

subbase not required)

ABCD

16 24-1/8 16- 5/8 24- 3/4

(406) (613) (422) (629)

15- 7/8 19 16-1/2 19- 5/8

(403) (483) (419) (498)

17 ½ 15-1/8 19 16-3/4 20-3/8

(445) (384) (483) (425) (518)

15-1/2 19 16-1/2 20

(394) (483) (419) (508)

19-1/2 24-1/8 20-1/8 24-3/4

(495) (613) (511 ) (629)

19-3/8 19 20 19-5/8

21 (492) (483) (508) (498)

(533) 18- 5/8 19 20-1/4 20- 3/8

(473) (483) (514) (518)

19 19 20 20

(483) (483) (508) (508)

23 24-1/8 23 - 5/8 24- 3/4

(584) (613) (600) (629)

22 - 7/8 19 23 - 1/2 19- 5/8

24 - 1/2 (581) (483) (597) (498)

(622) 22 -1/8 19 23 - 3/4 20- 3/8

(562) (483) (603) (518)

22-1/2 19 23-1/2 20

(572) (483) (597) (508)

AIR DUCTS

General Requirements

The duct system should be designed and sized according to

accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA)

or American Society of Heating, Refrigerating and Air

Conditioning Engineers (ASHRAE) or consult The Air Systems

Design Guidelines reference tables available from 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 carry air

circulated by the furnace to areas outside the space containing the

furnace, the return air must also be handled by a duct(s) sealed to

the furnace casing and ternfinating outside the space containing

the furnace.

Secure ductwork with proper fasteners for type of ductwork used.

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

approved tape or duct sealer.

Flexible connections should be used between ductwork and

furnace to prevent transnfission of vibration. Ductwork passing

through unconditioned space should be insulated to enhance

system performance. When air conditioning is used, a vapor

barrier is recommended.

Maintain a 1-in. (25 ram) clearance from combustible materials

to supply air ductwork for a distance of 36 in. (914 ram)

horizontally from the furnace. See NFPA 90B or local code for

further requirements.

For a furnace not equipped with a cooling coil, the outlet duct

shall be provided with a removable access panel. This opening

shall be accessible when the furnace is installed and shall be of

such a size that the heat exchanger can be viewed for possible

openings using light assistance or a probe can be inserted for

sampling the air stream. The cover attachment shall prevent leaks.

Ductwork Acoustical Treatment

Metal duct systems thatdo not have a 90 degree elbow and 10 ft.

(3M) of main duct to the first branch take-off may require

internal acoustical lining. As an alternative, fibrous ductwork may

be used if constructed and installed in accordance with the latest

edition of SMACNA construction standard on fibrous glass

ducts. Both acoustical lining and fibrous ductwork shall comply

with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid

air ducts.

Supply Air Connections

Upflow Furnaces

Connect supply-air duct to 3/4-in. (19 ram)flange on furnace

supply-air outlet. The supply-air duct attachment nmst ONLY be

connected to furnace supply-/outlet-air duct flanges or air

conditioning coil casing (when used). DO NOT cut main furnace

casing to attach supply side air duct, hunfidifier, or other

accessories. All accessories MUST be connected external to

furnace main casing.

Downflow Furnaces

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

supply-air duct attachment nmst ONLY be connected to furnace

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

installed on non-combustible material When installed on

combustible material, supply air duct attachment nmst ONLY be

connected to an accessory subbase or factory approved air

conditioning coil casing. DO NOT cut main furnace casing to

attach supply side air duct, hunfidifier, or other accessories. All

accessories MUST be connected external to furnace main casing.

Supply air opening duct flanges must be modified per Fig. 22.

Horizontal Furnaces

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

supply-air duct attachment must ONLY be connected to furnace

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

NOT cut main furnace casing to attach supply side air duct,

21

g

humidifier, or other accessories. All accessories MUST be

connected external to furnace main casing.

Return Air Connections

FIRE HAZARD

Failure to follow this warning could result in personal injury,

death or property damage.

Never connect return-air ducts to the back of the furnace.

Return air duct connections on furnace side(s) permitted in

upflow applications only.

Upflow Furnaces

The return-air duct must be connected to bottom, sides (left or

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

casing. 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 nmst be connected to return-air opening

provided. DO NOT cut into casing sides or back to attach any

portion of return-air duct. Bypass humidifier connections should

be made at ductwork or coil casing sides exterior to furnace.

Filter Arrangement

FIRE, CARBON MONOXIDE AND POISONING

HAZARD

Failure to follow this warning could result in personal

injury, death or property damage.

Never operate unit without a filter or with filter access door

removed.

The air filter arrangement will vary due to application, furnace

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

external Filter/Media cabinet (if provided) or the furnace blower

compartment. Factory supplied washable filters are shipped in the

blower compartment.

If a factory-supplied 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 factory-supplied washable filter or a factory-specified

high-efficiency disposable filter (see cabinet instructions).

If installing the filter in the furnace blower compartment,

determine location for filter and relocate filter retaining wire, if

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

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

shipped with this furnace. See Fig. 2 for location and size of

bottom and side return-air openings.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Use care when cutting support rods in filters to protect

against flying pieces and sharp rod ends. Wear safety

glasses, gloves, and appropriate protective clothing.

[]NIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit

operation or performance satisfaction.

For airflow requirements above 1800 CFM, see Air

Delivery table in Product Data literature for specific use of

single side inlets. The use of both side inlets, a combination

of one side and the bottom, or the bottom only will ensure

adequate return air openings for airflow requirements above

1800 CFM.

Table 2-Filter Information - In. (mm)

AIR FILTER LOCATED IN BLOWER COMPARTMENT

Filter Size

Furnace

Casing Width Side

Return

Bottom

Return*

Filter Type

Framed

17-1/2 (1) 16x 25 x 3/4 t (1) 16 x 25 x 3/4t Washable

(445) (406 x 635 x 19) (406 x 635 x 19)

2t (1) 16 x 25 x 3/4" (1) 20 x 25 x 3/4t Washable

(533) (406 x 635 x 19) (508 x 635 x 19)

24-1/2 (1 or 2)

t6 x 25 x 3/4" (1) 24 x 25 x 3/4t Washable

(622) (406 x 635 x 19) (610 x 635 x 19)

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

Alternate sizes can be ordered from your distributor or dealer

t Factory-provided with the furnace

FILTER

RETAINER

Fig. 24 - Filter Installed for Side Inlet

A93045

22

NOTE: Side return-air openings can ONLY be used in Upflow

configurations. Install filter(s) as shown in Fig. 24.

For bottom return-air applications, filter may need to be cut to fit

some furnace widths. Install filter as shown in Fig. 25.

21-iN. (533mm) WIDE

171/2-1N.(444mm) WIDE CASINGS ONLY:

CASINGS ONLY: SUPPORT RODS (3)

INSTALL FIELD-SUPPLIED EXTEND 1/4" (6mm) ON

FILTER FILLER STRIP EACH SIDE OF FILTER AND

INDER FILTER. REST ON CASING FLANGE

WASHABLE

FILTER

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

3. Remove bottom closure panel.

4. Reinstall front filler panel and screws.

Gas PiDin_

Gas piping nmst be installed in accordance with national and

local codes. Refer to NFGC in the U.S. Canadian installations

must be made in accordance with CAN/CSA-B149.1-05 and all

authorities having jurisdiction. Gas supply line should be a

separate line running directly from meter to furnace, if possible.

Refer to Table 3 for recommended gas pipe sizing. Risers nmst be

used to connect to furnace and to meter. Support all gas piping

with appropriate straps, hangers, etc. Use a minimum of one

hanger every 6 ft. (1.8M). Joint compound (pipe dope) should be

applied sparingly and only to male threads of joints. Pipe dope

must be resistant to propane gas.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

iniury, death, or property damage.

- Connect gas pipe to furnace using a backup wrench to

avoid damaging gas controls.

- Gas valve shutoff switch MUST be facing forward or

tilted upward.

- Never purge a gas line into a combustion chamber.

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

commercially available soap solution made specifically

for the detection of leaks to check all connections.

- Use proper length of pipe to avoid stress on gas

control manifold.

- If a flexible connector is required or allowed by

authority having jurisdiction, black iron pipe shall be

installed at furnace gas valve and extend a minimum

of 2 in. (51 ram) outside furnace casing.

-Protect gas valve from water and debris. Gas valve

inlet and/or inlet piping nmst remain capped until gas

supply line is permanently installed to protect the valve

from moisture and debris. Also, install a sediment trap

in the gas supply piping at the inlet to the gas valve.

FILTER

FILTER RETAINER

SUPPORT

Fig. 25 -Bottom Filter Arrangement

A00290

NOTE: Remove and discard bottom closure panel when bottom

inlet is used.

Bottom Closure Panel

These furnaces are shipped with bottom closure panel installed in

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

side return air is used.

To remove bottom closure panel, perform following:

1. Tilt or raise furnace and remove two screws holding front

filler panel. (See Fig. 26.)

Install a sediment trap in riser leading to furnace. Trap can be

installed by connecting a tee to riser leading to furnace so

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

nipple into lower end of tee. Capped nipple should extend below

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

control manifold and manual gas shutoff valve. (See Fig. 27.)

An accessible manual shutoff valve MUST be installed external

to furnace casing and within 6 ft. (1.8M) of furnace. A l/8-in.

NPT (3 ram) plugged tapping, accessible for test gauge

connection, MUST be installed immediately upstream of gas

supply connection to furnace and downstream of manual shutoff

valve.

Gas line grommet (factory-supplied loose parts bag) should be

used when installing gas piping. Gas line entry hole filler plug

should be installed in unused gas line entry hole. (See Fig. 28.)

23

g

I

I

II

I I

i

PANEL

BOTTOM

CLOSURE

PANEL

Fig. 26 -Removing Bottom Closure Panel

SUPPLY _

MANUAL _/ II

SHUTOFF ._ _

VALVE

SEDIMENT /

TRAP /

UNION -J

A93047

Fig. 27 - Typical Gas Pipe Arrangement

A93324

COMBUSTION-AIR PIPE GROMMET

J UNUSED 1-3/4 -IN. (44 mm)

DIAMETER GAS

/)--I'°_'%T'_GIsL_ ,. _ /CONN.HOLE

GAS LINE GROMMET

----_4--- GAS LINE ENTRY

____WJ HOLE FILLER PLUG

VENT PIPE GROMMET

NOTE: PIPE GROMMETS AND ENTRY HOLE FILLER

PLUGS ARE INCLUDED IN FACTORY-SUPPLIED

LOOSE PARTS BAG

Fig. 28 - Casing Pipe Grommets

A05057

24

Table 3- Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE

SIZE

IN. (MM)

1/2 (13)

3/4 (19)

1 (25)

1-1/4 (32)

1-1/2 (38)

INTERNAL LENGTH OF PIPE - FT (M)

DIA.

IN. (MM) 10 20 30 40 50

(3.0) (6.0) (9.1) (12.1) (15.2)

0.622 (158) 175 120 97 62 73

0.824 (21) 360 250 200 170 151

1.049 (27) 680 465 375 320 285

1.380 (35) 1400 950 770 660 580

1.610 (41) 2100 1460 1180 990 900

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

pressure drop of O,5-in, wc (based on a 0.60 specific gravity gas). Ref: Table 9-2

NFPA 54-2002,

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 valve. (See

Fig. 60.)

Piping should be pressure and leak tested in accordance with

NFGC in the United States or CAN/CSA-B149.1-05 in Canada,

local, and national plumbing and gas codes before the furnace has

been connected. If pressure exceeds 0.5 psig (14-in. wc), gas

supply pipe must be disconnected from furnace and capped

before pressure test.

If test pressure is equal to or less than 0.5 psig (14-in. wc), turn

off electric shutoff switch located on gas valve before test. It is

recommended that ground joint union be loosened before

pressure testing. After all connections have been made, purge

lines and check for leakage at furnace prior to placing it into

service.

The gas supply pressure shall be within the maximum (13.6-in.

wc) and minimum (4.5-in. wc) inlet supply pressures marked on

the rating plate with the furnace burners ON at HI-HEAT and

OFF.

Electrical Connections

See Fig. 29 for field wiring diagram showing typical field l15-v

and 24-v wiring. Check all factory and field electrical

connections for tightness.

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

injury or death,

Blower access door switch opens 115-v power to furnace

control. No component operation can occur. Do not bypass

or close switch with panel removed,

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent

unit operation,

Furnace control must be grounded for proper operation

or control will lock out. Control is grounded through

green/yellow wire connected to gas valve and burner

box screw,

llS-v Wiring

Before proceeding with electrical connections, make certain that

voltage, frequency, and phase correspond to that specified on

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

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 National

Electrical Code (NEC) ANSI/NFPA 70-2008 and any local codes

or ordinances that might apply. For Canadian installations, all

electrical connections must be made in accordance with Canadian

Electrical Code CSA C22.1 or authorities having jurisdiction.

Field-supplied wiring shall conform with the limitations of 63 °F

(33 °C) rise.

The furnace must be electrically grounded in accordance with

local codes; or in the absence of local codes, with the National

Electric Code ANSI/NFPA 70 and/or the Canadian Electric Code,

CSA C22.1, Part I, if an external electrical source is utilized.

Use a separate branch electrical circuit containing a properly sized

fuse or circuit breaker for this furnace. See Table 4 for wire size

and fuse specifications. A disconnecting means must be located

within sight from and readily accessible to furnace.

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

polarity is incorrect or furnace is not grounded properly, furnace

control status code indicator light will flash rapidly and furnace

will NOT operate.

FIRE HAZARD

Failure to follow this warning could result in personal iniury,

death, or property damage.

Do not connect aluminum wire between disconnect switch

and furnace. Use only copper wire. (See Fig. 30.)

25

B

115-V f

SINGLE

PHASE

.... FIELD 24-V WIRING

.... FIELD 115-, 208/280-, 460-V WIRING

-- FACTORY 24-V WIRING

FACTORY 115-, 208/230-, 460-V WIRING

115-V AUXILIARY

FIELD-SUPPLIED J-BOX

DISCONNECT

SWITCH

FURNACE

CONTROL

CENTER

NOTE 5 , _ _ I THERMOSTAT

WIRE _ ' I I I I tDISCONNECT

IIJ I ..........................

THREE-W,RE-----' ' '11

HEATING _L_---I I I

ONLY _'-

-- I I

, 11 I

I }N;NN{i {

@ NOTE',

3 *

f_ tr-J--A--e----eh o-4l-e.==_o=== ;_ SINGLE

f-J ', ', { } _ .... 4_______L==J PHASE

(_ .... NOTE1 J Ii [-_--O---_ND r-_ -]------_NDI

/ 1 ............. ....... I _, CONDENSING

L_Y \ UNIT

24-V TWO Wl RE

TERMINAL

BLOCK NOTES:

1. Connect Y or Y/Y2 terminal as shown for proper cooling operation.

2. Proper polarity must be maintained for 115-v wiring.

8. Use W2 with 2-stage thermostat when zoning.

4. If any of the original wire, as supplied, must be replaced, use

same type or equivalent wire.

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

208/230- OR

460-V

THREE PHASE

Fig. 29 -Heating and Cooling Application Wiring Diagram

A98325

Table 4-Electrical Data

UNIT SIZE

VOLTS-

HERTZ-

PHASE

OPERATING VOYAGE

RANGE MAXIMUM

UNIT

AMPS

Maximum*

127

127

127

127

127

Minimum*

104

104

104

104

104

MINIMUM

WIRE SIZE

060-14/042060 115-60-1 8.96 14

080-14/042080 115-60-1 8.96 14

080-20/060080 115-60-1 14.06 12

100-20/060100 115-60-1 14.06 12

120-20/060120 115-60-1 14.06 12

MAXIMUM

WIRE

LENGTH

FT (M)_

30 (9.1)

60 (9.1)

31 (9.4)

31 (9.4)

31 (9.4)

MAXIMUM

FUSE OR CKT

BKR

AMPS**

15

15

2O

2O

2O

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

1- 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 as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

** Time-delay type is recommended.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in electrical

shock, fire, or death.

The cabinet MUST have an uninterrupted or unbroken

ground according to NEC ANSI/NFPA 70-2008 and

Canadian Electrical Code CSA C22.1 or local codes to

nfininfize personal injury if an electrical fault should occur.

This may consist of electrical wire or conduit approved for

electrical ground when installed in accordance with existing

electrical codes. Do not use gas piping as an electrical

ground.

ELECTRIC

DISCONNECT

SWITCH

Q

Fig. 30 -Disconnect Switch and Furnace

A93033

Install power entry hole filler plugs (factory-supplied in loose

parts bag) in unused power entry holes. (See Fig. 31.)

26

INSTALED

LOCATION

POWER ENTRY HOLE

FILLER PLUG (FACTORY

SUPPLIED LOOSE PARTS BAG)

A05113

Fig. 31 - Factory Installed J-Box Location

J-Box Relocation

1. Remove two screws holding auxiliary J-box. (See Fig.

32.)

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

provided.

ALTERNATE--

FIELD

LOCATION

...........OLE_

FILLER PLUG (FACTORY U

SUPPLIED LOOSE PARTS BAG)

/

UNUSED 7/8 IN DIAMETER

POWER ENTRY HOLES

///NoSoATTA LEND

i/ POWERENTRYNOLE

• L SUPPLIED LOOSE PARTS BAG)

POWER ENTRY HOLES

POWER ENTRY HOLE

FILLER PLUG (FACTORY-

SUPPLIED LOOSE PARTS BAG)

POWER ENTRY HOLE

(FACTORY-

SUPPUED LOOSE PARTS BAG)

Fig. 32 - J-Box Relocation

A05058

3. Install power entry hole filler plugs (factory-supplied

loose parts bag) in unused power entry holes. (See Fig.

31.)

24-v wiring

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

on furnace control. Y wire from thermostat MUST be connected

to Y/Y2 ternfinal on control, as shown in Fig. 19, for proper

cooling operation. The 24-v ternfinal block is marked for easy

connection of field wiring. (See Fig. 33.) The 24-v circuit

contains a 3-amp, automotive-type fuse located on furnace

control. (See Fig. 33.)

Any electrical shorts of 24-v wiring during installation, service,

or maintenance may cause fuse to blow. If fuse replacement is

required, use only a fuse of identical size (3 amp) and type. The

furnace control will flash status code 24 when fuse needs

replacement.

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

for lengths up to 100 ft. (30.4M). For wire lengths over 100 ft.,

(30.4M) use AWG No. 16 wire.

NOTE: For additional thermostat connection diagrams,

reference Fig. 52-59.

Accessories

1. Electronic Air Cleaner (EAC)

The furnace control EAC ternfinals are energized with

115v (1.0-amp naaxinmm) during blower operation.

Connect an accessory Electronic Air Cleaner (if used) us-

ing 1/4-in. female quick connect ternfinals to the two male

1/4-in. quick-connect ternfinals on the control board

marked EAC-1 and EAC-2. The ternfinals are rated for

115VAC, 1.0 amps maximum and are energized during

blower motor operation. (See Fig. 33.)

NOTE: Low stage airflow may slightly increase the trace

amount of ozone created by an electronic air cleaner. Individual

sensitivity levels to ozone, along with other operating

characteristics of electronic air cleaners may affect the amount

noticed by an individual. Refer to the air cleaner manufacturer's

installation instructions for more information regarding ozone

and ozone reduction methods available for your air cleaner.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component

damage.

DO NOT connect furnace control HUM ternfinal to HUM

(hunfidifier) ternfinal on Thernfidistat :_, Zone Controller or

sinfilar device. See Thermidistat :_,Zone Controller,

thermostat, or controller manufacturer's instructions for

proper connection.

FIRE OR ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury, death, or property damage.

If manual disconnect switch is to be mounted on furnace,

select a location where a drill or fastener will not contact

electrical or gas components.

NOTE: If modulating dampers are used, blower motor

automatically compensates for modulating dampers. If manual

disconnect switch is to be mounted on furnace, select a location

where a drill or fastener will not contact electrical or gas

components.

2. Hunfidifier (HUM)

Connect an accessory 24 VAC, 0.5 amp maximum hunfid-

ifier (if used) to the 1/4-in. male quick-connect HUM ter-

nfinal and COM-24V screw ternfinal on the control board

thermostat strip. The HUM ternfinal is energized when

blower is energized in heating. (See Fig. 33.)

Removal of Existing Furnaces from Common Vent Systems

When an existing Category I furnace is removed or replaced, the

original venting system may no longer be sized to properly vent

the remaining attached appliances. An improperly sized Category

I venting system could cause the formation of condensate in the

furnace and vent, leakage of condensate and combustion

products, spillage of combustion products into the living space,

etc.

27

g

AIR FOR COMBUSTION AND VENTILATION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in premature

component failure.

This furnace can be vented as either a direct vent (2-pipe)

furnace or as an optional ventilated combustion air

application. A direct vent system shall be installed in

accordance with the direct vent (2- pipe) procedures in the

Combustion Air and Vent Pipe Systems section within this

supplemental instruction. For optional ventilated

combustion air applications, refer to the ventilated

combustion air option procedures in the same section.

Application of this furnace should be indoors with special

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

air temperature rise, unit leveling, and unit sizing.

Combustion-Air and Vent Pipe Systems

For additional venting information contact www.Carrier.com.

General

Vent system or vent connectors of other appliances may need to

be re-sized. For any other appliances when resizing vent systems

or vent connectors, system or connector must be sized to

approach minimum size as determined using appropriate table

found in the NFGC or CAN/CSA-BI49.1-05.

The 58MVC furnaces can be vented as either a direct vent furnace

or as an optional ventilated combustion air application. A direct

vent system shall be installed in accordance with the direct vent

(2-pipe) procedures in the following Combustion Air and Vent

Pipe Systems section. For optional ventilated combustion air

applications, refer to the ventilated combustion air option

procedures in the same section. Common venting prohibited.

Direct Vent /2-Pipe System

In a direct-vent (2-pipe) system, all air for combustion is taken

directly from outdoor atmosphere, and all flue products are

discharged to outdoor atmosphere. Combustion-air and vent

pipes must terminate together in the same atmospheric pressure

zone, either through the roof or a sidewall (roof termination

preferred). A factory accessory vent termination kit MUST be

used in a direct vent (2-pipe) system. See Fig. 34 for required

clearances.

Ventilated Combustion Air Option Materials

In a ventilated combustion air option, the vent terminates and

discharges the flue products directly to the outdoors similar to a

direct vent system. See Fig. 35 for required clearances. All air for

combustion is piped directly to the furnace from a space that is

well ventilated with outdoor air (such as an attic or crawl space)

and the space is well isolated from the living space or garage.

Materials

Combustion-air and vent pipe, fittings, primers, and solvents

nmst conform to American National Standards Institute (ANSI)

standards and American Society for Testing and Materials

(ASTM) standards. See Table 5 for approved materials for use in

the USA.

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal

iniury, death, or property damage.

Solvent cements are combustible. Keep away from heat,

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

Avoid breathing in vapor or allowing contact with skin or

e}zes.

In Canada, construct all combustion-air and vent pipes for this

unit of CSA or ULC listed schedule-40 PVC, PVC-DWV or

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

Canada.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury, death, or property damage.

All combustion-air and vent pipes must be airtight and

watertight. Pipes must also terminate exactly as shown in

Fig. 36 for direct vent (2-pipe) system or Fig. 37 for

ventilated combustion air option.

An abandoned masonry chinmey may be used as a raceway for

properly insulated and supported combustion-air (when

applicable) and vent pipes. Each furnace must have its own set of

combustion-air and vent pipes and be terminated individually, as

shown in Fig. 36 for Direct Vent (2-Pipe) system or Fig. 37 for

ventilated combustion air option.

A furnace shall not be connected to a chinmey flue serving a

separate appliance designed to burn solid fuel.

Other gas appliances with their own venting system may also use

the abandoned chinmey as a raceway providing it is permitted by

local code, the current edition of the National Fuel Gas Code and

the vent or liner manufacturer's installation instructions. Care

must be taken to prevent the exhaust gases from one appliance

from contaminating the combustion air of other gas appliances.

Do not take combustion air from inside the chinmey when using

the Ventilated Combustion Air option.

[]NIT MAY NOT OPERATE HAZARD

Failure to follow this caution may result in intermittent unit

operation.

When vent pipe is exposed to temperatures below freezing,

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

chinmey is used as a raceway, pipe nmst be insulated as

shown in Table 6 with Armaflex-type insulation.

Furnace combustion air and vent pipe connections are sized for

2- in. pipe. Any pipe size change should be made outside furnace

casing in vertical pipe. The transition has to be made as close to

the furnace as reasonably possible. (See Fig. 380

28

ASTM

SPECIFICATION

(MARKED ON

MATERIAL)

D1527

D1785

D2235

D2241

D2466

D2468

D2564

D2661

D2665

F438

F441

F442

F493

F628

F656

F891

Table 5-Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials

MATERIAL PIPE FITTINGS

Fittings

Fittings

Fittings

Fittings

Fittings

SOLVENT

CEMENT

AND PRIMERS

Solvent

Cement

Solvent

Cement

Solvent

Cement

Primer

ABS Pipe

PVC Pipe

For ABS

PVC Pipe

PVC

ABS

For PVC

ABS Pipe

PVC Pipe

CPVC

CPVC Pipe

CPVC Pipe

For CPVC

ABS Pipe

For PVC

PVC Pipe

DESCRIPTION

Schedule40

Schedule40

For ABS

SDR21 & SDR26

Schedule40

Schedule40

For PVC

DWV at Schedule40 IPS sizes

DWV

Schedule40

Schedule40

SDR

For CPVC

Cellular Core DWV at Schedule40

IPS sizes

For PVC

Cellular Core Schedule 40 & DWV

Installation Guidelines for Combustion Air Pipe and Vent

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

preassembled before permanently cementing any joint.

1. Attach combustion air pipe and vent pipe per instructions

in sections "Combustion Air Pipe" and "Vent Pipe."

2. Working from furnace to outside, cut pipe to required

length(s).

3. Deburr inside and outside of pipe.

4. Chamfer outside edge of pipe for better distribution of

primer and cement.

5. Clean and dry all surfaces to be joined.

6. Check dry fit of pipe and mark insertion depth on pipe.

7. After pipes have been cut and preassembled, apply gener-

ous 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 ce-

ment in a light, unifom_ coat on inside of socket to prevent

buildup of excess cement. Apply second coat.

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

turn. Be sure pipe is fully inserted into fitting socket.

9. Wipe excess cement from joint. A continuous bead of ce-

ment will be visible around perimeter of a properly made

joint.

10. Handle pipe joints carefully until cement sets.

11. Horizontal portions of the venting system shall be suppor-

ted to prevent sagging. Support combustion air piping and

vent piping a n_ininmm of every 5ft. (1.5M)(3 ft. (.91M)

for SDR-21 or -26 PVC) using perforated metal hanging

strap.

12. Slope combustion air piping and vent piping downward

towards furnace a minimum of l/4-in, per linear ft. with

no sags between hangers.

13. Horizontal portions of the venting system shall be installed

so as to prevent the accumulation of condensate.

14. Use appropriate methods to seal openings where combus-

tion air pipe and vent pipe pass through roof or sidewall.

Combustion-Air and Vent Pipe Diameter

Determine combustion-air and vent pipe diameter.

1. Using Table 7, individually determine the diameter of the

combustion-air and vent pipe allowed. If different, pick

the larger of these two diameters and use this diameter for

both combustion-air 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 or incomplete combustion, flame dis-

turbance, or flame sense lockout may occur.

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

within furnace.

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

casing. Make all pipe diameter transitions outside furnace casing.

29

MODEL PLUG

CONNECTOR

SWl SETUP

SWITCHESAND

BLOWER OFF-

DELAY

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

24-V THERMOSTAT

TERMINALS

STATUS AND COMM --------------

LED LIGHTS

3-AMP FUSE

TRANSFORMER24-VAC

CONNECTIONS

11S-VAC (L2) NEUTRAL

CONNECTIONS

USERINTERFACE

OR ADVANCED

PRODUCT

MONITOR

CONNECTOR

\

PL4

CONTINUOUS FAN SW4 SETUP

(CF) AIRFLOW OAT SWITCHES

SETUPSWITCHES CONNECTOR

OAT

EAC-1 TERMINAL

(11S -VAC 1.0AMP MAX,)

[]

[]

[]

[]

[]

m

PL1 - LOW VOLTAGE MAIN EXAMPLE:

HARNESS CONNECTOR

SOFTWARE PART DATE

VERSION NUMBER CODE

NUMBER

/ AMP@ 1/5 VAC

EAC-1

PL2

VS HSI HI LOK,,

115-VAC (L1) LINE

VOLTAGE CONNECTIONS

Fig. 33 - Furnace Control

HUMIDIFIER

-----'- TERMINAL (24-VAC

O.SAMP MAX,

I ACRDJ - AIR

CONDITIONING

RELAYDISABLE

JUMPER

FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

\PL3-ECM BLOWER

HARNESS

CONNECTOR

BOARD SERIAL

NUMBER

PL2 - HOT SURFACE

IGNITER& INDUCER

MOTOR CONNECTOR

A07422

3O

/

/

/,

/

/

2_24_=2

_=_,000 B_uh(30 kW), 36 _50,000 _uh (_Skw"), 12 _r_ (_)for a_r_ >

(91 cm) _ _es >100,_ Bt_ (30 _W) 5O,OOOBtuh (_SkW)

C_,E_:e _oa per_ar_ closed _r_

J _r_n_e _o n_-me_ar_lcal air s_pi'y _nlet to l_J_idit_ or 12 inches (30 cm) for applieances >10,000 Btuh(3 kW)

the _,_t _nl_ I0 _t ap_ and <_ 100,000 Btuh(30kW), 36 inches (91cm) for

appliances > 100,000 Btuh(30kW)

9 inches (23 _) _, app_ > 10._ Btuh (3P,W) and

50i000 Btuh (i 5k_V), 12 troches(30_)_'or _

>50,000 _h (_SkW)

Fig. 34 -Direct Vent Termination Clearance

A08600

31

O _- //

/

/

//

/

[]VENTTERMINAL \\ _ AIR SUPPLY INLET

25-24-65-2

AREA WHERE TERMINAL IS NOT PERMITED

Item Clearance Descriptions Canadian Installation (1) U.S. Installation (2)

A Clearance above grade, veranda, porch, deck, balcony, or 12 inches (30cm) # 12 inches (30 cm)

anticipated snow level

B Clearance to a window or door that may be opened 6 inches (15 cm) for appliances <_ 10,000 Btuh (3 kW) 4 feet(l.2 m) below or to the side of the opening. 1 foot(30 cm

12 inches ( 30 cm) for appliances > 10,000 Btuh (3 kW0) above the opening.

and -< 100,000 Btuh (30 kW), 36 inches (9t cm) for

appliances > 100,000 Btuh (30 kW)

C Clearance to a permanently closed window

D Vertical clearance to a ventilated soffit located above the

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

centerline of the terminal

E Clearance to an unventilated soffit

F Clearance to an outside corner

G Clearance to an inside corner

H Clearance to each side of the centerline extended above 3 feet (91 cm) within 15 feet(4.5 m) above the meter/regulator 3 feet (91 cm) _iithin 15 feet (4.5 m) above the meter/regulator

electrical meter or gas service regulator assembly assembly assembly

I Clearance to service regulator vent outlet 3 feet (91 cm)

J Clearance to non-mechanical air supply inlet to building or 6 inches (15 cm) for appliances -< 10,000 Btuh (3 kW) 4 feet(t .2 m) below or to the side of opening: 1 foot (30 cm)

the combustion air inlet to any other appliance 12 inches ( 30 cm) for appliances > 10,000 Btuh (3 kW0) above opening.

and -< 100,000 Btuh (30 kW)

36 inches (91 cm) for appliances > t00,000 Btuh (30 kW)

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

L Clearance under a veranda, porch, deck, or balcony 12 inches(30 cm) +

M

7 feet (2.13m)

Clearance to each side of the centerline extended above or

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

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

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

vent, or other appliances direct vent intake or exhaust.

O Clearance from a plumbing vent stack

p Clearance above paved sidewalk or paved 7 feet (2.13m)**

driveway located on public property

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

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

# 18" (46 cm) above roof surface

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

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.t, clearances shall be in accordance with local installation codes and the requirements of the gas supplier and the

Manufacturer's installation instructions.

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

Notes:

1. The vent for this appliance shall not terminate

a. Over public walkways; or

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

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

2. When locating vent terminations, consideration must be given to prevailing winds, location, and other c onditions which may cause recirculation of the combustiob 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. Recirculation could occur and cause performance or system problems.

A08601

Fig. 35 - Ventilated Combustion Air Vent Termination Clearance

32

Roof Te rmLnation (Preferred)

between combustbn

aErand vent

8 3/4 in (222ram)for 3 in (76ram)kit

Maintain 12 in (305mm)_n

clearance above

....... hslghwe__e_aenI.......

Concwntric Vent and Combustion Air

Roof [urmination (pm_rmd) ......

Fig. 36 - Combustion Air and Vent Termination for Direct Vent (2-pipe) System

R_f Term_natbn (Preferred)

A05090

_._-f _"_" _'_'_ aboveMaintainminimumh_hest12 ciearanceinanticipated(305ram) ......... _": i[

snow level maximum of

24 in (610ram) abova roof ....... _--. [

Abandoned masonry

used as raceway

(per code)

Side wall termination

X\\x\\x\ \ with 2 elbows (preferred)

12 in (3O5 ram) rain from

overhang or roof

Maintain 12in 305ram

minimum c earance

above highest anticipated

s_qow leve[ or glade

",_hichever is greate_

12 in rain (305 mm)fron

overhang or r_f

6 in (152ram) minimum cieara_e

between waiJ and end of vent pipe

10 in (254mm) maximum pipe Jen_[h

305ram)

minimum clearance

above highest anticipated

snow leveJ or grade

whichever is greater

Sidewall Tel minat_n

with Stra_Jht Pipe (preferred)

Fig. 37 -Vent Pipe Termination for Ventilated Combustion Air System

A05091

33

(FURNACE

J

NOT IN

HORIZONTAL

SECTION

TRANSITION IN

VERTICAL SECTION

A93034

Fig. 38 - Combustion Air and Vent Pipe Transition

Location and Elbow Configuration

UNIT OPERATION HAZARD

Failure to follow this caution may result in internfittent unit

operation.

When installing combustion air and vent system of short

pipe length, the smallest allowable pipe diameter must be

used.

UNIT CORROSION HAZARD

Failure to follow this caution may result in unit component

damage.

Excessive exposure to contaminated combustion air may

result in safety and performance related problems.

Combustion air nmst not be taken from inside structure

because that 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 fresheners, adhesives, paint, and

other household products. Locate combustion-air inlet as

far as possible from swimming pool and swimming pool

pump house.

EXAMPLE: This 80,000 BTUH furnace located in Indianapolis,

elevation 650 ft. (198.1M) above sea level, could be installed as a

direct Vent /2-pipe system that requires 3 elbows and 17 ft.

(5.1M) of vent pipe, along with 5 elbows and 16 ft. (4.8M) of

combustion-air pipe. Table 7 indicates this application would

allow a l-l/2-in, diameter vent pipe, but require a 2-in. diameter

combustion air pipe. According to Table 7, l-l/2-in, diameter

pipe is good for 20 ft. (6.0M) with 3 elbows, but only 10 ft.

(3.0M) with 5 elbows. Therefore, 2-in. diameter pipe nmst be

used for both vent and combustion-air pipes since the largest

required diameter nmst always be used for both pipes. If the same

installation was made in Albuquerque, elevation 5250 ft.

(1600.2M) above sea level, installation would require 2- in.

diameter vent pipe and combustion-air pipe. At 5001 to 6000-ft

(1524M - 1828M) elevation, l-l/2-in, pipe is not allowed with

5 elbows, but 2-in. pipe is good for 68 ft. (20.7M) with 5 elbows

are required.

COMBUSTION AIR PIPE

General

Furnace combustion-air connection nmst be attached as shown in

Fig. 39. Combustion-air intake housing plug may need to be

relocated in some applications.

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.

VENT

COMBUSTION- @ COMBUSTION-

AIR AIR AIR

FLOW

DOWNFLOW

COMBUSTION-

AIR

VENT

HORIZONTAL-RIGHT DISCHARGE

A96187

Fig. 39 - Combustion Air and Vent Pipe Connections

NOTE: All pipe joints nmst be cemented except attachment of

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

necessary to remove pipe for servicing.

NOTE: A 2-in. diameter pipe nmst be used within the furnace

casing. Make all pipe diameter transitions outside furnace casing.

Attachment of Combustion Air Pipe

NOTE: Combustion air pipe system has the same diameter and

same length as the vent pipe as mentioned in section

"Combustion- -Air and Vent Pipe Diameter."

1. Deternfine location of combustion-air intake pipe connec-

tion to combustion-air intake housing as shown in Fig. 39

for application.

2. Verify combustion-air intake housing plug fitting is in-

stalled in appropriate unused intake housing connection.

3. Install combustion-air pipe grommet (factory-supplied in

loose parts bag) into selected furnace casing combustion

air pipe hole.

4. Deternfine the number of combustion air disk halves to be

installed in the combustion air intake housing. Insert per-

forated disk half or assembly (factory supplied in loose

parts bag) in intake housing where combustion-air intake

pipe will be connected.

5. Insert assembled combustion air inlet pipe into intake

housing as shown in Fig. 39.

NOTE: Do not cement combustion air intake pipe permanently

to combustion air intake housing since it may be necessary to

remove pipe for service of igniter or flame sensor.

6. Drill a l/8-in, hole in 2-in, combustion air pipe using the

hole in intake housing as a guide.

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

into combustion air pipe.

34

AIR

INTAKE HOUSING

3/8" ID TUBE

3/16"

DRILL

TO OPEN

DRAIN

BURNER

BOX

_COMBUSTION

AIR PIPE

A93035

Fig. 40 -Intake Housing Plug Fitting Drain

8. Install casing hole filler cap (factory-supplied in loose

parts bag) in unused combustion air pipe casing hole.

Attachment of Combustion Air Intake Housing Plug Fitting

The combustion-air intake plug fitting nmst be installed in

unused combustion air intake housing. This fitting nmst be

attached by using RTV sealant, or by drilling a 1/8-in. hole in

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

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

NOTE: DO NOT OVER-TIGHTEN 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 when moisture is found in combustion air intake pipe and

combustion box.

If use of this drain connection is desired, drill out fitting's tap

plug with 3/16-in. drill and connect a field-supplied 3/8-in. tube.

This tube should be routed to open condensate drain for furnace

and A/C (if used), and should be trapped, as shown in Fig. 40.

NOTE: (Direct Vent /2-Pipe System ONLY). Moisture in

combustion air intake may be a result of improper ternfination.

Ensure combustion air pipe ternfination is sinfilar to those as

shown in Fig. 36 so that it will not be susceptible to area where

light snow or others sources of moisture could be pulled in.

Combustion Air Termination - Ventilated Combustion Air

Option

Provisions for adequate combustion, ventilation, and dilution air

must be provided in accordance with:

• U.S. Installations: Section 9.3 NFPA 54/ANSI

Z223.1-2006, Air for Combustion and Ventilation and

applicable provisions of the local building codes.

• Canadian Installations: Part 8 of CAN/CS-B149.1-05.

Venting Systems and Air Supply for Appliances and all

authorities having jurisdiction.

Combustion air is piped directly to the burner box on furnace

using the same materials used to vent the furnace. (See Table 5.)

The combustion air pipe is ternfinated in an attic or crawl space

that is well ventilated with OUTDOOR AIR and is well isolated

from the living space or garage. If the furnace is installed in a well

ventilated attic, crawlspace or other enclosure, the combustion air

pipe can be ternfinated in the same space.

[]NIT CORROSION HAZARD

Failure to follow this caution may result in reduced furnace

component life.

Air for combustion nmst not be contanfinated by halogen

compounds, which include fluoride, chloride, bronfide, and

iodide. These elements may corrode heat exchangers and

shorten furnace life. Air contanfinants are found in aerosol

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

fresheners, and other household products.

The combustion air pipe cannot be ternfinated in attics or

crawlspaces that use ventilation fans designed to operate during

the heating season. If ventilation fans are present in these areas,

the combustion air pipe must ternfinate outdoors as a Direct Vent/

2-Pipe system.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury or death.

The operation of exhaust fans, kitchen ventilation fans,

clothes dryers, attic exhaust fans or fireplaces could create a

NEGATIVE PRESSURE CONDITION at the furnace.

Makeup air MUST be provided for the ventilation devices,

in addition to that required by the furnace. Refer to the

Carbon Monoxide Poisoning Hazard warning at the end of

this section to deternfine if an adequate amount of make-up

air is available.

NOTE: Combustion air pipe must have the same diameter as

vent pipe.

An attic or crawlspace may be considered a space that freely

communicates with the outdoors provided there are adequate

permanent ventilation openings directly to outdoors having free

area of at least 1-in.2/4,000 Btuh of total input rating for all gas

appliances in the space.

NOTE: In deternfining the free area of an opening, the blocking

effect of the louvers, grilles, and screens nmst be considered. If

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

assumed that wood louvers have a 20 percent free area, and metal

louvers or grilles have a 60 percent free area. Screens, when used,

must not be smaller than l/4-in, mesh. Louvers and grilles must

be constructed so they cannot be closed.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

iniury or death.

Many homes require air to be supplied from outdoors for

furnace combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in

accordance with this instruction manual.

g

Attic terminations require at least (1) 90 degree elbow, with the

open end pointing horizontally or downward. The open end of

the elbow must be at least 12-in. (305 ram) above any insulation

35

g

or other materials. Screen the elbow with a wire mesh screen no

smaller than 3/8-inch square. (See Fig. 41.)

Crawlspace ternfinations require the open end of the combustion

air intake pipe to point downward. Maintain 3 inches (76 ram) of

clearance below the floor joist insulation and 12 inches (305 ram)

above the grade. Screen the elbow with a wire mesh screen no

smaller than 3/8-in. (10 ram) square. (See Fig. 42 and 43.)

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each

appliance connected to the venting system being placed into

operation could result in carbon monoxide poisoning or

death.

The following steps shall be followed 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 for proper size and

horizontal pitch, as required in the National Fuel Gas

Code, ANSI Z223.1-2006/NFPA 54-2006 or the

CSA B149.1-05, Natural Gas and Propane

Installation Code and these instructions. Deternfine

that there is no blockage or restriction, leakage,

corrosion and other deficiencies, which could cause

an unsafe condition.

3. As far as practical, close all building doors and

windows and all doors between the space in which

the appliance(s) connected to the venting system are

located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not

connected to the venting system. Turn on any

exhaust fans, such as range hoods and bathroom

exhausts, so they are operating at maximum speed.

Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance

being inspected into operation. Adjust the thermostat

so appliance is operating continuously.

7. Test for spillage from draft hood equipped

appliances at the draft hood relief opening after 5

nfinutes of main burner operation. Use the flame of a

match or candle.

8. If improper venting is observed during any of the

above tests, the venting system must be corrected in

accordance with the National Fuel Gas Code, ANSI

Z223.1-2006/NFPA 54-2006 and/or CSA

B149.1-05, Natural Gas and Propane Installation

Code.

9. After it has been deternfined that each appliance

connected to the venting system properly vents when

tested as outlined above, return doors, windows,

exhaust fans, fireplace dampers and any other

gas-fired burning appliance to their previous

conditions of use.

Combustion Air Termination-Direct Vent /2-Pipe System

Combustion air pipe must terminate outside the structure with the

vent pipe as shown in Fig. 36. Follow the clearance requirements

shown in Fig. 39. Refer to Vent Termination section for complete

details on ternfination options.

VENT PIPE

General

Furnace vent connection must be attached as shown in Fig. 39.

CARBON MONOXIDE POISONING AND

PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal

iniury or death.

Vent pipes must be airtight.

NOTE: A 2-in. (51 ram) diameter pipe nmst be used within the

furnace casing. Make all pipe diameter transitions outside furnace

casing per Fig. 38.

The nfininmm vent pipe length for these furnaces is 5 ft. (I.5M)

Short pipe lengths (5-8 ft. or 1.5M-2.4M) may discharge

condensate droplets. These condensate droplets may be

undesirable. A 12-in. (305 ram) nfininmm offset pipe section is

recommended to reduce excessive condensate droplets from

exiting vent pipe outlet. (See Fig. 44.)

Attachment of Vent Pipe

NOTE: Vent pipe system has the same diameter and same length

as combustion air pipe as mentioned in section "Combustion Air

Pipe and Vent Pipe Diameter."

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in unit component

damage.

Inducer housing outlet cap nmst be installed and fully

seated against inducer housing. Clamp must be tightened to

prevent any condensate leakage.

Vent pipe must be installed and fully seated against inducer

housing. Clamp must be tightened to prevent any

condensate leakage.

1. Deternfine location of vent pipe connection to inducer

housing as shown in Fig. 39 for application.

2. Verify synthetic rubber inducer housing outlet cap and

clamp are installed on appropriate unused inducer housing

connection and that clamp is tight.

3. Install vent pipe grommet (factory-supplied in loose parts

bag) into selected furnace casing vent pipe hole. (See Fig.

28.)

4. Be certain that mating surfaces of inducer housing connec-

tion synthetic rubber coupling, and 2-in. diameter vent

pipe are clean and dry. Assemble the synthetic rubber vent

coupling (with 2 loose clamps) onto inducer housing con-

nection. Insert the 2-in. diameter vent pipe through the

synthetic rubber coupling and fully into inducer housing

connection until it touches a stop inside the inducer hous-

ing outlet. Tighten the screws on both clamps to 15-in lb.

of torque.

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

parts bag) in unused vent pipe casing hole.

36

B

Fig. 41 -Attic Termination

A06672

Pipe hangar

Ventilated Combustion Air

intake termination in crawl

3" (76.2 mm)

minimum

t

(304.8 mm)

Fig. 42 - Crawlspace Termination

A06673

37

3" (76.2mm)

minimum

Ventilated Combustion Air |

intake termination in crawl 12" (304.8mm)

space i minimum

Fig. 43 -Crawlspace Termination

A06674

/ _3osmm__:_H

VENTP'PE--'_II __

!! !If c°MBusm'°"-A'RP'PE

VENT PIPE

-t_---- 12" MIN---_

(305mm_ _

if r- COMBUSTION-AIR PIPE

HORIZONTAL TO ROOF HORIZONTAL TO S IDEWALL

COMBUSTION-AIR

COMBUSTION-AIR PIPE

F VENT PIPE

VENT PIPE

VERTICAL TO ROOF VERTICAL TO SIDEWALL

NOTE: A 12-in. (304.8mm) minimum offset pipe section is recommended

with short (5 to 8 ft /1.5 to 2.5M) vent systems. This recommendation

is to reduce excessive condensate droplets.

Fig. 44 - Short Vent (5 to 8 ft. /1.5M to 2.4M) System

A96230

38

NOTE: Starting at furnace, slope vent pipe a minimum of

1/4-in. (6 ram) per linear ft. back toward furnace with no sags

between hangers.

VENT TERMINATION

General

Combustion-air (direct Vent /2-pipe system only) and vent pipe

must terminate outside structure, either through sidewall or roof.

For vent termination clearance, refer to Fig. 34 for Direct Vent /

2- Pipe system and Fig. 35 for Ventilated Combustion Air

option.

Roof termination is preferred since it is less susceptible to damage

or contamination, and it has less visible vent vapors. Sidewall

termination require sealing or shielding of building surfaces with

a corrosive resistance material due to corrosive combustion

products of vent system.

NOTE: (Direct Vent /2-Pipe system ONLY) A factory

accessory termination kit MUST be used. See section "Vent

Termination Kit (Direct Vent /2-Pipe System Only)" in this

instruction.

When determining appropriate location for termination, consider

the following guidelines:

1. Comply with all clearance requirements stated in Fig. 34

or Fig. 35 per application.

2. Termination or termination kit should be positioned where

vent vapors will not damage plants/shrubs or air condi-

tioning equipment.

3. Termination or termination kit should be positioned so that

it will not be affected by wind eddy, such as inside build-

ing corners, nor by recirculation of flue gases, airborne

leaves, or light snow.

4. Termination or termination kit should be positioned where

it will not be damaged by or subjected to foreign objects

such as stones, balls, etc.

5. Termination or termination kit should be positioned where

vent vapors are not objectionable.

Extended Exposed Sidewall Pipes

Sidewall combustion air pipe termination (direct Vent /2-pipe

system only) and vent pipe termination may be extended beyond

area shown in Fig. 36 or in Fig. 37 per application in outside

ambient by insulating pipe as indicated in Table 6.

1. Determine combustion air pipe diameter (direct Vent /

2-pipe system only) and vent pipe diameter, as stated

above, using total pipe length and number of elbows.

2. Using winter design temperature (used in load calcula-

tions), find appropriate temperature for your application

and furnace model.

3. Determine required insulation thickness for exposed pipe

length(s).

NOTE: Pipe length (ft /M) specified for n_axinmm pipe lengths

located in unconditioned spaces cannot exceed total allowable

pipe length as specified in Table 6.

Vent Termination Kit (Direct Vent /2-Pipe System Only)

NOTE: Always refer to the instructions in termination kit for the

latest version.

Combustion air and vent pipes MUST terminate outside structure.

A factory accessory termination kit must be installed as shown in

Table 8. There are four options of vent/combustion air

termination kits available as shown in Table 8.

NOTE: Combustion air pipe must have the same diameter as

vent pipe.

Concentric Vent /Combustion Air Termination Kit (Direct

Vent /2-Pipe System Only

Determine an appropriate location for termination kit using the

guidelines provided in section "Vent Termination: General" in

this instruction.

1. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in. dia-

meter hole for 3-in. kit.

2. Loosely assemble concentric vent/combustion air termina-

tion components together using instructions in kit.

3. Slide assembled kit with rain shield REMOVED through

hole.

NOTE: Do not allow insulation or other materials to accumulate

inside of pipe assembly when installing it through hole.

Roof terminations-Locate assembly through roof to

appropriate height as shown in Fig. 36 or Fig. 37.

Sidewall terminations-Locate assembly through sidewall

with rain shield positioned no more than 1-in (25 ram).

from wall as shown in Fig. 36 and Fig. 37.

4. Disassemble loose pipe fittings. Clean and cement using

same procedures as used for system piping.

5. Check required dimensions as shown.

Two-Pipe Termination Kit (Direct Vent /2-Pipe System

Determine an appropriate location for termination kit using the

guidelines provided in section "Vent Termination: General" in

this instruction.

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

size being used.

2. Loosely install elbow in bracket and place assembly on

combustion-air pipe.

Roof terminations-Loosely install pipe coupling on

properly cut vent pipe. Coupling nmst be positioned so

bracket will mount as shown in Fig. 38.

For applications using combustion-air pipe option, indic-

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

into 90 ° elbow, making a U-fitting. A 180 ° U-fitting may

be used.

Sidewall terminations-Install bracket as shown in Fig.

36.

For applications using vent pipe option indicated by dashed lines

in Fig. 36, rotate vent elbow 90 ° from position shown in Fig. 36.

3. Disassemble loose pipe fittings. Clean and cement using

same procedures as used for system piping.

4. Check required dimensions as shown in Fig. 36.

(Direct Vent /2-Pipe System ONLY)-When 2 or more 58MVC

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

installed as shown in Fig. 36, but next vent termination must be at

least 36 in. (914 ram) away from first 2 terminations. It is

important that vent terminations be made as shown in Fig. 36 to

avoid recirculation of flue gases.

39

Table6-Maximum Allowable Exposed Vent Pipe Length with Insulation in

Winter Design Temperature Ambient*

UNIT SIZE WINTER DESIGN

TEMPERATURE

20OF/-7oc

060 O°F/-18°C

-20 ° F /-29 ° C

20OF/-7oc

080 O°F/-18°C

-20 ° F /-29 ° C

20OF/-7oc

100 O°F/-18°C

-20 ° F /-29 ° C

20OF/-7oc

OOF/-18oc

-20 ° F /-29 ° C

MAXIMUM PIPE

DIAMETER IN.

(MM)

2 (51)

2 (51)

2 (51)

2 (51)

2 (51)

2 (51)

2-1/2 (64)

2-1/2 (64)

2-1/2 (64)

3 (76)

3 (76)

3 (76)

0

28 (8.5)

11 (6.4)

4 (1.2)

36 (11.0)

16 (4.9)

8 (2.4)

42 (12.8)

18 (5.5)

9 (2.7)

44 (13.4)

18 (5.5)

8 (2.4)

12O

Pipe length (if/m) specified for maximum pipe lengths located in unconditioned spaces.

pipe length as specified in Table 7.

1qnsulation thickness based on R value of 3.5 per in.

INSULATION THICKNESS1"

3/8

50 (15.2)

25 (7.6)

15 (4.6)

65 (19.8)

34 (10.4)

21 (6.4)

70 (21.6)

38 (11.6)

26 (7.0)

70 (21.6)

38 (11.6)

26 (7.0)

1/2

56 (17.1)

29 (8.8)

18 (5.5)

70 (21.3)

69 (11.9)

25 (7.6)

70 (21.3)

43 (13.1)

27 (8.2)

70 (21.3)

44 (13.4)

27 (8.2)

6/4

66 (20.1)

35 (10.7)

26 (7.0)

70 (21.3)

47 (14.6)

31 (9.4)

70 (21.3)

53 (16.2)

34 (10.4)

70 (21.3)

54 (16.5)

35 (10.7)

1

70 (21.6)

41 (12.5)

27 (8.2)

70 (21.6)

55 (16.8)

37 (11.6)

70 (21.6)

61 (18.6)

41 (12.5)

70 (21.3)

63 (19.2)

41 (12.5)

Pipes located in unconditioned space cannot exceed total allowable

40

Table 7 - Maximum Allowable Pipe Length - Ft (M)

UNIT SIZE

ALTITUDE (BTUH)

80,000

80,000

0 to 2000

(0 to 610) 100,000

120,000

UNIT SIZE

ALTITUDE (BTUH)

60,000

80,000

2001 to 3000

(610 to 914) 100,000

120,000

UNIT SIZE

ALTITUDE (BTUH)

60,000

80,000

3001 to 4000

(914 to 1219) 100,000

120,000

UNIT SIZE

ALTITUDE (BTUH)

60,000

80,000

4001 to 5000

(1219 to 1524)$ 100,000

120,000

UNIT SiZE

ALTITUDE (BTUH)

60,000

80,000

5001 to 6000

(1524 to 1829)$ 100,000

120,000

*See notes on next page.

Direct Vent (2-Pipe Only)

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In. (76)

Concentric

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In. (76)

Concentric

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In.

Concentric

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In. (76)

Concentric

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In. (76)

Concentric

Pipe Dia

In, (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2 - 1/2 (84)

2-1/2 one disk

3 (76) one disk

3 (76) one disM-

Pipe Dia

In, (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2 - 1/2 (84)

3 (78) one disk

3 (76) one

diskl-

Pipe Dia

In, (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2 - 1/2 (84)

3 (78) one disk

3 (76) one

diskl-

Pipe Dia

In, (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2 - 1/2 (84)

3 (76) one

diskl-

Pipe Dia

In, (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2 - 1/2 (84)

3 (76) one

disk1-

NUMBER OF 90 ° ELBOWS

123456

50 (15.2) 45 (13.7) 40 (12.9) 35 (10.7) 30 (9.1) 25 (7.6)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

30 (9.14) 25 (7.6) 20 (8.1) 15 (4.6) 10 (3.0) 5 (1.5)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

45 (13.7) 40 (12.9) 35 (10.7) 30 (9.1) 25 (7.6) 20 (6.1)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

10 (3.0) NA NA NA NA NA

35 (10.7) 30 (9.1) 15 (4.8) NA NA NA

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

NUMBER OF 90 ° ELBOWS

123456

45 (13.7) 40 (12.9) 35 (10.7) 30 (9.14) 25 (7.6) 20 (8.1)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

26 (7.9) 21 (8.4) 18 (4.9) 11 (3.4) 8 (1.8) NA

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

40 (12.2) 35 (10.7) 30 (9.1) 25 (7.6) 20 (6.1) 15 (4.6)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

31 (9.4) 26 (7.9) 12 (3.7) NA NA NA

63 (19.2) 62 (18.9) 62 (18.9) 61 (18.6) 61 (18.6) 61 (18.6)

NUMBER OF 90 ° ELBOWS

123456

42 (12.8) 37 (11.2) 32 (9.8) 27 (8.2) 22 (8.7) 17 (5.2)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

25 (7.6) 20 (6.1) 15 (4.6) 10 (3.0) 5 (1.5) NA

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

38 (11.6) 33 (10.1) 28 (8.5) 23 (7.0) 18 (5.5) 13 (4.0)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

29 (8.8) 24 (7.3) 10 (3.0) NA NA NA

59 (18.0) 59 (18.0) 58 (17.8) 57 (17.4) 57 (17.4) 56 (17.0)

NUMBER OF 90 ° ELBOWS

123456

40 (12.2) 35 (10.7) 30 (9.1) 25 (7.6) 20 (8.1) 15 (9.6)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

23 (7.0) 18 (5.5) 13 (4.0) 8 (2.4) NA NA

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 88 (20.7)

36 (11.0) 31 (9.4) 26 (7.9) 21 (8.4) 18 (4.8) 11 (3.4)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

56 (17.1) 55 (18.8) 54 (18.5) 53 (8.2) 52 (15.8) 52 (15.8)

NUMBER OF 90 ° ELBOWS

123456

37 (11.3) 32 (9.8) 27 (8.2) 22 (8.7) 17 (5.2) 12 (3.7)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

22 (6.7) 17 (5.2) 12 (3.7) 7 (2.1) NA NA

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 88 (20.7) 83 (19.2)

33 (10) 28 (8.5) 23 (7.0) 18 (5.5) 13 (4.0) 8 (2.4)

70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3) 70 (21.3)

53 (16.2) 52 (15.8) 50 (15.2) 49 (14.9) 48 (14.6) 47 (14.3)

41

Table 7 -- Maximum Allowable Pipe Length - Ft (M) (Continued)

UNIT SIZE

ALTITUDE (BTUH)

80,000

80,000

6001 to 7000

(1829 to 2134)$

100,000

120,000

UNIT SIZE

ALTITUDE (BTUH)

80,000

80,000

7001 to 8000

(2134 to 2438):[: 100,000

120,000

UNIT SIZE

ALTITUDE (BTUH)

60,000

80,000

800! to 9000

(2438 to 2743)$ 100,000

120,000

UNIT SiZE

ALTITUDE (BTUH)

60,000

80,000

9001 to 10000

(2743 to 3048)$ 100,000

120,000

Disk usage-Unless otherwise stated

Wide radius elbow.

Direct Vent (2-Pipe Only)

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In. (78)

Concentric

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In. (78)

Concentric

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In. (78)

Concentric

Termination

Type

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 2-In. (51)

Concentric

2 Pipe or 3-In. (78)

Concentric

use perforated disk as!

Pipe Dia

In. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2- 1/2 (64)

3 (76) one disk1-

Pipe Dia

In. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2- 1/2 (64)

3 (76) one disk1-

Pipe Dia

In. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2- 1/2 (64)

3 (76) one disk1-

Pipe Dia

In. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2 (51)

2- 1/2 (64)

3 (76) one diskl-

embly (factory-sup

NUMBER OF 90 ° ELBOWS

123456

35 (10.7) 30 (9.1) 25 (7.8) 20 (6.1) 15 (4.8) 10 (3.0)

70 (21.3) 70 (21.3) 68 (20.7) 87 (20.4) 86 (20.1) 84 (19.5)

20 (6.1) 15 (4.8) 10 (3.0) 5 (1.5) NA NA

62

70 (21.3) 70 (21.3) 88 (20.7) 87 (20.4) (18.9) 57 (17.4)

31 (9.4) 26 (7.9) 21 (8.4) 18 (4.9) 11 (3.4) 6 (1.8)

70 (21.3) 70 (21.3) 88 (20.7) 87 (20.4) 68 (20.1) 84 (19.5)

49 (14.9) 48 (14.6) 47 (14.3) 45 (13.7) 44 (13.4) 43 (13.1)

NUMBER OF 90 ° ELBOWS

123456

32 (9.8) 27 (8.2) 22 (8.7) 17 (5.2) 12 (3.7) 7 (2.1)

68 (20.1) 85 (19.8) 83 (19.2) 82 (18.9) 60 (18.3) 59 (18.0)

18 (5.5) 13 (4.0) 8 (2.4) NA NA NA

68 (20.1) 85 (19.8) 83 (19.2) 82 (18.9) 57 (17.4) 52 (15.8)

29 (8.8) 24 (7.3) 19 (5.8) 14 (4.3) 9 (2.7) NA

86 (20.1) 85 (19.8) 83 (19.2) 82 (18.9) 60 (18.3) 59 (18.0)

48 (14.0) 44 (13.4) 43 (13.1) 41 (12.5) 40 (12.2) 38 (11.6)

NUMBER OF 90 ° ELBOWS

123456

30 (9.1) 25 (7.6) 20 (8.1) 15 (4.6) 10 (3.0) 5 (1.5)

82 (18.9) 80 (17.8) 58 (17.7) 56 (17.1) 55 (18.8) 53 (18.2)

17 (5.2) 12 (3.1) 7 (2.1) NA NA NA

82 (18.9) 80 (18.3) 58 (17.7) 56 (17.1) 51 (15.5) 48 (14.0)

27 (8.2) 22 (6.7) 17 (5.2) 12 (3.7) 7 (2.1) NA

82 (18.9) 80 (18.3) 58 (17.7) 56 (17.1) 55 (18.8) 53 (18.2)

43 (13.1) 41 (12.5) 39/11.9) 37 (11.3) 35 (10.7) 34 (10.4)

NUMBER OF 90 ° ELBOWS

123456

27 (8.2) 22 (8.7) 17 (5.2) 12 (3.7) 7 (2.1) NA

57 (17.4) 55 (18.8) 53 (18.2) 51 (15.5) 49 (14.9) 47 (14.3)

15 (4.6) 10 (3.0) 5 (1.5) NA NA NA

57 (17.4) 55 (18.8) 53 (18.2) 51 (15.5) 48 (14.0) 41 (12.5)

24 (7.3) 19 (5.8) 14 (4.3) 9 (2.7) NA NA

57 (17.4 55 (18.8) 53 (18.2) 51 (15.5) 49 (14.9) 47 (14.3)

39 (11.9) 37 (11.3) 35 (10.7) 33 (10.1) 31 (9.5) 29 (8.8)

parts bag).

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

NA-Not Allowed; pressure switch will not make.

NOTES:

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

2. Size both the combustion -air and vent pipe independently, determine the smallest diameter allowed by the table for each pipe, 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. (1.5M) for all applications.

42

Table 8- Vent Termination Kit for Direct Vent/2-Pipe System

DIRECT VENT (2-PIPE) TERMINATION KIT TERMINATION SYSTEM DIAM. OF COMBUSTION AIR AND VENT

PIPES - IN (mm)

2-in. (51 mm) Concentric Vent Kit Single Penetration of Wall or Roof 1, 1-1/2, 2, or 2-1/2 (25, 38, 51,64 mm)

3-in. (76 ram)Concentric Vent Kit Single Penetration of Wall or Roof 2-1/2, 3 or 4 (64, 76, 102 mm)

2-in. (51 ram)Termination Bracket Kit 2- Pipe Termination System 1, 1- 1/2 or 2 (25, 38, 51 mm)

3-in. (76 ram) Termination Bracket Kit 2-Pipe Termination System 2-1/2, 3 or 4 (64, 76, 102 mm)

Multi-venting and Vent Terminations

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

each furnace must be individually vented. NEVER common vent

or breach vent 58MVC furnaces,

/\

OPEN STAND y

PiPE FOR

A/C OR

HUMIDIFIER

DRAIN

TE

A94054

Fig. 45 -Example of Field Drain Attachment

CONDENSATE DRAIN

General

Condensate trap is shipped installed in the blower shelf and

factory connected for UPFLOW applications. Condensate trap

must be RELOCATED for use in DOWNFLOW and

HORIZONTAL applications.

Condensate trap MUST be used for all applications.

An external trap is not required when connecting the field drain

to this condensate trap.

The field drain connection (condensate trap or drain tube

coupling) is sized for l/2-in. CPVC, l/2-in. PVC, or 5/8-in. ID

tube connection.

Drain pipe and fittings must conform to ANSI standards and

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

conform to ASTM D2564 or F493. Primer nmst conform to

ASTM F656. In Canada, use CSA or ULC certified schedule 40

CPVC or PVC drain pipe, fittings, and cement.

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

approved for condensing furnace applications. To avoid

condensate 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 A/C drain must have an external,

field-supplied trap prior to the furnace drain connection. All

drain connections (furnace, A/C, or humidifier) nmst be

terminated into an open or vented drain as close to the respective

equipment as possible to to prevent siphoning of the

equipment's drain.

CONDENSATE

WIRE TIE4

HEAT TAPE_

(3WRAPS MINIMUM)_

Fig. 46 - Condensate Trap Heat Tape

A93036

See Fig. 45 for example of possible field drain attachment using

l/2-in. CPVC or PVC tee for vent and A/C or humidifier drain

connection.

Outdoor draining of the furnace is permissible if allowed by local

codes. Caution should be taken when freezing ambient may

freeze drain pipe and prohibit draining.

PERSONAL INJURY HAZARD

Failure to follow this warning could result in personal

iniury or death.

Caution should be taken to prevent draining where slippery

conditions may cause personal iniuries. Excessive

condensate draining may cause saturated soil conditions

which may result in damage to plants.

Condensate Drain Protection

Freezing condensate left in condensate trap and drain line may

cause cracks, and possible water damage may occur. If freeze

protection is required, use condensate freeze protection accessory

or equivalent 3 to 6 watt per ft. (.3M) at 120v and 40°F (4.4 ° C)

self-regulating, shielded, and waterproof heat tape. See

Installation Instructions supplied with accessory or heat tape

manufacturer's recommendations.

43

g

1. Fold heat tape in half and wrap on itself 3 times.

2. Locate heat tape between sides of condensate trap back.

(See Fig. 46.)

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

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

46.)

4. Wrap field drain pipe with remaining heat tape, approxim-

ately 1 wrap per ft. (.3M).

5. When using field-supplied heat tape, follow heat tape

manufacturer's instructions for all other installation

guidelines.

START-UP, ADJUSTMENT AND SAFETY

CHECK

Step 1-- General

1. Furnace must have a 115-v power supply properly con-

nected and grounded.

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

polarity is incorrect, control status indicator light flashes rapidly

and furnace does not operate.

2. Thermostat wire connections at terminals R, W/W1, G,

and Y/Y2 must be made at 24-v terminal block on furnace

control.

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

in. wc), but must be no less than 0.16 psig (4.5-in. wc).

4. Blower access panel must be in place to complete 115-v

electrical circuit to furnace.

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit

operation or ped\,rmance satisfaction.

These furnaces are equipped with a manual reset limit

switch in burner box. This switch opens and shuts off

power to the gas valve if an overheat condition (flame

rollout) occurs in burner enclosure. Correct inadequate

combustion-air supply or improper venting condition

before resetting switch. DO NOT jumper this switch.

Before operating furnace, check flame rollout manual reset switch

for continuity. If necessary, press button to reset switch.

Step 2 -- Select Setup Switch Positions

Air Conditioning (A/C) Setup Switches

The air conditioning setup switches are used to match furnace

airflow to cooling unit used.

To set the desired cooling airflow:

1. Remove main furnace door and blower access panel.

2. Locate A/C setup switches on furnace control. (See Fig.

33.)

3. Determine air conditioning tonnage used.

4. Use Fig. 47 or wiring schematic to determine proper setup

position of A/C switches. (See Fig. 48 and Fig. 49.)

NOTE: Excessive airflow caused by improper A/C switch setup

may cause condensate blow-off in cooling mode.

5. Replace main furnace door and blower access panel.

NOTE: EAC-1 terminal is energized whenever blower operates.

HUM terminal is only energized when blower is energized in

heating.

Continuous Fan (CF) Setup Switches

The CF setup switches are used to select desired airflow when

thermostat is in continuous fan mode or to select low-cooling

airflow for two-speed cooling units. This setup feature allows

continuous fan airflow or low-cooling airflow to be adjusted. To

set desired continuous fan airflow or low-cooling airflow:

1. Remove main furnace door and blower access panel.

2. Locate CF setup switches on furnace control. (See Fig.

33.)

3. Determine desired continuous fan airflow or low-cooling

airflow.

4. Use Fig. 47 or wiring schematic to determine proper setup

position of CF switches. (See Fig. 48 and Fig. 49.)

5. Replace main furnace door and blower access panel.

AIR CONDITIONING (A/C) OR CONTINUOUS-FAN (CF)

AIRFLOW SELECTION CHART

BASED ON 350 CFM/TON (SETUP SWITCH SW1-5 OFF)

SETUP SWITCH SW3 POSITIONS

MODEL

m_-'-i_ mll:_o, mll:_co mll:_co ml---l_ mr,,-l_ mr-leo mr,,-l¢_

060, 3.5T080 DEF. 5252 700 875 10501 1225 1225 1225

5T080, 100 DEF. 7002 875 1050 1225 1400 1750_ 1750

120 DEF. 700 8752 1050 1225 1400 17501 2100

BASED ON 400 CFM/TON (SETUP SWITCH SWl-5 ON)

SETUP SWITCH SW3 POSITIONS

MODEL

q,---,,_%--,,,.,°E::a_.o,_..,,_

mi._i_ ml,--i_ _l--ic,_ ml'--i¢..,o ml[_lc,: mr--i_, _l'--io_ mr--ioj

060, 3.5T080 DEF. 6002 800 1000 1200_ 1400 1400 1400

5T080, 100 DEF. 8002 1000 1200 1400 1600 2000_ 2000

120 DEF. 800 10002 1200 1400 1600 2000_ 2100

DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION

DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHESARE IN OFF POSITION

SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM

A07424

Fig. 47 - A/C or CF Airflow Selection Chart Based on 350

and 400 CFM/Ton

Setup Switches (SW1)

The furnace control has 8 setup switches that may be set to meet

the application requirements. To set these setup switches for the

@propriate requirement:

1. Remove main furnace door and blower access panel.

2. Locate setup switches on furnace control. (See Fig. 33.)

3. See Table 9 for setup switch description. (See Fig. 48 and

Fig. 49.)

4. Replace main furnace door and blower access panel.

NOTE: If a bypass humidifier is used, setup switch SW1-3

(Low Heat Rise Adjust) should be in ON position. This

compensates for the increased temperature in return air resulting

from bypass.

NOTE: If modulating dampers are used, blower motor

automatically compensates for modulating dampers.

Additional Setup Switches (SW4)

The furnace control has 3 additional setup switches labeled SW4.

(See Fig. 33.) Setup switch SW4-2 can be used to lock the

furnace into medium heat. When setup switch SW4-2 is ON the

furnace will remain at medium heat until W/W1 is de-energized

to end a heating cycle or when both W/W1 and W2 are energized.

When both W/W1 and W2 are energized the furnace will run at

high heat. The other 2 setup switches are currently not used for

anything. When setup switch SW4-2 is ON it will over ride setup

switch SW1-2 if it is ON. To activate setup switch SW4-2:

1. Remove main furnace door and blower access panel.

44

2.Locate setup switch SW4 on furnace control. (See Fig.

33.)

3. See Table 5 for setup switch description. (See Fig. 40 and

Fig. 49.)

4. Replace main Nrnace door and blower access panel.

Prime Condensate Trap with Water

UNIT OPERATION HAZARD

Failure to follow this caution may result in internfittent unit

operation or performance satisfaction.

Condensate trap must be PRIMED or proper draining may

not occur. The condensate trap has two internal chambers

which can ONLY be primed by pouring water into the

inducer drain side of condensate trap.

A04001

Fig. 48 - Example of Setup Switch in Off Position

45

i

E

o>

8

TO 11SVAC [INN_ N_ SCHN'I]C N I

_---_ ::::::: ........................................................................................................................................

[I.....I :

.......K_, _;_ ............._,

...............................................................................2 _/ \

.........................................................;_I _ -\

/L.... z

I

: ....................._,_._ ...............................................

Fig. 50 - Inducer Housing Drain 1hbe

A99118 A01050

Fig. 51 - Filling Condensate Trap

Table 9 -Furnace Setup Switch Description

SETUP SWITCH NORMAL

SWITCH NAME DESCRIPTION OF USE

NO. POSITION

Turn ON to retrieve up to 7 stored status codes for troubleshooting

SW1 - 1 Status Code Recovery OFF assistance when R thermostat lead is disconnected.

When SW1-2 and SW4-2 are OFF allows step-modulating opera-

Low Heat Only tion with a single stage thermostat. Turn ON when using 2 stage

SW1-2 (Adaptive Heat Mode when OFF

OFF) thermostat to allow Low Heat operation when R to W/W1 closes and

High Heat operation when R to W/W1 and W2 close.

Turn ON to increase Low and Medium Heat airflow by 18 percent.

This compensates for increased return air temperature caused with

SW1-3 Low/Medium Heat Rise Adjust OFF bypass humidifier. This also increases the Low and Medium Heat

inducer speed 15 percent

Turn ON to decrease Low Heat airflow 9 percent,

Comfort/Efficiency Adjust- ON Medium Heat airflow 7 percent,

SW1-4 ment and High Heat airflow 15 percent for maximum comfort.

SW1-5 CFM per ton adjust OFF Turn ON for 400 CFM per ton. Turn OFF for 350 CFM per ton.

Turn ON to initiate Component Self Test for troubleshooting

SW1-6 Component Self Test OFF assistance when R thermostat lead is disconnected. Turn OFF

when Self Test is completed.

SW1-7 Blower OFF delay ON or OFF Blower Off Delay time.

and SW1-8 See Table 6.

Medium Heat Only (Adaptive When SW1-2 and SW4-2 are OFF allows step-modulating opera-

tion with a single stage thermostat. Turn ON when using 2 stage

SW4-2 Heat Mode OFF

when OFF) thermostat to allow Medium Heat operation when R to W/W1 closes

and High Heat operation when R to W/W1 and W2 close.

1. Remove upper inducer housing drain connection cap. (See

Fig. 500

2. Connect field-supplied 1/2-in. ID tube to upper inducer

housing drain connection.

3. Insert field-supplied flmnel into tube.

4. Pour 1 quart of water into flmnel/tube. Water should run

through inducer housing, overfill condensate trap, and

flow into open field drain. (See Fig. 51.)

47

Purge Gas Lines

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

been made and check for leaks.

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in a fire,

explosion, personal iniury, or death.

Never purge a gas line into a combustion chamber. Never

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

available soap solution made specifically for the detection

of leaks to check all connections.

Step 3 -- Sequence of Operation

UNIT OPERATION HAZARD

Failure to follow this caution may result in intermittent unit

operation.

Furnace control must be grounded for proper operation, or

control will lock out. Control is grounded through

green/yellow wire routed to gas valve and burner box

screw.

Using the schematic diagram (See Fig. 48), follow the sequence

of operation through the different modes. Read and follow the

wiring diagram very carefully. ! !

NOTE: If a power interruption occurs during a call for heat

(W/W1 or W/Wl-and-W2), the control will start a 90-second

blower-only ON period two seconds after power is restored, if

the thermostat is still calling for gas heating. The amber LED

light will flash code 12 during the 90-second period, after which

the LED will be ON continuous, as long as no faults are detected.

After the 90-second period, the furnace will respond to the

thermostat normally.

The blower door nmst be installed for power to be conducted

through the blower door interlock switch ILK to the furnace

control CPU, transformer TRAN, inducer motor IDM, blower

motor BLWM, hot surface igniter HSI, throttling valve TV, and

gas valve GV.

Sin_le-Sta_e Thermostat and Steo-Modulatin_ Heatin_

(Adaptive Mode)

See Fig. 29 or Fig. 59 for thermostat connections.

NOTE: Low-heat only switch SWl-2 selects the low-heat only

operation mode when ON. Medium-heat only switch SW4-2

selects medium-heat only operation mode when ON. If both

switches are ON the furnace control will default to medium-heat.

If either or both switches are ON the furnace control will operate

at two-stages only as referenced in Section 2 below. If both

switches are OFF the furnace control will operate in the adaptive

heating mode in response to a call for heat. (See Fig. 33.) When

the W2 thermostat terminal is energized it will always cause

high-heat operation as long as the R to W circuit is closed,

regardless of the setting of the low-heat or medium-heat only

switches.

This furnace can operate as a step-modulating furnace with a

single-stage thermostat because the furnace control CPU includes

a programmed adaptive sequence of controlled operation, which

selects low-heat, medium-heat, or high-heat operation. This

selection is based upon the stored history of the length of

previous gas-heating periods of the single-stage thermostat.

The furnace will start up in either medium-, or high-heat. The

furnace will operate in low-heat after starting and operating for 1

minute at medium-heat before transitioning to low-heat. The

furnace control CPU determines the combined low-heat and

medium-heat on-time (from 0 to 16 minutes) which is permitted

before switching to high heat.

If the power is interrupted, the stored history is erased and the

furnace control CPU will select medium-heat for 1 minute,

low-heat for 15 minutes and then switch to high-heat, as long as

the thermostat continues to call for heat. Subsequent selection is

based on stored history of the thermostat cycle times.

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

The furnace control CPU performs a self-check, verifies the

low-heat and medium-heat pressure switch contacts LPS and

MPS are open, then de-energizes the HPSR relay to close the NC

contact.

1. Inducer Prepurge Period - The furnace control CPU turns

on inducer motor IDM and slowly increases the inducer

motor speed. After the low-heat pressure switch LPS

closes the furnace control CPU continues to increase the

inducer motor speed until the medium-heat pressure

switch MPS closes. When the medium-heat pressure

switch MPS closes, throttling valve TV is energized, in-

ducer motor RPM is noted by the furnace control CPU,

and a 25-second prepurge period begins. The RPM is

used to evaluate vent system resistance. This evaluation is

then used to determine the required RPM necessary to op-

erate the inducer motor during medium-heat prepurge, the

first minute of medium-heat mode, and low-heat mode.

NOTE: The heat cycle can start in either high- or medium-heat.

If a high-heat cycle is initiated, the furnace control CPU will

continue to increase the inducer motor speed after the

medium-heat pressure switch MPS closes. When the

medium-heat pressure switch closes, throttling valve TV is

energized, inducer motor RPM is noted by the furnace control

CPU, and a 25-second prepurge period begins. The RPM is used

to evaluate vent system resistance. This evaluation is then used to

determine the required RPM necessary to operate the inducer

motor in high-heat pre-purge, and high-heat mode.

2. Igniter Warm-Up -- At the end of the prepurge period,

the Hot-Surface Igniter HSI is energized for a 17-second

igniter warm-up period.

3. Trial-For-Ignition Sequence -- When the igniter warm-

up period is completed the main gas valve relay contact

GVR closes to energize the gas valve solenoid GV-M.

The gas valve solenoid GV-M permits gas flow to the

burners where it is ignited. Five seconds after the GVR

closes, a 2- second Flame-Proving period begins. The

HSI igniter will remain energized until flame is sensed or

until the 2-second flame proving period begins.

If the furnace control CPU selects high-heat operation, the

high-heat gas valve solenoid GV-HI is energized when

the high-heat pressure switch HPS closes.

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

flame-proving sensor electrode FSE, the furnace control

CPU begins the blower-ON delay period and continues to

hold the gas valve GV-M open. If the burner flame is not

proved within two seconds, the furnace control CPU will

close the gas valve GV-M, and the furnace control CPU

will repeat the ignition sequence for up to three more Tri-

als-For-Ignition before going to Ignition-Lockout. Lock-

out will be reset automatically after three hours, by mo-

mentarily interrupting 115 vac power to the furnace, or by

interrupting 24 vac power at SEC1 or SEC2 to the furnace

control CPU (not at W/Wl, G, R, etc.).

If flame is proved when flame should not be present, the

furnace control CPU will lock out of Gas-Heating mode

48

andoperatethe inducer motor IDM at full speed until

flame is no longer proved.

5. Inducer Speed Change -- If the cycle starts in medium

heat, the furnace control CPU reduces the inducer speed

slightly after flame sense. If cycle starts in high-heat, the

furnace control CPU increases the inducer speed after

flame sense. The reduction in speed in medium-heat is to

optimize combustion for maximum efficiency.

6. Blower-On delay -- If the burner flame is proven the

blower-ON delay for medium-heat and high-heat are as

follows:

Medium-heat -- 60 seconds after the gas valve GV-M is

opened the blower motor BLWM is turned ON at low- or

medium-heat airflow.

High-heat -- 35 seconds after the gas valve GV-M is

opened the BLWM is turned ON at high-heat airflow.

Simultaneously, the humidifier terminal HUM and elec-

tronic air cleaner terminal EAC-I are energized and re-

main energized throughout the heating cycle.

7. Switching from Medium- to Low-Heat -- If the fur-

nace control switches from medium-heat to low-heat, the

furnace control will turn the blower ON at low-heat air-

flow, energize the HPSR relay to open the NC contact, and

slowly decrease the inducer motor speed. When the HPSR

relay is energized and the NC contact opens the throttling

valve TV is deenergized and the gas flow reduces to low-

heat rate.

Switching from Low- to Medium-Heat -- If the fur-

nace control CPU switches from low-heat to medium-

heat, the furnace control CPU will de-energize the HPSR

relay to close the NC contact and slowly increase the in-

ducer motor speed until the medium-heat pressure switch

MPS closes. When the medium-heat pressure switch MPS

closes, the throttling valve solenoid TV is energized and

the inducer motor RPM is noted by the furnace control

CPU. The RPM is used to evaluate vent system resistance.

This evaluation is then used to determine the required

RPM necessary to operate the inducer motor in medium-

heat and high-heat mode. The blower motor BLWM will

transition to medium-heat airflow five seconds after the

furnace control CPU switches from low-heat to medium-

heat.

Switching from Low- to High-Heat -- If the furnace

control CPU switches from low-heat to high-heat, the fur-

nace control CPU will de-energize the HPSR relay to

close the NC contact and slowly increase the inducer mo-

tor speed until the medium-heat pressure switch MPS

closes. When the medium-heat pressure switch MPS

closes, the throttling valve solenoid TV is energized and

the inducer motor RPM is noted by the furnace control

CPU. The RPM is used to evaluate vent system resistance.

This evaluation is then used to determine the required

RPM necessary to operate the inducer motor in medium-

and high-heat mode. The blower motor BLWM will trans-

ition to high-heat airflow five seconds after the furnace

control CPU switches from low-heat to high-heat. As the

inducer RPM gradually increases the high-heat pressure

switch HPS closes and the gas valve solenoid GV-HI is

energized.

Switching from Medium- to High-Heat -- If the fur-

nace control CPU switches from medium-heat to high-

heat, the furnace control CPU will gradually increase the

inducer motor speed to the required high-heat RPM. The

blower motor BLWM will transition to high-heat airflow

five seconds after the furnace control CPU switches from

medium-heat to high heat. As the inducer RPM gradually

increases the high-heat pressure switch HPS closes and

the gas valve solenoid GV-HI is energized.

Switching from High- to Medium- or Low-Heat --

The furnace control CPU will not switch from high-heat

to medium- or low-heat while the thermostat R to W cir-

cuit is closed when using a single-stage thermostat.

8. Blower-Off Delay -- When the thermostat is satisfied,

the R to W circuit is opened, de-energizing the gas valve

GV-M, stopping gas flow to the burners, and de-energiz-

ing the throttling valve TV, and humidifier terminal HUM.

The inducer motor IDM will remain energized for a

15-second post-purge period. The blower motor BLWM

and air cleaner terminal EAC-I will remain energized at

low-heat airflow or transition to low-heat airflow for 90,

120, 150, or 180 seconds (depending on selection at

blower-OFF delay switches). The furnace control CPU is

factory-set for a 120-second blower- OFF delay.

Two-Stage Thermostat and Two-Stage Low /High Heating

See Fig. 58 for thermostat connections.

NOTE: In this mode the low-heat only switch SWI-2 must be

ON to select the low-heat only operation mode in response to

closing the thermostat R to WI circuit. Closing the thermostat R

to Wl-and-W2 circuits always causes high-heat operation,

regardless of the setting of the low-heat only switch.

The furnace will start up in either medium-, or high-heat. The

furnace will operate in low-heat after starting and operating for 1

minute at medium-heat before transitioning to low-heat.

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

for low-heat or closing the R to Wl-and-W2 circuits for

high-heat. The furnace control performs a self-check, and

verifies the low-heat and medium-heat pressure switch contacts

LPS and MPS are open, then de-energizes the HPSR relay to

close the NC contact.

The start up and shut down functions and delays described above

apply to the 2-stage low/high heating mode as well, except for

switching from high- to low-heat.

1. Switching from High- to Low-Heat -- If the thermostat

R to W2 circuit opens, and the R to Wl circuit remains

closed, the furnace control CPU will gradually decrease

the inducer motor speed to the required medium-heat

RPM. When the inducer motor IDM reduces pressure suf-

ficiently, the high heat pressure switch HPS will open and

the high-heat gas valve solenoid GV-HI will be de-ener-

gized. The gas valve solenoid GV-M will remain ener-

gized as long as the low-heat pressure switch LPS remains

closed. When the inducer motor speed gets within 15% of

the required medium-heat RPM the furnace control CPU

will start a 5 second blower airflow change delay. After the

5 second blower airflow change delay is completed the

blower airflow will transition to low-heat airflow. At this

point the furnace control CPU will energize the HPSR re-

lay to open the NC contact and slowly decrease the in-

ducer motor speed to the required low-heat RPM. When

the HPSR relay is energized and the NC contact opens the

throttling valve TV is de-energized and the gas flow re-

duces to low-heat rate. When the inducer motor IDM re-

duces pressure sufficiently, the medium-heat pressure

switch MPS will open.

Two-Stage Thermostat and Two-Stage Medium/High

Heating

See Fig. 58 for thermostat connections.

NOTE: In this mode the medium-heat only switch SW4-2 must

be ON to select the medium-heat only operation mode in

response to closing the thermostat R to WI circuit. Closing the

thermostat R to Wl-and-W2 circuits always causes high-heat

operation, regardless of the setting of the medium-heat only

switch.

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

for medium-heat or closing the R to Wl-and-W2 circuits for

49

high-heat.Thefurnacecontrolperformsa self-check,and

verifiesthelow-heatandmedium-heatpressureswitchcontacts

LPSandMPSareopen,thende-energizestheHPSRrelayto

closetheNCcontact.

Thestartupandshutdownfunctionsanddelaysdescribedabove

applytothe2-stagemedium/highheatingmodeaswell,except

forswitchingfromhigh-tomedium-heat.

1.SwitchingfromHigh-to Medium-Heat -- If the ther-

mostat R to W2 circuit opens, and the Rto Wl circuit re-

mains closed, the furnace control CPU will gradually de-

crease the inducer motor speed to the required

medium-heat RPM. When the inducer motor IDM re-

duces pressure sufficiently, the high heat pressure switch

HPS will open and the high-heat gas valve solenoid GV-

HI will be de-energized. The gas valve solenoid GV-M

will remain energized as long as the low-heat pressure

switch LPS remains closed. When the inducer motor speed

gets within 15% of the required medium-heat RPM the

furnace control CPU will start a 5 second blower airflow

change delay. After the 5 second blower airflow change

delay is completed the blower airflow will transition to

medium-heat airflow.

Cooling Mode

The thermostat "calls for cooling."

2. Single-Speed Cooling

See Fig. 29 for thermostat connections.

The thermostat closes the R to G-and-Y circuits. The R to

Y circuit starts the outdoor unit, and the R to G-and-Y/Y2

circuits start the furnace blower motor BLWM on cooling

airflow. Cooling airflow is based on the A/C selection

shown in Fig. 47.

The electronic air cleaner ternfinal EAC-1 is energized

with 115 vac when the blower motor BLWM is operating.

When the thermostat is satisfied, the R to G-and-Y cir-

cuits are opened. The outdoor unit will stop, and the fur-

nace blower motor BLWM will continue operating at

cooling airflow for an additional 90 seconds. Jumper

Y/Y2 to DHUM to reduce the cooling off-delay to 5

seconds. (See Fig. 33.)

3. Single-Stage Thermostat and Two-Speed Cooling (Ad-

aptive Mode)

See Fig. 59 for thermostat connections.

This furnace can operate a two-speed cooling unit with a

single-stage thermostat because the furnace control CPU

includes a programmed adaptive sequence of controlled

operation, which selects low-cooling or high-cooling op-

eration. This selection is based upon the stored history of

the length of previous cooling period of the single-stage

thermostat.

NOTE: The air conditioning relay disable jumper ACRDJ nmst

be connected to enable the adaptive cooling mode in response to

a call for cooling. (See Fig. 33.) When in place the furnace

control CPU can turn on the air conditioning relay ACR to

energize the Y/Y2 ternfinal and switch the outdoor unit to

high-cooling.

The furnace control CPU can start up the cooling unit in either

low- or high-cooling. If starting up in low-cooling, the furnace

control CPU deternfines the low-cooling on-time (from 0 to 20

nfinutes) which is pernfitted before switching to high-cooling.

If the power is interrupted, the stored history is erased and the

furnace control CPU will select low-cooling for up to 20 nfinutes

and then energize the air conditioning relay ACR to energize the

Y/Y2 ternfinal and switch the outdoor unit to high-cooling, as

long as the thermostat continues to call for cooling. Subsequent

selection is based on stored history of the thermostat cycle times.

The wall thermostat "calls for cooling", closing the R to G and-

Y circuits. The R to Y1 circuit starts the outdoor unit on

5O

low-cooling speed, and the R to G-and-Y1 circuits starts the

furnace blower motor BLWM at low-cooling airflow which is the

true on-board CF selection as shown in Fig. 47.

If the furnace control CPU switches from low-cooling to high

cooling, the furnace control CPU will energize the air

conditioning relay ACR. When the air conditioning relay ACR is

energized the R to Yl-and-Y2 circuits switch the outdoor unit to

high-cooling speed, and the R to G-and-Y1- and-Y/Y2 circuits

transition the furnace blower motor BLWM to high-cooling

airflow. High-cooling airflow is based on the A/C selection

shown in Fig. 47.

NOTE: When transitioning from low-cooling to high-cooling

the outdoor unit compressor will shut down for 1 nfinute while

the furnace blower motor BLWM transitions to run at

high-cooling airflow.

The electronic air cleaner ternfinal EAC-1 is energized with 115

vac whenever the blower motor BLWM is operating.

When the thermostat is satisfied, the R to G-and-Y circuit are

opened. The outdoor unit stops, and the furnace blower BLWM

and electronic air cleaner ternfinal EAC-1 will remain energized

for an additional 90 seconds. Jumper Y1 to DHUM to reduce the

cooling off-delay to 5seconds. (See Fig. 33.)

4. Two-Stage Thermostat and Two-Speed Cooling

See Fig. 58 for thermostat connections.

NOTE: The air conditioning relay disable jumper ACRDJ nmst

be disconnected to allow thermostat control of the outdoor unit

staging. (See Fig. 33.)

The thermostat closes the R to G-and-Y1 circuits for low cooling

or closes the R to G-and-Yl-and-Y2 circuits for high cooling.

The R to Y1 circuit starts the outdoor unit on low cooling speed,

and the R to G-and-Y1 circuit starts the furnace blower motor

BLWM at low-cooling airflow which is the true on-board CF

selection as shown in Fig. 47. The R to Yl-and-Y2 circuits start

the outdoor unit on high-cooling speed, and the R to

G-and-Y/Y2 circuits start the furnace blower motor BLWM at

high-cooling airflow. High-cooling airflow is based on the A/C

selection shown in Fig. 47.

The electronic air cleaner ternfinal 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-Yl-and-Y2 circuits are opened. The outdoor unit stops,

and the furnace blower BLWM and electronic air cleaner ternfinal

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. 33.)

Thermidistat Mode

See Fig. 52-55 for thermostat connections.

The dehumidification output, DHUM on the Thermidistat should

be connected to the furnace control thermostat terminal DHUM.

When there is a dehumidify demand, the DHUM input is

activated, which means 24 vac signal is removed from the

DHUM input terminal. In other words, the DHUM input logic is

reversed. The DHUM input is turned ON when no dehumidify

demand exists. Once 24 vac is detected by the furnace control on

the DHUM input, the furnace control operates in Thernfidistat

mode. If the DHUM input is low for more than 48 hours, the

furnace control reverts back to non-Thernfidistat mode.

The cooling operation described above also applies to operation

with a Thernfidistat. The exceptions are listed below:

1. Low cooling - When the R to G-and-Yl circuit is closed

and there is a demand for dehunfidification, the furnace

blower motor BLWM will drop the blower airflow to 86%

of low cooling airflow which is the true on-board CF se-

lection as shown in Fig. 47.

2. High cooling - When the R to G-and Y/Y2 circuit is

closed and there is a demand for dehunfidification, the fur-

naceblowermotorBLWMwilldroptheblowerairflowto

86%of high-coolingairflow.High-coolingairflowis

basedontheA/CselectionshowninFig.47.

3.Coolingoff-delay- Whenthe"callforcooling"issatis-

fiedandthereisademandfordehumidification,thecool-

ingblower-offdelayisdecreasedfrom90secondsto5

seconds.

Super Dehumidify Mode

Super-Dehumidify mode can only be entered if the furnace

control is in the Thermidistat mode and there is a demand for

dehumidification. The cooling operation described in item 4.

above also applies to operation with a Thermidistat. The

exceptions are listed below:

1. Low cooling - When the R to Y1 circuit is closed, R to G

circuit is open, and there is a demand for dehumidification,

the furnace blower motor BLWM will drop the blower air-

flow to 65% of low-cooling airflow for a maximum of 10

minutes each cooling cycle or until the R to G circuit

closes or the demand for dehumidification is satisfied.

Low-cooling airflow is the true on-board CF selection as

shown in Fig. 47.

2, High cooling - When the R to Y/Y2 circuit is closed, R to

G circuit is open, and there is a demand for dehumidifica-

tion, the furnace blower motor BLWM will drop the

blower airflow to 65% of high-cooling airflow for a max-

imum of 10 minutes each cooling cycle or until the R to G

circuit closes or the demand for dehumidification is satis-

fied. High-cooling airflow is based on the A/C selection

shown in Fig. 47.

3. Cooling off-delay - When the "call for cooling" is satis-

fied and there is a demand for dehumidification, the cool-

ing blower-off delay is decreased from 90 seconds to 5

seconds.

Continuous Blower Mode

When the Rto G circuit is closed by the thermostat, the blower

motor BLWM will operate at continuous blower airflow.

Continuous blower airflow selection is initially based on the CF

selection shown in Fig. 47. Factory default is shown in Fig. 47.

Terminal EAC-1 is energized as long as the blower motor

BLWM is energized.

During a call for heat, the furnace control CPU will transition the

blower motor BLWM to continuous blower airflow, low-heat

airflow, or the mid-range airflow, whichever is lowest. The

blower motor BLWM will remain ON until the main burners

ignite then shut OFF and remain OFF for the blower-ON delay

(60 seconds in medium heat, and 35 seconds in high-heat),

allowing the furnace heat exchangers to heat up more quickly,

then restarts at the end of the blower-ON delay period at

low-heat, medium-heat, or high-heat airflow respectively.

The blower motor BLWM will revert to continuous-blower

airflow after the heating cycle is completed. In high-heat, the

furnace control CPU will drop the blower motor BLWM to

low-heat airflow during the selected blower-OFF delay period

before transitioning to continuous-blower airflow.

When the thermostat "calls for low-cooling", the blower motor

BLWM will operate at low-cooling airflow. When the thermostat

is satisfied, the blower motor BLWM will operate an additional

90 seconds at low-cooling airflow before transitioning back to

continuous-blower airflow.

When the thermostat "calls for high-cooling", the blower motor

BLWM will operate at high cooling airflow. When the thermostat

is satisfied, the blower motor BLWM will operate an additional

90 seconds at high-cooling airflow before transitioning back to

continuous-blower airflow.

When the R to G circuit is opened, the blower motor BLWM will

continue operating for an additional 5seconds, if no other

flmction requires blower motor BLWM operation.

Continuous Blower Speed Selection from Thermostat

To select different continuous-blower airflows from the room

thermostat, momentarily turn off the FAN switch or push button

on the room thermostat for 1-3 seconds after the blower motor

BLWM is operating. The furnace control CPU will shift the

continuous-blower airflow from the factory setting to the next

highest CF selection airflow as shown in Fig. 47. Momentarily

turning off the FAN switch again at the thermostat will shift the

continuous-blower airflow up one more increment. If you repeat

this procedure enough you will eventually shift the continuous

blower airflow to the lowest CF selection as shown in Fig. 47.

The selection can be changed as many times as desired and is

stored in the memory to be automatically used following a power

interruption.

Heat Pump

See Fig. 54-57 for thermostat connections. When installed with

a heat pump, the furnace control automatically changes the timing

sequence to avoid long blower off times during demand defrost

cycles. Whenever W/W1 is energized along with Y1 or Y/Y2, the

furnace control CPU will transition to or bring on the blower

motor BLWM at cooling airflow, low-heat airflow, or the

mid-range airflow, whichever is lowest. The blower motor

BLWM will remain on until the main burners ignite then shut

OFF and remain OFF for 25 seconds before coming back on at

heating airflow. When the W/W1 input signal disappears, the

furnace control begins a normal inducer post-purge period while

changing the blower airflow. If Y/Y2 input is still energized the

furnace control CPU will transition the blower motor BLWM

airflow to cooling airflow. If Y/Y2 input signal disappears and

the Y1 input is still energized the furnace control CPU will

transition the blower motor BLWM to low-cooling airflow. If

both the Y1 and Y/Y2 signals disappear at the same time, the

blower motor BLWM will remain on at low-heat airflow for the

selected blower-OFF delay period. At the end of the

blower-OFF delay, the blower motor BLWM will shut OFF

unless G is still energized, in which case the blower motor

BLWM will operate at continuous blower airflow.

Component Test

The furnace features a component test system to help diagnose a

system problem in the case of a component failure. To initiate the

component test procedure, ensure that there are no thermostat

inputs to the control and all time delays have expired. Turn on

setup switch SWl-6. (See Fig. 33)

NOTE: The component test feature will not operate if the control

is receiving any thermostat signals or until all time delays have

expired.

The component test sequence is as follows:

1. The furnace control CPU turns the inducer motor IDM

ON at medium speed and keeps it ON through step 3.

2. After waiting 15 seconds the furnace control CPU turns

the hot surface igniter ON for 15 seconds, then OFF.

3. The furnace control CPU then turns the blower motor

BLWM ON at mid-range airflow for 15 seconds, then

OFF.

4. After shutting the blower motor BLWM OFF the furnace

control CPU shuts the inducer motor IDM OFF.

NOTE: The EAC terminals are energized when the blower is

operating.

After the component test is completed ,1 or more status codes

(11, 25, 41, or 42) will flash. See Service Label on blower access

panel or Service/Status Code Instructions for explanation of

status codes.

NOTE: To repeat component test, turn setup switch SWl-6 to

OFF and then back ON.

51

'H4ERMIDISTAT STEP M©D S NGLD-SPEED

FURNACE AIR C©NOtTIONER

HEAT STAGE 1 ................

COOL STAGE I

I

HU:M ©IP;ER I_._ "

(24 VAC) ....

O{JTDOOR

SEI';SOR

See motes 2i 5 7 10 a_d II

A06678

Fig. 52 - Step-Modulating Furnace with Single-Speed Air

Conditioning

TH£RM: DIS_'AT STEP, MOD, TW%_,SP_ED

_ URNACE AR CONOH iONER

4_AiT STAGE 2

COOL STAGE

H_AT STAGE

COOL STAGE 2

AN

24 ",/AC H©*[

OEHUM_D_:Y

24 VAC CGMM

J '7¢2 t

j ........

.4_ I

.4_ iI

SENSOR

See r_otes 2 5 8, I0, i I, a#d 12

SH£RN DISTAT 8TSP-MOD

?URNACE

$aNGLE SPE_D

_q£AT PUMP

,_2_oTE!.

H£AT STAGE 2.......................................

PAN _ .....................

24 VAC HOT _ ..............

CONNBCSIO .,

See noes I 2 4, 6, 7, 9, 10, 1t _nd _5

A06680

Fig. 54 - Step Modulating Furnace with Single-Speed Heat

Pump (Dual Fuel)

TH_RM DiS rA'l srsP_Moo TWO-SPEED

FURNAC_ HEAT PUMP

A06679

Fig. 53 -Step Modulating Furnace with Two-Speed Air

Conditioner

A06681

Fig. 55 -Step Modulating Furnace with Two-Speed Heat

Pump (Dual Fuel)

52

DUAL _-UEL

T_ RMOSTAT

STEP,MOD Sling8_S_EED TWOSTAGE STEP,,MOD_ TWOSPEED

FUR:NAC£ HEAT FUMP THERMOSTAT FURNACE AiRCONDITIONER

Seenet_si,2 4, 11 I4 15 ae16

A06682

Fig. 56 - Step Modulating Furnace with Single-Speed Heat

Pump

NOTE11 ).

NOTEi2 "'_]

Seenoie_2, _1.an_12

A06684

Fig. 58 - Two-Stage Thermostat with Step Modulating

Furnace and Two-Speed Air Conditioner

DUAL F_Et ST_P.MOD T¢/,O_BPE_D

fHERMO TAT FURNACE HEAl P_J_P

A06683

Fig. 57 - Dual Fuel thermostat with Step-Modulating

Furnace and Two-Speed Heat Pump

SINGLEoSTAGE STEP,MOD TWOoSPEED

THERMOSTAT FURNACE AIRCONDITIONER

HUN

See_'_ote2

A06685

Fig. 59 - Single-Stage Thermostat with Step Modulating

Furnace and Two-Speed Air Conditioner

53

NOTE: Reference Fig. 52-59:

1. Heat pump MUST have a high pressure switch for dual

fuel applications.

2. Refer to outdoor equipment Installation Instructions for

additional information 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.l on Thermidistat should be set in OFF po-

sition for air conditioner installations. This is factory de-

fault.

6. Dip switch No. 1 on Thermidistat should be set in ON po-

sition for heat pump installations.

7. Dip switch No. 2 on Thermidistat should be set in OFF

position for single-speed compressor operation. This is

factory default.

8. Dip switch No. 2 on Thermidistat should be set in ON po-

sition for two-speed compressor operation.

9. Configuration Option No. 10 "Dual Fuel Selection" must

be turned ON in all dual fuel applications.

10. NO connection should be made to the furnace HUM ter-

minal when using a Thermidistat.

11. Optional connection. If wire is connected to W2 on fur-

nace control board, either dip switch SWI-2 or SW4-2 on

furnace control should be set in ON position to allow

Thernaidistat/Thernmstat to control furnace at 2 stages

Low/High or Medium/High.

12. Optional connection. If wire is connected, ACRDJ jumper

on furnace control should be removed to allow Thermidis-

tat/Thermostat to control outdoor unit staging.

13. Furnace nmst control its own staging operation via furnace

control algorithm. This is factory default.

14. The RVS Sensing terminal "L" should not be connected.

This is internally used to sense defrost operation.

15. DO NOT SELECT the "FURNACE INTERFACE" or

"BALANCE POINT" option on the two-speed heat pump

control board. This is controlled internally by the Thermi-

distat/Dual Fuel Thermostat.

16. Dip switch D on Dual Fuel Thermostat should be set in

OFF position for single-speed compressor operation. This

is factory default.

17. Dip switch D on Dual Fuel Thermostat should be set in

ON position for two-speed compressor operation.

Step 4 -- Adjustments

Set Gas Input Rate

Furnace gas input rate on rating plate is for installations at

altitudes up to 2000 ft. (609.6M).

In the USA., the input rating for altitudes above 2000 ft.

(609.6M) nmst be reduced by 2 percent for each 1000 ft.

(304.8M) above sea level.

In Canada, the input rating must be derated by 5percent for

altitudes of 2000 ft. (609.6M) to 4500 ft. (1371.6M) above sea

level.

Adjust manifold pressure to obtain input rate.

Furnace input rate must be within +2 percent of input rate on

furnace rating plate.

1. Determine natural gas orifice size and manifold pressure

for correct input.

a. Obtain average heat value (at installed altitude) from local

gas supplier.

b. Obtain average specific gravity from local gas supplier.

c. Verify furnace model. Table 10 can only be used for mod-

el 58MVC Furnaces.

d. Find installation altitude in Table 10.

NOTE: For Canadian altitudes of 2000 to 4500 ft. (609.6 to

1371.6M), use USA. altitudes of 2001 to 3000 ft. (609.6 to

914.4M) in Table 10.

e. Find closest natural gas heat value and specific gravity

in Table 10.

f. Follow heat value and specific gravity lines to point of

intersection to find orifice size and low-, medium-, and

high-heat manifold pressure settings for proper opera-

tion.

EXAMPLE: 0 - 2000 ft. (0 - 609.6M) altitude

Heating value = 1050 Btu/cu ft.

Specific gravity = 0.62

Therefore: Orifice No. 45

Manifold pressure: 3.8-in. wc for high heat 1.6-in. wc for medium

heat 0.6-in. wc for low heat

* Furnace is shipped with No. 45 orifices. In this example, all main

burner orifices are the correct size and do not need to be changed to

obtain proper input rate.

g. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE; ALWAYS CHECK AND

VERIFY.

2. Adjust manifold pressure to obtain input rate.

HIGH-HEAT

ON/OFF (UNDERCAP)

INLET

_i PRE_SAU_E

BURNER

ENCLOSURE

REFERENCE

TAP

MEDIUM-HEAT

ADJUSTMENT

(UNDERCAP) LOW-HEAT

ADJUSTMENT

(UNDERCAP) MANIFOLDJ

PRESSURE

TAP

Fig. 60 - Redundant Automatic Gas Valve

A07280

a. Remove burner enclosure front.

NOTE: Manifold pressure MUST always be measured with the

burner box cover REMOVED.

b. Remove regulator seal caps that conceal adjustment

screws for medium- and high-heat gas valve regulators.

(See Fig. 60.)

c. Move setup switch SW4-2 on control center to ON posi-

tion. (See Fig. 33.) This keeps furnace locked in medium-

heat operation.

54

d.JumperRand W/W1 thermostat connections on control

to start furnace.

e. Turn medium-heat adjusting screw counterclockwise

(out) to decrease manifold pressure or clockwise (in) to

increase manifold pressure.

NOTE: DO NOT set medium-heat manifold pressure less than

1.3- in. wc or more than 1.7-in. wc for natural gas.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in reduced furnace

life.

DO NOT bottom out gas valve regulator adjusting screws.

This can result in unregulated manifold pressure and result

in excess over-fire and heat exchanger failures,

NOTE: If orifice hole appears damaged or it is suspected to have

been redrilled, check orifice hole with a numbered drill bit of

correct size. Never redrill an orifice. A burr-free and squarely

aligned orifice hole is essential for proper flame characteristics.

(See Fig. 61.)

f. Move setup switch SW4-2 to OFF position after com-

pleting medium-heat adjustment.

g. Jumper R and W/WI and W2 thermostat connections on

furnace control. (See Fig. 33.) This keeps furnace locked

in high-heat operation.

h. Turn high-heat adjusting screw counterclockwise (out)

to decrease manifold pressure or clockwise (in) to in-

crease manifold pressure.

NOTE: DO NOT set high-heat manifold pressure less than

3.2-in. wc or more than 3.8-in. wc for natural gas.

i. Remove jumpers R to W/WI and R to W2.

j. Wait for blower off-delay to finish then reset l15-v

power to furnace.

k. Jumper R and W/WI thermostat connections on control

to start furnace.

1. Wait for the blower to turn ON then check low-heat mani-

fold pressure. It should be between .5 to .6-in. wc. This

setting should not require adjustment but if it does re-

move the low-heat adjustment cap (See Fig. 60) and turn

the low-heat adjusting screw clockwise (in) to decrease

manifold pressure or counterclockwise (out) to increase

manifold pressure. You will only have 15 minutes to

make an adjustment if needed. If you need more time then

move setup switch SW1-2 on control center to ON posi-

tion (See Fig. 33).

NOTE: DO NOT set low-heat manifold pressure before setting

medium-heat manifold pressure. DO NOT set low-heat manifold

pressure less than .5-in. wc or more than .6-in. wc for natural

gas.

m. When correct manifold pressures are obtained, replace

caps that conceal gas valve adjustment screws. Main

burner flame should be clear blue, almost transparent.

(See Fig. 62.)

n. Remove jumper across R and W/Wl. If necessary move

setup switch SWI-2 to the OFF position.

3. Verify natural gas input rate by clocking gas meter.

NOTE: Be sure all pressure tubing, combustion-air and vent

pipes, and burner enclosure front are in place when checking

input by clocking gas meter.

a. Calculate high-altitude adjustment (if required).

UNITED STATES

At altitudes above 2000 ft. (609.6M), this furnace has

been approved for 2 percent derate for each 1000 ft.

(304.8M) above sea level. See Table 11 for derate multi-

plier factor and example.

CANADA

At installation altitudes from 2000 to 4500 ft. (609.6 to

1371.6M), this furnace must be derated 5 percent by an

authorized Gas Conversion Station or Dealer. To determ-

ine correct input rate for altitude, see example and use

0.95 as derate multiplier factor.

EXAMPLE: 80,000 BTUH HIGH-HEAT INPUT

FURNACE INSTALLED AT 4,300 ft. (1310.6M).

Furnace Input Rate at Sea Level X Derate Multiplier Fact-

or = Furnace Input Rate at Installation Altitude

80,000 X 0.91 = 72,800

b. Reinstall burner box cover.

NOTE: Clocking gas input rate MUST always be performed

with the burner box cover INSTALLED.

c. Check that gas valve adjustment caps are in place for

proper input to be clocked.

d. Obtain average heat value (at altitude) from local gas sup-

plier.

NOTE: Be sure heating value of gas used for calculations is

correct for your altitude. Consult local gas utility for altitude

adjustment of gas heating value.

e. Check and verify orifice size in furnace. NEVER

ASSUME THE ORIFICE SIZE. ALWAYS CHECK

AND VERIFY.

f. Turn off all other gas appliances and pilots.

g. Move setup switch SW4-2 to ON position. (See Fig. 33.)

This keeps furnace locked in medium-heat operation.

BURNER

ORIFICE

Fig. 61 - Burner Orifice

A93059

55

Table 10 -Orifice Size* and Manifold Pressures for Gas Input Rate

(Tabulated Data Based on 20,000 BTUH High Heat /13,000 Btuh Med-Heat /8,000 Btuh Low-Heat per Burner.

Derated 2% /1000 Ft. (304.8M) Above Sea Level)

ALTITUDE AVG. GAS

RANGE HEAT VALUE

AT ALTITUDE Orifice

ff lml (Btu/cu ft INo.

900 43

0 925 44

(0) 950 44

975 44

to 1000 44

_.. 1025 45

cn 2000 1050 45

"_ (610) 1075 45

1100 45

U.S.A. 800 43

2001 (611) 825 43

to 850 43

3000 (914) 875 44

900 44

Canada 925 44

_n 2001 (611) 950 45

to 975 45

450011372/ 1000 45

1 1

775 43

3001 800 43

--_ (915) 825 44

I_ 850 44

to 875 44

4000 900 44

(1219) 925 45

950 45

750 43

4001 775 43

--_ (1220) 800 44

I_ 825 44

4 to 850 44

"_ 5000 875 45

(1524) 900 45

925 45

725 43

5001 750 43

(1525) 775 44

I_ 800 44

4 to 825 44

"_ 6000 850 45

(1829) 875 45

900 45

675 42

6001 700 43

--_ (1830) 725 44

I_ 750 44

4 to 775 44

"_ 7000 800 45

(2133) 825 45

850 45

0.58

Mnfld Press

Hiclh/Med/Low

3.5 /1.5 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.4 /1.5 /0.55

3.3 /1.4 /0.50

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.3 /1.4 /0.50

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.7 /1.5 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.50

3.7 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.2 /1.3 /0.50

3.7 /1.5 /0.60

3.5 /1.5 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.7 /1.5 /0.60

3.4 /1.5 /0.55

3.2 /1.4 /0.50

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.50

3.2 /1.3 /0.50

3.6 /1.5 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice Mnfld Press Orifice

No. Hiclh/Med/Low No.

43 3.6 /1.5 /0.60 43

43 3.5 /1.5 /0.55 43

44 3.8 /1.6 /0.60 43

44 3.6 /1.5 /0.55 44

44 3.4 /1.4 /0.55 44

44 3.2 /1.4 /0.50 44

45 3.7 /1.6 /0.60 45

45 3.5 /1.5 /0.55 45

45 3.4 /1.4 /0.55 45

42 3.2 /1.4 /0.50 42

43 3.7 /1.6 /0.60 43

43 3.5 /1.5 /0.55 43

44 3.8 /1.6 /0.60 43

44 3.6 /1.5 /0.55 44

44 3.4 /1.4 /0.55 44

44 3.2 /1.4 /0.50 44

45 3.7 /1.6 /0.60 45

45 3.5 /1.5 /0.55 45

42 3.2 /1.3 /0.50 42

43 3.6 /1.5 /0.60 43

43 3.4 /1.4 /0.55 43

44 3.7 /1.6 /0.60 44

44 3.5 /1.5 /0.55 44

44 3.3 /1.4 /0.55 44

45 3.8 /1.6 /0.60 44

45 3.6 /1.5 /0.55 45

43 3.8 /1.6 /0.60 42

43 3.6 /1.5 /0.55 43

43 3.4 /1.4 /0.55 43

44 3.6 /1.5 /0.60 44

44 3.4 /1.4 /0.55 44

44 3.2 /1.4 /0.50 44

45 3.7 /1.6 /0.60 45

45 3.5 /1.5 /0.55 45

43 3.8 /1.6 /0.60 42

43 3.5 /1.5 /0.55 43

44 3.8 /1.6 /0.60 43

44 3.6 /1.5 /0.55 44

44 3.3 /1.4 /0.55 44

45 3.8 /1.6 /0.60 44

45 3.6 /1.5 /0.55 45

45 3.4 /1.4 /0.55 45

42 3.3 /1.4 /0.55 42

43 3.7 /1.6 /0.60 43

43 3.5 /1.5 /0.55 43

44 3.7 /1.6 /0.60 44

44 3.5 /1.5 /0.55 44

44 3.3 /1.4 /0.50 44

45 3.7 /1.6 /0.60 45

45 3.5 /1.5 /0.55 45

0.62

Mnfld Press

Hiclh/Med/Low

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.7 /1.5 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.5 /1.5 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.2 /1.4 /0.50

3.7 /1.6 /0.60

3.2 /1.4 /0.50

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.2 /1.4 /0.50

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.7 /1.6 /0.60

3.4 /1.5 /0.55

3.2 /1.4 /0.50

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.4 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

Orifice

No.

42

43

43

44

44

44

44

45

45

42

42

43

43

44

44

44

44

45

42

42

43

43

44

44

44

45

42

43

43

43

44

44

44

45

42

43

43

44

44

44

45

45

42

42

43

43

44

44

44

45

0.64

Mnfld Press

Hiclh/Med/Low

3.2 /1.3 /0.50

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.4 /1.5 /0.55

3.3 /1.4 /0.50

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.5 /1.5 /0.55

3.2 /1.4 /0.50

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.2 /1.4 /0.50

3.7 /1.6 /0.60

3.4 /1.4 /0.55

3.2 /1.3 /0.50

3.7 /1.5 /0.60

3.4 /1.5 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.6 /1.5 /0.60

3.4 /1.5 /0.55

3.2 /1.4 /0.50

3.7 /1.6 /0.60

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.5 /1.5 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.4 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.50

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.50

3.7 /1.6 /0.60

* Orifice numbers shown in BOLD are factory-installed.

A08202

56

Table 10 - Orifice Size* and Manifold Pressures for Gas Input Rate (Continued)

(Tabulated Data Based on 20,000 BTUH High Heat /13,000 Btuh Meal-Heat /8,000 Btuh Low-Heat per Burner,

Derated 2% /1000 Ft. (304.8M) Above Sea Level)

ALTITUDE AVG. GAS

RANGE HEAT VALUE

AT ALTITUDE Orifice

(m) (Btu/cu R} No.

650 43

7001 675 43

-->' (2134) 700 44

725 44

_ to 750 44

8000 775 45

(2438) 800 45

825 45

625 43

8001 650 43

= (2439) 675 44

O

--_ to 700 44

725 44

9000 750 45

(27431 775 45

9001 600 43

(2744) 625 43

650 44

_ to 675 44

10000 700 44

(3048) 725 45

0.58

Mnfld Press

Hiqh/Med/Low

3.8 /1.6 /0.60

3.5 /1.5 /0.55

3.8 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.55

3.7 /1.6 /0,60

3.5 /1.5 /0,55

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.5 /1.5 /0.55

3.7 /1.6 /0.60

3.5 /1.5 /0.55

3.2 /1.4 /0.50

3.7 /1.5 /0,60

3.4 /1.5 /0.55

3.8 /1.6 /0.60

3.5 /1.5 /0.55

3.7 /1.6 /0.60

3.4 /1.4 /0.55

3.2 /1.3 /0.50

3.6 /1.5 /0.55

Orifice

No.

42

43

43

44

44

44

45

45

42

43

43

44

44

45

45

42

43

44

44

44

45

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Mnfld Press

Hiqh/Med/Low

3.2 /1.4 /0.50

3.7 /1.6 /0.60

3.4 /1.4 /0.55

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.2 /1.3 /0.50

3.6 /1.5 /0,60

3.4 /1.4 /0.55

3.2 /1.4 /0.50

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.8 /1.6 /0,60

3.6 /1.5 /0.55

3.2 /1.4 /0.50

3.6 /1.5 /0.60

3.8 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.55

3.7 /1.6 /0.60

0.62

Orifice Mnfld Press

No. Hiqh/Med/Low

42 3.4 /1.4 /0.55

43 3.8 /1.6 /0.60

43 3.5 /1.5 /0.55

44 3.8 /1.6 /0.60

44 3.5 /1.5 /0.55

44 3.3 /1.4 /0.55

45 3.7 /1.6 /0.60

45 3.5 /1.5 /0.55

42 3.3 /1.4 /0.55

43 3.8 /1.6 /0.60

43 3.5 /1.5 /0.55

44 3.7 /1.6 /0.60

44 3.5 /1.5 /0.55

44 3.2 /1.4 /0.50

45 3.7 /1.6 /0.60

42 3.3 /1.4 /0.55

43 3.7 /1.6 /0.60

43 3.4 /1.5 /0.55

44 3.7 /1.5 /0.60

44 3.4 /1.4 /0.55

45 3.8 /1.6 /0.60

Orifice

No.

42

42

43

43

44

44

44

45

42

42

43

44

44

44

45

42

43

43

44

44

44

0.64

Mnfld Press

Hiqh/Med/Low

3.5 /1.5 /0.55

3.2 /1.4 /0.50

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.6 /1.5 /0.60

3.4 /1.4 /0.55

3.2 /1.4 /0.50

3.6 /1.5 /0.60

3.4 /1.5 /0.55

3.2 /1.3 /0.50

3.6 /1.5 /0.60

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.3 /1.4 /0.55

3.8 /1.6 /0.60

3.4 /1.4 /0.55

3.8 /1.6 /0.60

3.6 /1.5 /0.55

3.8 /1.6 /0.60

3.5 /1.5 /0.55

3.3 /1.4 /0.50

* Orifice numbers shown in BOLD are factory-installed.

A08203

57

UNIT DAMAGE HAZARD

Failure to follow this caution may result in component

damage.

DO NOT redrill orifices. Improper drilling (burrs,

out-of-round holes, etc.) can cause excessive burner noise

and misdirection of burner flames. (See Fig. 61.)

h. Jumper R to W/W1.

i. Let furnace run for 3 minutes in medium-heat operation.

j. Measure time (in sec) for gas meter to complete I revolu-

tion. Note reading.

k. Refer to Table 12 for cubic ft. of gas per hr.

1. Multiply gas rate cu ft/hr by heating value (Btu/cu ft).

m. Move setup switch SW4-2 to OFF position and jumper

R and W/WI and W2 thermostat connections. (See Fig.

33.) This keeps furnace locked in high-heat operation.

Repeat items i through 1 for high-heat operation.

EXAMPLE: High-heat operation at 0 - 2000 ft. (0-609.6M)

altitude

Furnace input from rating plate is 80,000 Btuh

Btuh heating input = Btuh/cu ft. X cu ft/hr

Heating value of gas = 975 Btuh/cu ft.

Time for 1 revolution of 2-cu ft. dial = 88 sec

Gas rate = 82 cu ft/hr (from Table 12)

Btuh heating input = 103 X 975 = 79,950 Btuh

In this example, the orifice size and manifold pressure adjustment

is within +/- 2 percent of the furnace input rate.

n. Remove jumper across R, W/WI, and W2 thermostat

connections to terminate call for heat.

o. Wait for blower off-delay to finish then reset l15-v

power to furnace.

p. Wait for blower off-delay to finish then reset l15-v

power to furnace.

q. Jumper R and W/WI thermostat connections on control

to start furnace.

r. Wait for the blower to turn ON then repeat items i through

1for low-heat operation. This setting should not require

adjustment but if it does you will only have 15 minutes

to make the adjustment. If you need more time then move

setup switch SWI-2 on control center to ON position

(See Fig. 33).

NOTE: Measured gas inputs (high heat, medium heat, and low

heat) nmst be within +/-2 percent of that stated on furnace rating

plate when installed at sea level or derated as stated above when

installed at higher altitudes.

Table 11 -Altitude Derate Multiplier for USA

ALTITUDE % OF DERATE MULTIPLIER

FT (M) DERATE FACTOR FOR USA.*

0--2000 (0--61 O) 0 1.00

2001 --3000 4--6 0.95

(610--914)

3001 --4000 6--8 0.93

(914--1219)

4001 --5000 8--10 0.91

(1219--1524)

5001 --6000 10--12 0.89

(1524--1829)

6001 --7000 12--14 0.87

(1829--2134)

7001 --8000 14--16 0.85

(2134--2438)

8001 --9000 16--18 0.86

(2438--2743)

9001 --10,000 18--20 0.81

(2746--3048)

*Derate multiplier factor is based on midpoint altitude for altitude range.

BURNER FLAME

/_," r- BURNER

MANIFOLD J

Fig. 62 -Burner Flame

A89020

58

Table 12 - Gas Rate cu Ft/Hr

SECONDS SIZE OF TEST DIAL SECONDS

FOR 1 1 2 5 FOR 1

REVOLUTION REVOLUTION

cu _. cu _. cu _.

10 360 720 1800 50

11 327 655 1636 51

12 300 600 1500 52

13 277 555 1385 53

14 257 514 1286 54

15 240 480 1200 55

16 225 450 1125 56

17 212 424 1059 57

18 200 400 1000 58

19 189 379 947 59

20 180 360 900 60

21 171 343 857 62

22 164 327 818 64

23 157 313 783 66

24 150 300 750 68

25 144 288 720 70

26 138 277 692 72

27 133 267 667 74

28 129 257 643 76

29 124 248 621 78

30 120 240 600 80

31 116 232 581 82

32 113 225 563 84

33 109 218 545 86

34 106 212 529 88

35 103 206 514 90

36 100 200 500 92

37 97 195 486 94

38 95 189 474 96

39 92 185 462 98

40 90 180 450 100

41 88 176 439 102

42 86 172 429 104

43 84 167 419 106

44 82 164 409 108

45 80 160 400 110

46 78 157 391 112

47 76 153 383 116

48 75 150 375 120

49 73 147 367

SIZE OF TEST DIAL

125

cu _. cu_. cu _.

72 144 360

71 141 355

69 138 346

68 136 340

67 133 333

65 131 327

64 129 321

63 126 316

62 124 310

61 122 305

60 120 300

58 116 290

56 112 281

54 109 273 1

U

53 106 265

51 103 257

50 100 250

48 97 243

47 95 237

46 92 231

45 90 225

44 88 220

43 86 214

42 84 209

41 82 205

40 80 200

39 78 196

38 76 192

38 75 188

37 74 184

36 72 180

35 71 178

35 69 173

34 68 170

33 67 167

33 65 164

32 64 161

31 62 155

30 60 150

Set Temperature Rise

UNIT DAMAGE HAZARD

Failure to follow this caution may result in component

damage.

Temperature rise must be within limits specified on unit

rating plate. Operation is within a few degrees of midpoint

of rise range when setup switch SWI-4 is OFF.

Furnace must operate within ranges of temperature rise specified

on the furnace rating plate. Determine air temperature rise as

follows:

1. Place thermometers in return and supply ducts as near fur-

nace as possible. Be sure thermometers do not see heat ex-

changer 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

temperature from supply-air temperature to determine air

temperature rise.

NOTE: Temperature rise can be determined for low-heat

operation by placing setup switch SWI-2 on furnace control in

ON position. Temperature rise can be determined for

medium-heat operation by placing setup switch SW4-2 on

furnace control in ON position. For high-heat operation, place

setup switch SWl-2 and SW4-2 in OFF position and jumper

R-W2 on furnace control. DO NOT forget to return setup switch

to OFF position and remove R-W2 jumper upon completion of

testing. (See Fig. 33 for switch and terminal location.)

3. This furnace is capable of automatically providing proper

airflow to maintain the temperature rise within the range

specified on furnace rating plate. If temperature rise is out-

side this range, proceed as follows:

a. Check gas input for low-, medium-, and high-heat oper-

ation.

b. Check derate for altitude if applicable.

c. Check all return and supply ducts for excessive restric-

tions causing static pressure greater than 0.5-in. wc.

d. Ensure Low Heat Rise Adjust switch SWI-3 on furnace

control is in ON position when a bypass humidifier is

used. (See Fig. 33 for switch location.)

e. Check Troubleshooting Guide for Variable-Speed Step

Modulating Condensing Furnaces.

Set Thermostat Heat Anticipator

When using a non-electronic thermostat, the thermostat heat

anticipator must be set to match the amp draw of components in

59

the R-W/W1 circuit. Accurate amp draw measurements can be

obtained only at the thermostat subbase terminals R and W.

The thermostat and anticipator should NOT be in the circuit while

measuring current. If thermostat has no subbase, the thermostat

must be disconnected from R and W/WI wires during current

measurement.

Fig. 63 illustrates an easy method of obtaining thermostat amp

draw measurements. The amp reading should be taken after

blower motor has started and furnace is operating in low-heat.

1. To operate furnace in low-heat, turn setup switch SWl-2

to ON position (See Fig. 33) and connect ammeter leads

across thermostat subbase R-W.

2. See thermostat manufacturer's instructions for adjusting

the heat anticipator and for varying heating cycle length.

NOTE: When using an electronic thermostat, set cycle rate for 3

cycles per hr.

3. Return setup switch SWI-2 to OFF position and replace

thermostat on subbase.

Check Safety Controls

This section covers the safety controls that nmst be checked

before the installation is complete. The flame sensor, gas valve,

and pressure switches were all checked in the Start-up procedure

section as part of normal operation.

Check Primary Limit Control

This control shuts off the gas control system and energizes the

air-circulating blower motor if furnace overheats.

1. The recommended method of checking this limit control is

to gradually block off return air after furnace has been op-

erating for a period of at least 5 minutes.

2. As soon as limit control has shut off burners, a status code

33 will appear on furnace control.

3. The return-air opening should be unblocked to permit

normal air circulation.

By using this method to check the limit control, it can be

established that the limit is functioning properly and the furnace

will operate safely if there is a restricted return-air duct or motor

failure. If the limit control does not function during this test, the

cause nmst be determined and corrected.

Check Pressure Switches

This control proves operation of the draft inducer. Check switch

operation as follows:

1. Turn off l15-v power to furnace.

2. Remove control access door and disconnect inducer motor

12-pin wire harness at inducer motor.

3. Turn on l15-v power to furnace.

4. Set thermostat to "call for heat." When pressure switches

are functioning properly, status code 42 will flash on fur-

nace control approximately 20 sec after thermostat switch

is closed. If either a status code 31 or 32 is flashed when

inducer motor is disconnected, the furnace will shut itself

down immediately. Determine the reason pressure

switches did not function properly and correct the condi-

tion.

5. Turn off l15-v power to furnace.

6. Reconnect inducer motor wire harness. Reinstall furnace

access door.

7. Turn on l15-v power to furnace.

8. Reset thermostat to desired temperature.

CHECKLIST

1. Put away tools and instruments. Clean up debris.

2. Verify flame rollout manual reset switch has continuity.

3. Verify that blower and main access doors are properly in-

stalled.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer's instruc-

tions.

6. Review User's Manual with owner.

7. Leave literature packet near furnace.

THERMOSTAT SUBBASE

TERMINALS WITH

THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,

MUST BE OUT OF CIRCUIT.)

HOOK-AR(

AMMETER

FROM UNIT 24-V

CONTROL TERMINALS

EXAMPLE: 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

Fig. 63 -Amp Draw with Ammeter

A96316

60

CHECKLIST-INSTALLATION

LOAD CALCULATION

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

COMBUSTION AND VENT PIPING

Termination Location

Vent

Roof

Sidewall

Combustion -Air

Roof

Sidewall

Attic

Crawl Space

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 Ceilings

Low-Ambient Exposed Pipes

Condensate Drain

Unit Level or Pitched Forward

Internal Tubing Connections

Free of Kinks and Traps

External Drain Connection Leak

Tight and Sloped

Condensate Trap Primed before

Start- Up

Heat Tape Installed if Required

CHECKLIST - START-UP

Gas Input Rate (Set Within 2

percent of Rating Plate)

Temperature Rise Adjusted

Thermostat Anticipator

Anticipator Setting Adjusted or

Cycle Rate (3 Cycles per Hr)

Selected

Safety Controls Check Operation

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 Check Operation

Primary Limit

Pressure Switches

51

Copyright 2008 Carrier Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in USA. Edition Date: 12/08

Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,

62

Catalo_ No: 58MVC-4SI

Replaces: 58MV( 3SI