Carrier WEATHERMAKER 8000 58WAV Operating instructions

WeatherMaker 8000™
58WAV
Upflow Induced-Combustion Furnaces
Visit www.carrier.com
Installation, Start-Up, and Operating Instructions
Sizes 045-155, Series 140 (LIMITED)
NOTE: Read the entire instruction manual before starting the
installation.
Index
Page
SAFETY CONSIDERATIONS .....................................................1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE........................................................................2-3
Dimensional Drawing ...............................................................2
Clearances From Combustible Materials .................................3
INTRODUCTION.....................................................................3
LOCATION ..............................................................................4
General.................................................................................4
Location Relative to Cooling Equipment ...........................4
Hazardous Locations ...........................................................4
AIR FOR COMBUSTION AND VENTILATION..............4-6
Unconfined Space................................................................4
Confined Space....................................................................5
AIR DUCTS..............................................................................6
General Requirements .........................................................6
Ductwork Acoustical Treatment .........................................6
Supply-Air Connections ......................................................6
Return-Air Connections.......................................................6
FILTER ARRANGEMENT .....................................................6
LEVELING LEGS (IF REQUIRED).......................................7
GAS PIPING .........................................................................7-8
ELECTRICAL CONNECTIONS.............................................8
115-v Wiring........................................................................8
24-v Wiring..........................................................................8
Accessories .......................................................................8-9
VENTING .................................................................................9
START-UP, ADJUSTMENT, AND SAFETY CHECK..12-20
General...............................................................................12
Sequence Of Operation ................................................12-15
Heating Mode ....................................................................13
Cooling Mode...............................................................13-15
Continuous Blower Mode .................................................15
Continuous Blower Speed Selection from Thermostat ....15
Heat Pump Mode...............................................................15
Start-Up Procedures .....................................................15-16
Adjustments ..................................................................16-20
Set Gas Input Rate .......................................................16-19
Set Temperature Rise...................................................19-20
Set Thermostat Heat Anticipator ......................................20
Check Safety Controls ............................................................20
Checklist..................................................................................21
ama
CERTIFIED
REGISTERED QUALITY SYSTEM
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA
54-1999/ANSI Z223.1-1999 and the Installation Standards, Warm
Air Heating and Air Conditioning Systems (NFPA 90B)
ANSI/NFPA 90B.
In Canada, refer to CAN/CGA-B149.1- and .2-M95 National
Standard of Canada, Natural Gas and Propane Installation Codes
(NSCNGPIC).
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing residential construction practices. We require these instructions as a
minimum for a safe installation.
Wear safety glasses and work gloves. Have fire extinguisher
available during start-up and adjustment procedures and service
calls.
Recognize safety information. This is the safety-alert symbol
.
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which would result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-757
Printed in U.S.A.
Form 58WAV-9SI
Pg 1
1-00
Replaces: New
Tab 6a 8a
AIRFLOW
28 1⁄2″
2 1⁄16″
VENT CONN
A
D
DIA HOLE
POWER ENTRY
7⁄8-IN. DIA
ACCESSORY
DIA
POWER ENTRY
2 11⁄16″
5 13⁄16″
13⁄16″
2 3⁄8″
1 3⁄4-IN. DIA HOLE
GAS ENTRY
1 1⁄2-IN. DIA
R.H. GAS ENTRY
7⁄8-IN.
DIA ACCESSORY
1⁄2-IN. DIA THERMOSTAT
WIRE ENTRY
2 3⁄8″
DIA HOLE
THERMOSTAT
WIRE ENTRY
13⁄16″
7⁄8-IN.
5 3⁄8″
12 5⁄16″
1⁄2-IN.
OUTLET
1″
5 3⁄8″
5
19″
13⁄16″
1″
7⁄8-IN.
39 7⁄8″
2 1⁄16″
SIDE INLET
SIDE INLET
141⁄2″
TYP 1″
1 3⁄4″
5⁄16″
24
AIR INLET
11⁄16″
3″
11⁄16″
11⁄16″
E
1″
231⁄4″
SIDE RETURN
DUCT LOCATION
5⁄8″
TYP
NOTES: 1. Two additional 7⁄8-in. dia holes are located in the top plate.
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturer's recommendations for equivalent diameters.
3. Minimum return-air opening at furnace:
a. For 800 CFM–16-in. round or 141⁄2 x 12-in. rectangle.
b. For 1200 CFM–20-in. round or 141⁄2 x 191⁄2-in. rectangle.
c. For 1600 CFM–22-in. round or 141⁄2 x 231⁄4-in. rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific
use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
A99060
Fig. 1—Dimensional Drawing
Table 1—Dimensions (In.)
UNIT SIZE
045-08
045-12
070-08
070-12
091-14
091-16
111-12
111-16
111-20
136-16
136-20
155-20
A
14-3/16
14-3/16
14-3/16
14-3/16
17-1/2
21
17-1/2
21
24-1/2
21
24-1/2
24-1/2
D
12-9/16
12-9/16
12-9/16
12-9/16
15-7/8
19-3/8
15-7/8
19-3/8
22-7/8
19-3/8
22-7/8
22-7/8
E
12-11/16
12-11/16
12-11/16
12-11/16
16
19-1/2
16
19-1/2
23
19-1/2
23
23
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
VENT CONN
4
4
4
4
4
4
4
4
4
5
5
5
SHIP. WT (LB)
119
121
126
129
147
159
155
164
182
173
186
196
3. 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 ungrounded
objects, etc.).
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching
control or wires.
5. Use this procedure for installed and uninstalled (ungrounded)
furnaces.
6. Before removing a new control from its container, discharge
your body’s electrostatic charge to ground to protect the
control from damage. If the control is to be installed in a
furnace, follow items 1 through 5 before bringing the control
or yourself into contact with the furnace. Put all used AND
new controls into containers before touching ungrounded
objects.
7. An ESD service kit (available from commercial sources) may
also be used to prevent ESD damage.
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.
1. Disconnect all power to the furnace. DO NOT TOUCH THE
CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the furnace
chassis which is close to the control. Tools held in a person’s
hand during grounding will be satisfactorily discharged.
2
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
TOP / PLENUM
This forced air furnace is equipped for use with This furnace is approved for UPFLOW installations only.
natural gas at altitudes 0 - 10,000 ft (0-3,050m).
An accessory kit, supplied by the manufacturer,
1"
shall be used to convert to propane gas use or
may be required for some natural gas applications.
m
This furnace is for indoor installation in
building constructed on site.
1"
0"
BA
#
This furnace may be installed on combustible
E
CK
D
SI
E
flooring in alcove or closet at minimum clearance
AC
RN
from combustible material.
FU
T
ON
This furnace may be used with a Type B-1 Vent
FR
SE
a nd may be vented in common with other gas-fired
RV
IC
a ppliances.
E
E
SI
##
FR
For furnaces wider than 14.25 inches
(362mm) may be 0 inches.
For single wall vent type 6 inches.
For Type B-1 vent type 3 inches.
0"
Clearance in inches.
ON
T
30"
MIN
##
BOTTOM
DESSOUS
#
D
1" #
320325-101 REV. H
Vent Clearance to combustibles:
For Single Wall vents 6 inches (6 po).
For Type B-1 vent type 1 inch (1 po).
A98122
Fig. 2—Clearances to Combustibles
INTRODUCTION
The Model 58WAV, Series 140 Limited Furnace is available in
sizes 44,000 through 154,000 Btuh input capacities.
The design of the upflow gas-fired furnace is A.G.A./C.G.A.
certified for natural and propane gas and for installation on
combustible flooring, in alcoves, attics, basements, closets, or
utility rooms. The furnace is factory-shipped for use with natural
gas. A factory accessory gas conversion kit, as listed on the
furnace rating plate is required to convert furnace for use with
propane gas. The design of this furnace line is not A.G.A./C.G.A.
certified for installation in mobile homes, recreation vehicles, or
outdoors.
FRONT
°F
°F
RETURN
AIR
Before installing the furnace in the United States, refer to the
current edition of the NFGC and the NFPA 90B. For copies of the
NFGC and NFPA 90B, contact the National Fire Protection
Association Inc., Batterymarch Park, Quincy, MA 02269; or for
only the NFGC contact the American Gas Association, 400 N.
Capitol St., N.W., Washington DC 20001.
MAX 85°F
MIN 55°F
A93042
Before installing the furnace in Canada, refer to the NSCNGPIC.
For a copy of the NSCNGPIC, contact Standard Sales, CSA
International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada.
This furnace is designed for a minimum continuous return-air temperature of 60°F db or an intermittent operation down to 55°F db such
as when used with a night setback thermostat. Return-air temperature
must not exceed a maximum of 85°F db.
Installation must comply with regulations of serving gas supplier
and local building, heating, plumbing or other codes in effect in the
area in which installation is made. In absence of local building
codes, installation must comply with NFGC in the United States
and the NSCNGPIC and all authorities having jurisdiction in
Canada.
Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may
cause personal injury 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.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, and unit sizing. Improper installation or
misapplication of the furnace can require excessive servicing
or cause premature component failure.
For accessory installation details, refer to the applicable instruction
literature.
3
NOTE: Remove all shipping brackets and materials before
operating the furnace.
Step 1—Location
GENERAL
Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.
18-IN. MINIMUM
TO BURNERS
Do not use this furnace during construction when adhesives,
sealers, and/or new carpets are being installed. If the furnace
is required during construction, use clean outside air for
combustion and ventilation. Compounds of chlorine and
fluorine when burned with combustion air form acids which
cause corrosion of the heat exchangers and metal vent system.
Some of these compounds are found in paneling and dry wall
adhesives, paints, thinners, masonry cleaning materials, and
many other solvents commonly used in the construction
process.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
A93044
Step 2—Air For Combustion and Ventilation
Provisions for adequate combustion and ventilation air must be
provided in accordance with Section 5.3 of the NFGC, Air for
Combustion and Ventilation, or applicable provisions of the local
building codes.
Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and
other household products.
DO NOT install the furnace on its back or sides. Safety
control operation will be adversely affected. A failure to
follow this warning can cause fire, personal injury, or death.
All fuel-burning equipment must be supplied with air for combustion of the fuel. Sufficient air MUST be provided to ensure there
will not be a negative pressure in the equipment room or space. In
addition, a positive seal MUST be made between the furnace
cabinet and the return-air duct to prevent pulling air from the
burner area and blocked vent safeguard opening.
This furnace must be installed so the electrical components are
protected from water. This furnace shall not be installed directly on
carpeting, tile, or any combustible material other than wood
flooring.
Locate furnace as close to the chimney/vent and as near the center
of the air distribution system as possible. The furnace should be
installed as level as possible.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, or fireplaces could create a NEGATIVE
PRESSURE CONDITION at the furnace. Make-up air MUST
BE PROVIDED for the ventilation devices, in addition to that
required by the furnace.
Provide ample space for servicing and cleaning. Always comply
with the minimum fire protection clearances shown on the unit
rating plate.
LOCATION RELATIVE TO COOLING EQUIPMENT — The
cooling coil must be installed parallel with or on the downstream
side of the unit to avoid condensation in the heat exchangers.
When installed parallel with a furnace, dampers or other means
used to control the flow of air must prevent chilled air from
entering the unit. If the dampers are manually operated, they must
be equipped with means to prevent operation of either unit unless
the damper is in the full-heat or full-cool position.
The requirements for combustion and ventilation air depend upon
whether the furnace is located in an unconfined or confined space.
UNCONFINED SPACE
An unconfined space has volume of at least 50 cu ft for each 1000
Btuh of total input for all appliances (such as furnaces, clothes
dryers, water heaters, etc.) in the space.
For Example:
HAZARDOUS LOCATIONS
58WAV FURNACE
INPUT BTUH
44,000
66,000
88,000
110,000
132,000
154,000
When furnace is installed in a residential garage, it must be
installed so that burners and ignition sources are located a
minimum of 18 in. above floor. The furnace must 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.
MINIMUM SQ FT WITH
7-1/2 FT CEILING
293
440
587
733
880
1026
If the unconfined space is of unusually tight construction, air for
combustion and ventilation MUST come from either the outdoors
or spaces freely communicating with the outdoors. Combustion
and ventilation openings must be sized the same as for a confined
4
12″ MAX
1 SQ IN.
PER 2000
BTUH*
CONFINED
SPACE
12″ MAX
INTERIOR
HEATED
SPACE
A
D
VENT
THROUGH
SUPPLY ROOF
AIR
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
DUCTS
TO
OUTDOORS
UNCONFINED
SPACE
12″
MAX
F
1 SQ IN.
PER
4000
BTUH*
OUTDOORS
VENT THROUGH ROOF
CONFINED
SPACE
SUPPLY
AIR
1 SQ IN.
PER 4000
BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN.
PER
4000
BTUH*
6″ MIN
(FRONT) †
1 SQ IN.
PER 2000
BTUH*
12″ MAX
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
E
B
G
12″
MAX
C
12″ MAX
12″ MAX
RETURN AIR
RETURN AIR
DUCT
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
*Minimum dimensions of 3 in.
* Minimum opening size is 100 sq in. with
minimum dimensions of 3 in.
† Minimum of 3 in. when type-B1 vent is used.
NOTE: Use any of the following
combinations of openings:
A&B C&D D&E F&G
A89012
A89013
Fig. 3—Confined Space: Air for Combustion and
Ventilation from an Unconfined Indoor Space
Fig. 4—Confined Space: Air for Combustion and
Ventilation from Outdoors
b. If building is constructed unusually tight, a permanent
opening directly communicating with the outdoors shall be
provided. See item 2 below.
c. If furnace is installed on a raised platform to provide a
return-air plenum, and return air is taken directly from
hallway or space adjacent to furnace, all air for combustion
must come from outdoors.
2. Air from outside the structure requires 1 of the following
methods:
a. If combustion air is taken from outdoors through 2 vertical
ducts, the openings and ducts MUST have at least 1 sq in.
of free area per 4000 Btuh of total input for all equipment
within the confined space. (See Fig. 4 and Table 2.)
b. If combustion air is taken from outdoors through 2 horizontal ducts, the openings and ducts MUST have at least 1
sq in. of free area per 2000 Btuh of total input for all
equipment within the confined space. (See Fig. 4 and Table
2.)
c. If combustion air is taken from outdoors through a single
opening or duct (horizontal or vertical) commencing within
12 in. of the top of the confined space, opening and duct
MUST have at least 1 sq in. of free area per 3000 Btuh of
the total input for all equipment within the confined space
and not less than the sum of the areas of all vent connectors
in the confined space. (See Fig. 4 and Table 2.) Equipment
clearances to the structure shall be at least 1 in. from the
sides and back and 6 in. from the front of the appliances.
space as defined below. Return air must not be taken from the
room unless an equal or greater amount of air is supplied to the
room.
CONFINED SPACE
A confined space is defined as a space whose volume is less than
50 cu ft per 1000 Btuh of total input ratings of all appliances
installed in that space. A confined space MUST have provisions
for supplying air for combustion, ventilation, and dilution of flue
gases using 1 of the following methods. (See Fig. 3, 4, and Table
2.)
NOTE: In determining free area of an opening, the blocking
effect of louvers, grilles, and screens must be considered. If free
area of louver or grille design is unknown, assume 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 1/4-in. mesh. Louvers and grilles must be constructed
so they cannot be closed.
The size of the openings depends upon whether air comes from
outside of the structure or an unconfined space inside the structure.
1. All air from inside the structure requires 2 openings (for
structures not usually tight):
a. Each opening MUST have at least 1 sq in. of free area per
1000 Btuh of total input for all equipment within the
confined space, but not less than 100 sq in. per opening.
(See Fig. 3 and Table 2.) The minimum dimension of air
openings shall not be less than 3 in.
5
Table 2—Minimum Free Area Of Combustion Air Opening*
58WAV
FURNACE
INPUT
(BTUH)
44,000
66,000
88,000
110,000
132,000
154,000
AIR FROM INDOOR
UNCONFINED SPACE
Free Area
of Opening
(Sq In.)
100
100
100
110
132
154
OUTDOOR AIR THROUGH
VERTICAL DUCTS
Free Area of
Round
Opening and Duct
Pipe
(Sq In.)
(In. Dia)
11.0
4
16.5
5
22.0
6
27.5
6
33.0
7
38.5
8
OUTDOOR AIR THROUGH
HORIZONTAL DUCTS
Free Area of
Round
Opening and Duct
Pipe
(Sq In.)
(In. Dia)
22.0
6
33.0
7
44.0
8
55.0
9
66.0
10
77.0
10
OUTDOOR AIR THROUGH
SINGLE DUCT
Free Area of
Round
Opening and Duct
Pipe
(Sq In.)
(In. Dia)
14.67
5
22.00
6
29.33
7
36.67
7
44.00
8
51.33
9
* Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances
in the space require combustion air.
Step 4—Return Air Connections
When ducts are used, they must be of the same cross-sectional area
as the free area of the openings to which they connect. The
minimum dimension of ducts must not be less than 3 in. (See Fig.
4.)
Never connect return-air ducts to the back of the furnace. A
failure to follow this warning can cause a fire, personal injury,
or death.
AIR DUCTS
Step 1—General Requirements
The return-air duct must be connected to bottom , sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. 1. 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.
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 factory The Air Systems Design
Guidelines reference tables available from your local distributor.
The duct system should be sized to handle the required system
design airflow CFM at the design external static pressure.
Step 5—Filter Arrangement
The factory-supplied filter(s) is shipped in the blower compartment. Determine location for the filter and relocate filter retaining
wire if necessary. See Fig. 5 for side return application and Fig. 6
for bottom return application. See Table 3 to determine correct
filter size for desired filter location. Table 3 indicates filter size,
location, and quantity shipped with the furnace.
When a furnace is installed so that the supply ducts carry air 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
terminating outside the space containing the furnace.
WASHABLE
FILTER
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.
FILTER
RETAINER
Flexible connections should be used between ductwork and
furnace to prevent transmission 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. clearance from combustible materials to supply air
ductwork for a distance of 36 in. horizontally from the furnace. See
NFPA 90B or local code for further requirements.
Step 2—Ductwork Acoustical Treatment
A93045
Metal duct systems that do not have a 90 degree elbow and 10 ft
of main duct to the first branch take-off may require internal
acoustical lining. As an 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.
Fig. 5—Side Filter Arrangement
(Control Removed for Clarity)
For bottom air-return applications, filter may need to be cut to fit
some furnace casing widths. A bottom closure panel is factory
installed in the bottom of the furnace. When bottom return inlet is
desired, remove and discard the bottom closure panel. Two sets of
hardware are needed for furnaces in 24-1/2-in. wide casings using
2 filters for bottom return. All hardware is provided for filter
installation.
Step 3—Supply Air Connections
Connect supply-air duct to 3/4-in. flange on furnace supply-air
outlet. The supply-air duct attachment must 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, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.
NOTE: Furnaces with a 17-1/2-in. wide casing require an additional procedure when locating the filter for bottom return-air
application. Field fabricate a sheet metal filler strip 1 X 3 X 24-1/2
in. and install it along side of the filter as shown in Fig. 6. Drive
2 screws through the casing side and into the filler strip to secure
6
171⁄2-IN. WIDE
CASINGS ONLY:
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
5⁄16″
241⁄2-IN. WIDE
CASINGS ONLY:
CUT AND FOLD
FACTORY-PROVIDED
FILTERS AS SHOWN
TO DESIRED SIZE.
5⁄16″
1 3⁄4″
3″
24 1/2″
1 3⁄4″
1″
5⁄16″
5⁄16″
1 3⁄4″
1 3⁄4″
A89014
Fig. 7—Leveling Leg Installation
NOTE: The length of the bolt should not exceed 1-1/2 in.
1. Lay furnace on its back. Locate and drill 5/16-in. diameter
hole in each bottom corner of furnace as shown in Fig. 7.
2. Install nut on bolt and 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.
Step 7—Gas Piping
Gas piping must be installed in accordance with national and local
codes. Refer to the current edition of the NFGC. Canadian
installations must be installed in accordance with NSCNGPIC and
all authorities having jurisdiction.
Refer to Table 4 for the recommended gas pipe size. Risers must
be used to connect to the furnace and the meter.
WASHABLE
FILTER
FILTER
SUPPORT
FILTER
RETAINER
A96030
Fig. 6—Bottom Filter Arrangement
(Control Removed for Clarity)
Table 3—Filter Information (In.)
FURNACE
CASING WIDTH
14-3/16
17-1/2
21
24-1/2
FILTER SIZE*
Side Return
Bottom Return
(1) 16 X 25 X 1† (1) 14 X 25 X 1
(1) 16 X 25 X 1† (1) 16 X 25 X 1
(1) 16 X 25 X 1 (1) 20 X 25 X 1†
(2) 16 X 25 X 1† (1) 24 X 25 X 1
If a flexible connector is required or allowed by the authority
having jurisdiction, black iron pipe shall be installed at the
gas valve and extend a minimum of 2 in. outside the furnace
casing.
FILTER
TYPE
Cleanable
Cleanable
Cleanable
Cleanable
* Filters can be field modified by cutting the frame as marked and folding to the
desired size. Alternate sizes can be ordered from your distributor or dealer.
† Factory provided with the furnace.
Use the proper length of pipes to avoid stress on the gas
control manifold. Failure to follow this warning can result in
a gas leak, causing fire, explosion, personal injury, or death.
it in place. Filter should rest on the top of the filler strip when
installed.
Connect the gas pipe to the furnace using a backup wrench to
avoid damaging gas controls.
Never operate unit without a filter or with filter access door
removed. Failure to follow this warning can cause fire,
personal injury, or death.
Step 6—Leveling Legs (If Required)
When the furnace is used with side inlet(s) and leveling legs are
required, refer to Fig. 7, and install field-supplied, corrosionresistant 5/16-in. machine bolts and nuts.
7
GAS
SUPPLY
Never purge a line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition for the
purpose of checking leakage. Use a soap-and-water solution
to check for leakage. Failure to follow this warning can cause
a fire, explosion, personal injury, or death.
MANUAL
SHUTOFF
VALVE
(REQUIRED)
Table 4—Maximum Capacity of Pipe*
NOMINAL IRON
PIPE SIZE
(IN.)
1/2
3/4
1
1-1/4
1-1/2
INTERNAL
DIAMETER
(IN.)
0.622
0.824
1.049
1.380
1.610
LENGTH OF PIPE (FT)
10
20
30
40
50
175
360
680
1400
2100
120
250
465
950
1460
97
200
375
770
1180
82
170
320
660
990
73
151
285
580
900
SEDIMENT
TRAP
UNION
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a
pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table
10-2 NFPA 54-1999.
Install a sediment trap in the riser leading to the furnace. The trap
can be installed by connecting a tee to the riser leading from the
furnace. Connect a capped nipple into the lower end of the tee. The
capped nipple should extend below the level of the gas controls.
(See Fig. 8.)
Apply joint compound (pipe dope) sparingly and only to the male
threads of each joint. The compound must be resistant to the action
of propane gas.
An accessible manual shutoff valve MUST be installed upstream
of the furnace gas controls and within 72 in. of the furnace. A
1/8-in. NPT plugged tapping, accessible for test gage connection,
MUST be installed immediately upstream of the gas supply
connection to the furnace and downstream of the manual shutoff
valve. Place ground joint union between the gas control manifold
and the manual shutoff valve.
Piping should be pressure tested in accordance with local and
national plumbing and gas codes before the furnace has been
attached. If the pressure exceeds 0.5 psig (14-in. wc), the gas
supply pipe must be disconnected from the furnace and capped
before the pressure test. If the test pressure is equal to or less than
0.5 psig (14-in. wc), turn off electric shutoff switch located on the
gas valve before the test. It is recommended that the ground joint
union be loosened before pressure testing. After all connections
have been made, purge the lines and check for leakage with
regulated gas supply pressure.
Step 8—Electrical Connections
A89417
Fig. 8—Typical Gas Pipe Arrangement
The cabinet MUST have an uninterrupted or unbroken ground
according to NEC, ANSI/NFPA 70-1999 and Canadian
Electrical Code, CSA C22.1 or local codes to minimize
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. Failure
to follow this warning could result in electrical shock, fire, or
death.
The junction box (J-box) can be moved to the left-hand side of the
furnace when a left-side power supply is desired. Remove the 2
screws holding the auxiliary J-box. Mount the J-box on the
left-hand side of the furnace (holes have been pre-drilled in
casing). When moved, tuck the wiring harness behind the clip
provided to keep extra wire lengths out of the way.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control status indicator light will flash rapidly
and the furnace will not operate.
115-V WIRING — Refer to the unit rating plate or Table 5 for
equipment electrical requirements. The control system requires an
earth ground for proper operation.
24-V WIRING
Make field 24-v connections at the 24-v terminal strip. (See Fig.
15.) Connect terminal Y/Y2 as shown in Fig. 9 for proper cooling
operation. Use only AWG No. 18, color-coded, copper thermostat
wire.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the main control board. Any 24-v shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3-amp fuse of identical size.
Make all electrical connections in accordance with the National
Electrical Code (NEC) ANSI/NFPA 70-1999 and local codes or
ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with CSA C22.1
Canadian Electrical Code, or authorities having jurisdiction.
ACCESSORIES
1. Electronic Air Cleaner (EAC)
Two quick-connect terminals, marked EAC-1 and EAC-2, are
provided for EAC connection. (See Fig. 15). These terminals
are energized with 115-v, (1.0-amp maximum) during blower
motor operation.
8
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
NOTE 2
W
FIVE WIRE
THREE-WIRE
HEATING-ONLY
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
DISCONNECT
208/230- OR
460-V
THREE
PHASE
BLOWER DOOR SWITCH
BLK
BLK
WHT
WHT
W
GND
115-V FIELDSUPPLIED
DISCONNECT
GND
AUXILIARY
J-BOX
C
O
N
T
R
O
L
R
208/230-V
SINGLE
PHASE
G
COM
GND
NOTE 1
CONDENSING
UNIT
Y/Y2
24-V
TERMINAL
BLOCK
FURNACE
TWO
WIRE
NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A99440
Fig. 9—Standard Heating and Cooling Application Wiring Diagram
Table 5—Electrical Data
UNIT SIZE
VOLTS—
HERTZ—
PHASE
045-08
045-12
070-08
070-12
091-14
091-16
111-12
111-16
111-20
136-16
136-20
155-20
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
OPERATING
VOLTAGE RANGE
Maximum*
Minimum*
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
MAXIMUM
UNIT AMPS
MINIMUM
WIRE GAGE
MAXIMUM
WIRE LENGTH (FT)‡
MAXIMUM
FUSE OR CKT BKR
AMPS†
6.0
8.3
5.9
8.7
9.0
10.4
8.0
10.1
14.4
10.1
13.3
14.0
14
14
14
14
14
14
14
14
12
14
12
12
47
34
47
32
31
27
35
28
31
28
33
31
15
15
15
15
15
15
15
15
20
15
20
20
* Permissible limits of the voltage range at which the unit operates satisfactorily.
† Time-delay type is recommended.
‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
Step 9—Venting
Refer to the national or local installation code such as NFGC in the
United States or the NSCNGPIC in Canada for proper vent sizing
and installation requirements. Use the enclosed Installation Instruction (Single-Stage Vent Tables for Category I Fan-Assisted
Furnaces) for a quick, easy reference.
After fully assembling the vent connector to the furnace flue collar,
securely fasten the vent connector to the collar with two fieldsupplied, corrosion-resistant, sheet metal screws located 180° apart
and midway up the collar.
The horizontal portion of the venting system shall maintain a
minimum of 1/4-in. upward slope per linear ft and it shall be
rigidly supported every 5 ft or less with hangers or straps to ensure
that there will be no movement after installation.
2. Humidifier (HUM)
Quick-connect terminal (HUM) and screw terminal (COM24V) are provided for 24-v humidifier connection. The terminals are energized with 24-v 0.5-amp maximum after inducer
motor prepurge period.
DO NOT connect furnace control HUM terminal to HUM
(humidifier) terminal on Thermidistat™, Zone Controller or
similar device. See Thermidistat, Zone Controller, thermostat,
or controller manufacturer’s instructions for proper connection. A failure to follow this warning could result in fire.
NOTE: A field-supplied, 115-v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
9
THERMIDISTAT
FURNACE
CONTROL
1-SPEED
AIR CONDITIONER
N/A O/W2
N/A Y1/W2
Y1
HEAT STAGE 1 W/W1
W
Y/Y2
Y/Y2
FAN
G
G
24 VAC HOT
R
R
COOL STAGE 1
DEHUMIDIFY DHUM
24 VAC COMM
Y
DHUM
C
COM
C
HUM
HUMIDIFY
HUMIDIFIER
(24 VAC)
HUM
N/A
B
OUTDOOR
SENSOR
CONNECTION
S1
OUTDOOR
SENSOR
S2
See notes 5, 7, and 10
A99435
Fig. 10—Single-Stage Furnace with 1-Speed Air Conditioner
THERMIDISTAT
FURNACE
CONTROL
2-SPEED
AIR CONDITIONER
N/A O/W2
COOL STAGE 1 Y1/W2
Y1
HEAT STAGE 1 W/W1
W
Y/Y2
Y/Y2
FAN
G
G
24 VAC HOT
R
R
COOL STAGE 1
DEHUMIDIFY DHUM
24 VAC COMM
Y1
Y2
R
DHUM
COM
C
C
HUM
HUMIDIFY
HUMIDIFIER
(24 VAC)
HUM
N/A
B
OUTDOOR
SENSOR
CONNECTION
S1
OUTDOOR
SENSOR
S2
See notes 5, 8, and 10
A99436
Fig. 11—Single-Stage Furnace with 2-Speed Air Conditioner
10
FURNACE
CONTROL
THERMIDISTAT
1-SPEED
HEAT PUMP
O
RVS COOLING O/W2
N/A Y1/W2
Y1
HEAT STAGE 2 W/W1
W
W2
Y/Y2
Y/Y2
Y
FAN
G
G
24 VAC HOT
R
R
(FURNACE)
HEAT/COOL STAGE 1
(COMPRESSOR)
DEHUMIDIFY DHUM
24 VAC COMM
R
DHUM
COM
C
C
HUM
HUMIDIFY
HUMIDIFIER
(24 VAC)
HUM
N/A
B
OUTDOOR
SENSOR
CONNECTION
S1
OUTDOOR
SENSOR
S2
See notes 1, 4, 6, 7, 9, and 10.
A99437
Fig. 12—Single-Stage Furnace with 1-Speed Heat Pump (Dual Fuel)
FURNACE
CONTROL
THERMIDISTAT
2-SPEED
HEAT PUMP
O
RVS COOLING O/W2
Y1
Y1
W
W2
Y/Y2
Y/Y2
Y2
FAN
G
G
W3
24 VAC HOT
R
R
R
HEAT/COOL STAGE 1 Y1/W2
(COMPRESSOR LO)
HEAT STAGE 3 W/W1
(FURNACE)
HEAT/COOL STAGE 2
(COMPRESSOR HI)
DEHUMIDIFY DHUM
24 VAC COMM
DHUM
COM
C
C
HUM
HUMIDIFY
HUMIDIFIER
(24 VAC)
HUM
N/A
B
OUTDOOR
SENSOR
CONNECTION
S1
OUTDOOR
SENSOR
S2
See notes 1, 2, 3, 4, 6, 8, 9, and 10.
A99438
Fig. 13—Single-Stage Furnace with 2-Speed Heat Pump (Dual Fuel)
11
FURNACE
CONTROL
TWO-STAGE
THERMOSTAT
2-SPEED
AIR CONDITIONER
OR HEAT PUMP
Heat Pump only
O
O
Y1
Y1
W
W
W2
Y2
Y/Y2
Y2
G
G
W3
R
R
R
Heat Pump
only
Y1
DHUM
C
COM
C
HUM
HUMIDIFIER
(24 VAC)
See notes 1, 2, and 9.
A99439
Fig. 14—Single-Stage Furnace with 2-Speed Outdoor Unit
Notes:
1. Heat pump must have a high pressure switch for dual fuel applications.
2. Refer to outdoor equipment Installation Instructions for proper setup.
3. Select the "zone" position on the 2-speed heat pump control.
4. Outdoor air sensor must be attached in all dual fuel applications.
5. Dip switch No. 1 on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.
6. Dip switch No. 1 on Thermidistat should be set in ON position 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 position for 2-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 terminal when using a Thermidistat.
Step 10—Start-Up, Adjustment, and Safety Check
SEQUENCE OF OPERATION
GENERAL
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control status indicator light will flash rapidly
and furnace will not operate.
Furnace control must be grounded for proper operation, or
control will lockout. Control is grounded through green wire
routed to gas valve and burner bracket screw.
The furnace must have a 115-v power supply properly connected
and grounded. Proper polarity must be maintained for correct
operation. Thermostat wire connections at R, W, C, and Y must be
made at the 24-v terminal block on the control board. The 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).
Using the schematic diagram shown in Fig. 16, follow the
sequence of operation through the different modes. Read and
follow the wiring diagram very carefully.
NOTE: If there is a power interruption and any thermostat call,
the control initiates a 90-sec blower only on period before starting
another cycle.
This furnace is equipped with a manual reset limit switch or
fuse link in the gas control area. The switch or fuse link opens
and shuts off power to the gas valve if a flame rollout or
overheating condition occurs in the gas control area. DO NOT
bypass the switch. Correct inadequate combustion air supply
problem and reset the switch or replace the fuse link.
Before operating the furnace, check each manual reset switch for
continuity. If necessary, press the button to reset the switch.
The blower compartment door must be in place to complete the
115-v circuit to the furnace.
12
BLOWER OFF DELAY
JUMPER SELECT
Y1 DHUM G Com W Y/Y 2 R
24V
J1
TEST/TWIN
HUM
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX)
HARNESS CONNECTOR
3-AMP FUSE
SEC-1
24-V TRANSFORMER SEC-2
LED OPERATION &
DIAGNOSTIC LIGHT
EAC-2
115-VAC (L2) NEUTRAL
CONNECTION
1 2 3 4 5 6 7 8 9 10 11
24-V THERMOSTAT
TERMINALS
1
2
3
4
5
90
135
180
225
COOL
HOT SURFACE
IGNITOR CONNECTOR
HEAT
BLOWER SPEED
SELECTION TERMINALS
PRI
SPARE-1
115-VAC (L1)
POWER SUPPLY
FAN
SPARE-2
INDUCER MOTOR
CONNECTOR
EAC-1 ELECTRONIC AIR CLEANER
TERMINALS (115-VAC 1.0 AMP MAX)
A99417
Fig. 15—Furnace Control
1. Heating mode
When the wall thermostat "calls for heat," the R-W circuit
closes. The furnace control performs a self-check, verifies the
pressure switch contacts are open, and starts inducer motor.
stopping gas flow to the burners. The blower motor and
EAC remain energized 90, 135, 180, or 225 sec (depending
on the blower off-time selection). The furnace is factory set
for a 135-sec blower off delay.
a. Prepurge period—As the inducer motor comes up to speed,
the pressure switch contacts close to begin a 15-sec
prepurge period.
h. Post-purge—The inducer motor remains energized 5 sec
after the burners are extinguished. If jumper is across PL
7-6 and PL 7-9, the post-purge period is 15 sec.
2. Cooling mode
b. Igniter warm-up—At the end of the prepurge period, the
igniter is energized for a 17-sec igniter warm-up period.
a. Single-Speed Outdoor Unit-See Figures 9,10 and 12.
The thermostat closes the R to G and Y circuits. The
R-Y/Y2 circuit starts the outdoor unit, and the R to G and
Y/Y2 circuits start the furnace blower motor on COOL
speed. Electronic air cleaner EAC-1 terminal is energized
with 115v whenever blower is operating.
When thermostat is satisfied, R to G and Y/Y2 circuits are
opened. The outdoor unit stops and the furnace blower
continues operating on COOL speed for an additional 90
sec. Jumper Y/Y2 to DHUM on the furnace control to
reduce the cooling off-delay to 3 sec from 90. See figure
15.
b. Two-Speed Outdoor Unit without Thermidistat-See Fig.
14.
c. Ignition sequence—When the igniter warm-up period is
completed, the gas valve opens, permitting gas flow to the
burners where it is ignited. After 5 sec, the igniter is
de-energized and a 2-sec flame-sensing period begins.
d. HUM terminal is energized with the gas valve. See
accessories in the Electrical Connections section.
e. Flame-sensing—When burner flame is sensed, the control
begins the blower on delay period and continues holding
the gas valve open. If burner flame is not sensed, the
control closes the gas valve and repeats ignition cycle.
NOTE: Ignition sequence will repeat 3 additional time before a
lockout occurs. Lockout automatically resets after 3 hr, or can be
manually reset by turning 115v off (not at thermostat) for 3 sec
minimum, then on again.
The thermostat closes the R to G and Y1 circuits for low
cooling and the R to G, Y1 and Y/Y2 circuits for high
cooling. The R to Y1 circuit starts the outdoor unit on low
cooling and the R to G and Y1 circuits start the furnace
blower on FAN speed. The R to Y1 and Y2 circuits start
the outdoor unit on high cooling and the R to G, Y1 and Y2
circuits start the furnace blower on COOL speed.
If the R to Y2 circuit opens with the R to G and Y1 circuits
still closed, the outdoor unit will drop to low cooling and
the furnace control will drop the blower speed to FAN.
f. Blower on delay—Forty-five sec after burner flame is
proven, the blower motor is energized on heating speed.
Simultaneously, the humidifier and electronic air cleaner
terminals (HUM and COM-24V for humidifier, EAC-1 and
EAC-2 for electronic air cleaner) are energized. If jumper is
across PL 7-6 and PL 7-9.
g. Blower off delay—When the thermostat is satisfied, the
circuit between R-W is broken, de-energizing the gas valve
13
14
SEC-2
R
Y/Y2
GND
GV
GVR
HI/LO
HSI
HSIR
HUM
IDM
IDR
ILK
JB
LED
LGPS
LS
OL
PCB
BLWR
BLWM
CAP
CPU
EAC-1
EAC-2
FAN
FL
FRS
FSE
FU1
FU2
EAC-1
START
L1
6 5 4
9 8 7
BRN
BRN
WHT
WHT
3 2 1
BLU
ORN
PL1
RED
PL2
1
CAP -1
GRN
PR1
2
GRN
PL7
ORN
BLK
BLK
WHT
ILK
WHT (COM)
BLK
RED
FSE
BLU
2
1
PL6
2
1
FRS2
FL
NOTE #5
GV
NOTE #11
(WHEN USED)
LGPS
WHT
IDM
WHT
BLK
YEL
PRS
FU1
HSIR
IDR
GVR-2
SEC-1
2
1
CPU
HI/LO
PL6
GVR-1
GVR
SEC-2
PL3
2
1
COOL
SPARE-1
HEAT
FAN
2
3
1
2
8
6
HSI
OL
9 NOT USED
3
11
7
NOT USED
FRS2
GV
NOTE #5
FSE
FL
(WHEN USED)
NOTE #10
ALS
NOTE #12
PRS
(WHEN USED)
NOTE #12
BVSS
6
5
8
2
DSS
L2
EAC-2
(WHEN USED)
NOTE #10
FRS1
IDM
BLWM
LGPS
(WHEN USED)
NOTE #11
LS
9
1
5
10
3
PL7
4
1
7
START
CAP-1
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
NOT USED
4
PL1
2
1
COM
LO
MED LO
MED HI
HI
EQUIPMENT GROUND
PL5
HI/LO
GND
BLWR
24VAC
115VAC
NOTE #6
TRAN
PR1
PL2
FAN
EAC-1
HSIR
L2
A99407
1. If any of the original equipment wire is replaced use wire rated for 105°C.
2. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).
3. Blower motor speed selections are for average conditions, see installation instructions for details on
optimum speed selection.
4. Use only copper wire between the disconnect switch and the furnace junction box (JB).
5. This wire must be connected to furnace sheet metal for control to detect flame.
6. Replace only with a 3 amp fuse.
7. Blower-on delay, gas heating 45 seconds, cooling or heat pump 2 seconds.
8. Blower-off delay, gas heating 90, 135, 180 or 225 seconds, cooling or heat pump 90 seconds.
9. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will auto-reset
after three hours.
10. When used, auxiliary limit switch (ALS) is on some downflow models only. When used, FL is on
upflow models only. FRS1 and FRS2 only used downflow and horizontal models.
11. Factory connected when LGPS is not used.
12. Factory connected when BVSS is not used. BVSS used when Chimney Adapter Accessory Kit is
installed.
325771-101 REV. B
NOTES:
COM
G
Y1
IDR
TEST/TWIN
DHUM
Y/Y2
W
R
HUM
ILK
BLWR
L1
L1
TO 115VAC FIELD DISCONNECT
NOTE #4
Fig. 16—Furnace Wiring Diagram
PLUG RECEPTACLE
FIELD SPLICE
EQUIPMENT GROUND
FIELD EARTH GROUND
FIELD WIRING TERMINAL
CONDUCTOR ON PCB
FIELD WIRING (24VAC)
FIELD WIRING (115VAC)
FACTORY WIRING (24VAC)
FACTORY WIRING (115VAC)
PCB TERMINAL
UNMARKED TERMINAL
10-CIRCUIT PCB CONNECTOR
2-CIRCUIT PCB CONNECTOR
3-CIRCUIT ADAPTER CONNECTOR
2-CIRCUIT ADAPTER CONNECTOR
2-CIRCUIT HSI, PCB CONNECTOR
9-CIRCUIT ADAPTER CONNECTOR
PRESSURE SWITCH, SPST-(N.O.)
COMPONENT TEST & TWIN TERMINAL
TRANSFORMER-115VAC/24VAC
JUNCTION
FUSED OR CIRCUIT BREAKER
DISCONNECT SWITCH (WHEN REQ'D)
NOTE #4
NEUTRAL
WHT
L1
BLK
FU2
GRN
WHT
BLK
WHT
BLK
WHT
WHT
GND
GRN
JB
BLK
PL5
RED
BLU
FRS1
(WHEN USED) NOTE #10
PL1
PL2
PL3
PL5
PL6
PL7
PRS
TEST/TWIN
TRAN
1
2
3
PL3
GRN
LS
NOTE #12
ORN
(WHEN USED)
NOTE #10
ALS
ORN ORN
(WHEN USED)
NOTE #12
BVSS
ORN
RED
DSS
WHT
BLOWER MOTOR RELAY, SPST-(N.O.)
BLOWER MOTOR
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FAN SELECT RELAY
FUSE LINK
FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FLAME PROVING ELECTRODE
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
(FIELD INSTALLED & SUPPLIED)
EQUIPMENT GROUND
GAS VALVE-REDUNDANT OPERATORS
GAS VALVE RELAY, DPST-(N.O.)
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
HOT SURFACE IGNITOR (115 VAC)
HOT SURFACE IGNITOR RELAY, SPST-(N.O.)
24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)
INDUCED DRAFT MOTOR
INDUCED DRAFT RELAY, SPST-(N.O.)
BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
JUNCTION BOX
LIGHT-EMITTING DIODE FOR STATUS CODES
LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LIMIT SWITCH, AUTO RESET, SPST(N.C.)
AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.
PRINTED CIRCUIT BOARD
LEGEND
RED (LO)
OL
SPARE 2
PL1
J1
BLWM
HUM
FAN
EAC-2
LED 1
SEC-1
FU1
BLK (HI)
YEL
(MED HI)
BLU
(MED LO)
WHT
(COM)
SPARE 1
5
4
3
2
1
TEST/TWIN
225
180
G
Com
24V
W
90
135
1 2 3 4 5 6 7 8 9 10 11
Y1
RED
WHT
WHT
GRN
DHUM
L2
HEAT COOL
WHT
YEL
PCB
TRAN
BLOWER OFF DELAY
JUMPER SELECT
HSI
setting of FAN to HEAT speed. Momentarily turning off the
FAN switch again at the thermostat will shift the continuous
blower speed selection from HEAT to COOL. Repeating the
procedure will cause the control to shift from COOL to FAN
speed. The selection can be changed as many times as desired
and is stored in the memory to be automatically used following a power interruption.
When the R to G and Y1 circuit open, the furnace blower
continues operating on FAN speed for an additional 90 sec.
To set the cooling off-delay to 3 sec instead of 90, connect
a jumper between the Y1 and DHUM thermostat connects
on the furnace control.
c. Two-Speed Outdoor Unit with Thermidistat-See Figure 11
and 13.
5. Heat pump mode
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 and is
turned OFF when demand exists. Once 24 vac is detected
by the furnace control on the DHUM input, the control
operates in Thermidistat mode.
When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower
off time during demand defrost cycles. When the W-Y1,
W-Y/Y2, W-Y1-G, or W-Y/Y2-G thermostat inputs are received at the same time, the control changes the blower to
HEAT speed or starts the blower if it was off, and begins a
heating cycle. The blower remains on until the end of the
prepurge period, then shuts off until the end of the ignition
warm-up and trial for ignition periods (a total of 24 sec). The
blower then comes back on at HEAT speed.
The thermostat closes the R to G and Y1 circuits for low
cooling and the R to G, Y1 and Y/Y2 circuits for high
cooling. The R to Y1 circuit starts the outdoor unit on low
cooling and the R to G and Y1 circuits start the furnace
blower on FAN speed. The R to Y1 and Y2 circuits start the
outdoor unit on high cooling and the R to G, Y1 and Y2
circuits start the furnace blower in COOL speed. If the R to
Y2 circuit opens with the R to G and Y1 circuits still
closed, the outdoor unit will drop to low cooling and the
furnace control will drop the blower speed to FAN. When
the thermostat is satisfied, the R to G and Y1 circuits are
opened. The outdoor unit stops. When there is a dehumidify demand, the cooling blower off-delay is decreased
from 90 to 3 sec.
When the W input signal disappears, the control begins the
normal inducer post-purge period and the blower changes to
COOL speed after a 1-sec delay. If the W-Y/Y2-G or W-Y1-G
signals disappear at the same time, the blower remains on for
the selected heating blower off delay period and the inducer
goes through its normal post-purge period. If the W-Y1 or
W-Y/Y2 inputs should disappear, leaving the G signal input,
the blower remains on at HEAT speed for the selected blower
off-delay period and the inducer remains on for the normal
post-purge period. After the blower off-delay is completed the
control switches the blower to FAN speed.
Anytime the control senses false flame, the control locks out
of the heating mode. This occurs because the control cannot
sense the W input due to the false flame signal, and as a result,
sees only the Y/Y2 and/or Y1 input and goes into cooling
mode, blower off delay. All other control functions remain in
standard format.
In Two-Speed Cooling with only the R to G and Y1 circuits
closed and there is a demand for dehumidification, the
furnace control blower will remain at FAN speed. In high
cooling with a demand for dehumidification, the furnace
control will drop the blower speed from COOL to HEAT
for a maximum of 10 minutes before reverting back to
COOL speed. If there is still a demand for dehumidification
after 20 minutes, the control will drop the blower speed
back to HEAT speed. This alternating 10-minute cycle will
continue as long as there is a call for cooling. If the DHUM
input is low for more than 48 hours, the control reverts back
to non-Thermidistat operation.
NOTE: EAC-1 terminal is energized whenever blower operates.
HUM terminal is only energized when gas valve is energized
START-UP PROCEDURES
1. Purge gas lines—After all connections have been made, purge
the lines and check for leaks.
3. Continuous blower mode
Never purge a line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition for the
purpose of checking leakage. Use a soap-and-water solution
to check for leakage. Failure to follow this warning can cause
fire, explosion, personal injury, or death.
NOTE: EAC-1 terminal is energized with 115v whenever blower
operates.
When the R-G circuit is made, the blower motor operates on
FAN speed. During a call for heat, the blower stops, allowing
the furnace heat exchangers to heat up more quickly, then
restarts at the end of the 45-sec blower on delay period at
HEAT speed. If jumper is across PL7-6 AND PL7-9, the
blower on delay is 66 sec.
2. Component test—The furnace control board allows all components, except gas valve, to be run for a short period of time.
This feature helps diagnose a system problem in case of a
component failure. To initiate component test procedure, short
(jumper) the TEST 3/16-in. quick connect terminal on control
(behind the Y/Y2 terminal) and the COM-24V terminal on
furnace thermostat connection block for approximately 2 sec.
(See Fig. 15.)
The blower reverts back to FAN speed after the heating
blower OFF delay is completed.
When the thermostat "calls for cooling," the blower operates
on COOL speed. When the thermostat is satisfied, the blower
operates an additional 90 sec before reverting back to continuous operation on FAN speed.
NOTE: Component test feature will not operate if any thermostat
signal is present at control board.
4. Continuous blower speed selection from thermostat
Component test sequence is as follows.
To select different continuous blower speeds from the room
thermostat, momemtarily turn off the FAN switch or pushbutton on the room thermostat for 1-3 sec after the blower is
operating. The control will shift the blower speed from factory
a. Momentarily jumper TEST and COM-24V terminals until
LED goes off.
b. LED will display previous status code 4 times.
15
c. Inducer motor starts and continues to run for entire component test.
DO NOT bottom out gas valve regulator adjusting screw.
This can result in unregulated manifold pressure and result in
excess overtire and heat exchanger failures.
d. Hot surface igniter is energized for 15 sec, then deenergized.
e. Blower motor operates on FAN speed for 10 sec, then
stops.
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.
f. Blower motor operates on HEAT speed for 10 sec, then
stops.
g. Blower motor operates on COOL speed for 10 sec, then
stops
h. Inducer motor stops
3. To operate furnace, follow procedures on operating instructions label attached to furnace.
4. With furnace operating, set thermostat below room temperature and observe that furnace goes off. Set thermostat above
room temperature and observe that furnace restarts.
ADJUSTMENTS
1. Set gas input rate
Furnace gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft. Furnace input rate must be
within ±2 percent of input on furnace rating plate.
BURNER
ORIFICE
a. Determine natural gas orifice size and manifold pressure
for correct input.
(1.) Obtain average yearly gas heat value (at installed
altitude) from local gas supplier.
A93059
(2.) Obtain average yearly specific gas gravity from local
gas supplier.
DO NOT redrill orifices. Improper drilling (burrs, out-ofround holes, etc.) can cause excessive burner noise and
misdirection of burner flames. This can result in flame
impingement of burners and heat exchangers, causing failures.
(3.) Verify furnace model. Table 6 can only be used for
model 58WAV Furnaces.
(4.) Find installation altitude in Table 6.
NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A.
altitudes of 2001 to 3000 ft in Table 6.
(3.) After correct manifold pressure is obtained, replace
gas valve regulator adjustment screw cap and verify
adjusted gas input rate using method outlined in item
c.
(5.) Find closest natural gas heat value and specific gravity
in Table 6.
(6.) Follow heat value and specific gravity lines to point of
intersection to find orifice size and manifold pressure
settings for proper operation .
(4.) Burner flame should be clear blue, almost transparent.
(See Fig. 18.)
c. Verify natural gas input rate by clocking gas meter.
EXAMPLE: (0—2000 ft altitude)
Heating value = 1025 Btu/cu ft
Specific gravity = 0.62
Therefore: Orifice No. 43*
Manifold pressure 3.3-in. wc
* Furnace is shipped with No. 43 orifices. In this example
all main burner orifices are the correct size and do not need
to be changed to obtain proper input rate.
NOTE: High-Altitude Adjustment
United States
At installation altitudes above 2000 ft, this furnace has been
approved for a 4 percent derate for each 1000 ft above sea level.
See Table 7 for derate multiplier factor.
EXAMPLE:
88,000 Btuh input furnace installed at 4300 ft.
(7.) Check and verify burner orifice size in furnace.
NEVER ASSUME ORIFICE SIZE. ALWAYS
CHECK AND VERIFY.
Furnace Input
Rate at
Sea Level
X
Derate
Multiplier
Factor
=
88,000
X
0.82
=
b. Adjust manifold pressure to obtain input rate.
Furnace Input Rate
at Installation Altitude
72,160
(1.) Remove regulator adjustment seal cap. (See Fig. 17.)
(2.) Turn adjusting screw, counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase
manifold pressure.
Canada
At installation altitudes from 2000 to 4500 ft, this furnace must be
derated 10 percent by an authorized Gas Conversion Station. To
determine correct input rate for altitude, see example above and
use 0.90 as derate multiplier factor.
NOTE: This furnace has been approved for a manifold pressure
of 3.2-in. wc to 3.8-in. wc when installed at altitudes up to 2000 ft.
For altitudes above 2000 ft, the manifold pressure can be adjusted
from 2.0-in. wc to 3.8-in. wc.
a. Turn off all other gas appliances and pilots.
16
Table 6—Model 58WAV Orifice Size* and Manifold Pressure for Correct Input
(Tabulated Data Based on 22,000 Btuh per Burner, Derated 4 Percent per 1000 Ft Above Sea Level)
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
0
to
2000
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
4500
U.S.A. Only
ALTITUDE
RANGE
(FT)
3001
to
4000
U.S.A. Only
ALTITUDE
RANGE
(FT)
4001
to
5000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
850
875
900
925
950
975
1000
1025
1050
1075
1100
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
775
800
825
850
875
900
925
950
975
1000
1025
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
750
775
800
825
850
875
900
925
950
975
1000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
725
750
775
800
825
850
875
900
925
950
0.58
Orifice Manifold
No.
Pressure
42
3.6
42
3.4
42
3.2
43
3.7
43
3.6
43
3.4
43
3.2
44
3.5
44
3.3
45
3.8
45
3.7
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.8
41
3.5
41
3.6
42
3.6
42
3.7
42
3.8
42
3.4
42
3.5
42
3.6
42
3.2
42
3.3
42
3.4
43
3.7
43
3.8
42
3.2
43
3.5
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
43
3.2
43
3.3
43
3.4
44
3.4
44
3.6
43
3.2
44
3.3
44
3.4
44
3.5
45
3.8
44
3.2
44
3.4
Orifice
No.
41
41
42
42
42
43
43
43
43
43
44
0.66
Manifold
Pressure
3.7
3.5
3.7
3.5
3.3
3.8
3.6
3.5
3.3
3.2
3.5
0.58
Orifice Manifold
No.
Pressure
42
3.4
43
3.8
43
3.6
43
3.4
43
3.2
43
3.0
43
2.9
43
2.7
43
2.6
43
2.5
43
2.3
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.5
42
3.6
42
3.7
42
3.3
42
3.4
42
3.5
43
3.7
42
3.2
42
3.3
43
3.5
43
3.6
43
3.8
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
3.0
43
3.1
43
3.2
43
2.8
43
2.9
43
3.0
43
2.7
43
2.8
43
2.9
43
2.5
43
2.6
43
2.7
43
2.4
43
2.5
43
2.6
Orifice
No.
42
42
42
42
43
43
43
43
43
43
43
0.66
Manifold
Pressure
3.8
3.6
3.4
3.2
3.6
3.4
3.3
3.1
2.9
2.8
2.7
0.58
Orifice Manifold
No.
Pressure
43
3.8
43
3.6
43
3.4
43
3.2
43
3.0
43
2.8
43
2.7
43
2.5
43
2.4
43
2.3
43
2.2
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.3
42
3.4
42
3.5
43
3.7
43
3.8
42
3.3
43
3.5
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
2.9
43
3.0
43
3.1
43
2.8
43
2.9
43
2.9
43
2.6
43
2.7
43
2.8
43
2.5
43
2.6
43
2.6
43
2.4
43
2.4
43
2.5
43
2.2
43
2.3
43
2.4
Orifice
No.
42
42
43
43
43
43
43
43
43
43
43
0.66
Manifold
Pressure
3.6
3.4
3.8
3.6
3.4
3.2
3.0
2.9
2.7
2.6
2.5
0.58
Orifice Manifold
No.
Pressure
43
3.6
43
3.4
43
3.2
43
3.0
43
2.8
43
2.6
43
2.5
43
2.3
43
2.2
43
2.1
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.7
42
3.2
42
3.3
43
3.5
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
2.9
43
3.0
43
3.1
43
2.7
43
2.8
43
2.9
43
2.6
43
2.6
43
2.7
43
2.4
43
2.5
43
2.6
43
2.3
43
2.4
43
2.4
43
2.2
43
2.2
43
2.3
Orifice
No.
42
43
43
43
43
43
43
43
43
43
0.66
Manifold
Pressure
3.4
3.8
3.6
3.4
3.2
3.0
2.8
2.7
2.5
2.4
* Orifice sizes shown in BOLD are factory installed.
17
Table 6—Model 58WAV Orifice Size* and Manifold Pressure for Correct Input (Continued)
(Tabulated Data Based on 22,000 Btuh per Burner, Derated 4 Percent per 1000 Ft Above Sea Level)
U.S.A. Only
ALTITUDE
RANGE
(FT)
5001
to
6000
U.S.A. Only
ALTITUDE
RANGE
(FT)
6001
to
7000
U.S.A. Only
ALTITUDE
RANGE
(FT)
7001
to
8000
U.S.A. Only
ALTITUDE
RANGE
(FT)
8001
to
9000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
700
725
750
775
800
825
850
875
900
925
950
975
1000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
650
675
700
725
750
775
800
825
850
875
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
625
650
675
700
725
750
775
800
825
850
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
600
625
650
675
700
725
750
775
800
0.58
Orifice Manifold
No.
Pressure
43
3.4
43
3.1
43
2.9
43
2.7
43
2.6
43
2.4
43
2.3
43
2.2
43
2.0
48
3.6
48
3.4
49
3.8
49
3.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.5
43
3.6
43
3.7
43
3.2
43
3.4
43
3.5
43
3.0
43
3.1
43
3.2
43
2.8
43
2.9
43
3.0
43
2.7
43
2.8
43
2.8
43
2.5
43
2.6
43
2.7
43
2.4
43
2.4
43
2.5
43
2.2
43
2.3
43
2.4
43
2.1
43
2.2
43
2.2
48
3.8
43
2.1
43
2.1
48
3.6
48
3.7
43
2.0
48
3.4
48
3.5
48
3.6
49
3.8
48
3.3
48
3.4
Orifice
No.
43
43
43
43
43
43
43
43
43
43
43
48
48
0.66
Manifold
Pressure
3.8
3.6
3.3
3.1
2.9
2.8
2.6
2.5
2.3
2.2
2.1
3.7
3.5
0.58
Orifice Manifold
No.
Pressure
43
3.4
43
3.1
43
2.9
43
2.7
43
2.5
43
2.4
43
2.2
43
2.1
48
3.7
48
3.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.5
43
3.6
43
3.7
43
3.2
43
3.4
43
3.5
43
3.0
43
3.1
43
3.2
43
2.8
43
2.9
43
3.0
43
2.6
43
2.7
43
2.8
43
2.5
43
2.5
43
2.6
43
2.3
43
2.4
43
2.5
43
2.2
43
2.2
43
2.3
43
2.0
43
2.1
43
2.2
48
3.6
48
3.8
43
2.1
Orifice
No.
43
43
43
43
43
43
43
43
43
43
0.66
Manifold
Pressure
3.8
3.6
3.3
3.1
2.9
2.7
2.5
2.4
2.3
2.1
0.58
Orifice Manifold
No.
Pressure
43
3.1
43
2.9
43
2.7
43
2.5
43
2.3
43
2.2
43
2.0
48
3.6
48
3.4
49
3.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.3
43
3.4
43
3.5
43
3.0
43
3.1
43
3.2
43
2.8
43
2.9
43
3.0
43
2.6
43
2.7
43
2.8
43
2.4
43
2.5
43
2.6
43
2.3
43
2.3
43
2.4
43
2.1
43
2.2
43
2.3
48
3.7
43
2.1
43
2.1
48
3.5
48
3.6
48
3.8
48
3.3
48
3.4
48
3.5
Orifice
No.
43
43
43
43
43
43
43
43
43
48
0.66
Manifold
Pressure
3.6
3.3
3.1
2.9
2.7
2.5
2.3
2.2
2.1
3.6
0.58
Orifice Manifold
No.
Pressure
43
2.9
43
2.7
43
2.5
43
2.3
43
2.2
43
2.0
48
3.5
48
3.3
49
3.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.0
43
3.1
43
3.2
43
2.8
43
2.9
43
3.0
43
2.6
43
2.7
43
2.8
43
2.4
43
2.5
43
2.6
43
2.2
43
2.3
43
2.4
43
2.1
43
2.1
43
2.2
48
3.6
43
2.0
43
2.1
48
3.4
48
3.5
48
3.6
49
3.8
48
3.3
48
3.4
Orifice
No.
43
43
43
43
43
43
43
48
48
0.66
Manifold
Pressure
3.3
3.1
2.8
2.6
2.4
2.3
2.1
3.8
3.5
* Orifice sizes shown in BOLD are factory installed.
18
Table 6—Model 58WAV Orifice Size* and Manifold Pressure for Correct Input (Continued)
(Tabulated Data Based on 22,000 Btuh per Burner, Derated 4 Percent per 1000 Ft Above Sea Level)
U.S.A. Only
ALTITUDE
RANGE
(FT)
9001
to
10,000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
575
600
625
650
675
700
725
750
775
0.58
Orifice Manifold
No.
Pressure
43
2.7
43
2.5
43
2.3
43
2.1
48
3.7
48
3.4
49
3.8
49
3.5
49
3.3
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice Manifold Orifice Manifold Orifice Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
2.8
43
2.9
43
3.0
43
2.6
43
2.7
43
2.7
43
2.4
43
2.4
43
2.5
43
2.2
43
2.3
43
2.3
43
2.0
43
2.1
43
2.2
48
3.6
48
3.7
43
2.0
48
3.3
48
3.4
48
3.5
49
3.6
49
3.8
48
3.3
49
3.4
49
3.5
49
3.6
Orifice
No.
43
43
43
43
43
43
48
48
49
0.66
Manifold
Pressure
3.1
2.8
2.6
2.4
2.2
2.1
3.6
3.4
3.7
* Orifice sizes shown in BOLD are factory installed.
Table 7—Altitude Derate Multiplier for U.S.A.
ALTITUDE
(FT)
0—2000
2001—3000
3001—4000
4001—5000
5001—6000
6001—7000
7001—8000
8001—9000
9001—10,000
% OF
DERATE
0
8—12
12—16
16—20
20—24
24—28
28—32
32—36
36—40
Table 8—Gas Rate (Cu Ft/Hr)
DERATE MULTIPLIER
FACTOR FOR U.S.A.*
1.00
0.90
0.86
0.82
0.78
0.74
0.70
0.66
0.62
SECONDS
FOR 1
REVOLUTION
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
* Derate multiplier factor is based on midpoint altitude for altitude range.
b. Start furnace and let operate for 3 minutes.
c. Measure time (in sec) for gas meter test dial to complete 1
revolution.
d. Refer to Table 8 for cu ft of gas per hr.
e. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft)
using natural gas heating value from local gas
utility/supplier.
EXAMPLE: (0—2000 ft altitude)
Furnace input from rating plate is 110,000
Btu heating input = Btu/cu ft X cu ft/hr
Heating value of gas = 1050 Btu/cu ft Time for 1 revolution
of 2-cu ft dial = 70 sec
Gas rate = 103 cu ft/hr (from Table 8)
Btu heating input = 103 X 1050 = 108,150 Btuh
In this example, the orifice size and manifold pressure
adjustment is within ±2 percent of the furnace input rate.
2. Set temperature rise.
Furnace must operate within range of temperature rise specified on the furnace rating plate. Determine the air temperature
rise as follows.
a. Place duct thermometers in return and supply ducts as near
furnace as possible. Be sure thermometers do not "see" heat
exchangers so that radiant heat will not affect thermometer
readings. This is particularly important with straight-run
ducts.
b. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine temperature rise.
19
SIZE OF
SIZE OF
SECONDS
TEST DIAL
TEST DIAL
FOR 1
1
2
5
2
5
REVOLUTION 1
cu ft cu ft cu ft
cu ft cu ft cu ft
360 720 1800
50
72 144 360
327 655 1636
51
71 141 355
300 600 1500
52
69 138 346
277 555 1385
53
68 136 340
257 514 1286
54
67 133 333
240 480 1200
55
65 131 327
225 450 1125
56
64 129 321
212 424 1059
57
63 126 316
200 400 100
58
62 124 310
189 379 947
59
61 122 305
180 360 900
60
60 120 300
171 343 857
62
58 116 290
164 327 818
64
56 112 281
157 313 783
66
54 109 273
150 300 750
68
53 106 265
144 288 720
70
51 103 257
138 277 692
72
50 100 250
133 267 667
74
48
97 243
129 257 643
76
47
95 237
124 248 621
78
46
92 231
120 240 600
80
45
90 225
116 232 581
82
44
88 220
113 225 563
84
43
86 214
109 218 545
86
42
84 209
106 212 529
88
41
82 205
103 206 514
90
40
80 200
100 200 500
92
39
78 196
97 195 486
94
38
76 192
95 189 474
96
38
75 188
92 185 462
98
37
74 184
90 180 450
100
36
72 180
88 176 439
102
35
71 178
86 172 429
104
35
69 173
84 167 419
106
34
68 170
82 164 409
108
33
67 167
80 160 400
110
33
65 164
78 157 391
112
32
64 161
76 153 383
116
31
62 155
75 150 375
120
30
60 150
73 147 367
ON AND
OFF SWITCH
Recheck temperature rise. It must be within limits specified
on unit rating plate. Recommended operation is at midpoint of
rise or above.
GAS
PRESSURE
REGULATOR
ADJUSTMENT
3. Set thermostat heat anticipator.
The thermostat heat anticipator must be set to match the amp
draw of the electrical components in the R-W circuit. Accurate
amp draw readings can be obtained at thermostat subbase
terminals R and W. Fig. 19 illustrates an easy method of
obtaining the actual amp draw. The amp reading should be
taken after the blower motor has started. See the thermostat
manufacturer’s instructions for adjusting the heat anticipator
and for varying the heating cycle length.
INLET
PRESSURE TAP
NOTE: When using an electronic thermostat, set the cycle rate for
3 cycles per hr.
MANIFOLD
PRESSURE TAP
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
A95618
Fig. 17—Redundant Automatic Gas Control Valve
BURNER FLAME
HOOK-AROUND
AMMETER
BURNER
R Y W G
10 TURNS
MANIFOLD
FROM UNIT 24-V
CONTROL TERMINALS
A89020
Fig. 18—Burner Flame
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
c. Adjust air temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise. Decrease
blower speed to increase temperature rise.
A96316
Fig. 19—Amp Draw Check With Ammeter
CHECK SAFETY CONTROLS — The flame sensor, gas valve,
and pressure switch were all checked in the Start-Up Procedures
section as part of normal operation.
Disconnect the electrical power before changing the speed
tap. A failure to follow this warning can cause personal
injury.
1. Check primary limit control.
This control shuts off the combustion control system and
energizes the circulating-air blower motor if the furnace
overheats.
d. To change blower motor speed selections for heating mode,
remove blower motor lead from control HEAT terminal.
(See Fig. 15.) Select desired blower motor speed lead from
1 of the other terminals and relocate it to HEAT terminal.
See Table 9 for lead color identification. Reconnect original lead on SPARE terminal.
The preferred method of checking the limit control is to
gradually block off the return air after the furnace has been
operating for a period of at least 5 minutes. As soon as the
limit has shut off the burners, the return-air opening should be
unblocked. By using this method to check the limit control, it
can be established that the limit is functioning properly and
operates if there is a motor failure.
Table 9—Speed Selector
COLOR
SPEED
Black
Yellow (When
present)
Blue
Red
White
High
FACTORYATTACHED TO
COOL
Medium-High
SPARE
Medium-Low
Low
Common
HEAT
FAN
L2
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
2. Check blocked vent safeguard switch.
The purpose of this control is to permit the safe shutdown of
the furnace during certain blocked vent conditions.
a. Disconnect power to furnace and remove vent connector
from furnace outlet collar. Be sure to allow time for vent
pipe to cool down before removing.
20
b. Restore power to furnace and set room thermostat above
room temperature.
status code 31. If hot surface igniter glows when inducer
motor is disconnected, shut down furnace immediately.
Determine reason pressure switch did not function properly
and correct condition.
c. After normal start-up, allow furnace to operate for 2
minutes, then block flue outlet 100 percent. Furnace should
cycle off within 2 minutes.
e. Turn off 115-v power to furnace.
d. Remove blockage and reconnect vent pipe to furnace outlet
collar.
f. Reconnect inducer motor wires, replace control door, and
turn on 115-v power.
e. Wait 5 minutes and then reset blocked vent safeguard
switch.
CHECKLIST
1. Put away tools, instruments, and clean up debris.
3. Check pressure switch.
This control proves operation of draft inducer blower.
2. Verify manual reset switches have continuity.
a. Turn off 115-v power to furnace.
3. Ensure blower and control access doors are properly installed.
b. Remove control door and disconnect inducer motor lead
wires from wire harness.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s instructions.
c. Turn on 115-v power to furnace.
d. Set thermostat to "call for heat" and wait 1 minute. When
pressure switch is functioning properly, hot surface igniter
should NOT glow and control diagnostic light flashes a
6. Review User’s Manual with owner.
7. Leave literature packet near furnace.
21
CHECKLIST—INSTALLATION
LOAD CALCULATION
____________
Heating Load (Btuh)
____________
Cooling Load (Btuh)
____________
Furnace Model Selection
____________
AIR FOR COMBUSTION AND VENTILATION
Unconfined Space
____________
Confined Space
VENTING
____________
NFGC (United States)
____________
NSCNGPIC (Canada)
____________
Local Codes
____________
1/4-in. Upward Slope
____________
Joints Secure
____________
See Attached Vent Table Instructions
CHECKLIST—START-UP
____________
Gas Input Rate
(Set Within 2 percent of Rating Plate)
____________
Temperature Rise Adjusted
____________
Thermostat Anticipator Setting Adjusted or
____________
Thermostat Cycle Rate (3 cycles per Hr)
CHECK SAFETY CONTROLS OPERATION
____________
Primary Limit
____________
Pressure Switches
____________
Draft Safeguard Switch
22
23
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization
• Maintenance
• Installation Overview
• Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training
[ ] Classroom Service Training
A94328
Copyright 2000 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
58wav9si
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-757
Printed in U.S.A.
Form 58WAV-9SI
Pg 24
1-00
Replaces: New
Tab 6a 8a