Carrier 2-STAGE 58TMA Operating instructions

58TMA
Downflow/Horizontal 2-Speed, 2-Stage,
Induced-Combustion Gas Furnace
Visit www.carrier.com
Installation, Start-Up, and Operating Instructions
Sizes 065-125, Series 120 and 130
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index
Page
SAFETY CONSIDERATIONS .....................................................1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE ...........................................................................2
INTRODUCTION.......................................................................2-4
Dimensional Drawing ...............................................................2
Clearances to Combustibles......................................................3
LOCATION ................................................................................4-5
General ......................................................................................4
Location Relative to Cooling Equipment ................................4
Hazardous Locations.................................................................5
AIR FOR COMBUSTION AND VENTILATION...................5-6
Unconfined Space .....................................................................5
Confined Space......................................................................5-6
AIR DUCTS................................................................................6-7
General Requirements...............................................................6
Ductwork Acoustical Treatment...............................................6
Supply Air Connections............................................................6
Return Air Connections ............................................................7
SUPPLY-AIR PLENUM INSTALLATION (DOWNFLOW) .....7
Installation On Combustible Floor...........................................7
HORIZONTAL ATTIC INSTALLATIONN ................................7
HORIZONTAL CRAWLSPACE INSTALLATION ..................7
FILTER ARRANGEMENT...........................................................7
GAS PIPING...............................................................................7-9
ELECTRICAL CONNECTIONS.............................................9-13
115-v Wiring........................................................................9-11
24-v Wiring........................................................................11-12
Accessories .......................................................................12-13
VENTING ....................................................................................13
START-UP, ADJUSTMENT, AND SAFETY CHECK.......13-24
General ....................................................................................13
Sequence of Operation............................................................14
Adaptive Heating Mode ....................................................14-16
Non-Adaptive Heating Mode .................................................16
Cooling Mode .........................................................................16
Continuous Blower Mode .................................................16-17
Heat Pump Mode ....................................................................17
Defrost Mode ..........................................................................17
Start-Up Procedures...........................................................17-18
Adjustments .......................................................................18-24
Set Gas Input Rate ............................................................18-23
Set Temperature Rise ........................................................22-23
Set Thermostat Heat Anticipator............................................23
Check Safety Controls.......................................................23-24
Checklist..................................................................................24
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. In
Canada, refer to the current edition of the CAN/CGA-B149.1- and
.2-M95 National Standard of Canada, Natural Gas and Propane
Installation Codes (NSCNGPIC). Wear safety glasses and work
gloves. Have a 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 unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards 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.
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.
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. 535-790
Printed in U.S.A.
Form 58TMA-8SI
Pg 1
10-00
Replaces: 58TMA-7SI
Tab 6a 8a
28 1⁄2″
VENT CONNECTION
20″
13⁄16″
INLET
D
13⁄16″
4 3⁄16″
1⁄2″ DIA
2″
THERMOSTAT
WIRE ENTRY
7⁄8″ DIA
2 15⁄16″
7⁄8″ DIA HOLE
POWER ENTRY
39 7⁄8″
7⁄8″ DIA
ACCESSORY
1 3⁄4″ DIA HOLE
GAS ENTRY
11⁄16″
ACCESSORY
OUTLET
19″
1 1⁄2″ DIA
R.H. GAS ENTRY
9 1⁄8″
16 1⁄16″
10 1⁄4″
1″ TYP
ACCESSORY
1 1⁄16″
2 1⁄8″
8 1⁄4″
E
A
11⁄16″
NOTE: ADDITIONAL 7⁄8″ DIA K.O. ARE
LOCATED IN THE TOP PLATE
AND BOTTOM PLATE
7⁄8″ DIA
13 5 ⁄16″
10 1⁄4″
11⁄16″
5⁄8″ TYP
1 1⁄16″
2 1⁄8″
AIRFLOW DIMPLES TO DRILL HOLES
FOR HANGER BOLTS (4 PLACES)
IN HORIZONTAL POSITION
A99109
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.
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, must use entire return air opening.
Fig. 1—Dimensional Drawing
Table 1—Dimensions (In.)
UNIT SIZE
065-08
065-12
085-12
085-16
105-16
105-20
125-20
A
14-3/16
14-3/16
17-1/2
17-1/2
17-1/2
21
24-1/2
D
12-9/16
12-9/16
15-7/8
15-7/8
15-7/8
19-3/8
22-7/8
E
12-11/16
12-11/16
16
16
16
19-1/2
23
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
VENT CONN
4
4
4
4
4
4
5
SHIP. WT
141
145
154
154
171
181
192
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 natural This furnace is approved for DOWNFLOW and HORIZONTAL
installations.
gas at altitudes 0-10,000 ft (0-3,050m).
An accessory kit, supplied by the manufacturer,shall be
used to convert to propane gas use or may be required for Clearance arrows
some natural gas applications.
do not change with
This furnace is for indoor installation in a building furnace orientation.
1"
constructed on site.
This furnace may be installed on combustible flooring in
alcove or closet at minimum clearance from combustible
material.
This furnace may be used with a Type B-1 Vent and may
0"
1"
be vented in common with other gas-fired appliances.
†† B
E *#
A
D
C
installation on non-combustible floors only.
K
SI
† For
CE
For installation on combustible flooring only when
NA
R
FU
installed on special base, Part No. KGASB0201ALL,
T
ON
Coil Assembly, Part No. CD5 or CK5, or Coil Casing,
FR
S
Part No. KCAKC.
E
RV
IC
# For furnaces wider than 14.25 inches (362mm) may
E
E
F
D
I
R
be 0 inches.
S
30"
O
N
MIN
T
Ø 18 inches front clearance required for alcove.
##
1"
#
*
Indicates supply or return sides when furnace is in
Ø
the horizontal position. Line contact only permissible
between lines formed by intersections of the Top and
two Sides of the furnace jacket, and building joists,
Clearance in inches
studs or framing.
## For single wall vent type 6 inches.
For Type B-1 vent type 3 inches.
Vent Clearance to combustibles:
†† Clearance to Back 0 inches (0 po) in downflow and
For Single Wall vents 6 inches (6 po).
horizontal (attic/alcove & crawlspace) positions and
For Type B-1 vent type 1 inch (1 po).
3 inches (3 po) in horizontal closet positions.
322286-101 REV. E (LIT)
†1
"#
BOTTOM
*
A97617
Fig. 2—Clearances to Combustibles
INTRODUCTION
The model 58TMA Series 120 and 130 Furnace is available in
sizes 65,000 through 123,000 Btuh input capacities.
The design of the downflow/horizontal gas-fired furnace is C.S.A.
(A.G.A./C.G.A.) certified for natural and propane gases and for
installation on noncombustible flooring. The furnace is factoryshipped for use with natural gas. The manufacturer’s accessory gas
conversion kit is required to convert furnace for use with propane
gas.
These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring. In
downflow installations, the manufacturer’s accessory floor base
must be used when installed on combustible materials and wood
flooring. Special base is not required when this furnace is installed
on manufacturer’s Coil Assembly Part No. CD5 or CK5, or when
Coil Box Part No. KCAKC is used. This furnace is for installation
in alcoves, attics, crawlspaces, basements, closets, or utility rooms.
The design of this furnace line is not A.G.A./C.G.A. certified for
installation in mobile homes, recreation vehicles, or outdoors.
Before installing the furnace in the United States, refer to the
current edition of the NFGC and NFPA 90B. For copies of the
NFGC and NFPA 90B, contact the National Fire Protection
Agency Inc., Batterymarch Park, Quincy, MA 02269; or the
American Gas Association, 1515 Wilson Blvd., Arlington, VA.
22209.
Before installing the furnace in Canada, refer to the current edition
of the NSCNGPIC. For a copy of the NSCNGPIC, contact
Standard Sales, CSA International, 178 Rexdale Blvd., Etobicoke
(Toronto), Ontario, Canada M9W 1R3.
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 the absence of local building
codes, installation must comply with the NFGC in the United
States and the NSCNGPIC in Canada.
These instructions cover minimum requirements for a safe installation 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 pace with
changing residential construction practices. We require these
instructions as a minimum for a safe installation.
The duct system should be designed and sized according to
accepted national standards published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning
Contractors National Association (SMACNA). Or consult the
Residential Systems Design Guidelines reference tables available
from your local distributor. The duct system should be sized to
handle the maximum CFM capabilities of the equipment at the
optimum design static pressure.
3
NOTE: Remove all shipping brackets and materials before operating furnace.
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.
Step 1—Location
GENERAL
DO NOT install furnace in a corrosive or contaminated
atmosphere. Make sure all combustion and circulating air
requirements are followed.
DO NOT use this furnace during construction when adhesives, sealers, and/or new carpets are being installed and
curing. If the furnace is required during construction, use
clean outside air for combustion and ventilation. Compounds
of chlorine and fluorine when burned in combustion air form
acids which will cause corrosion of the heat exchangers and
metal vent systems. Some of these compounds are released
from 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.
Installation must conform to regulations of serving gas supplier
and local building, heating, and plumbing codes in effect in the
area in which installation is made, or in absence of local codes with
requirements of the NFGC.
°F
°F
RETURN AIR
MAX 85°F
MIN 55°F
This furnace must be installed so electrical components are
protected from water.
FRONT
Locate furnace as near to center of air distribution system and
chimney or vent as possible. The furnace should be installed as
level as possible.
When furnace is installed so that supply ducts carry air to areas
outside space containing furnace, the return air must also be
handled by a duct(s) sealed to furnace casing and terminating
outside space containing furnace.
Provide ample space for servicing and cleaning. Always comply
with minimum fire protection clearances shown on unit clearance
label. This furnace shall not be installed directly on carpeting, tile,
or any combustible material other than wood flooring. The furnace
may be installed on combustible flooring when installed with
accessory downflow subbase, which is available from your distributor or branch when required.
A99093
NOTE: These furnaces are designed for a minimum continuous return-air temperature of 60°F or intermittent operation
down to 55°F such as when used with a night setback
thermostat. Return-air temperature must not exceed a maximum of 85°F. Failure to follow these return-air temperature
limits may affect reliability of heat exchangers, motors, and
controls.
LOCATION RELATIVE TO COOLING EQUIPMENT
The cooling coil must be installed parallel with or on downstream
side of furnace to avoid condensation in heat exchangers. When
installed parallel with furnace, dampers or other means used to
control the flow of air must prevent chilled air from entering
furnace. If dampers are manually operated, they must be equipped
with means to prevent operation of either unit unless damper is in
full-heat or full-cooling position.
To aid in installation, troubleshooting, and service, a status code
label is located on blower component door. This label explains
how to use the LED status indicated on furnace control which is
viewed through the sight glass on door.
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, loss of life, 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. A failure to follow this warning could
result in electrical shock, fire, personal injury, or death.
For high-altitude installation, the high-altitude conversion kit must
be installed at or above 5500 ft above sea level.
For accessory installation details, refer to applicable installation
literature.
4
For Example:
HAZARDOUS LOCATIONS
58TMA FURNACE
HIGH-FIRE INPUT
BTUH
63,000
84,000
105,000
123,000
18-IN. MINIMUM
TO BURNERS
MINIMUM SQ FT
WITH
7-1/2 FT CEILING
420
560
700
820
If the unconfined space is constructed unusually tight, air for
combustion and ventilation MUST come from either the outdoors
or spaces freely communicating with outdoors. Combustion and
ventilation openings must be sized the same as for a confined
space as defined below. Return air must not be taken from the
room unless equal or greater amount of air is supplied to the room.
CONFINED SPACE
A93044
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.
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.
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.
Step 2—Air for Combustion and Ventilation
Provisions for adequate combustion and ventilation air must be
provided in accordance with Section 5.3, Air for Combustion and
Ventilation, of the NFGC or applicable provisions of local building
codes.
The size of the openings depends upon whether air comes from
outside of the structure or an unconfined space inside the structure.
Canadian installations must be in accordance with NSCNGPIC
and all authorities having jurisdiction.
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.
1. All air an unconfined space from inside the structure requires
2 openings (for structures not usually tight):
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.
b. If the 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 to obtain return air 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:
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, or fireplaces could create a negative air
pressure condition at the furnace. Make-up air must be
provided for these devices, in addition to that required by the
furnace.
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.)
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 equipment room or space. In
addition, a positive seal MUST be made between furnace cabinet
and return-air duct to avoid pulling air from the burner area and
draft safeguard opening into circulating air.
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.
The requirements for combustion and ventilation air depend upon
whether furnace is located in a CONFINED or UNCONFINED
space.
UNCONFINED SPACE
An unconfined space must have at least 50 cu ft for each 1000
Btuh of input for all appliances (such as furnaces, clothes dryer,
water heaters, etc.) in the space.
5
DUCTS TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
VENT THROUGH ROOF
(CATEGORY I)
12″ MAX
INTERIOR
HEATED
SPACE
12″ MAX
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6″ MIN
(FRONT) †
D
AIR
DUCTS
TO
OUTSIDE
1 SQ IN.
PER 2000
BTUH*
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12″ MAX
12″ MAX
SUPPLY AIR
SUPPLY AIR
12″
MAX
A RETURN VENT
THROUGH
ROOF
(CATEGORY I)
F
1 SQ IN.
PER 4000
BTUH*
CONFINED
SPACE
RETURN
AIR
1 SQ IN.
PER 2000
BTUH*
E
B
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
G
12″
MAX
C
12″ MAX
DUCT
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH
*Minimum dimensions of 3 in.
NOTE: Use any of the following
combinations of openings:
A&B C&D D&E F&G
* Minimum opening size is 100 sq in. with
minimum dimensions of 3 in.
† Minimum of 3 in. when type B-1 vent is used.
A93387
A93388
Fig. 3—Confined Space: Air for Combustion and
Ventilation from an Unconfined Space
Fig. 4—Confined Space: Air for Combustion and
Ventilation from Outdoors
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.
DUCTWORK ACOUSTICAL TREATMENT
Metal duct systems that do not have a 90 degree elbow and 10 ft
of main duct to the first branch take-off may require internal
acoustical lining. As an 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
DOWNFLOW FURNACES
Connect supply-air duct to supply-air opening on furnace. The
supply-air duct attachment must ONLY be connected to furnace
supply-air outlet or air conditioning coil casing (when used), when
installed on non-combustible material. When installed on combustible material, supply-air duct attachment must 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, humidifier, or other accessories. All accessories
MUST be connected external to furnace main casing.
HORIZONTAL FURNACES
Connect supply-air duct to supply air opening on furnace. The
supply-air duct attachment must ONLY be connected to furnace
supply-air outlet or air conditioning coil casing (when used). DO
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.)
Step 3—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 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 CFM at the design static pressure.
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.
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 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.
6
Table 2—Free Area Of Combustion Air Opening
58TMA
FURNACE
HIGH-FIRE
INPUT
(BTUH)
63,000
84,000
105,000
123,000
AIR FROM
UNCONFINED SPACE
Free Area
of Opening
(Sq In.)
100
100
105
123
OUTDOOR AIR THROUGH
VERTICAL DUCTS
Free Area of
Round
Opening and Duct
Pipe
(Sq In.)
(In. Dia)
15.8
5
21.0
6
26.3
6
30.8
7
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.
OUTDOOR AIR THROUGH
HORIZONTAL DUCTS
Free Area of
Round
Opening and Duct
Pipe
(Sq In.)
(In. Dia)
31.5
7
42.0
8
52.5
9
61.5
9
OUTDOOR AIR THROUGH
SINGLE DUCT
Free Area of
Round
Opening and Duct
Pipe
(Sq In.)
(In. Dia)
21.0
6
28.0
6
35.0
7
41.0
8
6. Install 24- X 24-in. sheet metal shield on platform in front of
louvered control panel as shown in Fig. 9.
RETURN AIR CONNECTIONS
DOWNFLOW AND HORIZONTAL FURNACES
Step 6—Horizontal Crawlspace Installation
The furnace can be installed horizontally with either the LH or RH
side up. In a crawlspace, furnace can either be hung from floor
joist (see Fig. 10) or installed on suitable blocks or pad. (See Fig.
11.) The furnace can be suspended from each corner by hanger
bolts (4 each 3/8-in. all-thread rod) cut to desired length, 1- X
3/8-in. flat washer, 3/8-in. lockwasher, and 3/8-in. nut. Dimples
are provided for hole locations. (See Fig. 1.)
Since horizontal crawlspace installation is very similar to attic
installation, refer to Step 4. The installation of a sheet metal shield
in front of louvered control panel is covered in Step 4. For a
crawlspace installation, this same sheet metal shield must be
installed above louvered control panel. Extend sheet metal shield
over furnace top far enough to cover gas pipe entry hole.
Step 7—Filter Arrangement
The return-air duct must be connected to return-air inlet opening
provided as shown in Fig. 1. 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.
Step 4—SUPPLY AIR PLENUM INSTALLATION (DOWNFLOW)
DOWNFLOW INSTALLATION
NOTE: This furnace is approved for use on combustible flooring
when manufacturer’s accessory floor base Part No.
KGASB0201ALL is used. Manufacturer’s accessory floor base is
not required when this furnace is installed on manufacturer’s Coil
Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is
used.
1. Determine application being installed from Table 3.
2. Construct hole in floor per dimensions specified in Table 3
and Fig. 5.
Never operate unit without a filter or with filter access door
removed. A failure to follow this warning could result in fire,
personal injury, or death.
3. Construct plenum to dimensions specified in Table 3.
4. If downflow subbase (KGASB) is used, install as shown in
Fig. 6.
The 2 factory-supplied filters are shipped in the blower compartment. After return-air duct has been connected to furnace, install
filters in a V-formation inside return-air plenum. See Fig. 12 and
Table 4 for horizontal applications. Horizontal filter retainers must
be field supplied. See Fig. 13 for downflow applications.
Step 8—Gas Piping
Gas piping must be installed in accordance with national and local
codes. Refer to the NFGC NFPA 54-1999/ANSI Z223.1-1999.
Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction.
The gas supply line should be a separate line directly from the
meter to the furnace, if possible. Refer to Table 5 for recommended gas pipe sizing. Risers should be used to connect to the
furnace and to the meter.
If coil assembly CD5, CK5, or Coil Box KCAKC is used,
install as shown in Fig. 7.
INSTALLATION ON COMBUSTIBLE FLOOR
1. Cut and frame hole in floor per dimensions in Installation
Instructions packaged with downflow subbase.
2. When completed, downflow subbase, plenum, and furnace (or
coil casing when used) should be installed as shown in Fig. 6.
Step 5—Horizontal Attic Installation
The furnace can be installed horizontally on either the left-hand
(LH) or right-hand (RH) side. A typical attic installation is shown
in Fig. 9.
If flexible connector is required or allowed by authority
having jurisdiction, black iron pipe shall be installed at gas
valve and extend a minimum of 2 in. outside furnace casing.
CONSTRUCT WORKING PLATFORM
Construct working platform on location where all required furnace
clearances are met. (See Table 1 and Fig. 9.)
INSTALL FURNACE
POSITION FURNACE IN DESIRED LOCATION.
3. Connect gas supply pipe. See Fig. 9 for typical piping entry.
4. Connect supply- and return-air ducts.
5. Install field-supplied filter retainers as indicated in Fig. 12 and
Table 4 before connecting return-air duct to furnace.
7
A
PLENUM
OPENING
D
B
FLOOR
OPENING
C
A96283
Fig. 5—Floor and Plenum Opening Dimensions
Table 3—Opening Dimensions (In.)
FURNACE
CASING
WIDTH
14-3/16
17-1/2
21
24-1/2
PLENUM OPENING
APPLICATION
Non-Combustible Flooring
Combustible Flooring Using KGASB Subbase
Combustible Flooring with CD5 or CK5 Coil Assembly
KCAKC Coil Box
Non-Combustible Flooring
Combustible Flooring Using KGASB Subbase
Combustible Flooring with CD5 or CK5 Coil Assembly
KCAKC Coil Box
Non-Combustible Flooring
Combustible Flooring Using KGASB Subbase
Combustible Flooring with CD5 or CK5 Coil Assembly
KCAKC Coil Box
Non-Combustible Flooring
Combustible Flooring Using KGASB Subbase
Combustible Flooring with CD5 or CK5 Coil Assembly
KCAKC Coil Box
Use a backup wrench at furnace gas control when connecting
gas pipe to furnace to avoid damaging gas controls or
manifold.
or
or
or
or
FLOOR OPENING
A
B
C
D
12-11/16
11-13/16
19
19
13-3/8
13-7/16
19-5/8
20-3/8
12-5/16
19
13-5/16
20
16
15-1/8
19
19
16-5/8
16-3/4
19-5/8
20-3/8
15-1/2
19
16-1/2
20
19-1/2
18-5/8
19
19
20-1/8
20-1/4
19-5/8
20-3/8
19
19
20
20
23
22-1/8
19
19
23-5/8
23-3/4
19-5/8
20-3/8
22-1/2
19
23-1/2
20
Never purge a line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition to check
for gas leakage. Use a soap-and-water solution to check for
gas leaks. A failure to follow this warning could result in fire,
explosion, personal injury, or death.
Piping should be pressure tested in accordance with local and
national plumbing and gas codes before furnace has been attached.
If test pressure exceeds 0.5 psig (14-in. wc), the 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 the gas valve before test.
It is recommended that ground joint union be loosened before
pressure testing.
Joint compounds (pipe dope) should be applied sparingly and only
to male threads of joints. This pipe dope must be resistant to action
of propane gas.
Install accessible manual shutoff valve upstream of furnace gas
controls and within 72 in. of furnace. A 1/8-in. NPT plugged
Use the proper length of pipes and adequate piping support to
avoid stress on the gas control manifold. A failure to follow
this warning can cause a gas leak resulting in a fire,
explosion, personal injury, or death.
8
FURNACE
(OR COIL CASING
WHEN USED)
FURNACE
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
SHEET METAL
PLENUM
FLOOR
OPENING
FLOOR
OPENING
A96285
A96284
Fig. 6—Furnace, Plenum, and Subbase Installed on a
Combustible Floor
Fig. 7—Furnace, Plenum, and Coil Assembly or Coil
Box Installed on a Combustible Floor
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
Fig. 8—Typical Gas Pipe Arrangement
A89414
After all connections have been made, purge lines and check for
gas leakage with regulated gas supply pressure.
Step 9—Electrical Connections
115-V WIRING
Refer to unit rating plate or Table 6 for equipment electrical
requirements. The control system requires an earth ground for
proper operation.
tapping is provided on gas value for test gage connection.
Installation of additional 1/8-in. NPT plugged tapping, accessible
for test gage connection, installed immediately upstream of gas
supply connection to furnace and downstream of manual shutoff
valve is not required. Place ground joint union between gas control
manifold and manual shutoff.
Install sediment trap in riser leading to furnace. The trap can be
installed by connecting a tee to riser leading from furnace. Connect
capped nipple into lower end of tee. The capped nipple should
extend below level of gas controls. (See Fig. 8.)
9
LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OF THE FURNACE
JACKET AND BUILDING JOISTS,
STUDS, OR FRAMING.
GAS
ENTRY
TYPE-B
VENT
IN
6″ M
30-IN. MIN
WORK AREA
24″
SHEET
METAL
24″
MANUAL SHUTOFF
GAS VALVE
SEDIMENT
TRAP
A97516
Fig. 9—Typical Attic Installation
3⁄8-IN.
ROD
ANGLE
IRON OR
EQUIVALENT
(B)
(A)
(B)
(A)
(A) ROD LOCATION
USING DIMPLE
LOCATORS
(SEE DIMENSIONAL
DWG FOR
LOCATIONS)
(B)
(A)
(B)
3/8-IN.
HEX NUT
& WASHER (4)
REQD PER ROD
NOTES: 1. A 1 In. clearance minimum between top of
furnace and combustible material.
(A) PREFERRED ROD LOCATION
2. The entire length of furnace must be
supported when furnace is used in horizontal
position.
(B) ALTERNATE ROD LOCATION
A96633
Fig. 10—Horizontal Crawlspace Installation on Hanger Rods
10
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
AIRFLOW
INSTALLATION
POSITION
OF FILTERS
RETURN-AIR
PLENUM
A95235
Fig. 11—Horizontal Installation on Blocks
;;;
;;;
;; ;
;
;;;;;
;;;;;;;;
;;; ;;
AIRFLOW
12″
4″
D
ACCESS DOOR
FIELD-SUPPLIED
FILTER RETAINERS
A82173
→
Fig. 13—Downflow Filter Arrangement
Fig. 12—Horizontal Filter Arrangement
Table 4—Filter Retainer (In.)
FURNACE CASING WIDTH
14-3/16
17-1/2
21
24-1/2
(2)
(2)
(2)
(2)
FILTERS
16 X 20 X
16 X 20 X
16 X 20 X
16 X 20 X
1
1
1
1
D
15-3/8
14-3/4
13-3/4
12-1/2
A88486
FRONT
B
A
C
K
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
BACK
Make all electrical connections in accordance with the current
edition of the National Electrical Code (NEC) ANSI/NFPA
70-1999 and any 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.
FRONT
A93043
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, the furnace control status LED will flash
rapidly and prevent heating operation.
Do not install furnace on its back. Safety control operation
will be adversely affected. Never connect return-air ducts to
back of furnace. Failure to follow this warning could result in
fire, personal injury, or death.
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.
Table 5—Maximum Capacity of Pipe*
NOMINAL
IRON PIPE
SIZE (IN.)
1/2
3/4
1
1-1/4
1-1/2
24-V WIRING
Refer to ESD Precautions Procedure before proceeding with 24-v
connections.
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
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a
11
Table 6—Electrical Data
UNIT
SIZE
VOLTS—
HERTZ—
PHASE
065-08
065-12
085-12
085-16
105-16
105-20
125-20
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
OPERATING
VOLTAGE RANGE
Max*
Min*
127
104
127
104
127
104
127
104
127
104
127
104
127
104
MAX
UNIT
AMPS
MIN
WIRE
GAGE
MAX WIRE
LENGTH
FT‡
MAXIMUM
FUSE OR
CKT BKR AMPS†
8.0
10.5
12.0
14.2
13.2
17.2
17.9
14
14
14
14
14
12
12
46
35
30
26
29
33
32
15
15
15
15
15
20
20
* Permissible limits of the voltage range at which the unit will operate 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.
supply line pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas).
Ref: Table 10-2, NFPA 54-1996.
PARK
EAC-1
FU1
3
EAC-2
10 11
7
8
SEC-2
SEC-1
HI-GAS
-HEAT
3
LED DIAGNOSTIC
LIGHT
When furnace is installed in horizontal position with RH discharge
air, 24-v wire connections can be made easier by removing the 2
control box mounting screws and letting control box turn so that
24-v screw terminals are visible. Be sure to reinstall control box
after connections are made.
12
9
4
5
6
1
2
3
LED
MASTER SLAVE
1
W2 COM W/W1 Y/Y2 R
24 V
G HUM
1
TWIN
TEST
Make field 24-v connections at the 24-v terminal block. (See Fig.
14.) Connect terminal Y/Y2 as shown in Fig. 15 or 16 for proper
operation in cooling mode. Use AWG No. 18 color-coded, copper
thermostat wire only.
3-AMP
FUSE
LO-GAS
-HEAT
6
2
L2
5
1
COM
4
HI-COOL
9
L1
8
PR1
7
PR2
EAC - ELECTRONIC
AIR CLEANER
(115-VAC 1 AMP MAX)
TWIN / TEST
TERMINAL
HUM HUMIDIFIER
(24-VAC 0.5
AMP MAX)
The 24-v circuit contains an automotive-type, 3-amp fuse located
on main control. Any 24-v electrical shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3-amp fuse. The control will
flash code 24 when fuse needs replacement.
24-VOLT
THERMOSTAT
TERMINALS
1 2 3 4
OFF
ON
ACCESSORIES
1. Electronic air cleaner (EAC)
FURNACE AND
BLOWER OFF DELAY
SETUP SWITCHES
A terminal block (EAC-1 [hot] and EAC-2 [neutral]) is
provided for EAC connection. (See Fig. 14.) The terminals are
energized with 115v, 1-amp maximum during blower motor
operation.
A93348
Fig. 14—Control Center
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
1-STAGE THERMOSTAT TERMINALS
W
FIVE
WIRE
Y
R
G
C
FIELD-SUPPLIED
FUSED DISCONNECT
TWO-WIRE
HEATINGONLY
BLK
BLK
WHT
WHT
208/230- OR
460-V
THREE
PHASE
W2
GND
GND
COM
208/230-V
SINGLE
PHASE
W/W1
GND
115-V FUSED
DISCONNECT
SWITCH
(WHEN REQUIRED)
GND
Y/Y2
JUNCTION
BOX
CONTROL
BOX
R
G
24-V
TERMINAL
BLOCK
FURNACE
GND
GND
CONDENSING
UNIT
NOTES: 1. Connect Y-terminal as shown for proper 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.
A99071
Fig. 15—Heating and Cooling Application Wiring Diagram With 1-Stage Thermostat and Condensing Unit
12
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
2-STAGE THERMOSTAT TERMINALS
SEVEN
WIRE
W2
W1
Y2
R
G
Y1
C
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATINGONLY
W2
BLK
BLK
WHT
208/230- OR
460-V
THREE
PHASE
GND
GND
COM
WHT
208/230-V
SINGLE
PHASE
W/W1
GND
GND
C
Y/Y2
115-V FUSED
JUNCTION
DISCONNECT
BOX
SWITCH
CONTROL
(WHEN REQUIRED)
BOX
Y1
Y2
R
G
24-V
TERMINAL
BLOCK
FURNACE
GND
GND
2-SPEED
CONDENSING
UNIT
NOTES: 1. Connect Y-terminal as shown for proper 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.
A99072
Fig. 16—Heating and Cooling Application Diagram With 2-Stage Thermostat and Condensing Unit
heat for optimum comfort. Setup Switch-2 (SW-2) must be in the
factory-shipped OFF position. See Fig. 17 and Tables 6 and 7 for
setup switch information.
If 2-stage heating thermostat is to be used, move SW-2 to ON
position at end of furnace installation. This overrides built-in
control process for selecting high and low stage and allows 2-stage
thermostat to select gas heating modes. The W2 from thermostat
must be connected to W2 on control terminal block. (See Fig. 16.)
Before operating furnace, check each manual reset switch for
continuity. If necessary, press and release button to reset switch.
2. Humidifier (HUM)
Screw terminals (HUM-1 and COM) are provided for 24-v
humidifier connection. The terminals are energized with 24v,
0.5-amp maximum when the gas valve is energized.
Step 10—Venting
Refer to the enclosed Installation Instructions, (Vent Tables For 1and 2-Stage Category I Fan-Assisted Furnaces) for quick, easy
reference, and national or local installation code such as National
Fuel Gas Code NFPA 54-1999/ANSI Z223.1-1999 in the United
States, or the National Standard of Canada Natural and Propane
Installation Codes CAN/CGA-B149.1- and .2-M95 in Canada, for
proper vent sizing and installation requirements.
Table 7—Setup Switch Description
SETUP
SWITCH NO.
After fully assembling the vent connector to the furnace flue collar,
securely fasten the vent connector to the collar with 2 fieldsupplied, corrosion-resistant, sheet metal screws located 180
degrees apart and midway up the collar.
NORMAL
POSITION
DESCRIPTION OF USE
OFF
(Staged Gas
Heat)
Turn switch on to obtain only
high-gas-heat operation on
any call for heat regardless of
whether R-W/W1, or
R-W/W1, -W2
is closed. SW-1 overrides
SW-2.
SW-2
Low-Gas Heat
(Adaptive Algorithm)
OFF
(Single-Stage
Thermostat)
Turn switch off for installations
with single-stage thermostats;
control selects low-gas-heat
or high-gas-heat operation
based on previous cycles.
Turn switch on for installations
with 2-stage thermostats to
permit only low-gas-heat operation in response to closing
R-W/W1. High-gas heat is
supplied only when R to
W/W1 and W2 is closed.
SW-3 and
SW4
ON, OFF
SW-1
Only High-Gas Heat
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.
Step 11—Start-Up, Adjustment, and Safety Check
GENERAL
The furnace must have a 115-v power supply properly connected
and grounded. Correct polarity must be maintained to enable gas
heating operation.
The gas service pressure must not exceed 0.5 psig (14-in. wc), and
be no less than 0.16 psig (4.5-in. wc).
Thermostat wire connections at R and W/W1 are the minimum
required for gas heating operation. W2 must be connected for
2-stage heating thermostats. Com, Y/Y2, and G are required for
cooling, heat pumps, and some clock thermostats. These must be
made at 24-v terminal block on control. (See Fig. 14.)
This furnace can be installed with either single-stage heating or
2-stage heating thermostat.
For single-stage thermostats, connect thermostat W to W/W1 at
furnace control terminal block. (See Fig. 15.) For single-stage
thermostats the control determines, based on length of previous
heating on and off cycles, when to operate in low- and high-gas
13
Switches control gas heating
algorithm blower off delay.
(See Table 8.)
Table 8—Blower Off Delay
Setup Switch Position
is on, it always causes high-gas-heat operation when R-W/W1
circuit is closed, regardless of the setting of low-heat-only switch
SW-2.
DESIRED HEATING ALGORITHM OFF DELAY
(SEC)
SW-3
SW-4
OFF
SETUP SWITCH
90
OFF
135
OFF
ON
180
ON
OFF
225
ON
ON
This furnace can operate as a 2-stage furnace with a singlestage thermostat because furnace control CPU includes a
programmed adaptive sequence of controlled operation which
selects low-gas-heat or high-gas-heat operation. This selection
is based upon stored history of the length of previous gas
heating on/off periods of single-stage thermostat.
The furnace starts up in either low- or high-gas heat. If furnace
starts up in low-gas heat, control CPU determines low-gas
heat on time (from 0 to 16 minutes) which is permitted before
switching to high-gas heat.
This furnace is equipped with 2 manual reset limit switches in
gas control area. The switches will open and shut off power
to gas valve if a flame rollout or an overheating condition
occurs in gas control area. DO NOT bypass switches. Correct
inadequate combustion air supply, component failure, restricted flue gas passageway before resetting switches.
4
3
2
If power is interrupted, stored history is erased, and control
CPU selects low-gas heat for up to 16 minutes and then
switches to high-gas heat as long as thermostat continues to
"call for heat." Subsequent selection is based on stored history
of thermostat cycle times.
When the wall thermostat "calls for heat," R-W1 circuit
closes. The furnace control performs a self-check, verifies
low-heat and high-heat pressure switch contacts LPS and HPS
are open, and starts inducer motor IDM in low speed or high
speed as appropriate.
1
OFF
a. Inducer prepurge period—As inducer motor IDM comes up
to low speed or high speed, the low-heat pressure switch
contacts LPS (or LPS and HPS) close to begin a 15-sec
prepurge period.
ON
BLOWEROFF
DELAY
LOW
HEAT
(ADAPTIVE
ALGORITHM)
b. Ignitor warm-up—At the end of prepurge period, hot
surface ignitor HSI is energized for a 17-sec ignitor
warm-up period.
c. Trial-for-ignition sequence—When ignitor warm-up period
is completed, main gas valve relay contacts MGVR-1 and
-2 close to energize low-heat gas valve solenoid GV, gas
valve opens, and 24-v power is supplied for a field-installed
humidifier at terminals HUM and Com. Low-heat gas valve
solenoid GV permits gas flow to the burners where it is
ignited. After 5 sec, ignitor HSI is de-energized, and a 2-sec
flame-proving period begins.
HIGH
HEAT
ONLY
A96402
Fig. 17—Setup Switches on Control Center
(Factory Settings)
If furnace control CPU selects high-gas-heat operation,
high-heat gas valve solenoid GV is also energized after
normally closed high-heat pressure switch relay HPSR
closes and after inducer motor IDM goes to high speed and
provides sufficient pressure to close high-heat pressure
switch HPS. HPSR is open while furnace is powered in
standby mode. If high-heat pressure switch HPS fails to
close and low-heat pressure switch LPS closes, furnace
operates at low-heat gas flow rate until high-heat pressure
switch closes.
SEQUENCE OF OPERATION
Using the schematic diagram follow sequence of operation through
different modes. (See Fig. 18.) Read and follow wiring diagram
very carefully.
NOTE: If power interruption occurs during "call for heat" (W/W1
or W/W1-and-W2), control starts 90-sec blower only on period 2
sec after power is restored if thermostat is still calling for gas
heating. The red LED flashes code 12 during 90-sec period, after
which LED will be on continuously as long as no faults are
detected. After 90-sec period, furnace responds to thermostat
normally.
d. Flame-proving—When burner flame is proved at flameproving sensor electrode FSE, control CPU begins blower
on delay period and continues to hold gas valve GV open.
If burner flame is not proved within 2 sec, control CPU
closes gas valve GV, and control CPU repeats ignition
sequence for up to 3 more trials-for-ignition before going
to ignition lockout. LOCKOUT IS RESET AUTOMATICALLY after 3 hr, or by momentarily interrupting 115-v
power to furnace, or by interrupting 24-v power at SEC1 or
SEC2 to control CPU (not at W/W1, G, R, etc.). Opening
thermostat R-W circuit will not reset ignition lockout.
Blower door must be installed for power to be conducted through
blower door interlock switch ILK to furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot
surface ignitor HSI, and gas valve GV.
1. Adaptive Heating Mode—Single-Stage Thermostat and
2-Stage Heating
(See Fig. 16 for thermostat connections.)
NOTE: With high-heat-only switch SW-1 off, low-heat-only
switch SW-2 selects either low-heat-only operation mode when on
(see item 2. below), or adaptive heating mode when off in response
to "call for heat." (See Fig. 17.) When high-heat-only switch SW-1
If flame is proved when flame should not be present,
control CPU locks out of gas heating mode and operates
inducer motor IDM on high speed until flame is no longer
proved.
14
CONNECTION DIAGRAM
LPS NOTE #8
FRS2
YEL
RED
RED
HPS
GRY
ORN
FSE
RED
WHT
1
2
3
BLK
WHT
1
7
2
8
3
9
YEL
EAC-1
HSIR
HI
COM
NOTE #4 BRN
BLU
RED
RED
EAC-2
PL2
R
G HUM
LED
1
12 11 10
15
TJ
2
ON
OFF
TWIN
TEST
WHT
SEC1
115VAC
PR2
7
3 COM
TRAN
SEC2
NOTE #4
EAC-1
SEC1
WHT
BRN
COM
WHT
BLK
HI
MED HI
YEL
MED
ORN
NOTE #15
BLU
MED LO
LO
RED
RED
EAC-2
IDM
1
5 N/A
6 N/A
HPSR
BRN
BLWM
FRS1
3 (WHEN USED)
R
SLAVE
W/W1
TWINNING
JUMPER
TJ
DSS
PL1
NOTE #8 LPS
MASTER
SW1
TJ
TRAN
TWIN/TEST
TERMINAL
CONTROL TERMINAL
FACTORY POWER WIRING (115VAC)
FACTORY CONTROL WIRING (24VAC)
FIELD POWER WIRING (115VAC)
FIELD CONTROL WIRING (24VAC)
CONDUCTOR ON CONTROL
FIELD WIRING SCREW TERMINAL
FIELD GROUND
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE
NOTE #8
HPS
CPU
MGVR-1
P
1
M
10
Y/Y2
C
HI
GV
NOTE#7
G
7
8 N/A
COM
NOTES:
FSE
11 N/A
SW4
SW3
SW2
PL1
PL2
PL3
PL6
SW1
SW2
SW3 & 4
(WHEN USED)
LGPS
4
W2
ALS1
6
5
MAIN GAS VALVE RELAY, DPST (N.O.)
-1 = VALVE
-2 = HUMIDIFIER
12-CIRCUIT CONNECTOR
9-CIRCUIT CONNECTOR
3-CIRCUIT IDM CONNECTOR
2-CIRCUIT HSI CONNECTOR
HIGH-HEAT-ONLY SWITCH, SPST (MANUAL) *
LOW-HEAT-ONLY SWITCH, SPST (MANUAL) *
BLOWER-OFF DELAY SETTING SWITCHES,
SPST (MANUAL)*
TWINNING JUMPER, SPDT FOR MASTER OR
SLAVE STATUS (MANUAL CHANGE OVER)
TRANSFORMER-115VAC/24VAC
1-CIRCUIT TWINNING BUSS CONNECTOR,
ALSO STATUS CODE RECALL
JUNCTION
LS
ALS2
9
TWIN
TEST
TRAN
BLU
MGVR
FRS2
2
MGVR-2
HUM
BLK
LEGEND
AUXILIARY LIMIT SWITCH, OVERTEMP. MANUAL RESET, SPST (N.C.)
AUXILIARY LIMIT SWITCH, OVERTEMP. AUTO RESET, SPST (N.C.)
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLOWER MOTOR, 4 or 5 -SPEED, PERMANENT-SPLIT-CAPACITOR
BLOWER MOTOR RELAY, SPST (N.O.)
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
DRAFT SAFEGUARD SWITCH (N.C.)
ELECTRONIC AIR CLEANER CONNECTION (115 VAC, 1 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FLAME ROLLOUT SWITCH OVERTEMP. MANUAL RESET, SPST (N.C.)
FLAME ROLLOUT SWITCH OVERTEMP. MANUAL RESET, SPST (N.C.)
FLAME-PROVING SENSOR ELECTRODE
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FUSE, FIELD INSTALLED
GAS VALVE, REDUNDANT LOW-HEAT OPERATORS, 2-STAGE
HIGH-HEAT PRESSURE SWITCH, SPST (N.O.)
HIGH-HEAT PRESSURE SWITCH RELAY, SPST (N.C.)
HOT-SURFACE IGNITER (115 VAC)
HOT-SURFACE IGNITOR RELAY, SPST (N.O.)
24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
INDUCED DRAFT MOTOR, 2-SPEED, SHADED-POLE
INDUCER MOTOR RELAY, SPST (N.O.)
INDUCER MOTOR SPEED CHANGE RELAY, SPDT
BLOWER DOOR INTERLOCK SWITCH, SPST (N.O.)
JUNCTION BOX
LIGHT-EMITTING DIODE FOR STATUS CODES
LOW GAS-PRESSURE SWITCH, SPST (N.O.)
LOW-HEAT PRESSURE SWITCH, SPST (N.O.)
LIMIT SWITCH, OVERTEMPERATURE-AUTO RESET, SPST (N.C.)
HI
12 N/A
CAP
L2
FU1
2
1
8
NOTE #5
WHT
SPARE SPARE
SEC2
4 PL3
HSI
LO
IDR
24VAC
PR2
S
1
2
2
HI-COOL
P1
PL6
3
9
PL3
FU1
COMMON
HI-GAS
HEAT
LO-GAS
HEAT
BRN
CAP
IHI / LOR
BLU
GRY
BRN
PR1
L1
ORN
M
ALS1
ALS2
BHI / LOR
BHT / CLR
BLWM
BLWR
CAP
CPU
DSS
EAC-1
EAC-2
FRS1
FRS2
FSE
FU1
FU2
GV
HPS
HPSR
HSI
HSIR
HUM
IDM
IDR
IHI / LOR
ILK
JB
LED
LGPS
LPS
LS
MED
MED HI
FU2
WHT
BLWM
NOTE #15
BLK
BLOWER-OFF DELAY
BLOWER-OFF DELAY
LOW-HEAT ONLY
HIGH-HEAT ONLY
Com W/W1 Y/Y2
24V
SPARE
SPARE
L2
LO
MED LO
COMMON
RED
BLK
HI-GAS-HEAT
HI-COOL
GND
BLK
YEL
2-STAGE
FURNACE
CONTROL
3
1 2 3 4
L2
BLK
PL2
*
W2
BLWR
PR1
FACTORY
SETTINGS
ON
OFF
ON
OFF
*
WHT
2
BLK
BLU
BLOWEROFF DELAY SWITCH
(SEC.)
3
4
90 SEC
135 SEC
180 SEC
225 SEC
PL6
1
ORN
ON
OFF
ON
OFF
ALS2
JB
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
NOTE #1
BLK
WHT
*
ILK
GRY
NOTE #8
SWITCH
1
2
L1
IDM
L1
(WHEN USED)
NOTE #6
GRN/YEL
HEAT
SET-UP
SWITCH
NORM
HI HT
LO HT
C
GRN/YEL
M
GRN/YEL
WHT
ORN
(WHEN USED)
ORN
RED
ALS1
LO-GAS-HEAT
BHT / CLR
GRN/YEL
HSI
NOTE #1
BHI / LOR
GV
BLU
FRS1
(WHEN USED)
EQUIPMENT
GROUND
ILK
BRN
LGPS
DSS
BRN
SCHEMATIC DIAGRAM (NATURAL GAS & PROPANE)
TO 115VAC FIELD
DISCONNECT SWITCH
HI
P
GRN/YEL
RED
RED
LS
1. Use only copper wire between the disconnect switch and
the unit.
2. If any of the original wire, as supplied, must be replaced,
use the same or equivalent type wire.
3. Inducer (IDM) and blower (BLWM) motors contain
internal auto-reset thermal overload switches.
4. Blower motor speed selections are for average
conditions. See Installation Instructions for details on
optimum speed selection.
5. Replace only with a 3-AMP fuse.
6. Auxiliary limit switches (ALS1 & 2) used on some
horizontal and some downflow models.
7. This wire must be connected to furnace sheet metal for
control to prove flame.
8. Factory connected when LGPS not used.
9. Symbols are an electrical representation only.
10. BLOWER-ON DELAY: Gas heating 45 seconds,
Cooling/Heat Pump 2 seconds.
11. Cooling/Heat Pump BLOWER-OFF DELAY is 90
seconds.
12. IGNITION-LOCKOUT will occur after four
consecutive unsuccessful trials-for-ignition.
Control will automatically reset after three hours.
13. Control must be grounded at pin 10 of 12-pin
connector.
14. NA - Not Applicable
15. Spare terminal and wire not available on some
applications. Insulate connector if not available.
324459-101 REV. C
A00301
Fig. 18—Unit Wiring Diagram
pressure sufficiently, high-heat pressure switch HPS opens.
The low-heat gas valve solenoid GV remains energized as
long as low-heat pressure switch LPS remains closed.
Blower motor BLWM switches speed for low-gas heat 5
sec after R-W2 circuit opens.
e. Blower on delay—If burner flame is proven, 45 sec after
gas valve GV is opened blower motor BLWM is energized
on appropriate heating speed, low-gas-heat or high-gasheat speed. Simultaneously, EAC terminals EAC-1 and
EAC-2 are energized with 115v and remain energized as
long as blower motor BLWM is energized.
3. Cooling Mode
f. Switching from low- to high-gas heat—If furnace control
CPU switches from low-gas heat to high-gas heat, control
CPU switches inducer motor IDM speed from low to high.
The high-heat pressure switch relay HPSR closes. When
inducer motor IDM provides sufficient pressure to close
high-heat pressure switch HPS, high-heat gas valve solenoid GV is energized. Blower motor BLWM switches
speed for high-gas heat 5 sec after control CPU switches
from low-gas heat to high-gas heat.
a. Single-Speed Cooling Outdoor Unit
(See Fig. 15 for thermostat connections.)
(1.) The thermostat closes R to G-and-Y circuits. The
R-Y circuit starts outdoor unit, and R to G-and-Y
circuits start furnace blower motor BLWM on highcool speed.
(2.) The EAC terminals EAC-1 and EAC-2 are energized
with 115v when blower motor BLWM is operating.
g. Switching from high- to low-gas heat—Control CPU will
not switch from high-gas heat to low-gas heat while
thermostat R-W circuit is closed when a single-stage
thermostat is used.
(3.) When thermostat is satisfied, R to G-and-Y circuits
are opened. The outdoor unit stops, and furnace
blower motor BLWM continues operating on highcool speed for an additional 90 sec.
h. Blower off delay—When thermostat is satisfied, R-W
circuit is opened, de-energizing gas valve GV, stopping gas
flow to burners, and de-energizing humidifier terminals
HUM and Com. Inducer motor IDM remains energized for
a 5-sec post-purge period. Blower motor BLWM and EAC
terminals EAC-1 and EAC-2 remain energized for 90, 135,
180, or 225 sec (depending on selection at blower off delay
switches SW-3 and SW-4). Furnace control CPU is factory
set for a 135-sec blower off delay.
b. Two-Speed Cooling Outdoor Unit
(See Fig. 16 for thermostat connections.)
(1.) The thermostat closes R to G-and-Y1 circuits for low
cooling or closes R to G-and-Y1-and-Y/Y2 circuits
for high cooling. The R-Y1 circuits start outdoor unit
on low-cooling speed, and R-G circuit starts furnace
blower motor BLWM on low-cooling speed (same
speed as for low-gas heat). The R to Y1-and-Y2
circuits start outdoor unit on high-cooling speed, and
R to G-and-Y2 circuits start furnace blower motor
BLWM on high-cooling speed.
2. Non-Adaptive Heating Mode—Two-Stage Thermostat and
2-Stage Heating
(See Fig. 16 for thermostat connections.)
NOTE: Y1 is not located on furnace control, but is found in
outdoor unit. The furnace control CPU controls blower motor
BLWM speed by sensing only G for low-cooling speed and Y/Y2
for high-cooling speed.
NOTE: The low-heat-only switch SW-2 ON selects low-heatonly operation mode in response to closing thermostat R-W/W1
circuit. When high-heat-only switch SW-1 is off, closing thermostat R to W1-and-W2 circuits is required for high-gas-heat
operation. When high-heat-only switch SW-1 is on, it always
causes high-gas-heat operation when R-W/W1 circuit is closed,
regardless of setting of low-heat-only switch SW-2 and regardless
of whether R-W2 circuit is closed or open.
(2.) The EAC terminals EAC-1 and EAC-2 are energized
with 115v when blower motor BLWM is operating on
either cooling speed.
(3.) When thermostat is satisfied, R to G-and-Y1 or
R to G-and-Y1-and-Y/Y2 circuits open. The outdoor
unit stops, and furnace blower continues operating on
cooling speed for an additional 90 sec.
The start-up and shutdown functions and delays described in
item 1 above apply to 2-stage heating mode as well, except for
switching from low- to high-gas heat and vice versa.
4. Continuous Blower Mode
a. When wall thermostat "calls for heat," R-W/W1 circuit
closes for low-gas heat or R to W1-and-W2 circuits close
for high-gas heat. The furnace control performs a selfcheck, verifies low-heat and high-heat pressure switch
contacts LPS and HPS are open, and starts inducer motor
IDM in low speed or high speed as appropriate.
a. When R to G circuit is closed by thermostat, blower motor
BLWM operates on low-gas-heat speed (identical to lowcool speed). Terminals EAC-1 and EAC-2 are energized
with 115v as long as blower motor BLWM is energized.
b. During "call for heat," blower motor BLWM stops during
ignitor warm-up (17 sec), ignition (7 sec), and blower on
delay (45 sec), allowing furnace heat exchangers to heat up
quickly.
b. Switching from low- to high-gas heat—If thermostat
R-W/W1 circuit for low-gas heat is closed and R-W2
circuit for high-gas heat closes, control CPU switches
inducer motor IDM speed from low to high. The high-heat
pressure switch relay HPSR closes. When inducer motor
IDM provides sufficient pressure to close high-heat pressure switch HPS, high-heat gas valve solenoid GV is
energized. Blower motor BLWM switches speed for highgas heat 5 sec after R-W2 circuit closes.
(1.) The blower motor BLWM reverts to continuous
blower speed after heating cycle is completed. In
high-gas-heat, furnace control CPU holds blower motor BLWM at high-gas-heat speed during selected
blower off delay period before reverting to continuous
blower speed.
(2.) When thermostat "calls for low cooling," blower
motor BLWM continues to operate on low-cool speed.
When thermostat is satisfied, blower motor BLWM
continues on continuous blower speed.
c. Switching from high- to low-gas heat—If thermostat R-W2
circuit for high-gas heat opens and R-W/W1 circuit for
low-gas heat remains closed, control CPU switches inducer
motor IDM speed from high to low. The high-heat pressure
switch relay HPSR opens to de-energize high-heat gas
valve solenoid GV. When inducer motor IDM reduces
(3.) When thermostat "calls for high cooling," blower
motor BLWM operates on high-cool speed. When
16
(3.) When thermostat is satisfied, R to G or R to G-andY2 circuits are opened. After opening R to G-and-Y2
circuit, the furnace blower motor BLWM continues
operating on heating speed for an additional 90 sec.
(4.) Opening R-Y2 circuit reduces blower motor BLWM
speed to heat pump low-heat speed.
6. Defrost
a. When furnace control R to W/W1-and-Y/Y2 circuits are
closed, furnace control CPU continues blower motor
BLWM operation at heat pump heating speed until end of
prepurge period, then shuts off until end of HSI ignitor on
period (22 sec).
b. When installed with a heat pump, furnace control CPU
automatically holds blower off time to 22 sec during HSI
ignitor on period. After 17 sec of HSI ignitor on period, a
trial-for-ignition sequence occurs as described above for
gas heating. After flame is proved and without blower on
delay, blower motor BLWM then operates on high-gasheat speed during defrost. For both single-speed and
2-speed heat pumps, defrost mode is in high-gas heat only.
c. When furnace control R to W/W1 circuit is opened, furnace
control CPU begins normal inducer post-purge period, and
blower motor BLWM remains on for blower off delay
period. If R-G circuit remains closed, blower motor
BLWM reverts to continuous operation.
START-UP PROCEDURES
1. Component test—The furnace features a component test
system to help diagnose a system problem in case of component failure. To initiate component test procedure, ensure that
there are no thermostat inputs to control and that all time
delays have expired. Short TWIN/TEST terminal to ground or
Com for 1 to 4 sec. See Fig. 14 for terminal locations.
NOTE: The component test feature will not operate if control is
receiving any thermostat signals and until all time delays have
expired.
The component test sequence is as follows:
a. The furnace control checks itself, operates inducer motor
on low speed for 7 sec and on high speed for 7 sec, then
stops.
b. The hot surface ignitor is then energized for 15 sec, then
de-energized.
c. The blower motor operates on low-gas-heat/heat pump
low-heat/low-cool/continuous fan speed for 7 sec, then
stops.
d. The blower motor operates on high-gas-heat speed for 7
sec, then stops. The gas valve and humidifier terminal
HUM are not energized for safety reasons.
NOTE: The EAC terminals are energized when blower is energized.
e. The blower operates on heat pump high-heat/high-cool
speed for 7 sec, then stops.
2. After all connections have been made, purge gas lines and
check for leaks.
thermostat is satisfied, blower motor BLWM operates
an additional 2 sec on high-cool speed before reverting
back to continuous blower speed.
(4.) When R to G circuit is opened, blower motor BLWM
continues operating for an additional 90 sec if no other
function requires blower motor BLWM operation.
5. Heat Pump
NOTE: An accessory interface kit or manufacturing accessory
dual fuel thermeostat is required with single-speed heat pumps.
See interface kit Installation Instructions or manufacturing accessory dual fuel thermostat for single-speed heat pump thermostat
and interface connections. No interface kit is needed for 2-speed
heat pumps. See 2-speed heat pump Installation Instructions for
thermostat connections.
a. Single-Speed Heat Pump Cooling
(1.) The thermostat and interface kit close R to G-andY/Y2 circuit to start furnace blower motor BLWM on
high-cooling speed. (Y/Y2 input to furnace control is
necessary to provide adequate cooling airflow.)
(2.) The EAC terminals EAC-1 and EAC-2 are energized
with 115v when blower motor BLWM is operating.
(3.) When thermostat is satisfied, furnace blower motor
BLWM continues operating on high-cooling speed for
an additional 90 sec.
b. Two-Speed Heat Pump Cooling
(1.) The thermostat R to G circuits start furnace blower
motor BLWM on low-cooling speed. Thermostat
R to G-and-Y/Y2 circuits start furnace blower motor
BLWM on high-cool speed.
NOTE: The furnace control CPU controls blower motor BLWM
speed by sensing only G (for low-cooling speed) and Y2 (for
high-cooling speed).
(2.) The EAC terminals EAC-1 and EAC-2 are energized
with 115v when blower motor BLWM is operating on
either cooling speed.
(3.) When thermostat is satisfied, furnace blower motor
BLWM continues operating on cooling speed for an
additional 90 sec.
c. Single-Speed Heat Pump Heating
(1.) The thermostat and accessory interface kit R to Gand-Y/Y2 circuits start furnace blower motor BLWM
on heat pump high-heat speed (identical to high-cool
speed).
(2.) The EAC terminals EAC-1 and EAC-2 are energized
with 115v when blower motor BLWM is operating.
(3.) When thermostat is satisfied, furnace blower motor
BLWM continues operating on heat pump high-heat
speed for an additional 90 sec.
d. Two-Speed Heat Pump Heating
(1.) The thermostat closes R to G circuit for low heat and
starts furnace blower motor BLWM on heat pump
low-heat speed (identical to low-cooling speed). Closing R-Y/Y2 circuit to furnace provides blower motor
BLWM heat pump high-heat speed.
NOTE: The furnace control CPU controls blower motor BLWM
speed by sensing only G (for heat pump low-heat speed) and Y2
(for heat pump high-heat speed).
(2.) The EAC terminals EAC-1 and EAC-2 are energized
with 115v when blower motor BLWM is operating on
either heating speed.
17
d. Turn low-heat adjusting screw (5/64 hex Allen wrench)
counterclockwise (out) to decrease input rate or clockwise
(in) to increase input rate.
Never purge a line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition to check
for gas leakage. Use a soap-and-water solution to check for
gas leaks. A failure to follow this warning could result in fire,
explosion, personal injury, or death.
NOTE: DO NOT set low-heat manifold pressure less than 1.3-in.
wc or more than 1.7-in. wc for natural gas. If manifold pressure is
outside this range, change main burner orifices.
3. To operate furnace, follow procedures on operating instruction
label attached to furnace.
DO NOT bottom out gas valve regulator adjusting screw.
This can result in unregulated manifold pressure and result in
excess overfire and heat exchanger failures.
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.
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.
ADJUSTMENTS
1. Set gas input rate.
Furnace gas input rate on rating plate is for installations at
altitudes up to 2000 ft.
In the U.S.A., input rating for altitudes above 2000 ft must be
reduced by 4 percent for each 1000 ft above sea level.
In Canada, input rating must be derated by 10 percent for
altitudes of 2000 ft to 4500 ft above sea level.
Furnace input rate must be within ±2 percent of input on
furnace rating plate.
2. Determine natural gas orifice size and manifold pressure for
correct input.
a. Obtain yearly heat value average (at installed altitude) from
local gas supplier.
BURNER
ORIFICE
b. Obtain yearly specific gravity average from local gas
supplier.
c. Verify furnace model. Table 10 can only be used for model
58TMA Furnaces.
A93059
d. Find installation altitude in Table 10.
NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A.
altitudes of 2001 to 3000 ft in Table 10.
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.
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- and high-heat
manifold pressure settings for proper operation.
e. Move setup switch SW-2 to OFF position after completing
low-heat adjustment.
EXAMPLE: (0—2000 ft altitude)
Heating value = 1075 Btu/cu ft
Specific gravity = 0.62
Therefore: Orifice No. 45
Manifold pressure: 3.7-in. wc for high heat
1.5-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.
f. Jumper R and W2 thermostat connections on control center.
(See Fig. 14.) This keeps furnace locked in high-heat
operation.
g. Turn high-heat adjusting screw (5/64 hex Allen wrench)
counterclockwise (out) to decrease input rate or clockwise
(in) to increase rate.
NOTE: DO NOT set high-heat manifold pressure less than 3.2-in.
wc or more than 3.8-in. wc for natural gas. If manifold pressure is
outside this range, change main burner orifices.
g. Check and verify burner orifice size in furnace. NEVER
ASSUME ORIFICE SIZE; ALWAYS CHECK AND
VERIFY.
h. When correct input is obtained, replace caps that conceal
gas valve regulator adjustment screws. Main burner flame
should be clear blue, almost transparent. (See Fig. 20.)
3. Adjust manifold pressure to obtain input rate.
i. Remove jumper R to W2.
a. Remove caps that conceal adjustment screws for low- and
high-heat gas valve regulators. (See Fig. 19.)
4. Verify natural gas input rate by clocking gas meter.
a. Calculate high-altitude adjustment (if required).
b. Move setup switch SW-2 on control center to ON position.
(See Fig. 17.) This keeps furnace locked in low-heat
operation.
UNITED STATES
At altitudes above 2000 ft, this furnace has been approved
for a 4 percent derate for each 1000 ft above sea level. See
Table 9 for derate multiplier factor and example.
c. Jumper R and W/W1 thermostat connections on control
center to start furnace.
18
Table 9—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
18—32
32—36
36—40
EXAMPLE: (High-heat operation at 0—2000 ft altitude)
Furnace input from rating plate is 85,000 Btuh
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 = 90 sec
Gas rate = 80 cu ft/hr (from Table 11)
Btu heating input = 80 X 1050 = 84,000 Btuh In this
example, the orifice size and manifold pressure adjustment
is within ±2 percent of the furnace input rate.
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
NOTE: Measured gas inputs (high heat and low heat) must be
within ±2 percent of that stated on furnace rating plate when
installed at sea level or derated per that stated above when installed
at higher altitudes.
* Derate multiplier factor is based on midpoint altitude for altitude range.
m. Remove jumper across R, W/W1, and W2 thermostat
connections to terminate call for heat.
EXAMPLE:
85,000 Btuh input furnace installed at 4300 ft.
5. Set temperature rise.
Furnace Input
Derate
Furnace Input Rate
Rate at
X Multiplier =
at Installation
Sea Level
Factor
Altitude
85,000
X
0.82
=
Place SW-2 in ON position. Jumper R to W/W1 and W2 to
check high-gas-heat temperature rise. To check low-gas-heat
temperature rise, remove jumper to W2. Determine air temperature rise for both high and low heat using the following
steps. DO NOT exceed temperature rise ranges specified on
unit rating plate for high and low heat.
69,700
CANADA
At installation altitudes from 2000 to 4500 ft, this furnace
must be derated 10 percent by an authorized Gas Conversion Station or Dealer. To determine correct input rate for
altitude, see example above and use 0.82 as derate multiplier factor.
b. Check that gas valve adjustment caps are in place for
proper input to be clocked.
c. Obtain yearly heat value average for local gas supply.
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.
d. Check and verify orifice size in furnace. NEVER ASSUME THE ORIFICE SIZE. ALWAYS CHECK AND
VERIFY.
e. Turn off all other gas appliances and pilots.
f. Move setup switch SW-2 to ON position. (See Fig. 17.)
This keeps furnace locked in low-heat operation.
g. Jumper R to W/W1.
h. Let furnace run for 3 minutes in low-heat operation.
i. Measure time (in sec) for gas meter to complete 1 revolution. Note reading.
j. Refer to Table 11 for cubic ft of gas per hr.
k. Multiply gas rate cu ft/hr by heating value (Btu/cu ft).
l. Move setup switch SW-2 to OFF position and jumper R and
W2 thermostat connections. (See Fig. 17.) This keeps
furnace locked in high-heat operation. Repeat items h
through k for high-heat operation.
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.
ON/OFF
SWITCH
INLET
PRESSURE
TAP
FF
O
LOW-FIRE
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
HIGH-FIRE
ADJUSTMENT
ALLEN SCREW
(UNDER CAP)
ON
MANIFOLD
PRESSURE
TAP
A97358
Fig. 19—Redundant Automatic Gas Control Valve
b. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine temperature rise.
NOTE: If temperature rise is outside this range, first check:
(1.) Gas input for low- and high-heat operation.
(2.) Derate for altitude if applicable.
(3.) Return and supply ducts for excessive restrictions
causing static pressures greater than 0.50-in. wc.
19
Table 10—Model 58TMA Orifice Size and Manifold Pressure for Correct Input
(Tabulated Data Based on 21,000 Btuh High Heat/13,500 Btuh Low Heat per Burner,
Derated 4% for Each 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
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
0.58
Manifold
Orifice
Pressure
No.
High/Low
42
3.3/1.4
43
3.8/1.6
43
3.6/1.5
43
3.4/1.4
44
3.7/1.5
44
3.5/1.5
44
3.3/1.4
44
3.2/1.3
45
3.7/1.5
46
3.7/1.5
46
3.5/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
42
3.4/1.4
42
3.5/1.5
42
3.7/1.5
42
3.2/1.3
42
3.3/1.4
42
3.5/1.4
43
3.7/1.5
42
3.2/1.3
42
3.3/1.3
43
3.5/1.5
43
3.6/1.5
43
3.8/1.6
44
3.8/1.6
43
3.5/1.4
43
3.6/1.5
44
3.6/1.5
44
3.8/1.6
43
3.4/1.4
44
3.5/1.4
44
3.6/1.5
44
3.7/1.5
44
3.3/1.4
44
3.4/1.4
44
3.5/1.5
45
3.8/1.6
44
3.2/1.3
44
3.4/1.4
46
3.8/1.6
45
3.7/1.5
44
3.2/1.3
46
3.6/1.5
46
3.8/1.6
45
3.7/1.5
0.66
Manifold
Orifice
Pressure
No.
High/Low
42
3.8/1.6
42
3.6/1.5
42
3.4/1.4
42
3.2/1.3
43
3.7/1.5
43
3.5/1.4
44
3.8/1.6
44
3.6/1.5
44
3.5/1.4
44
3.3/1.4
45
3.8/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
43
3.7/1.5
43
3.5/1.4
44
3.8/1.6
44
3.6/1.5
44
3.4/1.4
44
3.2/1.3
46
3.8/1.6
46
3.6/1.5
46
3.4/1.4
47
3.7/1.5
47
3.5/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
42
3.2/1.3
42
3.3/1.4
42
3.4/1.4
43
3.6/1.5
43
3.7/1.5
42
3.2/1.3
43
3.4/1.4
43
3.5/1.5
43
3.6/1.5
44
3.7/1.5
44
3.8/1.6
43
3.4/1.4
44
3.5/1.4
44
3.6/1.5
44
3.7/1.5
44
3.3/1.4
44
3.4/1.4
44
3.5/1.4
45
3.8/1.6
44
3.2/1.3
44
3.3/1.4
46
3.7/1.5
45
3.7/1.5
45
3.8/1.6
46
3.5/1.5
46
3.7/1.5
46
3.8/1.6
47
3.8/1.6
46
3.5/1.4
46
3.6/1.5
47
3.6/1.5
47
3.8/1.6
46
3.4/1.4
0.66
Manifold
Orifice
Pressure
No.
High/Low
42
3.5/1.4
42
3.3/1.3
43
3.7/1.5
43
3.5/1.5
44
3.8/1.6
44
3.6/1.5
44
3.4/1.4
44
3.2/1.3
45
3.7/1.5
46
3.7/1.5
46
3.5/1.5
0.58
Manifold
Orifice
Pressure
No.
High/Low
43
3.5/1.4
44
3.8/1.6
44
3.5/1.5
44
3.3/1.4
45
3.8/1.6
46
3.7/1.5
46
3.5/1.5
47
3.8/1.6
47
3.6/1.5
47
3.4/1.4
48
3.7/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
43
3.6/1.5
43
3.7/1.5
42
3.2/1.3
43
3.4/1.4
43
3.5/1.4
43
3.6/1.5
44
3.7/1.5
44
3.8/1.6
43
3.4/1.4
44
3.4/1.4
44
3.5/1.5
44
3.7/1.5
44
3.2/1.3
44
3.3/1.4
44
3.4/1.4
45
3.7/1.5
44
3.2/1.3
44
3.3/1.3
46
3.7/1.5
46
3.8/1.6
45
3.7/1.5
46
3.5/1.4
46
3.6/1.5
46
3.7/1.5
47
3.7/1.5
46
3.4/1.4
46
3.5/1.5
47
3.5/1.5
47
3.7/1.5
47
3.8/1.6
48
3.8/1.6
47
3.5/1.4
47
3.6/1.5
0.66
Manifold
Orifice
Pressure
No.
High/Low
42
3.3/1.4
43
3.7/1.5
43
3.5/1.4
44
3.8/1.6
44
3.6/1.5
44
3.4/1.4
44
3.2/1.3
46
3.8/1.6
46
3.6/1.5
46
3.4/1.4
47
3.7/1.5
* For 060125 size only, input is 20,500 Btuh for high fire. Deduct 0.1-in. from manifold pressure shown in table. Change orifice size if manifold pressure falls below 3.2-in.
wc.
20
Table 10—Model 58TMA Orifice Size and Manifold Pressure for Correct Input Continued
(TABULATED DATA BASED ON 21,000 BTUH HIGH HEAT/13,500 BTUH LOW HEAT PER BURNER,
DERATED 4% FOR EACH 1000 FT ABOVE SEA LEVEL)*
U.S.A. Only
ALTITUDE
RANGE
(FT)
4001
to
5000
U.S.A. Only
ALTITUDE
RANGE
(FT)
5001
to
6000
U.S.A. Only
ALTITUDE
RANGE
(FT)
6001
to
7000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
725
750
775
800
825
850
875
900
925
950
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
700
725
750
775
800
825
850
875
900
925
950
975
1000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
650
675
700
725
750
775
800
825
850
875
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.8/1.6
44
3.5/1.5
44
3.3/1.4
45
3.7/1.5
46
3.7/1.5
46
3.5/1.4
47
3.7/1.5
47
3.5/1.5
48
3.8/1.6
48
3.6/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
43
3.4/1.4
43
3.5/1.4
43
3.6/1.5
44
3.6/1.5
44
3.8/1.6
43
3.4/1.4
44
3.4/1.4
44
3.5/1.5
44
3.6/1.5
44
3.2/1.3
44
3.3/1.4
44
3.4/1.4
46
3.8/1.6
45
3.8/1.6
44
3.2/1.3
46
3.6/1.5
46
3.7/1.5
46
3.8/1.6
46
3.4/1.4
46
3.5/1.5
46
3.6/1.5
47
3.6/1.5
47
3.8/1.6
46
3.4/1.4
47
3.4/1.4
47
3.6/1.5
47
3.7/1.5
48
3.7/1.5
48
3.8/1.6
47
3.5/1.4
0.66
Manifold
Orifice
Pressure
No.
High/Low
43
3.7/1.5
43
3.5/1.4
44
3.7/1.5
44
3.5/1.5
44
3.3/1.4
45
3.8/1.6
46
3.7/1.5
46
3.5/1.5
47
3.8/1.6
47
3.6/1.5
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.5/1.5
44
3.3/1.4
45
3.7/1.5
46
3.6/1.5
46
3.4/1.4
47
3.7/1.5
47
3.4/1.4
48
3.7/1.5
48
3.5/1.4
48
3.3/1.4
49
3.7/1.5
49
3.5/1.4
49
3.3/1.4
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
44
3.6/1.5
44
3.8/1.6
43
3.4/1.4
44
3.4/1.4
44
3.5/1.4
44
3.6/1.5
44
3.2/1.3
44
3.3/1.4
44
3.4/1.4
46
3.8/1.6
45
3.7/1.5
44
3.2/1.3
46
3.5/1.5
46
3.7/1.5
46
3.8/1.6
47
3.8/1.6
46
3.4/1.4
46
3.6/1.5
47
3.6/1.5
47
3.7/1.5
47
3.8/1.6
48
3.8/1.6
47
3.5/1.4
47
3.6/1.5
48
3.6/1.5
48
3.7/1.5
47
3.4/1.4
48
3.4/1.4
48
3.5/1.5
48
3.6/1.5
49
3.8/1.6
48
3.3/1.4
48
3.5/1.4
49
3.6/1.5
49
3.7/1.5
48
3.3/1.4
49
3.4/1.4
49
3.6/1.5
49
3.7/1.5
0.66
Manifold
Orifice
Pressure
No.
High/Low
43
3.5/1.4
44
3.7/1.5
44
3.5/1.4
44
3.3/1.4
45
3.7/1.5
46
3.7/1.5
46
3.5/1.4
47
3.7/1.5
47
3.5/1.4
48
3.8/1.6
48
3.6/1.5
48
3.4/1.4
49
3.8/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.5/1.5
44
3.3/1.4
45
3.7/1.5
46
3.6/1.5
47
3.8/1.6
47
3.6/1.5
48
3.8/1.6
48
3.6/1.5
48
3.4/1.4
49
3.8/1.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
44
3.7/1.5
44
3.8/1.6
43
3.4/1.4
44
3.4/1.4
44
3.5/1.4
44
3.6/1.5
44
3.2/1.3
44
3.3/1.3
44
3.4/1.4
46
3.7/1.5
45
3.7/1.5
45
3.8/1.6
46
3.5/1.4
46
3.6/1.5
46
3.7/1.5
47
3.7/1.5
47
3.8/1.6
46
3.5/1.4
47
3.5/1.4
47
3.6/1.5
47
3.7/1.5
48
3.7/1.5
48
3.8/1.6
47
3.5/1.4
48
3.5/1.4
48
3.6/1.5
48
3.7/1.5
48
3.3/1.4
48
3.4/1.4
48
3.5/1.5
0.66
Manifold
Orifice
Pressure
No.
High/Low
43
3.5/1.4
44
3.7/1.5
44
3.5/1.4
44
3.2/1.3
46
3.8/1.6
46
3.6/1.5
47
3.8/1.6
47
3.6/1.5
47
3.4/1.4
48
3.6/1.5
* For 060125 size only, input is 20,500 Btuh for high fire. Deduct 0.1-in. from manifold pressure shown in table. Change orifice size if manifold pressure falls below 3.2-in.
wc.
21
Table 10—Model 58TMA Orifice Size and Manifold Pressure for Correct Input Continued
(TABULATED DATA BASED ON 21,000 BTUH HIGH HEAT/13,500 BTUH LOW HEAT PER BURNER,
DERATED 4% FOR EACH 1000 FT ABOVE SEA LEVEL)*
U.S.A. Only
ALTITUDE
RANGE
(FT)
7001
to
8000
U.S.A. Only
ALTITUDE
RANGE
(FT)
8001
to
9000
U.S.A. Only
ALTITUDE
RANGE
(FT)
9001
to
10,000
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
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
575
600
625
650
675
700
725
750
775
0.58
Manifold
Orifice
Pressure
No.
High/Low
44
3.3/1.4
45
3.7/1.5
46
3.6/1.5
47
3.8/1.6
47
3.5/1.5
48
3.7/1.5
48
3.5/1.5
48
3.3/1.4
49
3.6/1.5
49
3.4/1.4
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
44
3.4/1.4
44
3.5/1.5
44
3.6/1.5
45
3.8/1.6
44
3.3/1.3
44
3.4/1.4
46
3.7/1.5
46
3.8/1.6
45
3.8/1.6
46
3.4/1.4
46
3.6/1.5
46
3.7/1.5
47
3.6/1.5
47
3.8/1.6
46
3.4/1.4
47
3.4/1.4
47
3.5/1.5
47
3.6/1.5
48
3.6/1.5
48
3.8/1.6
47
3.4/1.4
48
3.4/1.4
48
3.5/1.5
48
3.6/1.5
49
3.8/1.6
48
3.3/1.4
48
3.4/1.4
49
3.5/1.5
49
3.7/1.5
49
3.8/1.6
0.66
Manifold
Orifice
Pressure
No.
High/Low
44
3.7/1.5
44
3.5/1.4
44
3.2/1.3
46
3.8/1.6
46
3.5/1.5
47
3.7/1.5
47
3.5/1.4
48
3.7/1.5
48
3.5/1.5
48
3.3/1.4
0.58
Manifold
Orifice
Pressure
No.
High/Low
45
3.7/1.5
46
3.6/1.5
47
3.8/1.6
47
3.5/1.4
48
3.7/1.5
48
3.4/1.4
49
3.8/1.6
49
3.5/1.5
49
3.3/1.4
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
44
3.2/1.3
44
3.3/1.4
44
3.4/1.4
46
3.7/1.5
46
3.8/1.6
45
3.8/1.6
46
3.4/1.4
46
3.5/1.5
46
3.7/1.5
47
3.6/1.5
47
3.7/1.5
47
3.8/1.6
48
3.8/1.6
47
3.5/1.4
47
3.6/1.5
48
3.6/1.5
48
3.7/1.5
48
3.8/1.6
48
3.3/1.4
48
3.4/1.4
48
3.5/1.5
49
3.7/1.5
49
3.8/1.6
48
3.3/1.4
49
3.4/1.4
49
3.5/1.5
49
3.7/1.5
0.66
Manifold
Orifice
Pressure
No.
High/Low
44
3.5/1.4
44
3.2/1.3
46
3.8/1.6
46
3.5/1.4
47
3.7/1.5
47
3.4/1.4
48
3.7/1.5
48
3.4/1.4
49
3.8/1.6
0.58
Manifold
Orifice
Pressure
No.
High/Low
46
3.6/1.5
47
3.7/1.5
47
3.4/1.4
48
3.6/1.5
48
3.4/1.4
49
3.7/1.5
49
3.4/1.4
50
3.8/1.6
50
3.5/1.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Manifold
Manifold
Manifold
Orifice
Orifice
Orifice
Pressure
Pressure
Pressure
No.
No.
No.
High/Low
High/Low
High/Low
46
3.7/1.5
46
3.8/1.6
45
3.8/1.6
46
3.4/1.4
46
3.5/1.5
46
3.6/1.5
47
3.6/1.5
47
3.7/1.5
47
3.8/1.6
48
3.8/1.6
47
3.4/1.4
47
3.5/1.5
48
3.5/1.4
48
3.6/1.5
48
3.7/1.5
49
3.8/1.6
48
3.3/1.4
48
3.5/1.4
49
3.5/1.5
49
3.7/1.5
49
3.8/1.6
49
3.3/1.4
49
3.4/1.4
49
3.5/1.5
50
3.7/1.5
50
3.8/1.6
49
3.3/1.4
0.66
Manifold
Orifice
Pressure
No.
High/Low
44
3.2/1.3
46
3.8/1.6
46
3.5/1.4
47
3.6/1.5
48
3.8/1.6
48
3.6/1.5
48
3.3/1.4
49
3.6/1.5
49
3.4/1.4
* For 060125 size only, input is 20,500 Btuh for high fire. Deduct 0.1-in. from manifold pressure shown in table. Change orifice size if manifold pressure falls below 3.2-in.
wc.
22
Table 11—Gas Rate (Cu Ft/Hr)
SIZE OF TEST DIAL
SIZE OF TEST DIAL
SECONDS
SECONDS
FOR 1
FOR 1
1
2
5
1
2
5
REVOLUTION cu ft cu ft
cu ft REVOLUTION cu ft
cu ft
cu ft
10
11
12
13
14
360
327
300
277
257
720
655
600
555
514
1800
1636
1500
1385
1286
50
51
52
53
54
72
71
69
68
67
144
141
138
136
133
360
355
346
340
333
15
16
17
18
19
240
225
212
200
189
480
450
424
400
379
1200
1125
1059
1000
947
55
56
57
58
59
65
64
63
62
61
131
129
126
124
122
327
321
316
310
305
20
21
22
23
24
180
171
164
157
150
360
343
327
313
300
900
857
818
783
750
60
62
64
66
68
60
58
56
54
53
120
116
112
109
106
300
290
281
273
265
25
26
27
28
29
144
138
133
129
124
288
277
267
257
248
720
692
667
643
621
70
72
74
76
78
51
50
48
47
46
103
100
97
95
92
257
250
243
237
231
30
31
32
33
34
120
116
113
109
106
240
232
225
218
212
600
581
563
545
529
80
82
84
86
88
45
44
43
42
41
90
88
86
84
82
225
220
214
209
205
35
36
37
38
39
103
100
97
95
92
206
200
195
189
185
514
500
486
474
462
90
92
94
96
98
40
39
38
38
37
80
78
76
75
74
200
196
192
188
184
40
41
42
43
44
90
88
86
84
82
180
176
172
167
164
450
439
429
419
409
100
102
104
106
108
36
35
35
34
33
72
71
69
68
67
180
178
173
170
167
45
46
47
48
49
80
78
76
75
73
160
157
153
150
147
400
391
383
375
367
110
112
116
120
;;;;
33
32
31
30
65
64
62
60
Disconnect electrical power before changing speed tap (or
removing cap on 5-speed motors). A failure to follow this
warning can cause personal injury or death.
NOTE: For furnaces with 5-speed motors, ensure that unused
speed tap is capped before power is restored.
d. To change motor speed selection for high heat, remove
blower motor lead from control HIGH-GAS-HEAT terminal. (See Fig. 14 and Fig. 18.) Select desired blower motor
speed lead from 1 of the other terminals and relocate it to
HIGH-GAS-HEAT terminal. See Table 12 for lead color
identification. Reconnect original lead to PARK terminal
(or cover with insulating cap, applies only to furnaces with
5-speed blower motors). Follow this same procedure for
proper selection of cool and low-gas-heat speed selection.
6. Set thermostat heat anticipator.
Table 12—Speed Selection
COLOR
White
Black
Orange†
Yellow
Blue
Red
AS SHIPPED
COM
Cool
Capped
Park
High-Gas-Heat
Low-Gas-Heat
* Continuous fan speed.
† Available on 5-speed blowers only.
Recheck temperature rise. It must be within limits specified
on unit rating plate. Recommended operation is at midpoint of
rise range or above.
164
161
155
150
a. When using a nonelectronic thermostat, the thermostat heat
anticipation must be set to match amp draw of electrical
components in R-W/W1 circuit. Accurate amp draw readings can be obtained at wires normally connected to
thermostat subbase terminals R and W/W1. Fig. 21 illustrates an easy method of obtaining actual amp draw. The
amp reading should be taken after blower motor has started
and furnace is operating in low heat. To operate furnace in
low heat, first move SW-2 to ON position, THEN connect
ammeter wires as shown in Fig. 21. The thermostat
anticipator should NOT be in this circuit while measuring
current. If thermostat has no subbase, thermostat MUST be
disconnected from R and W/W1 wires during current
measurement. Return SW-2 to final desired location after
completing reading. See thermostat manufacturer’s instructions for adjusting heat anticipator and for varying heating
cycle length.
BURNER FLAME
BURNER
MANIFOLD
Fig. 20—Burner Flame
SPEED
Common
High
Med
Med-High
Med-Low
Low*
A89020
b. When using an electronic thermostat, set cycle rate for 3
cycles per hr.
c. Adjust air temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise. Decrease
blower speed to increase temperature rise. For high heat,
speed selection can be med-high, med (5-speed blowers
only), or med-low (factory setting). For low heat, speed tap
selection can be low (factory setting), med-low, or med
(5-speed blowers only).
CHECK SAFETY CONTROLS
The flame sensor, gas valve, and pressure switches were all
checked in the Start-Up section as part of normal operation.
1. Check primary limit control.
This control shuts off combustion control system and energizes circulating-air blower motor if furnace overheats.
The preferred method of checking limit control is to gradually
block off return air after furnace has been operating for a
period of at least 5 minutes. As soon as limit has shut off
23
b. Remove gas control door and disconnect inducer motor
lead wires from wire harness.
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)
c. Turn on 115-v power to furnace
d. Close thermostat switch as if making normal furnace start.
If hot surface ignitor does not glow within several minutes
and control flashes code 32, pressure switches are functioning properly.
HOOK-AROUND
AMMETER
e. Turn off 115-v power to furnace.
R Y W G
f. Reconnect inducer motor wires, replace gas control door,
and turn on 115-v power to furnace.
4. Check auxiliary limits.
a. Turn off 115-v power to furnace.
b. Remove blower access door.
c. Disconnect red motor lead at blower speed selector. Mark
terminal for proper reconnection.
10 TURNS
d. Replace blower access door.
FROM UNIT 24-V
CONTROL TERMINALS
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
e. Turn on 115-v power to furnace. Be sure room thermostat
is calling for low heat.
= 0.5 AMPS FOR THERMOSTAT
ANTICIPATOR SETTING
f. Allow furnace to operate until auxiliary limit activates, but
DO NOT operate furnace longer than 4 minutes.
A96316
g. If furnace operates for 4 minutes, check/replace limit
switch(es).
Fig. 21—Amp Draw Check With Ammeter
burners, return-air opening should be unblocked. By using this
method to check limit control, it can be established that the
limit is functioning properly and will operate if there is a
motor failure.
h. Turn off 115-v power to furnace.
i. Remove blower access door.
j. Reconnect red motor lead, reset switch, and replace door.
k. Turn on 115-v power to furnace.
2. Check draft safeguard switch.
The purpose of this control is to permit safe shutdown of he
furnace during certain blocked vent conditions.
CHECKLIST
1. Put away tools and instruments, and clean up debris.
a. Disconnect power to furnace and remove vent connector
from furnace flue collar. Be sure to allow time for vent
connector pipe to cool down before removing.
2. Check SW-1 through SW-4 after completing installation to
ensure desired settings for thermostat type (SW-1 and SW-2)
and blower off delay (SW-3 and SW-4). Refer to Tables 7 and
8.
b. Restore power to furnace and set room thermostat above
room temperature.
3. Verify manual reset switches have continuity.
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.
4. Ensure blower and gas control access doors are properly
installed.
5. Cycle test furnace with room thermostat.
d. Remove blockage and reconnect vent connector to furnace
flue collar.
6. Check operation of accessories per manufacturer’s instructions.
e. Wait 5 minutes and then reset draft safeguard switch.
7. Review User’s Manual with owner.
3. Check flow-sensing pressure switches.
8. Leave literature packet near furnace.
This control proves operation of draft inducer blower.
a. Turn off 115-v power to furnace.
24
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
25
26
27
Copyright 2000 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
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. 535-790
Printed in U.S.A.
Form 58TMA-8SI
Pg 28
10-00
Replaces: 58TMA-7SI
Tab 6a 8a