Installation, Start-Up, and Operating Instructions

58MCB
4-WAY MULTIPOISE FIXED CAPACITY
CONDENSING GAS FURNACE
Installation, Start-Up, and Operating Instructions
for Sizes 040---140, Series 110 & 120
Visit www.Carrier.com
ama
NOTE: Read the entire instruction manual before starting
the installation.
ISO 9001:2000
NOTE: This furnace can be installed as a (2-pipe) direct vent
or (1-pipe) non-direct vent condensing gas furnace.
CERTIFIED
REGISTERED
Special Venting Requirements for Installations in Canada
Consignes spéciales pour l’installation de ventillation au Canada
Installation in Canada must conform to the requirements of CSA
B149 code. Vent systems must be composed of pipe, fittings,
cements, and primers listed to ULC S636. The special vent
fittings and accessory concentric vent termination kits and
accessory external drain trap have been certified to ULC S636 for
use with those IPEX PVC vent components which have been
certified to this standard. In Canada, the primer and cement must
be of the same manufacturer as the vent system -- IPEX System
636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and
IPEX System 636(1)t, PVC Cement for Flue Gas Venting, rated
Class IIA, 65 deg C. must be used with this venting system -- do
not mix primers and cements from one manufacturer with a vent
system from a different manufacturer. Follow the manufacturer’s
instructions in the use of primer and cement and never use primer
or cement beyond its expiration date.
The safe operation, as defined by ULC S636, of the vent system
is based on following these installation instructions, the vent
system manufacturer’s installation instructions, and proper use of
primer and cement. All fire stop and roof flashing used with this
system must be UL listed material. Acceptability under Canadian
standard CSA B149 is dependent upon full compliance with all
installation instructions. Under this standard, it is recommended
that the vent system be checked once a year by qualified service
personnel.
The authority having jurisdiction (gas inspection authority,
municipal building department, fire department, etc) should be
consulted before installation to determine the need to obtain a
permit.
L’installation faite au Canada doit se conformer aux exigences du
code CSA B149. Ce systême de ventillation doit se composer de
tuyaux, raccords, ciments et apprêts conformes au ULC S636. La
tuyauterie de ventillation des gaz, ses accessoires, le terminal
concentrique mural ainsi que l’ensemble du drain de condensat
extérieur ont été certifiés ULCS 636 pour l’application des
composantes IPEX PVC qui sont certifiées à ce standard. Au
Canada l’apprêt et le ciment doivent être du même manufacturier
que le systême de ventillation -- IPEX Système 636, Apprêt
PVC/CPVC. Mauve Violette pour conduit en évacuation des gaz
et IPEX Système 636(1)t, ciment pour PVC pour conduit en
évacuation des gaz, évalué CLASSE IIA, 65 deg. C. doit ëtre
utilisé avec ce systèeme d’évacuation -- ne pas mélanger l’apprêt
et le ciment d’un manufacturier avec le systême de ventillation
d’un autre manufacturier. Bien suivre les indications du
manufacturier lors de l’utilisation de l’apprêt et du ciment et ne
pas utiliser ceux--ci si la date d’expiration est atteinte.
L’opération sécuritaire, tel que définit par ULC S636, du système
de ventilation est basé sur les instructions d’installation suivantes,
ainsi que l’usage approprié de l’apprêt et ciment. Tout arrët feu et
solin de toit utilisés avec ce système doivent être des matériaux
listés UL. L’acceptation du standard Canadien CSA B419 est
directement relié à l’installation conforme aux instructions ci-haut mentionnées. Le standard Canadien recommande l’
inspection par un personel qualifié et ce, une fois par année.
Les autoritées ayant juridiction (inspecteurs de gas, inspecteurs
en bâtiments, département des incendies, etc) devraient être
consultées avant l’installation afin de déterminer si un permis est
requis.
(1) System 636 is a trademark of IPEX Inc.
-- 1 --
Required Notice for Massachusetts Installations
58MCB
IMPORTANT
The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:
5.08: Modifications to NFPA--54, Chapter 10
2) Revise 10.8.3 by adding the following additional requirements:
a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used
in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where
the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an
alarm and battery back--up is installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is
installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for
the installation of hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery back--up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty
(30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas
fueled heating appliance or equipment. The sign shall read, in print size no less than one--half (1/2) inch in size, ”GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve
the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in
accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.
5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
(1.) The equipment listed in Chapter 10 entitled ”Equipment Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from
the dwelling, building or structure used in whole or in part for residential purposes.
c. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the
manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design
or venting system components with the equipment, the instructions provided by the manufacturer for installation
of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
d. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When
the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the
parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be
satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled
equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions
shall remain with the appliance or equipment at the completion of the installation.
For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers
and Gas Fitters, 239 Causeway Street, Boston, MA 02114. 617--727--9952.
-- 2 --
TABLE OF CONTENTS
UPFLOW
HORIZONTAL
RIGHT
HORIZONTAL
LEFT
DOWNFLOW
AIRFLOW
AIRFLOW
AIRFLOW
A93041
Fig. 1 -- Multipoise Orientations
SAFETY CONSIDERATIONS
Improper
installation,
adjustment,
alteration,
service,
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory--authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
include in literature and attached to the unit. Consult local
building codes, the current editions of the National Fuel Gas
Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical
Code (NEC) NFPA 70.
In Canada, refer to the current editions of the National Standards
of Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation Codes, and Canadian Electrical Code CSA C22.1
Recognize safety information. This is the safety--alert symbol .
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal 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 may 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.
!
CAUTION
UNIT RELIABILITY HAZARD
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, unit leveling, and unit sizing.
-- 3 --
58MCB
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIMENSIONAL DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS . . . 8
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Upflow Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Downflow Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Horizontal Left (Supply--Air Discharge) Applications . . . . . 12
Horizontal Right (Supply--Air Discharge) Applications . . . . 13
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Furnace Location Relative to Cooling Equipment . . . . . . . . . 17
Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Furnace Location and Application . . . . . . . . . . . . . . . . . . . . . 17
AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Leveling Legs (If Desired) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation in Upflow or Downflow Applications . . . . . . . . . 21
Installation in Horizontal Applications . . . . . . . . . . . . . . . . . 21
Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Ductwork Acoustical Treatment . . . . . . . . . . . . . . . . . . . . . 24
Supply Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Return Air Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Filter Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Bottom Closure Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
115--v Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24--v Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal of Existing Furnaces from
Common Vent Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Combustion Air and Vent Pipe Systems . . . . . . . . . . . . . . . . . 29
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Condensate Drain Protection . . . . . . . . . . . . . . . . . . . . . . . . 46
START-UP, ADJUSTMENT AND SAFETY CHECK . . . . . . . 47
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Prime Condensate Trap with Water . . . . . . . . . . . . . . . . . . . . 47
Purge Gas Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Heating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cooling Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Continuous Blower Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Heat Pump Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Component Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Set Gas Input Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Set Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Adjust Blower Off Delay (Heat Mode) . . . . . . . . . . . . . . . . 56
Set Thermostat Heat Anticipator . . . . . . . . . . . . . . . . . . . . . 56
Check Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Check Primary Limit Control . . . . . . . . . . . . . . . . . . . . . . . 56
Check Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
AIRFLOW
26 15⁄16"
(684mm)
26 1⁄4"
(667mm)
1
24 ⁄2"
(666mm)
22 5⁄16"
(567mm)
2-IN. COMBUSTIONAIR CONN
(51mm)
1⁄2-IN.
DIA
GAS CONN
(13mm)
28 1⁄2" (724mm)
26 15⁄16" (694mm)
AIRFLOW
⁄16"
(21mm)
13
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL LEFT)
1⁄2-IN.
58MCB
11⁄4" (32mm)
1"
(25mm)
7
⁄8-IN. DIA (22mm)
ACCESSORY
POWER ENTRY
CONDENSATE
DRAIN TRAP
LOCATION
(ALTERNATE
UPFLOW)
14 1⁄2"
TYP
(368mm)
⁄16"
(21mm)
13
D
OUTLET
SIDE INLET
9 7⁄16"
TYP
(240mm)
26
15⁄16"
⁄2-IN. DIA
GAS CONN
1
DIA
POWER CONN
⁄2-IN. DIA
THERMOSTAT ENTRY
1
30 1⁄2"
(775mm)
2-IN. VENT CONN
39 7⁄8"
(1013mm)
22 11 ⁄16"
27 9⁄16
TYP
(700mm)
24 1⁄2"
(622mm)
17 5⁄16"
(440mm)
18 1⁄4"
(464mm)
11 ⁄16"
(17mm)
11 ⁄16"
(17mm)
E
CONDENSATE
DRAIN LOCATION
(UPFLOW)
DIMPLE LOCATORS
FOR HORIZONTAL
HANGING
TYP (684mm)
SIDE INLET
1"
(25mm)
7⁄16" (11mm)
22 1⁄4" TYP
(565mm)
24 3⁄16"
BOTTOM INLET
(614mm)
11 ⁄16"
A05053
NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturer‘s recommendation for equivalent diameters.
2. Minimum return-air opening at furnace:
a. For 800 CFM 16-in . (406mm) round or 14 1/ 2 (368mm) x 12-in. (305mm) rectangle.
b. For 1200 CFM 20-in . (508mm) round or 14 1/ 2 (368mm) x 19 1/ 2-in. (495mm) rectangle.
c. For 1600 CFM 22-in .(559mm) round or 14 1/ 2 (368mm) x 23 1/ 4-in.(591mm) rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data
literature for specific use of single side inlets. The use of both side inlets, a
combination of 1 side and the bottom, or the bottom only will ensure adequate
return air openings for airflow requirements above 1800 CFM at 0.5“ W.C. ESP.
Dimensions --- IN. (mm)
UNIT SIZE
040 --- 08 / 024040
040 --- 12 / 036040
060 --- 08 / 024060
060 --- 12 / 036060
060 --- 16 / 048060
080 --- 12 / 036080
080 --- 16 / 048080
080 --- 20 / 060080
100 --- 16 / 048100
100 --- 20 / 060100
120 --- 20 / 060120
140 --- 20 / 060140
5⁄16"
(8mm)
7⁄8-IN.
30 ⁄16"
(783mm)
29 11 ⁄16"
TYP
(754mm)
32 5⁄8"
27 5⁄8"
TYP
(702mm)
(829mm)
"
CONDENSATE
DRAIN LOCATION
(UPFLOW)
⁄16" (21mm)
⁄8" (16mm)
13
5
2-IN. COMBUSTIONAIR CONN
33 1⁄4"
TYP
(845mm)
INLET
23 1⁄4" TYP (591mm)
SIDE INLET
19" (483mm)
OUTLET
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL RIGHT)
OR ALTERNATE
1
⁄2-IN. DIA GAS CONN
DIA (22mm)
POWER CONN
13
22 5⁄16" (567mm)
9
7⁄8-IN.
2-IN. VENT CONN
(51mm)
DIA THERMOSTAT
ENTRY
(13mm)
22 11 ⁄16"
(576mm)
26 1⁄4" (667mm)
⁄16"
TYP
(14mm)
A
A
17-1/2 (445)
17-1/2 (445)
17-1/2 (445)
17-1/2 (445)
17-1/2 (445)
17-1/2 (445)
17-1/2 (445)
21 (533)
21 (533)
21 (533)
24-1/2 (622)
24-1/2 (622)
D
15-7/8 (403)
15-7/8 (403)
15-7/8 (403)
15-7/8 (403)
15-7/8 (403)
15-7/8 (403)
15-7/8 (403)
19-3/8 (492)
19-3/8 (492)
19-3/8 (492)
19-3/8 (492)
22-7/8 (581)
Fig. 2 -- Dimensional Drawing
-- 4 --
E
16 (406)
16 (406)
16 (406)
16 (406)
16 (406)
16 (406)
16 (406)
19-1/2 (495)
19-1/2 (495)
19-1/2 (495)
23 (584)
23 (584)
(17mm)
58MCB
335122-201 REV. B LIT TOP
A08435
Fig. 3 -- Clearances to Combustibles
!
WARNING
FIRE, EXPLOSION, ELECTRICAL SHOCK
CARBON MONOXIDE POISONING HAZARD
!
AND
Failure to follow this warning could result in electrical shock,
fire, personal injury, or death.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which may
cause personal injury or property damage. Consult a qualified
installer, service agency, local gas supplier, or your distributor
or branch for information or assistance. The qualified installer
or agency must use only factory-authorized and listed kits or
accessories when modifying this product.
CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing and gloves when
handling parts.
The 58MCB Multipoise Condensing Gas-Fired Furnaces are CSA
(formerly AGA and CGA) design-certified for natural and
propane gases (see furnace rating plate) and for installation in
alcoves, attics, basements, closets, utility rooms, crawlspaces, and
garages. The furnace is factory-shipped for use with natural gas.
A CSA listed gas conversion kit is required to convert furnace for
use with propane gas.
See Fig. 3 for required clearances to combustibles.
Maintain a 1-in. (25 mm) clearance from combustible materials to
supply air ductwork for a distance of 36 in. (914 mm)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.
-- 5 --
58MCB
These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring.
In downflow installations, factory 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. CNPV, CAPV, CAP or
CAR or CK5, or when Coil Box Part No. KCAKC is used.
The 58MCB 040 through 120 size units are CSA (formerly AGA
and CGA) design-certified for use in manufactured (mobile)
homes when installed as a 2-pipe (direct vent) furnace and a
factory accessory conversion kit is used. The 140 size unit is
NOT design-certified for use in manufactured (mobile) homes.
These furnaces are suitable for installation in a structure built on
site or a manufactured building completed at final site. The
design of this furnace line is NOT CSA design-certified for
installation in recreation vehicles or outdoors.
This furnace is designed for continuous return-air minimum
temperature of 60°F (15°C)db or intermittent operation down to
55°F (13°C)db such as when used with a night setback
thermostat. Return-air temperature must not exceed 80°F (27°C)
db. Failure to follow these return-air limits may affect reliability
of heat exchangers, motors, and controls. (See Fig. 4.)
These furnaces are shipped with the drain and pressure tubes
connected for UPFLOW applications. Minor modifications
are required when used in DOWNFLOW, HORIZONTAL
RIGHT, or HORIZONTAL LEFT (supply-air discharge
direction) applications as shown in Fig. 1. See details in
Applications section.
Install this furnace only in a location and position as specified in
LOCATION and INSTALLATION sections of these instructions.
Always provide adequate combustion and ventilation air as
specified in section Combustion Air and Vent Pipe Systems of
these instructions to the furnace.
Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in the
Combustion Air and Vent piping sections of these instructions.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections as specified in the GAS PIPING section of
these instructions.
Always install the furnace to operate within the furnace’s
intended rise range with a duct system which has an external
static pressure within the allowable range as specified in the SET
TEMPERATURE RISE section of these instructions and furnace
rating plate.
When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by ducts sealed to the
furnace casing and terminating outside the space containing
the furnace.
A gas-fired furnace for installation in a residential garage must be
installed as specified in the Hazardous Locations section of
these instructions.
The furnace may be used for construction heat provided that the
furnace installation and operation complies with the first
CAUTION in the LOCATION section of these instructions.
This gas furnace may be used for construction heat provided that:
S The furnace is permanently installed with all electrical wiring,
S
S
S
S
S
S
S
piping, air filters, venting and ducting installed according to
these installation instructions. A return air duct is provided,
sealed to the furnace casing, and terminated outside the space
containing the furnace. This prevents a negative pressure
condition as created by the circulating air blower, causing a
flame rollout and/or drawing combustion products into
the structure.
The furnace is controlled by a thermostat. It may not be “hot
wired” to provide heat continuously to the structure without
thermostatic control.
Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and other
construction materials. It also prevents the entrainment of
drywall dust into combustion air, which can cause fouling and
plugging of furnace components.
The temperature of the return air to the furnace is maintained
between 55°F (13°C) and 80°F (27°C), with no evening
setback or shutdown. The use of the furnace while the structure
is under construction is deemed to be intermittent operation per
our installation instructions.
The air temperature rise is within the rated rise range on the
furnace rating plate, and the firing rate has been set to the
nameplate value.
The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
The furnace, ductwork and filters are cleaned as necessary to
remove drywall dust and construction debris from all HVAC
system components after construction is completed.
After construction is complete, verify furnace operating
conditions including ignition, input rate, temperature rise and
venting, according to the manufacturer’s instructions.
0
60
(27º C)
(16º C)
A05004
Fig. 4 -- Return-Air Temperature
These furnaces are shipped with the following materials to assist
in proper furnace installation. These materials are shipped in the
main blower compartment.
-- 6 --
* ONLY supplied with some furnaces.
The furnace shall be installed so that the electrical components
are protected from water.
For accessory installation details, refer to accessory
installation instructions.
CODES AND STANDARDS
Follow all national and local codes and standards in addition
to these instructions. The installation must comply with
regulations of the serving gas supplier, local building, heating,
plumbing, and other codes. In absence of local codes, the
installation must comply with the national codes listed below and
all authorities having jurisdiction.
In the United States and Canada, follow all codes and standards
for the following:
Step 1 -- Safety
S US: National Fuel Gas Code (NFGC) NFPA 54--2006/ANSI
Z223.1--2006 and the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B
S CANADA: National Standard of Canada, Natural Gas and
Propane Installation Code (NSCNGPIC) CSA B149.1--05.
Step 2 -- General Installation
S US: NFGC and the NFPA 90B. For copies, contact the
National Fire Protection Association Inc., Batterymarch Park,
Quincy, MA 02269; or for only the NFGC contact the
American Gas Association, 400 N. Capitol, N.W., Washington
DC 20001.
S A manufactured (Mobile) home installation must conform with
the Manufactured Home Construction and Safety Standard,
Title 24 CFR, Part 3280, or when this standard is not
applicable, the Standard for Manufactured Home Installation
(Manufactured Home Sites, Communities, and Set-Ups),
ANSI/NCS A225.1, and/or CAN/CSA--Z240, MH Series
Mobile Homes
S CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke
(Toronto), Ontario, M9W 1R3, Canada.
Step 3 -- Combustion and Ventilation Air
S US: Section 9.3 of the NFPA54/ANSI Z223.1--2006, Air for
Combustion and Ventilation
S CANADA: Part 8 of the CAN/CSA--B149.1--05, Venting
Systems and Air Supply for Appliances
Step 4 -- Duct Systems
S US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning
Contractors National Association (SMACNA), or American
Society of Heating, Refrigeration, and Air Conditioning
Engineers (ASHRAE) 2001 Fundamentals Handbook
Chapter 34.
Step 5 -- Acoustical Lining and Fibrous Glass Duct
S US and CANADA: current edition of SMACNA, NFPA 90B as
tested by UL Standard 181 for Class I Rigid Air Ducts
Step 6 -- Gas Piping and Gas Pipe Pressure Testing
S US: NFPA 54/ANSI Z223.1--2006; chapters 5, 6, 7, and 8 and
national plumbing codes
S CANADA: NSCNGPIC Parts 4, 5, and 6 A, B, E, and H.
In the state of Massachusetts:
S This product must be installed by a licensed plumber or gas fitter.
S When flexible connectors are used, the maximum length shall not
exceed 36-in. (914 mm).
S When lever types gas shutoffs are used they shall not
exceed 36-in. (914 mm).
S The use of copper tubing for gas piping is not approved by the
state of Massachusetts.
Step 7 -- Electrical Connections
S US: National Electrical Code (NEC) ANSI/NFPA 70--2008
S CANADA: Canadian Electrical Code CSA C22.1
-- 7 --
58MCB
Installer Packet Includes:
Installation, Startup, and Operating Instructions
Service and Maintenance Instructions
User’s Information Manual
Warranty Certificate
Loose Parts Bag Includes:
Quantity
Pressure tube extension
1
Collector Box or condensate trap extension tube
1
Inducer housing drain tube
1
1/2--in CPVC street elbow
2
Drain tube coupling
1
Drain tube coupling grommet
1
Vent and combustion-air pipe support
2
Condensate trap hole filler plug
3
Vent and combustion-air intake hole filler plug
2
Combustion-air pipe perforated disk assembly
1
Vent Pipe Extension
1*
FURNACE
DOOR
BLOWER SHELF
CONDENSATE
TRAP
CONDENSATE
TRAP (INSIDE)
FURNACE
DOOR
FURNACE
SIDE
4 7 8 (124mm)
4
(102mm)
FURNACE
SIDE
5 3 4(146mm)
5 3 4 (146mm)
4
(102mm)
ALTERNATE DRAIN
TUBE LOCATION
11 2
(38mm)
SIDE VIEW
CONDENSATE TRAP
DRAIN TUBE LOCATION
58MCB
26 1 4
(667mm)
FIELD
DRAIN
CONN
26 1 4
(667mm)
FIELD
DRAIN
CONN
FRONT VIEW
END VIEW
SLOT FOR SCREW
HORIZONTAL
APPLICATION
(OPTIONAL)
FRONT VIEW
HORIZONTAL
APPLICATIONS
DOWNFLOW AND ALTERNATE
EXTERNAL UPFLOW APPLICATIONS
UPFLOW APPLICATIONS
34
(19mm)
1/4” (6mm)
COLLECTOR BOX TO
TRAP RELIEF PORT
1 1 2 (88mm)
1/2 (13mm)
INDUCER HOUSING
DRAIN CONNECTION
(19mm) 3 4
5/8 (16mm)
COLLECTOR BOX
DRAIN CONNECTION
(181mm) 7 1 8
SCREW HOLE FOR
UPFLOW OR DOWNFLOW APPLICATIONS
(OPTIONAL)
13 4 (44mm)
WIRE TIE
GUIDES
(WHEN USED)
FRONT VIEW
(3mm) 7 8
21 4
(57mm)
1/2 IN. (13mm) PVC OR CPV
SIDE VIEW
A93026
Fig. 5 -- Condensate Trap
ELECTROSTATIC DISCHARGE (ESD)
PRECAUTIONS
!
5. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example;
DO NOT move or shuffle your feet, DO NOT touch
ungrounded objects, etc.).
6. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before
touching control or wires.
7. Use this procedure for installed and uninstalled
(ungrounded) furnaces.
8. 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.
9. An ESD service kit (available from commercial sources)
may also be used to prevent ESD damage.
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may damage furnace
components.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will
prevent electrostatic discharges from personnel and hand
tools which are held during the procedure. These precautions
will help to avoid exposing the control to electrostatic
discharge by putting the furnace, the control, and the person
at the same electrostatic potential.
3. Disconnect all power to the furnace. Multiple disconnects
may be required. DO NOT TOUCH THE CONTROL OR
ANY WIRE CONNECTED TO THE CONTROL PRIOR
TO DISCHARGING YOUR BODY’S ELECTROSTATIC
CHARGE TO GROUND.
4. Firmly touch a clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in
a person’s hand during grounding will be
satisfactorily discharged.
INTRODUCTION
The model 58MCB 4-way multipoise, Gas-Fired, Category IV,
condensing furnace is available in model sizes ranging from input
capacity of 40,000 to 138,000 Btuh as a direct vent (2-pipe)
application, and in model sizes ranging from input capacity of
40,000 to 120,000 Btuh as a non-direct vent (1-pipe) application.
-- 8 --
PLUG
PLUG
CAP
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
TUBE (GREEN)
58MCB
COLLECTOR BOX
DRAIN TUBE (BLUE)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
CONDENSATE
TRAP
COLLECTOR BOX
DRAIN TUBE (BLUE)
CONDENSATE
TRAP
INDUCER
HOUSING
DRAIN TUBE
(VIOLET)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
A00289
Fig. 7 -- Alternate Upflow Tube Configuration and
Trap Location
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED
1⁄2-IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
CONDENSATE TRAP LOCATION
(FACTORY-SHIPPED ORIENTATION)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
A00288
Fig. 6 -- Factory Shipped Upflow Tube Configuration (Shown
With Blower Access Panel Removed)
APPLICATIONS
!
CAUTION
MINOR PROPERTY DAMAGE
Failure to follow this caution may result in minor property
damage.
Local codes may require a drain pan under entire furnace and
condensate trap when a condensing furnace is used in an attic
application or over a finished ceiling.
Step 1 -- General
Some assembly and modifications are required for furnaces
installed in any of the 4 applications shown in Fig. 1. All drain
and pressure tubes are connected as shown in Fig. 6. See
appropriate application instructions for these procedures.
Step 2 -- Upflow Applications
An upflow furnace application is where furnace blower is located
below combustion and controls section of furnace, and
conditioned air is discharged upwards.
The condensate trap is factory installed in the blower shelf and
factory connected for UPFLOW applications. A factory-supplied
tube is used to extend the condensate trap drain connection to the
desired furnace side for field drain attachment. See Condensate
Trap Tubing (Factory-Shipped Orientation) section for drain tube
extension details. (See Fig. 5.)
CONDENSATE TRAP TUBING
(FACTORY-SHIPPED ORIENTATION)
NOTE: See Fig. 6 or tube routing label on main furnace door to
confirm location of these tubes.
1. Collector Box Drain, Inducer Housing Drain, Relief Port,
and Pressure Switch Tubes
These tubes should be factory attached to condensate trap
and pressure switch ready for use in UPFLOW
applications. These tubes can be identified by their
connection location and also by a color label on each tube.
These tubes are identified as follows: collector box drain
tube (blue label), inducer housing drain tube (violet label
or molded), relief port tube (green label), and pressure
switch tube (pink label).
2. Condensate Trap Drain Tube
The condensate trap drain connection must be extended
for field attachment by doing the following:
f. Determine location of field drain connection. (See
Fig. 2 or 6.)
NOTE: If internal filter is used, drain tube should be located to
opposite side of casing from return duct attachment to assist in
filter removal.
g. Remove and discard casing drain hole plug button
from desired side.
-- 9 --
COLLECTOR BOX
DRAIN TUBE (BLUE)
CAP
PLUG
PLUG
CAP
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (PINK)
58MCB
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
EXTENSION TUBE
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
CONDENSATE
TRAP
CONDENSATE
TRAP
COLLECTOR BOX
EXTENSION
DRAIN TUBE
INDUCER HOUSING
DRAIN TUBE (VIOLET)
DRAIN TUBE
COUPLING
A00296
Fig. 8 -- Downflow Tube Configuration
(Right-Hand Trap Installation)
A00262
Fig. 9 -- Downflow Tube Configuration
(Left-Hand Trap Installation)
h. Install drain tube coupling grommet (factory-supplied
in loose parts bag) in selected casing hole.
i. Slide drain tube coupling (factory-supplied in loose
parts bag) through grommet ensuring long end of
coupling faces blower.
j. Cement 2 factory-supplied 1/2-in. (13 mm) street
CPVC elbows to the rigid drain tube connection on the
condensate trap. (See Fig. 6.) These elbows must be
cemented together and cemented to condensate trap
drain connection.
To relocate condensate trap to the left-hand side, perform
the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose
parts bag) into blower shelf hole where trap was removed.
NOTE: Failure to use CPVC elbows may allow drain to kink
and prevent draining.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
k. Connect larger diameter drain tube and clamp
(factory-supplied in loose parts bag) to condensate trap
and clamp securely.
Failure to follow this warning could result in personal injury
or death.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the
equipment room.
l. Route tube to coupling and cut to appropriate length.
m. Attach tube to coupling and clamp securely.
CONDENSATE TRAP LOCATION (ALTERNATE
UPFLOW ORIENTATION)
An alternate location for the condensate trap is the left-hand side
of casing. (See Fig. 2 and 7.)
NOTE: If the alternate left-hand side of casing location is used,
the factory-connected drain and relief port tubes must be
disconnected and modified for attachment. See Condensate
Trap Tubing (Alternate Upflow Orientation) section for
tubing attachment.
-- 10 --
4. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
CONDENSATE TRAP TUBING (ALTERNATE
UPFLOW ORIENTATION)
NOTE: See Fig. 7 or tube routing label on main furnace door to
confirm location of these tubes.
1. Collector Box Drain Tube
Connect collector box drain tube (blue label) to
condensate trap.
CONDENSATE TRAP FIELD DRAIN ATTACHMENT
Refer to Condensate Drain section for recommendations
and procedures.
PRESSURE SWITCH TUBING
The LOWER collector box pressure tube (pink label) is
factory connected to the pressure switch and should not require
any modification.
NOTE: See Fig. 6 or 7 or tube routing label on main furnace
door to check for proper connections.
UPPER COLLECTOR BOX AND INDUCER
HOUSING (UNUSED) DRAIN CONNECTIONS
Upper Collector Box Drain Connection
Attached to the UPPER collector box drain connection is a
factory-installed corrugated, plugged tube (blue and white striped
label). This tube is plugged to prevent condensate leakage in this
application. Ensure this tube is plugged.
NOTE: See Fig. 6 or 7 or tube routing label on main furnace
door to check for proper connections.
Upper Inducer Housing Drain Connection
Attached to the UPPER (unused) inducer housing drain
connection is a cap and clamp. This cap is used to prevent
condensate leakage in this application. Ensure this connection
is capped.
NOTE: See Fig. 6 or 7 or tube routing label on main furnace
door to check for proper connections.
CONDENSATE TRAP FREEZE PROTECTION
Refer to Condensate Drain
recommendations and procedures.
Protection
section
for
Step 3 -- Downflow Applications
A downflow furnace application is where furnace blower is
located above combustion and controls section of furnace, and
conditioned air is discharged downwards.
CONDENSATE TRAP LOCATION
The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application
location as shown in Fig. 2, 8, or 9.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose
parts bag) into blower shelf hole where trap was removed.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the
equipment room.
4. Install condensate trap into desired casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
CONDENSATE TRAP TUBING
NOTE: See Fig. 8 or 9 or tube routing label on main furnace
door to check for proper connections.
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was connected to
condensate trap.
c. Connect LOWER collector box drain connection to
condensate trap.
(3.) Condensate Trap Located on Left Side of Casing
a. Connect LOWER collector box drain tube (blue
and white striped label) to condensate trap.
Tube does not need to be cut.
b. Clamp tube to prevent any condensate leakage.
(4.) Condensate Trap Located on Right Side of Casing
a. Install drain tube coupling (factory-supplied in
loose parts bag) into collector box drain tube
(blue and white striped label) which was
previously plugged.
b. Connect
larger
diameter
drain
tube
(factory-supplied in loose parts bag) to drain
tube coupling, extending collector box drain
tube for connection to condensate trap.
c. Route extended collector box drain tube
directly from collector box drain to condensate
trap as shown in Fig. 9.
d. Determine appropriate length and cut.
e. Connect to condensate trap.
f. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to
condensate trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
d. Use inducer housing drain tube (violet label and
factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to the
condensate trap.
-- 11 --
58MCB
NOTE: On 17-1/2-in. (445 mm) wide furnaces ONLY, cut tube
between corrugated sections to prevent kinks from occurring.
2. Inducer Housing Drain Tube
a. Remove and discard LOWER (molded) inducer
housing drain tube which was previously connected to
condensate trap.
b. Use inducer housing drain extension tube (violet label
and factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to the
condensate trap.
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
e. Connect relief port tube (green label) to
condensate trap.
f. Extend this tube (if required) by splicing to small
diameter tube (factory-supplied in loose parts bag).
g. Determine appropriate length, cut, and connect tube.
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)
58MCB
AUXILIARY "J" BOX
CONDENSATE
TRAP
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR
BOX EXTENSION
DRAIN TUBE
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
DRAIN TUBE (BLUE)
DRAIN TUBE COUPLING
COLLECTOR BOX TUBE (PINK)
RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR
040, 060, AND 080 HEATING INPUT FURNACES
A00215
Fig. 10 -- Horizontal Left Tube Configuration
e. Connect inducer housing drain connection to
condensate trap.
(1.) Condensate Trap Located on Left Side of Casing
a. Determine appropriate length and cut.
b. Connect tube to condensate trap.
c. Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
a. Route inducer housing drain tube (violet label)
directly from inducer housing to condensate
trap as shown in Fig. 9.
b. Determine appropriate length and cut.
c. Connect tube to condensate trap.
d. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
Refer to Pressure Switch Tubing section for connection
procedure.
CONDENSATE TRAP FIELD DRAIN ATTACHMENT
Refer to Condensate Drain section for recommendations
and procedures.
PRESSURE SWITCH TUBING
One collector box pressure tube (pink label) is factory connected
to the pressure switch for use when furnace is installed in
UPFLOW applications. This tube MUST be disconnected and
used for the condensate trap relief port tube. The other collector
box pressure tube (green label) which was factory connected to
the condensate trap relief port connection MUST be connected to
the pressure switch in DOWNFLOW or HORIZONTAL
RIGHT applications.
NOTE: See Fig. 8 or 9 or tube routing label on main furnace
door to check for proper connections.
-- 12 --
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label)
attached to pressure switch.
2. Extend collector box pressure tube (green label) which
was previously connected to condensate trap relief port
connection by splicing to small diameter tube
(factory-supplied in loose parts bag).
3. Connect collector box pressure tube (green label) to
pressure switch connection labeled COLLECTOR BOX.
4. Extend collector box pressure tube (pink label) which was
previously connected to pressure switch by splicing to
remaining small diameter tube (factory-supplied in loose
parts bag).
5. Route this extended tube (pink label) to condensate trap
relief port connection.
6. Determine appropriate length, cut, and connect tube.
7. Clamp tube to relief port connection.
CONDENSATE TRAP FREEZE PROTECTION
Refer to Condensate Drain
recommendations and procedures.
Protection
section
for
Step 4 -- Horizontal Left (Supply-Air Discharge)
Applications
A horizontal left furnace application is where furnace blower is
located to the right of combustion and controls section of furnace,
and conditioned air is discharged to the left.
CONDENSATE TRAP LOCATION
The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application
location as shown in Fig. 2 or 10.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the
equipment room.
4. Install condensate trap into desired casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
NOTE: See Fig. 10 or tube routing label on main furnace door to
check for proper connections.
Modify tube as described below.
1. Disconnect collector box pressure tube (pink label)
attached to pressure switch.
2. Use smaller diameter tube (factory-supplied in loose parts
bag) to extend tube disconnected in item 1.
3. Route extended tube:
a. Behind inducer housing.
b. Between blower shelf and inducer housing.
c. Behind inducer motor bracket.
d. Between inducer motor and pressure switch.
4. Determine appropriate length, cut, and reconnect tube to
pressure switch connection labeled COLLECTOR BOX.
CONDENSATE TRAP FREEZE PROTECTION
Refer to Condensate Drain
recommendations and procedures.
CONDENSATE TRAP FIELD DRAIN ATTACHMENTS
Refer to Condensate Drain section for recommendations
and procedures.
PRESSURE SWITCH TUBING
The LOWER collector box pressure tube (pink label) is factory
connected to the pressure switch for use when furnace is installed
in UPFLOW applications. This tube MUST be disconnected,
extended, rerouted, and then reconnected to the pressure switch in
HORIZONTAL LEFT applications.
section
for
CONSTRUCT A WORKING PLATFORM
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 11 or 12.)
CONDENSATE TRAP TUBING
NOTE: See Fig. 10 or tube routing label on main furnace door to
check for proper connections.
1. Collector Box Drain Tube
a. Install drain tube coupling (factory-supplied in loose
parts bag) into collector box drain tube (blue label)
which was previously connected to condensate trap.
b. Connect large diameter drain tube and clamp
(factory-supplied in loose parts bag) to drain tube
coupling, extending collector box drain tube.
c. Route extended tube (blue label) to condensate trap
and cut to appropriate length.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove and discard LOWER (molded) inducer
housing drain tube which was previously connected to
condensate trap.
b. Use inducer housing drain extension tube (violet label
and factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to the
condensate trap.
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
a. Extend collector box tube (green label) which was
previously connected to the condensate trap by
splicing to small diameter tube (factory-supplied in
loose parts bag).
b. Route extended collector box pressure tube to relief
port connection on the condensate trap.
c. Determine appropriate length, cut, and connect tube.
d. Clamp tube to prevent any condensate leakage.
Protection
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent
unit operation.
The condensate trap MUST be installed below furnace. See
Fig. 5 for dimensions. The drain connection to condensate
trap must also be properly sloped to an open drain.
NOTE: Combustion-air and vent pipes are restricted to a
minimum length of 5 ft. (1.5 M) (See Table 11.)
NOTE: A 12-in. (305 mm) minimum offset pipe section is
recommended with short (5 to 8 ft (1.5 to 2.4 M)) vent systems.
This recommendation is to reduce excessive condensate droplets
from existing vent pipe. (See Fig. 11, 12 or 41.)
Step 5 -- Horizontal Right (Supply-Air Discharge)
Applications
A horizontal right furnace application is where furnace blower is
located to the left of combustion and controls section of furnace,
and conditioned air is discharged to the right.
!
CAUTION
MINOR PROPERTY DAMAGE
Failure to follow this caution may result in minor
property damage.
Local codes may require a drain pan under entire furnace and
condensate trap when a condensing furnace is used in attic
application or over a finished ceiling.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC Installation Codes and/or local codes.
NOTE: The auxiliary junction box (J-Box) MUST be relocated
to opposite side of furnace casing. (See Fig. 13.) See Electrical
Connection section for J-Box relocation.
CONDENSATE TRAP LOCATION
The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application
location as shown in Fig. 2 or 13.
-- 13 --
58MCB
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose
parts bag) into blower shelf hole where trap was removed.
COMBUSTION - AIR
INTAKE
VENT
A 12-IN. (305 mm) MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT / 1.5 TO 2.4 M) VENT
SYSTEMS TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
30″ (762 mm)MIN
WORK AREA
58MCB
5 3/4″ (146 mm)
MANUAL
SHUTOFF
GAS VALVE
ACCESS OPENING
FOR TRAP
SEDIMENT
TRAP
DRAIN
CONDENSATE
TRAP
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
A93031
Fig. 11 -- Attic Location and Working Platform for Direct Vent (2-pipe) Application -- All Sizes
A 3-IN.(76mm) MINIMUM CLEARANCE
TO COMBUSTION-AIR INTAKE
IS REQUIRED.
VENT
COMBUSTION AIR
INTAKE
A 12-IN. (305mm) MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT / 1.5 TO 2.4M) VENT
SYSTEMS TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
5 3/4 IN. (146mm)
30-IN. (762mm) MIN
WORK AREA
MANUAL
SHUTOFF
GAS VALVE
ACCESS OPENING
FOR TRAP
SEDIMENT
TRAP
DRAIN
CONDENSATE
TRAP
NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE
FURNACE AND CONDENSATE TRAP WHEN A CONDENSING
FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.
A96184
Fig. 12 -- Attic Location and Working Platform for Non-Direct Vent (1-pipe) Applications-Sizes 040 Through 120 Only
-- 14 --
COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (GREEN)
CAP
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX TUBE (PINK)
PLUG
58MCB
AUXILARY “J” BOX RELOCATED HERE
CONDENSATE
TRAP
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
A00214
Fig. 13 -- Horizontal Right Tube Configuration
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs
inward and rotating trap.
3. Install casing hole filler cap (factory-supplied in loose
parts bag) into blower shelf hole where trap was removed.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated to prevent combustion
products being drawn in from appliances in the
equipment room.
4. Install condensate trap into desired casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (factory-supplied in loose parts bag).
CONDENSATE TRAP TUBING
NOTE: See Fig. 13 or tube routing label on main furnace door to
check for proper connections.
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector
box drain tube (blue and white striped label).
b. Install removed clamp and plug into UPPER collector
box drain tube (blue label) which was previously
connected to condensate trap.
c. Connect LOWER collector box drain tube (blue and
white striped label) to condensate trap. Tube does not
need to be cut.
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to
condensate trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
d. Use inducer housing drain extension tube (violet label
and factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to
condensate trap.
e. Determine appropriate length, cut, and connect tube to
condensate trap.
f. Clamp tube to prevent any condensate leakage.
3. Relief Port Tube
Refer to Pressure Switch Tubing section for
connection procedure.
CONDENSATE TRAP FIELD DRAIN ATTACHMENT
Refer to Condensate Drain section for recommendations
and procedures.
-- 15 --
FRONT
LEVEL (0”)
TO 1/2” (13mm)
MAX
FRONT
B
A
C
K
FRONT
MIN 1/4” (7mm)
TO 1/2” (13mm)
HORIZONTAL
MAX
BACK
UPFLOW OR DOWNFLOW
FRONT
58MCB
A02146
Fig. 14 -- Furnace Location for Proper Condensate Drainage
PRESSURE SWITCH TUBING
One collector box pressure tube (pink label) is factory connected
to the pressure switch for use when furnace is installed in
UPFLOW applications. This tube MUST be disconnected and
used for the condensate trap relief port tube. The other collector
box pressure tube (green label) which was factory connected to
the condensate trap relief port connection MUST be connected to
the pressure switch in DOWNFLOW or HORIZONTAL
RIGHT applications.
NOTE: See Fig. 13 or tube routing label on main furnace door to
check for proper connections.
Relocate tubes as described below:
1. Disconnect collector box pressure tube (pink label)
attached to pressure switch.
2. Extend collector box pressure tube (green label) which
was previously connected to condensate trap relief port
connection by splicing to small diameter tube
(factory-supplied in loose parts bag).
3. Route extended collector box pressure tube behind inducer
motor bracket then between inducer motor and
pressure switch.
4. Connect collector box pressure tube (green label) to
pressure switch connection labeled COLLECTOR BOX.
5. Use remaining smaller diameter tube (factory-supplied in
loose parts bag) to extend collector box pressure tube
(pink label) which was previously connected to
pressure switch.
6. Route this extended tube (pink label) to condensate trap
relief port connection.
7. Determine appropriate length, cut, and connect tube.
8. Clamp tube to relief port connection.
CONDENSATE TRAP FREEZE PROTECTION
Refer to Condensate Drain
recommendations and procedures.
Protection
section
A93043
Fig. 15 -- Installation on Back is Prohibited
for
CONSTRUCT A WORKING PLATFORM
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 11 or 12.)
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent
unit operation.
The condensate trap MUST be installed below furnace. See
Fig. 5 for dimensions. The drain connection to condensate
trap must also be properly sloped to an open drain.
NOTE: Vent pipe(s) and combustion-air pipe (when applicable)
are restricted to a minimum length of 5 ft. (See Table 11.)
NOTE: A 12-in. (305 mm) minimum offset pipe section is
recommended with short (5 to 8 ft) vent systems. This
recommendation is to reduce excessive condensate droplets from
existing vent pipe. (See Fig. 11, 12 or 41.)
NOTE: The 140 size unit may NOT be installed in non-direct
vent (1-pipe) application.
LOCATION
Step 1 -- General
This furnace must
S be installed so the electrical components are protected
from water.
S not be installed directly on any combustible material other than
wood flooring (refer to SAFETY CONSIDERATIONS).
S be located so combustion-air and vent pipe maximum lengths
are not exceeded. Refer to Table 11.
S be located where available electric power and gas supplies
meet specifications on the furnace rating plate.
S be attached to an air distribution system and be located as close
to the center of the distribution system as possible. Refer to Air
Ducts section.
S be provided with ample space for servicing and cleaning.
Always comply with minimum fire protection clearances
shown on the furnace clearance to combustibles label.
NOTE: For upflow/downflow applications install furnace so that
it is level or pitched forward within 1/2-in. (13 mm) for proper
furnace operation. For horizontal applications pitch 1/4-in. (6
mm) minimum to 1/2-in. (13 mm)maximum forward to ensure
proper condensate drainage from secondary heat exchangers.
(See Fig. 14.)
-- 16 --
When a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall also be handled by duct(s) sealed to
furnace casing and terminating outside the space containing the
furnace to ensure there will not be a negative pressure condition
within equipment room or space.
CAUTION
UNIT DAMAGE HAZARD
This gas furnace may be used for construction heat
provided that:
--The furnace is permanently installed with all electrical
wiring, piping, air filters, venting and ducting installed
according to these installation instructions. A return air duct
is provided, sealed to the furnace casing, and terminated
outside the space containing the furnace. This prevents a
negative pressure condition as created by the circulating air
blower, causing a flame rollout and/or drawing combustion
products into the structure.
--The furnace is controlled by a thermostat. It may not be
“hot wired” to provide heat continuously to the structure
without thermostatic control.
--Clean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and other
construction materials. It also prevents the entrainment of
drywall dust into combustion air, which can cause fouling
and plugging of furnace components.
--The temperature of the return air to the furnace is
maintained between 55°F (13°C) and 80°F (27°C), with no
evening setback or shutdown. The use of the furnace while
the structure is under construction is deemed to be
intermittent operation per our installation instructions.
--The air temperature rise is within the rated rise range on the
furnace rating plate, and the firing rate has been set to the
nameplate value.
--The filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
--The furnace, ductwork and filters are cleaned as necessary
to remove drywall dust and construction debris from all
HVAC system components after construction is completed.
--After construction is complete, verify furnace operating
conditions including ignition, input rate, temperature rise and
venting, according to the manufacturer’s instructions.
!
WARNING
FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in fire, property
damage, personal injury, or death.
Do not install furnace on its back. Safety control operation
will be adversely affected. Never connect return-air ducts to
back of furnace. (See Fig. 15.)
A07911
Fig. 16 -- Freeze Protection
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in minor property or
unit damage.
If this furnace is installed in an unconditioned space where
ambient temperatures may be 32°F (0°C)or lower, freeze
protection measures must be taken. (See Fig. 16.)
Step 3 -- Hazardous Locations
!
WARNING
FIRE, EXPLOSION, INJURY OR DEATH HAZARD
Improper location or inadequate protection could result in fire
or explosion.
When the furnace is installed in a residential garage, the
burners and ignition sources must be located at least 18-in.
(457 mm) above the floor. The furnace must be located
or protected to avoid physical damage by vehicles. When
the furnace is installed in a public garage, airplane hangar, or
other building having a hazardous atmosphere, the furnace
must be installed in accordance with the NFGC or
NSCNGPIC. (See Fig. 17.)
Step 4 -- Furnace Location and Application
DIRECT VENT (2-PIPE) APPLICATION
Furnace may be located in a confined space without special
provisions for dilution or ventilation air.
Step 2 -- Furnace Location Relative to Cooling
Equipment
The cooling coil must be installed parallel with or on downstream
side of furnace to avoid condensation in heat exchanger. When
installed parallel with a furnace, dampers or other means used to
control flow of air shall be adequate to prevent chilled air from
entering furnace. If dampers are manually operated, they must be
equipped with a means to prevent operation of either unit unless
damper is in full-heat or full-cool position.
18-IN. (457.2 mm)
MINIMUM TO BURNERS
A93044
Fig. 17 -- Installation in a Garage
-- 17 --
58MCB
!
Table 1 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors
FURNACE
INPUT
(BTUH)
44,000
66,000
88,000
110,000
132,000
154,000
TWO HORIZONTAL DUCTS
(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW)
Free Area of
Opening and Duct
Sq. In. (mm)
22 (14194)
33 (21290)
44 (28387)
55 (35484)
66 (42581)
77 (49677)
Round Duct
Dia.
In. (mm)
6 (152)
7 (178)
8 (203)
9 (229)
10 (254)
10 (254)
SINGLE DUCT OR OPENING
(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)
Free Area of Opening
and Duct
Sq. In (mm)
14.7 (9494)
22 (14193)
29.3 (18903)
36.7 (23677)
44 (28387)
51.3 (33096)
Round Duct
Dia.
In. (mm)
5 (127)
6 (152)
7 (178)
7 (178)
8 (203)
9 (229)
TWO OPENINGS OR VERTICAL DUCTS
(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)
Free Area of Opening
and Duct
Sq. In (mm)
11 (7097)
16.5 (10645)
22 (14193)
27.5 (17741)
33 (21290)
38.5 (24838)
Round Duct
Dia.
In. (mm)
4 (102)
5 (127)
6 (152)
6 (152)
7 (198)
8 (203)
58MCB
EXAMPLE: Determining Free Area
FURNACE
110,000
66,000
88,000
WATER HEATER
30,000
40,000
30,000
+
+
+
=
=
=
TOTAL INPUT
(140,000 divided by 4,000)
(106,000 divided by 3,000)
(118,000 divided by 2,000)
=
=
=
35.0 Sq. In. for each two Vertical Ducts or Openings
35.3 Sq. In. for a Single Duct or Opening
59.0 Sq. In. for each of two Horizontal Ducts
Table 2 – Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors
OTHER THAN FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
30
40
50
ACH
0.60
1,050
(29.7)
1,400
(39.6)
1,750
(49.5)
FAN-ASSISTED TOTAL
(1,000’S BTUH GAS INPUT RATE)
44
66
88
110
132
Space Volume Ft3 (M3)
1,100
1,650
2,200
2,750
3,300
(31.1)
(46.7)
(62.2)
(77.8)
(93.4)
0.50
1,260
(35.6)
1,680
(47.5)
2,100
(59.4)
1,320
(37.3)
1,980
(56.0)
2,640
(74.7)
3,300
(93.4)
3,960
(112.1)
4,620
(130.8)
0.40
1,575
(44.5)
2,100
(59.4)
2,625
(74.3)
1,650
(46.7)
2,475
(70.0)
3,300
(93.4)
4,125
(116.8)
4,950
(140.1)
5,775
(163.5)
0.30
2,100
(59.4)
2,800
(79.2)
3,500
(99.1)
2,200
(62.2)
3,300
(93.4)
4,400
(124.5)
5,500
(155.7)
6,600
(186.8)
7,700
(218.0)
0.20
3,150
(89.1)
4,200
(118.9)
5,250
(148.6)
3,300
(93.4)
4,950
(140.1)
6,600
(186.8)
8,250
(233.6)
9,900
(280.3)
11,550
(327.0)
0.10
6,300
(178.3)
8,400
(237.8)
10,500
(297.3)
6,600
(186.8)
9,900
(280.3)
13,200
(373.7)
16,500
(467.2)
19,800
(560.6)
23,100
(654.1)
0.00
NP
NP
NP
NP
NP
NP
NP
NP
NP
NON-DIRECT VENT (1-PIPE) APPLICATION
!
!
CAUTION
154
3,850
(109.0)
WARNING
FURNACE CORROSION HAZARD
Failure to follow this warning could result in reduced furnace
component life.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements could corrode heat exchangers and
shorten furnace life. Air contaminants are found in aerosol
sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in intermittent
unit operation.
Do not install furnace in a corrosive or contaminated
atmosphere. Make sure all combustion and circulating air
requirements are met.
Refer to the AIR FOR COMBUSTION AND VENTILATION
section for details.
AIR FOR COMBUSTION AND
VENTILATION
The following types of furnace installations may require
OUTDOOR AIR for combustion due to chemical exposures:
S Commercial buildings
Provisions for adequate combustion, ventilation, and dilution air
must be provided in accordance with:
S U.S. Installations: Section 9.3 of the NFPA 54/ANSI
Z223.1--2006, Air for Combustion and Ventilation and
applicable provisions of the local building codes.
S Canadian Installations: Part 8 of the CAN/CSA--B149.1--05,
Venting Systems and Air Supply for Appliances and all
authorities having jurisdiction.
S Buildings with indoor pools
S Laundry rooms
S Hobby or craft rooms, and
S Chemical storage areas
If air is exposed to the following substances, it should not be
used for combustion air, and outdoor air may be required
for combustion:
S Permanent wave solutions
S Chlorinated waxes and cleaners
-- 18 --
S Water softening chemicals
S De-icing salts or chemicals
S Carbon tetrachloride
S Halogen type refrigerants
S Cleaning solvents (such as perchloroethylene)
S Printing inks, paint removers, varnishes, etc.
S Hydrochloric acid
S Cements and glues
S Antistatic fabric softeners for clothes dryers
S Masonry acid washing materials
All fuel-burning equipment must be supplied with air for fuel
combustion. Sufficient air must be provided to avoid negative
pressure in the equipment room or space. A positive seal must be
made between the furnace cabinet and the return-air duct to
prevent pulling air from the burner area and from draft
safeguard opening.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
The operation of exhaust fans, kitchen ventilation fans, clothes
dryers, attic exhaust fans or fireplaces could create a
NEGATIVE PRESSURE CONDITION at the furnace.
Make-up air MUST be provided for the ventilation devices, in
addition to that required by the furnace. Refer to the Carbon
Monoxide Poisoning Hazard warning in the venting section of
these instructions to determine if an adequate amount of
make-up air is available.
The requirements for combustion and ventilation air depend upon
whether or not the furnace is located in a space having a volume
of at least 50 cubic feet per 1,000 Btuh input rating for all gas
appliances installed in the space.
S Spaces having less than 50 cubic feet per 1,000 Btuh require
the OUTDOOR COMBUSTION AIR METHOD.
S Spaces having at least 50 cubic feet per 1,000 Btuh may use
the INDOOR COMBUSTION AIR, STANDARD or
KNOWN AIR INFILTRATION METHOD.
Outdoor Combustion Air Method
1. Provide the space with sufficient air for proper
combustion, ventilation, and dilution of flue gases using
permanent horizontal or vertical duct(s) or opening(s)
directly communicating with the outdoors or spaces that
freely communicate with the outdoors.
2. Fig. 18 illustrates how to provide TWO OUTDOOR
OPENINGS, one inlet and one outlet combustion and
ventilation air openings to the outdoors.
a. One opening MUST commence within 12-in. (305
mm) of the ceiling and the second opening MUST
commence within 12-in. (305 mm) of the floor.
b. Size openings and ducts per Fig. 18 and Table 1.
c. TWO HORIZONTAL DUCTS require 1 square inch of
free area per 2,000 Btuh (1,100 mm2/kW) of combined
input for all gas appliances in the space per Fig. 18
and Table 1.
d. TWO OPENINGS OR VERTICAL DUCTS require 1
square inch of free area per 4,000 Btuh (550 mm2/kW)
for combined input of all gas appliances in the space
per Fig. 18 and Table 1.
3. ONE OUTDOOR OPENING requires:
a. 1 square inch of free area per 3,000 Btuh
(734 mm2/kW) for combined input of all gas
appliances in the space per Table 1 and
b. Not less than the sum of the areas of all vent connectors
in the space.
The opening shall commence within 12-in. (305 mm) of
the ceiling. Appliances in the space shall have
clearances of at least 1-in. (25 mm) from the sides and
back and 6-in. (152 mm) from the front. The opening
shall directly communicate with the outdoors or shall
communicate through a vertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
Indoor Combustion Air© NFPA & AGA
Standard and Known-Air-Infiltration Rate Methods
Indoor combustion air is permitted for combustion, ventilation,
and dilution, if the Standard or Known-Air-Infiltration Rate
Method is used.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to supply outdoor air via grilles or ducts could result in
death and/or personal injury.
Many homes require air to be supplied from outdoors for
furnace combustion, ventilation, and dilution of flue gases.
The furnace combustion air supply must be provided in
accordance with this instruction manual.
The Standard Method:
1. The space has no less volume than 50 cubic feet per
1,000 Btuh of the maximum input ratings for all gas
appliances installed in the space and
2. The air infiltration rate is not known to be less than 0.40
air changes per hour (ACH).
The Known Air Infiltration Rate Method shall be used, if the
infiltration rate is known to be:
1. Less than 0.40 ACH and
2. Equal to or greater than 0.10 ACH
Infiltration rates greater than 0.60 ACH shall not be used. The
minimum required volume of the space varies with the number of
ACH and shall be determined per Table 2 or Equations 1 and 2.
Determine the minimum required volume for each appliance in
the space and add the volumes together to get the total minimum
required volume for the space.
Table 2 -- Minimum Space Volumes were determined by using
the following equations from the National Fuel Gas Code NFPA
54/ANSI Z223.1--2006, 9.3.2.2:
1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater
A04002
2. For fan-assisted appliances such as this furnace:
A04003
-- 19 --
58MCB
S Chlorine based swimming pool chemicals
58MCB
1 SQ IN.
PER 2000
BTUH*
(305mm) 12″ MAX
A
F
1 SQ IN.
PER
4000
BTUH*
INTERIOR
HEATED
SPACE
OUTDOORS
DUCTS
TO
OUTDOORS
CIRCULATING
AIR DUCTS
B
12″ (305mm)
MAX
D
VENT
THROUGH
ROOF
CLEARANCE IN FRONT
OF COMBUSTION AIR
OPENINGS SHALL BE
AT LEAST 3 IN.
(76mm)
(305mm) 12″ MAX
1 SQ IN.
PER 2000
BTUH*
CIRCULATING AIR
DUCTS
1 SQ IN.
PER
4000
BTUH*
E
G
12″ (305mm)
MAX
C
DUCT
TO
OUTDOORS
12" MAX (305mm)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
6" MIN (152mm)
(FRONT)Ü
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12" MAX (305mm)
12″ MAX
(305mm)
CIRCULATING AIR DUCTS
VENT THROUGH ROOF
CLEARANCE IN FRONT OF COMBUSTION AIR
OPENINGS SHALL BE AT LEAST 3 IN.
1 SQ IN.
PER 4000
BTUH*
DUCTS
TO
OUTDOORS
CIRCULATING AIR DUCTS
1 SQ IN.
PER 4000
BTUH*
* Minimum opening size is 100 sq in. with minimum dimensions of 3 in. (76
mm)
† Minimum of 3 in. (76 mm) when type-B1 vent is used.
*Minimum dimensions of 3 in. (76 mm).
NOTE: Use any of the following combinations of openings:
A&BC&DD&EF&G
A03174
Fig. 18 -- Air for Combustion, Ventilation, and Dilution
for Outdoors
If:
Iother=combined input of all other than fan-assisted appliances
in Btu/hr
Ifan=combined input of all fan-assisted appliances in Btu/hr
ACH = air changes per hour (ACH shall not exceed 0.60.)
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
1. Adjoining rooms can be considered part of a space if:
a. There are no closable doors between rooms.
b. Combining spaces on same floor level. Each opening
shall have free area of at least 1-in.2/1,000 Btuh
(2,000 mm2/kW) of the total input rating of all gas
appliances in the space, but not less than 100-in.2
(0.06 m2). One opening shall commence within 12 in.
(305 mm) of the ceiling and the second opening shall
commence within 12-in. (305 mm) of the floor. The
minimum dimension of air openings shall be at least
3-in. (76 mm). (See Fig. 19.)
c. Combining space on different floor levels. The
volumes of spaces on different floor levels shall be
considered as communicating spaces if connected by
one or more permanent openings in doors or floors
having free area of at least 2 in.2/1,000 Btuh
(4,400 mm2/kW) of total input rating of all
gas appliances.
2. An attic or crawlspace may be considered a space that
freely communicates with the outdoors provided there are
adequate permanent ventilation openings directly to
outdoors having free area of at least 1-in.2/4,000 Btuh of
total input rating for all gas appliances in the space.
-- 20 --
A03175
Fig. 19 -- Air for Combustion, Ventilation, and Dilution
from Indoors
3. In spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for
combustion, permanent ventilation and dilution of flue
gases. However, in buildings with unusually tight
construction, additional air MUST be provided using
the methods described in the Outdoor Combustion Air
Method section.
Unusually tight construction is defined as
Construction with:
a. Walls and ceilings exposed to the outdoors have a
continuous, sealed vapor barrier. Openings are
gasketed or sealed and
b. Doors and openable windows are weatherstripped and
c. Other openings are caulked or sealed. These include
joints around window and door frames, between sole
plates and floors, between wall-ceiling joints, between
wall panels, at penetrations for plumbing, electrical
and gas lines, etc.
NOTE: In determining the free area of an opening, the blocking
effect of the louvers, grilles, and screens must be considered. If
the free area of a louver or grille design is unknown, it may be
assumed that wood louvers have a 20 percent free area, and metal
louvers or grilles have a 60 percent free area. Screens, when used,
must not be smaller than 1/4-in. (6 mm) mesh. Louvers and
grilles must be constructed so they cannot be closed.
When combustion air 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. (76 mm).
INSTALLATION
NOTE: The 140 size unit may not be installed in non-direct vent
(1-pipe) applications.
manufacturer) Part No. KGASB0201ALL is used. Special base is
not required when this furnace is installed on manufacturer’s Coil
Assembly Part No. CNPV, CAPV, CAP or CAR, 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. 21.
3. Construct plenum to dimensions specified in Table 3
and Fig. 21.
4. If downflow subbase (KGASB) is used, install as shown in
Fig. 22.
If Coil Assembly Part No. CNPV, CAPV, CAP or CAR or
Coil Box Part No. KCAKC is used, install as shown in
Fig. 23.
NOTE: Remove furnace perforated, discharge duct flanges when
they interfere with mating flanges on coil on downflow sub base.
To remove furnace perforated, discharge duct flange, use wide
duct pliers or duct flange tool or hand seamers to bend flange
back and forth until it breaks off. Be careful of sharp edges.
(See Fig. 24.)
Step 1 -- Leveling Legs (If Desired)
When furnace is used in upflow position with side inlet(s),
leveling legs may be desired. (See Fig. 20.) Install field-supplied,
corrosion-resistant 5/16-in. (8 mm) machine bolts and nuts.
NOTE: The maximum length of bolt should not exceed 1-1/2 in.
(38 mm).
1. Position furnace on its back. Locate and drill a 5/16-in. (8
mm) diameter hole in each bottom corner of furnace. (See
Fig. 20.) Holes in bottom closure panel may be used as
guide locations.
2. For each hole, install nut on bolt and then install bolt and
nut in hole. (Install flat washer if desired.)
3. Install another nut on other side of furnace base. (Install
flat washer if desired.)
4. Adjust outside nut to provide desired height, and tighten
inside nut to secure arrangement.
NOTE: Bottom closure must be used when leveling legs are
used. See Bottom Closure Panel section.
!
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent
unit operation.
Do not bend duct flanges inward as shown in Fig. 24. This
will affect airflow across heat exchangers and may cause
limit cycling or premature heat exchanger failure. Remove
duct flange completely or bend it inward a minimum of 210°
as shown in Fig. 24.
NOTE: For 140 size unit when installed in downflow orientation,
cut the white jumper wire off between terminals PL1--7 and PL1--9.
Do not cut white jumper between terminals PL1--7 and PL1--11.
Refer to Fig. 31 for location of jumper. Cut jumper close to
connector and remove wire to avoid a short circuit.
Step 3 -- Installation in Horizontal Applications
5/ 16″
!
(8mm)
(8mm)
5/ 16″
CAUTION
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent
unit operation.
1 3/4″
(44mm)
The entire length of furnace MUST be supported when
furnace is used in a horizontal position to ensure proper
draining. When suspended, bottom brace supports sides and
center blower shelf. When unit is supported from the ground,
blocks or pad should support sides and center blower
shelf area.
1 3/4″
(44mm)
(8mm)
5/16″
(8mm)
5/ 16″
(44mm) 1 3/ 4″
3/
(44mm) 1 4″
A89014
Fig. 20 -- Leveling Legs
Step 2 -- Installation in Upflow or Downflow
Applications
These furnaces can be installed horizontally in either horizontal
left or right discharge position. In a crawlspace, furnace can
either be hung from floor joist or installed on suitable blocks or
pad. Furnace can be suspended from each corner by hanger bolts
and angle iron supports. (See Fig. 25.) Cut hanger bolts (4 each
3/8-in. (10 mm) all-thread rod) to desired length. Use 1 X 3/8-in.
flat washers, 3/8-in. lock washers, and 3/8-in. nuts on hanger rods
as shown in Fig. 25. Dimples are provided for hole locations.
(See Fig. 2.)
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when special base (available from
-- 21 --
58MCB
Combination of Indoor and Outdoor Air
1. Indoor openings shall comply with the Indoor
Combustion Air Method below and,
2. Outdoor openings shall be located as required in the
Outdoor Combustion Air Method mentioned previously
and,
3. Outdoor openings shall be sized as follows:
a. Calculate the Ratio of all Indoor Space volume divided
by required volume for Indoor Combustion Air
Method below.
b. Outdoor opening size reduction Factor is 1 minus the
Ratio in a. above.
c. Minimum size of Outdoor openings shall be the size
required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The
minimum dimension of air openings shall be not less
than 3-in. (76 mm).
FURNACE
(OR COIL CASING
WHEN USED)
A
COMBUSTIBLE
FLOORING
PLENUM
OPENING
B
D
DOWNFLOW
SUBBASE
FLOOR
OPENING
SHEET METAL
PLENUM
FLOOR
OPENING
58MCB
C
A96283
Fig. 21 -- Floor and Plenum Opening Dimensions
A96285
Fig. 22 -- Furnace, Plenum, and Subbase
Installed on a Combustible Floor
FURNACE
FACTORY SUPPLIED
CASED COIL OR COIL BOX
COMBUSTIBLE
FLOORING
SHEET METAL
PLENUM
FLOOR
OPENING
A07586
Fig. 23 -- Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor
-- 22 --
Table 3 – Opening Dimension -- In. (mm)
17-1/2
(445)
21
(533)
24-1/2
(622)
PLENUM OPENING
APPLICATION
FLOOR OPENING
A
B
C
D
Upflow Applications
16 (406)
24-1/8 (613)
16-5/8 (422)
24-3/4 (629)
Downflow Applications on Non-Combustible Flooring
15-7/8 (403)
19 (483)
16-1/2 (419)
19-5/8 (498)
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC
Coil Box
15-1/8 (384)
19 (483)
16-3/4 (425)
20-3/8 (518)
Downflow Applications on Combustible Flooring NOT Using KGASB
Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC Coil
Box
15-1/2 (394)
19 (483)
16-1/2 (419)
20 (508)
Upflow Applications
19-1/2 (495)
24-1/8 (613)
20-1/8 (511)
24-3/4 (629)
Downflow Applications on Non-Combustible Flooring
19-3/8 (492)
19 (483)
20 (508)
19-5/8 (498)
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC
Coil Box
18-5/8 (473)
19 (483)
20-1/4 (514)
20-3/8 (518)
Downflow Applications on Combustible Flooring NOT Using KGASB
Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC Coil
Box
19 (483)
19 (483)
20 (508)
20 (508)
Upflow Applications
23 (584)
24-1/8 (613)
23-5/8 (600)
24-3/4 (629)
Downflow Applications on Non-Combustible Flooring
22-7/8 (581)
19 (483)
23-1/2 (597)
19-5/8 (498)
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC
Coil Box
22-1/8 (562)
19 (483)
23-3/4 (603)
20-3/8 (518)
Downflow Applications on Combustible Flooring NOT Using KGASB
Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or KCAKC Coil
Box
22-1/2 (572)
19 (483)
23-1/2 (597)
20 (508)
Step 4 -- Air Ducts
PERFORATED
DISCHARGE DUCT
FLANGE
GENERAL REQUIREMENTS
NO
YES
210 DEG.
MIN
YES
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA)
or American Society of Heating, Refrigerating and Air
Conditioning Engineers (ASHRAE) or consult The Air Systems
Design Guidelines reference tables available from your local
distributor. The duct system should be sized to handle the
required system design CFM at the design static pressure.
When a furnace is installed so that the supply ducts carry air
circulated by the furnace to areas outside the space containing the
furnace, the return air shall 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.
A93029
Fig. 24 -- Duct Flanges
-- 23 --
58MCB
FURNACE
CASING
WIDTH
COMBUSTION-AIR INTAKE
(NON-DIRECT VENT/1-PIPE
APPLICATION)
COMBUSTION-AIR PIPE
(DIRECT VENT/2-PIPE
APPLICATION,ALL SIZES)
VENT
58MCB
3-IN. (76 mm) MINIMUM CLEARANCE TO
COMBUSTION-AIR INTAKE IS REQUIRED
(NON-DIRECT VENT/1-PIPE
APPLICATION,)
3/8-IN. (10 mm) ROD
ANGLE
IRON OR
EQUIVALENT
5 3/4″ (146 mm)
ALTERNATE SUPPORT
LOCATION 4-IN. (102 mm) MIN
8-IN. (203 mm) MAX
(B)
(A)
DRAIN
(B)
(A)
(A) ROD LOCATION
USING DIMPLE
LOCATORS
(SEE DIMENSIONAL
DWG FOR
LOCATIONS)
(B)
3/8-IN.
HEX NUT
& WASHER (4)
REQD PER ROD
(A) PREFERRED ROD LOCATION
(B)
(A)
13/16-IN. (21 mm) MAX
ALTERNATE SUPPORT
LOCATION FROM BACK
NOTES: 1. A 1-in. (25.4 mm) clearance minimum
between top of furnace and combustible
material.
(B) ALTERNATE ROD LOCATION
2. The entire length of furnace must be
supported when furnace is used in horizontal
position to ensure proper drainage.
3. For non-direct vent/1-pipe application,
bottom side combustion-air entry cannot be
used when furnace is installed with hangers
as shown.
A05054
Fig. 25 -- Crawlspace Horizontal Application for Direct Vent/2-Pipe Installation (Sizes 040 Through 140) and for
Non-Direct Vent/1-Pipe Installation (Sizes 040 Through 120 Only)
Flexible connections should be used between duct work and
furnace to prevent transmission of vibration. Ductwork passing
through unconditioned space should be insulated to enhance
system performance. When air conditioning is used, a vapor
barrier is recommended.
Maintain a 1-in. (25 mm) clearance from combustible materials to
supply air ductwork for a distance of 36-in. (914 mm)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.
For a furnace not equipped with a cooling coil, the outlet duct
shall be provided with a removable access panel. This opening
shall be accessible when the furnace is installed and shall be of
such a size that the heat exchanger can be viewed for possible
openings using light assistance or a probe can be inserted for
sampling the air stream. The cover attachment shall
prevent leaks.
DUCTWORK ACOUSTICAL TREATMENT
Metal duct systems that do not have a 90 degree elbow and 10 ft
(3.0 M) of main duct to the first branch take-off may require
-- 24 --
internal acoustical lining. As an alternative, fibrous ductwork
may be used if constructed and installed in accordance with the
latest edition of SMACNA construction standard on fibrous glass
ducts. Both acoustical lining and fibrous ductwork shall comply
with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid
air ducts.
SUPPLY AIR CONNECTIONS
Upflow Furnaces
Connect supply-air duct to 3/4-in. (19 mm) flange on furnace
supply-air outlet. The supply-air duct attachment must ONLY be
connected to furnace supply-/outlet-air duct flanges or air
conditioning coil casing (when used). DO NOT cut main furnace
casing to attach supply side air duct, humidifier, or other
accessories. All accessories MUST be connected external to
furnace main casing.
Downflow Furnaces
Connect supply-air duct to supply-air opening on furnace. The
supply-air duct attachment must ONLY be connected to furnace
RETURN AIR CONNECTIONS
The furnace and its return air system shall be designed and
installed so that negative pressure created by the air circulating
fan cannot affect another appliance’s combustion air supply or act
to mix products of combustion with circulating air and the air
circulating fan of the furnace, if installed in an enclosure
communicating with another fuel-burning appliance not of the
direct-vent type, shall be operable only when any door or panel
covering an opening in the furnace fan compartment or in return
air plenum on ducts is in the closed position.
Step 5 -- Filter Arrangement
!
FIRE, CARBON
HAZARD
WARNING
MONOXIDE
AND
POISONING
Failure to follow this warning could result in fire, personal
injury, or death.
Never operate a unit without a filter or with filter access
door removed.
Determine location for filter and relocate filter retaining wire if
necessary. See Table 4 to determine correct filter size for desired
filter location. Table 4 indicates filter size and location for this
furnace. See Fig. 2 for location and size of bottom and side
return-air openings.
!
CAUTION
58MCB
supply/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 sub base 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.
Supply air opening duct flanges must be modified per Fig. 24.
Horizontal Furnaces
Connect supply-air duct to supply air opening on furnace. The
supply-air duct attachment must ONLY be connected to furnace
supply/outlet or air conditioning coil casing (when used). DO
NOT cut main furnace casing to attach supply side air duct,
humidifier, or other accessories. All accessories MUST be
connected external to furnace main casing.
CUT HAZARD
Failure to follow this caution may result in minor
personal injury.
Use care when cutting support rods in filters to protect
against flying pieces and sharp rod ends. Wear safety glasses,
gloves, and appropriate protective clothing.
Table 4 – Filter Information
AIR FILTER LOCATED IN BLOWER COMPARTMENT
FURNACE
FILTER SIZE --- IN (mm)
CASING
FILTER
WIDTH
TYPE
Side Return†*
Bottom Return*
IN (mm)
17–1/2
(445)
21 (533)
24–1/2
(622)
(1) 16 X 25 X 3/4
(406 X 635 X 19)
(1) 16 X 25 X 3/4
(406 X 635 X 19)
(1 or 2)16 X 25 X 3/4
(406 X 635 X 19)
(1) 16 X 25 X 3/4
(406 X 635 X 19)
1) 20 X 25 X 3/4
(508 X 635 X 19)
(1) 24 X 25 X 3/4
(610 X 635 X 19)
Washable
Washable
Washable
*Alternate sizes and additional filters can be ordered from your distributor or
dealer.
†Upflow only. Alternate sizes and additional filters may be ordered from
your dealer.
!
WARNING
FIRE HAZARD
A failure to follow this warning could result in fire, personal
injury, or death.
A08604
Fig. 26 -- Filter Installed for Side Inlet
Never connect return-air ducts to the back of the furnace.
Return-air duct connections on furnace side(s) permitted in
upflow applications only.
!
CAUTION
UNIT MAY NOT OPERATE
Upflow Furnaces
The return-air duct must be connected to end, sides (left or right),
or a combination of end and side(s) of main furnace casing as
shown in Fig. 2. Bypass humidifier may be attached into unused
side return air portion of the furnace casing. DO NOT connect
any portion of return-air duct to back of furnace casing.
Downflow and Horizontal Furnaces
The return-air duct must be connected to end inlet opening
provided as shown in Fig. 2. DO NOT cut into casing sides or
back to attach any portion of return-air duct. Bypass humidifier
connections should be made at ductwork or coil casing sides
exterior to furnace.
Failure to follow this caution may result in intermittent
unit operation.
For airflow requirements above 1800 CFM, see Air Delivery
table in Product Data literature for specific use of single side
inlets. The use of both side inlets, a combination of 1 side
and the bottom, or the bottom only will ensure adequate
return air openings for airflow requirements above
1800 CFM.
NOTE: Side return-air openings can ONLY be used in
UPFLOW configurations. Install filter(s) as shown in Fig. 26.
Bottom return-air opening may be used with all 4 orientations.
Filter may need to be cut to fit some furnace widths. Install filter
as shown in Fig. 27.
-- 25 --
NOTE: Remove and discard bottom closure panel when bottom
inlet is used.
Step 6 -- Bottom Closure Panel
These furnaces are shipped with bottom enclosure panel installed
in bottom return-air opening. This panel MUST be in place when
side return air is used.
To remove bottom closure panel, perform following:
1. Tilt or raise furnace and remove 2 screws holding front
filler panel. (See Fig. 28.)
2. Rotate front filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall front filler panel and screws.
BOTTOM
CLOSURE
PANEL
58MCB
Step 7 -- Gas Piping
Gas piping must be installed in accordance with national and
local codes. Refer to current edition of NFGC in the United
States. Canadian installations must be made in accordance with
NSCNGPIC and all authorities having jurisdiction.
Gas supply line should be a separate line running directly from
meter to furnace, if possible. Refer to Table 5 for recommended
gas pipe sizing. Risers must be used to connect to furnace and to
meter. Support all gas piping with appropriate straps, hangers,
etc. Use a minimum of 1 hanger every 6 ft (1.8 M). Joint
compound (pipe dope) should be applied sparingly and only to
male threads of joints. Pipe dope must be resistant to propane gas.
171⁄2-IN. (444mm) WIDE
CASINGS ONLY:
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
21-IN. (533mm) WIDE
CASINGS ONLY:
SUPPORT RODS (3)
EXTEND 1/4" (6mm) ON
EACH SIDE OF FILTER AND
REST ON CASING FLANGE
3″
(76mm)
24 1/2″
FRONT FILLER
PANEL
A93047
Fig. 28 -- Removing Bottom Closure Panel
Table 5 – Maximum Capacity of Pipe *
NOMINAL
IRON PIPE
SIZE
IN. (MM)
INTERNAL
DIA.
IN. (MM)
1/2 (12.7)
LENGTH OF PIPE --- FT (M)
10
(3.0)
20
(6.0)
30
(9.1)
40
(12.1)
50
(15.2)
0.622
(158)
175
120
97
82
73
3/4 (19.0)
0.824
(20.9)
360
250
200
170
151
1 (25.4)
1.049
(26.6)
680
465
375
320
285
1-1/4
(31.8)
1.380
(35.0)
1400
950
770
660
580
1-1/2
(38.1)
1.610
(40.9)
2100
1460
1180
990
900
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14---in. wc) or less and
a pressure drop of 0.5---in wc (based on a 0.60 specific gravity gas). Ref:
Table 9.2 NFGC.
(533mm)
1″
(25.4mm)
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in fire, explosion,
personal injury, or death.
-- Connect gas pipe to furnace using a backup wrench to
avoid damaging gas controls.
-- Gas valve shutoff switch MUST be facing forward or
tilted upward.
-- Never purge a gas line into a combustion chamber. Never
test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of
leaks to check all connections.
-- Use proper length of pipe to avoid stress on gas
control manifold.
-- If a flexible connector is required or allowed by authority
having jurisdiction, black iron pipe shall be installed at
furnace gas valve and extend a minimum of 2--in. (51 mm)
outside furnace casing.
-- Protect gas valve from water and debris. Gas valve inlet
and/or inlet piping must remain capped until gas supply line
is permanently installed to protect the valve from moisture
and debris. Also, install a sediment trap in the gas supply
piping at the inlet to the gas valve.
FILTER
FILTER
SUPPORT
FILTER
RETAINER
Fig. 27 -- Bottom Filter Arrangement
A08605
-- 26 --
Install a sediment trap in riser leading to furnace. Trap can be
installed by connecting a tee to riser leading to furnace so
straight-through section of tee is vertical. Then connect a capped
nipple into lower end of tee. Capped nipple should extend below
level of gas controls. Place a ground joint union between gas
control manifold and manual gas shutoff valve. (See Fig. 29.)
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
exceed maximum 0.5 psig (14-in. wc) stated on gas valve.
(See Fig. 48.)
Piping should be pressure and leak tested in accordance with
NFGC in the United States or NSCNGPIC in Canada, local, and
national plumbing and gas codes before the furnace has been
connected. After all connections have been made, purge lines and
check for leakage at furnace prior to operating furnace.
If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be
disconnected from furnace and capped before pressure test. If test
pressure is equal to or less than 0.5 psig (14-in. wc), turn off
electric shutoff switch located on furnace gas valve and
accessible manual shutoff valve before test.
The gas supply pressure shall be within the maximum and
minimum inlet supply pressures marked on the rating plate with
the furnace burners ON and OFF.
A93324
Fig. 29 -- Typical Gas Pipe Arrangement
If local codes allow the use of a flexible gas appliance connector,
always use a new listed connector. Do not use a connector which
has previously served another gas appliance.
!
See Fig. 30 for field wiring diagram showing typical field 115-v
and 24-v wiring. Check all factory and field electrical
connections for tightness.
Field-supplied wiring shall conform with the limitations of 63°F
(35°C) rise.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in serious injury
or death.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this safety warning exactly could result in
serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the
detection of leaks to check all connections. A fire or explosion
could result causing property damage, personal injury or loss
of life.
An accessible manual shutoff valve MUST be installed external
to furnace casing and within 6 ft (1.8 M) of furnace. A 1/8-in. (3
mm) NPT plugged tapping, accessible for test gauge connection,
MUST be installed immediately upstream of gas supply
connection to furnace and downstream of manual shutoff valve.
NOTE: The gas valve inlet pressure tap connection is suitable to
use as test gauge connection providing test pressure DOES NOT
Blower access panel door switch opens 115-v power to control
center. No component operation can occur. Do not bypass or
close switch with panel removed.
!
CAUTION
FURNACE MAY NOT OPERATE
Failure to follow this caution may result in furnace operation
stopping and water pipes freezing during cold weather.
Furnace control must be grounded for proper operation or
control will lock out. Control is grounded through
green/yellow wire routed to gas valve and burner box screw.
Table 6 – Electrical Data
UNIT SIZE
VOLTSHERTZPHASE
040---08 / 024040
040---12 / 036040
060---08 / 024060
060---12 / 036060
060---16 / 048060
080---12 / 036080
080---16 / 048080
080---20 / 060080
100---16 / 048100
100---20 / 060100
120---20 / 060120
140---20 / 060140
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
OPERATING
VOLTAGE RANGE
Max*
127
127
127
127
127
127
127
127
127
127
127
127
Min*
104
104
104
104
104
104
104
104
104
104
104
104
MAX UNIT
AMPS
UNIT AMPACITY†
MIN
WIRE
SIZE
MAX WIRE
LENGTH
FT (M)‡
MAX FUSE OR
CKT BKR AMPS**
6.1
7.3
6.1
7.1
9.5
7.6
10.0
14.1
10.2
14.8
14.6
14.3
8.4
10.0
8.4
9.8
12.8
10.4
13.4
18.4
13.5
19.3
19.1
18.8
14
14
14
14
14
14
14
12
14
12
12
12
44 (13.4)
37 (11.2)
44 (13.4)
38 (11.5)
29 (8.8)
36 (10.9)
28 (8.5)
31 (9.4)
27 (8.2)
30 (9.1)
30 (9.1)
30 (9.1)
15
15
15
15
15
15
15
20
15
20
20
20
* Permissible limits of voltage range at which unit will operate satisfactorily.
† Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier,
etc.) full load amps.
‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.** Time-delay type is recommended
-- 27 --
58MCB
Step 8 -- Electrical Connections
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
NOTE 2
FIVE WIRE
THREE-WIRE
HEATING-ONLY
W
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
DISCONNECT
208/230- OR
460-V
THREE
PHASE
BLOWER DOOR SWITCH
BLK
BLK
WHT
WHT
58MCB
GND
115-V FIELDSUPPLIED
DISCONNECT
W
C
O
N
T
R
O
L
GND
AUXILIARY
J-BOX
R
208/230-V
SINGLE
PHASE
G
COM
NOTE 1
Y
24-V
TERMINAL
BLOCK
FURNACE
GND
CONDENSING
UNIT
TWO
WIRE
NOTES: 1. Connect Y-terminal in furnace as shown for proper blower operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
Fig. 30 -- Heating and Cooling Application Wiring Diagram
A02174
115-V WIRING
Before proceeding with electrical connections, make certain that
voltage, frequency, and phase correspond to that specified on unit
rating plate. Also, check to be sure that service provided by
power supply is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 6 for equipment
electrical specifications.
The furnace must be electrically grounded in accordance with
local codes; or in the absence of local codes, with the National
Electric Code ANSI/NFPA 70 and/or the Canadian Electric Code,
CSA C22.1, Part I, if an external electrical source is utilized.
!
WARNING
!
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in serious injury,
death, or property damage.
The cabinet MUST have an uninterrupted or unbroken ground
according to NEC ANSI/NFPA 70--2008 and Canadian
Electrical Code CSA C22.1 or local codes to 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.
J-Box Relocation
1. Remove 2 screws holding auxiliary J-box. (See Fig. 32.)
2. Rotate J-box 180° and attach box to left side, using
holes provided.
FIRE HAZARD
Failure to follow this warning could result in serious injury,
death, or property damage.
Do not connect aluminum wire between disconnect switch and
furnace. Use only copper wire. (See Fig. 31.)
!
WARNING
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in serious injury,
death, or property damage.
ELECTRIC
DISCONNECT
SWITCH
If manual disconnect switch is to be mounted on furnace,
select a location where a drill or fastener will not contact
electrical or gas components.
COPPER
WIRE ONLY
24-V WIRING
ALUMINUM
WIRE
A93033
Fig. 31 -- Disconnect Switch and Furnace
Use a separate, fused branch electrical circuit containing a
properly sized fuse or circuit breaker for this furnace. See Table 6
for wire size and fuse specifications. A disconnecting means must
be located within sight from and readily accessible to furnace.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect or the furnace is not grounded, control center
LED status indicator light will flash rapidly and furnace will
NOT operate.
-- 28 --
Make field 24-v thermostat connections at 24-v terminal block on
furnace control center. For proper cooling operation, Y wire from
thermostat MUST be connected to Y terminal on furnace control
center, as shown in Fig. 30. The 24-v terminal block is marked
for easy connection of field wiring. (See Fig. 33.) The 24-v
circuit contains a 3-amp, automotive-type fuse located on furnace
control center. (See Fig. 34.) Any electrical shorts of 24-v wiring
during installation, service, or maintenance may cause fuse to
blow. If fuse replacement is required, use only a fuse of identical
size (3 amp) and type. The control will flash code 24 when fuse
needs replacement.
ALTERNATE
FIELD
LOCATION
FACTORY
INSTALLED
LOCATION
2. Humidifier (HUM)
A quick-connect terminal (HUM) and screw terminal (COM
24v) are provided for 24v humidifier connection. (See Fig.
34.) HUM terminal is energized with 24v (0.5-amp
maximum) when gas valve is energized.
NOTE: A field-supplied, 115-v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
When an existing Category I furnace is removed or replaced, the
original venting system may no longer be sized to properly vent
the remaining attached appliances. An improperly sized
Category I venting system could cause the formation of
condensate in the furnace and vent, leakage of condensate and
combustion products, spillage of combustion products into the
living space, etc.
Step 10 -- Combustion Air and Vent Pipe Systems
A00212
Fig. 32 -- Relocating J-Box
NOTE: Use AWG No. 18 color-coded copper thermostat wire
for lengths up to 100 ft (30.5 M). For wire lengths over 100 ft,
use AWG No. 16 wire.
ACCESSORIES
1. Electronic Air Cleaner (EAC)
Two quick-connect terminals marked EAC-1 and EAC-2
are provided for EAC connection. (See Fig. 34.) These
terminals are energized with 115v (1.0-amp maximum)
during blower motor operation.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit
component damage.
DO NOT connect furnace control HUM terminal to HUM
(humidifier) terminal on Thermidistatt, Zone Controller or
similar device. See Thermidistatt, Zone Controller,
thermostat, or controller manufacturer’s instructions for
proper connection.
GENERAL
Vent system or vent connectors may need to be resized. For any
other appliances when resizing vent systems or vent connectors,
system or connector must be sized to approach minimum size as
determined using appropriate table found in the NFGC
or NSCNGPIC.
The 58MCB can be vented as either a direct vent (all sizes) or as
a non-direct vent (except for 140 size) application. A direct vent
system shall be installed in accordance with the direct vent
(2-pipe) procedures in the following Combustion Air and Vent
Pipe Systems section. For non-direct vent (1-pipe)
applications, refer to the non-direct vent (1-pipe) procedures in
the same section.
Multistory and common venting are prohibited.
DIRECT VENT/2-PIPE SYSTEM (ALL SIZES)
In a direct-vent (2-pipe) system, all air for combustion is taken
directly from outdoor atmosphere, and all flue products are
discharged to outdoor atmosphere. A factory accessory vent
termination kit MUST be used in a direct vent (2-pipe) system.
-- 29 --
58MCB
Step 9 -- Removal of Existing Furnaces from
Common Vent Systems
L
E
G
E
N
D
R
Y
BHT/CLR
COOL
-- 30 --
Fig. 33 -- Wiring Diagram
GND
GV
GVR 1, 2
HSI
HSIR
HUM
IDM
IDR
ILK
J1
J2
JB
LED
LGPS
LS
BHT/CLR
BLWR
BLWM
CAP 1,2
CPU
EAC-1
EAC-2
FRS
FSE
FU 1
FU 2
BLU
(MED LO)
HUM
START
BLWM
EAC-1
PL1
RED
BRN
BRN
1
CAP -1
GRN/YEL
PR1
2
PL2
GRN/YEL
YEL
WHT
RED
GRN/YEL
WHT
WHT
ORN
BLU
BLK
BLK
WHT
ILK
WHT (COM)
BLK
FSE
RED
ORN
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLOWER MOTOR RELAY, SPST-(N.O.)
BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FLAME-PROVING ELECTRODE
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
(FIELD INSTALLED & SUPPLIED)
EQUIPMENT GROUND
GAS VALVE-REDUNDANT
GAS VALVE RELAY, DPST-(N.O.)
HOT SURFACE IGNITER (115 VAC)
HOT SURFACE IGNITER RELAY, SPST-(N.O.)
24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
INDUCED DRAFT MOTOR, PSC
INDUCED DRAFT MOTOR RELAY, SPST-(N.O.)
BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
BLOWER - OFF DELAY JUMPER SELECTOR
COOLING - OFF DELAY JUMPER
JUNCTION BOX
LIGHT-EMITTING DIODE FOR STATUS CODES - RED
LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LIMIT SWITCH, AUTO-RESET, SPST (N.C.)
OL
SPARE 2
L1
RED (LO)
NOTE #10
L2
BLWR
BLK (HI)
YEL
(MED HI)
WHT
(COM)
SPARE 1
HEAT
LED 1
180
J1
120
TEST/TWIN
150
90
SEC-1
EAC-2
SEC-2
FU1
NOTE #6
NOTE #8
J2
1 2 3 4 5 6 7 8 9 10 11
G
Com
24V
W
NEUTRAL
BLW
PCB
PCB
PL1
PL2
PL3
PL4
PRS
TEST/TWIN
TRAN
OL
JB
BLK
1
2
3
PL4
PL3
2
1
BRN
M
OL
WHT
IDM
BRN
AUX
CAP -2
WHT
GRN/YEL
NOTE #3
C
GV
GND
BLK
WHT
FU2
L1
NEUTRAL
FUSED OR CIRCUIT BREAKER
DISCONNECT SWITCH (WHEN REQ’D)
NOTE #2
WHT
BLK
WHT
BLK
GRN/YEL
WHT
WHT
BLK
M
YEL
PLUG RECEPTACLE
FIELD SPLICE
EQUIPMENT GROUND
FIELD EARTH GROUND
FIELD WIRING SCREW TERMINAL
CONDUCTOR ON CONTROL PCB
FIELD WIRING (24VAC)
FIELD WIRING (115VAC)
FACTORY WIRING (24VAC)
FACTORY WIRING (115VAC)
PCB CONTROL TERMINAL
UNMARKED TERMINAL
AUTO-RESET INTERNAL MOTOR OVERLOAD
TEMPERATURE SWITCH (N.C.)
PRINTED CIRCUIT BOARD CONTROL
11-CIRCUIT PCB CONNECTOR
2-CIRCUIT CONNECTOR
2-CIRCUIT HSI, CONNECTOR
3-CIRCUIT IDM EXTENSION CONNECTOR
PRESSURE SWITCH, SPST-(N.O.)
COMPONENT TEST & TWIN TERMINAL
TRANSFORMER-115VAC/24VAC
JUNCTION
RED
FRS
BLU
NOTE #11
(WHEN USED)
LGPS
GRN/YEL
BLU
RED
LS
RED
PRS
TRAN
PRINTED CIRCIUT BOARD
HSI
BLOWER OFF DELAY
JUMPER SELECT
58MCB
ILK
13.
14.
10.
11.
12.
1.
2.
3.
4.
5.
6.
7.
8.
9.
PCB
NOTE #5
SEC-1
CPU
24VAC
2
1
GVR-1
SEC-2
PL3
2
1
11
3
7
9
1
5
10
4
PL1
2
8
6
PL4
HSI
OL
1
2
3
IDM
FSE
M
L2
LS
EAC-2
NOTE #3
328150-101 REV. A
C
GV
(WHEN USED)
FRS
CAP - 2
AUX
OL
BLWM
NOTE #11
PRS
LGPS
M
START
CAP-1
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
COM
LO
MED LO
MED HI
HI
SPARE-1
NOTE #10
COOL
HEAT
SPARE-2
EQUIPMENT GROUND
If any of the original equipment wire is replaced use wire rated for 105°C.
Use only copper wire between the disconnect switch and the furnace junction box (JB).
This wire must be connected to furnace sheet metal for control to prove flame.
Symbols are electrical representation only.
Solid lines inside PCB are printed circuit board conductors and are not included in legend.
Replace only with a 3 amp fuse.
Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).
Neutral connections are interchangeable within the NEUTRAL connector block.
Blower motor speed selections are for average conditions, see installation instructions for details on
optimum speed selection.
YELLOW lead not on all motors.
Factory connected when LGPS is not used.
Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will
auto-reset after three hours.
Blower-on delay: gas heating 60 seconds, cooling or heat pump 2 seconds.
Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, cooling or heat pump
90 seconds or 5 seconds when J2 is cut.
NOTES:
COM
24V
G
Y
HUM
W
R
GND
115VAC
NOTE #6
TRAN
PR1
PL2
HI/LO
EAC-1
HSIR
L2
FU1
TEST/TWIN
IDR
BLWR
L1
L1
TO 115VAC FIELD DISCONNECT
NOTE #2
PRINTED CIRCIUT BOARD
A02271
NON-DIRECT VENT/1-PIPE SYSTEM (SIZES 040
THROUGH 120 ONLY)
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each appliance
connected to the venting system being placed into operation
could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance
connected to the venting system being placed into operation,
while all other appliances connected to the venting system are
not in operation:
1. Seal any unused openings in venting system.
2. Inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code, NFPA
54/ANSI Z223.1--2006/NFPA 54--2006 or the CSA
B149.1--05, Natural Gas and Propane Installation Code
and these instructions. Determine that there is no
blockage or restriction, leakage, corrosion and other
deficiencies, which could cause an unsafe condition.
3. As far as practical, close all building doors and windows
and all doors between the space in which the
appliance(s) connected to the venting system are located
and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not connected
to the venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they are
operating at maximum speed. Do not operate a summer
exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat so
appliance is operating continuously.
7. Test for spillage from draft hood equipped appliances at
the draft hood relief opening after 5 minutes of main
burner operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above
tests, the venting system must be corrected in
accordance with the National Fuel Gas Code, NFPA
54/ANSI Z223.1--2006 and/or CSA B149.1--05, Natural
Gas and Propane Installation Code.
9. After it has been determined that each appliance
connected to the venting system properly vents when
tested as outlined above, return doors, windows, exhaust
fans, fireplace dampers and any other gas-fired burning
appliance to their previous conditions of use.
MATERIALS
Combustion-air and vent pipe, fittings, primers, and solvents
must conform to American National Standards Institute (ANSI)
standards and American Society for Testing and Materials
(ASTM) standards. See Table 7 for approved materials for use in
the U.S.A.
WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in fire, property
damage, personal injury, or death.
Solvent cements are combustible. Keep away from heat,
sparks, and open flame. Use only in well-ventilated areas.
Avoid breathing in vapor or allowing contact with skin
or eyes.
In Canada, construct all combustion-air and vent pipes for this
unit of CSA or ULC listed schedule -- 40 PVC, PVC-DWV or
ABSDWV pipe and pipe cement. SDR pipe is NOT approved
in Canada.
In direct vent (2-pipe) systems, combustion air and vent pipes
must terminate together in same atmospheric pressure zone,
either through roof or sidewall (roof termination preferred), using
accessory termination kit. See Table 8 for required clearances.
In non-direct vent (1-pipe) system, vent pipe termination must be
installed with adequate clearances to building openings and
equipment to comply with national and local codes. See Table 9
for required clearances.
!
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in property damage,
personal injury, or death.
All combustion-air and vent pipes must be airtight and
watertight. Pipes must also terminate exactly as shown in Fig.
42 for direct vent (2-pipe) system and Fig. 43 for non-direct
vent (1-pipe) system.
An abandoned masonry chimney may be used as a raceway for
properly insulated and supported combustion-air (when
applicable) and vent pipes. Each furnace must have its own set of
combustion-air and vent pipes and be terminated individually, as
shown in Fig. 42 for Direct Vent (2-Pipe) system and Fig. 43 for
Non-Direct Vent (1-Pipe) system.
A furnace shall not be connected to a chimney flue serving a
separate appliance designed to burn solid fuel.
Other gas appliances with their own venting system may also use
the abandoned chimney as a raceway providing it is permitted by
local code, the current edition of the National Fuel Gas Code and
the vent or liner manufacturer’s installation instructions. Care
must be taken to prevent the exhaust gases from one appliance
from contaminating the combustion air of other gas appliances.
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent unit
operation.
When vent pipe is exposed to temperatures below
freezing,such as when it passes through an unheated space or
when a chimney is used as a raceway, pipe must be insulated
as shown in Table 10 with Armaflex-type insulation.
Furnace combustion air and vent pipe connections are sized for
2-in. (51 mm) pipe. Any pipe size change should be made outside
furnace casing in vertical pipe. The transition has to be made as
close to the furnace as reasonably possible.
-- 31 --
58MCB
In a non-direct vent (1-pipe) system, all air for combustion is
taken from the area adjacent to furnace, and all flue products are
discharged to outdoor atmosphere. A factory-supplied perforated
disk assembly (in loose parts bag) MUST be used in
combustion-air pipe elbow.
!
TWINNING AND/OR
COMPONENT TEST
TERMINAL
BLOWER OFF-DELAY
J2 JUMPER
BLOWER OFF-DELAY
120 180
90 150
J2
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
G
Com
24V
24-V THERMOSTAT
TERMINALS
W
HUM
R
0.5 AMP@24VAC
NUETRAL BLW
STATUS CODE LED
58MCB
PLT
Y
TEST/TWIN
TRANSFORMER 24-VAC
CONNECTIONS
3-AMP FUSE
FUSE 3-AMP
L2
PL1-LOW VOLTAGE MAIN
HARNESS CONNECTOR
1
115-VAC(L2)NEUTRAL
CONNECTIONS
EAC-2
PLT
LED OPERATION &
DIAGNOSTIC LIGHT
SEC-2 SEC-1
COOL
HEAT
COOL
HEAT
1-AMP@
EAC-1 115VAC
PR-1
L1
SPARE-1 SPARE-2
PL2
1
SPARE-1
115 VAC (L1) LINE
VOLTAGE CONNECTION
SPARE-2
BLOWER SPEED
SELECTION TERMINALS
PL2-HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
A02100
Fig. 34 -- Control Board
Table 7 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials
ASTM SPECIFICATION
(MARKED ON MATERIAL)
D1527
D1785
D2235
D2241
D2466
D2468
D2564
D2661
D2665
F438
F441
F442
F493
MATERIAL
PIPE
FITTINGS
ABS
PVC
For ABS
PVC
PVC
ABS
For PVC
ABS
PVC
CPVC
CPVC
CPVC
For CPVC
Pipe
Pipe
—
Pipe
—
—
—
Pipe
Pipe
—
Pipe
Pipe
—
—
—
—
—
Fittings
Fittings
—
Fittings
Fittings
Fittings
—
—
—
SOLVENT CEMENT
AND PRIMERS
—
—
Solvent Cement
—
—
—
Solvent Cement
—
—
—
—
—
Solvent Cement
F628
ABS
Pipe
—
—
F656
F891
For PVC
PVC
—
Pipe
—
—
Primer
—
-- 32 --
DESCRIPTION
Schedule---40
Schedule---40
For ABS
SDR---21 & SDR---26
Schedule---40
Schedule---40
For PVC
DWV at Schedule---40 IPS sizes
DWV
Schedule---40
Schedule---40
SDR
For CPVC
Cellular Core DWV at Schedule---40
IPS sizes
For PVC
Cellular Core Schedule---40 & DWV
V
58MCB
V
12 inches (30 cm) for applieances >10,000 Btuh(3 kW)
and < 100,000 Btuh(30kW), 36 inches (91cm) for
appliances > 100,000 Btuh(30kW)
A08600
Table 8 – Direct Vent Termination Clearance
-- 33 --
58MCB
A08601
Table 9 – Other than Direct Vent Termination Clearance
-- 34 --
FURNACE SIZE
040
060
080
100
120
140
WINTER DESIGN
TEMPERATURE
°F 〈°C)
MAX PIPE
DIAMETER
IN (mm)
WITHOUT
INSULATION
FT (M)
WITH 3/8–IN. (10 mm) OR
THICKER INSULATION†
FT (M)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
20 (---7)
0 (---18)
---20 (---29)
1.5 (38)
1.5 (38)
1.5 (38)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2 (51)
2.5 (64)
2.5 (64)
2.5 (64)
2.5 (64)
2.5 (64)
2.5 (64)
3 (76)
3 (76)
3 (76)
3 (76)
3 (76)
3 (76)
4 (102)
4 (102)
4 (102)
3 (76)
3 (76)
3 (76)
4 (102)
4 (102)
4 (102)
51 (16)
28 (9)
16 (5)
45 (14)
22 (7)
10 (3)
65 (20)
35 (11)
20 (6)
55 (17)
48 (15)
30 (9)
70 (21)
47 (14)
28 (9)
40 (12)
40 (12)
38 (12)
70 (21)
50 (15)
28 (9)
70 (21)
61 (19)
37 (11)
70 (21)
48 (15)
23 (7)
60 (18)
60 (18)
44 (13)
70 (21)
57 (17)
30 (9)
70 (21)
70 (21)
70 (21)
70 (21)
70 (21)
58 (18)
70 (21)
70 (21)
70 (21)
55 (17)
55 (17)
55 (17)
70 (21)
70 (21)
70 (21)
40 (12)
40 (12)
40 (12)
70 (21)
70 (21)
70 (21)
70 (21)
70 (21)
70 (21)
70 (21)
70 (21)
70 (21)
60 (18)
60 (18)
60 (18)
70 (21)
70 (21)
70 (21)
* Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe
length as specified in Table 10.
† Insulation thickness based on R value of 3.5 per in.
COMBUSTION AIR PIPE
General
Furnace combustion-air connection must be attached as shown in
Fig. 35. Combustion-air intake housing plug may need to be
relocated in some applications.
For Non-Direct Vent (1-Pipe) system, combustion-air must
terminate outside of furnace casing with 1 elbow. Orient elbow so
that its opening faces down for upflow or downflow applications.
Orient elbow so that its opening faces sideways (left or right) for
horizontal left or horizontal right applications (See Fig. 35.)
Maintain a 3-in minimum clearance between the opening of the
combustion-air inlet pipe and any object.
!
CAUTION
UNIT CORROSION HAZARD
Excessive exposure to contaminated combustion air may
result in safety and performance related problems.
Combustion air must not be taken from inside structure
because inside air is frequently contaminated by halogens,
which include fluorides, chlorides, bromides, and iodides.
These elements are found in aerosols, detergents, bleaches,
cleaning solvents, salts, air fresheners, adhesives, paint, and
other household products. Locate combustion-air inlet as far
as possible from swimming pool and swimming pool
pump house.
pipe. Pick the larger of these 2 pipe diameters and use this
diameter for both combustion-air and vent pipes.
NOTE: All pipe joints must be cemented except attachment of
the combustion-air pipe to the inlet housing connection, since it
may be necessary to remove the pipe for servicing.
-- 35 --
58MCB
Table 10 – Maximum Allowable Exposed Vent Pipe Length -- Ft. (M) With and Without Insulation
in Winter Design Temperature Ambient*
NOTE: The 60,000 model includes an inducer outlet restrictor in
the loose parts bag that must be installed for certain vent system
configurations. Referring to Table 12, locate the altitude for the
installation. Discard the restrictor if the vent length is greater
than that shown in Table 12; install the restrictor if the vent length
is less than or equal. Refer to Fig. 37 for positioning of the
restrictor in the inducer outlet. The restrictor is to be trapped
between the vent pipe and inducer outlet. Certain installations
may require removal of the coupling for easier installation of the
inducer outlet restrictor.
NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and
1 combustion-air pipe connection.
1 combustion-air pipe connection.
COMBUSTIONAIR
AIR
FLOW
COMBUSTIONAIR
VENT
VENT
VENT
*
VENT
*
†
58MCB
UPFLOW
COMBUSTIONAIR
COMBUSTIONAIR
AIR
FLOW
FIELD-SUPPLIED
2-IN. (51 mm) DIA.
PVC 90° ELBOW
DOWNFLOW
FIELD-SUPPLIED
2-IN. (51 mm) DIA.
PVC PIPE
COMBUSTIONAIR
VENT
VENT
**
**
AIR
FLOW
††
†
COMBUSTIONAIR
AIR
FLOW
†
HORIZONTAL-LEFT DISCHARGE
†
A
COMBUSTION-AIR DISC
(FACTORY-SUPPLIED IN
LOOSE PARTS BAG)
††
HORIZONTAL-RIGHT DISCHARGE
A96211
Length of Straight Pipe Portion of
Combustion-Air Inlet Pipe Assembly -- In. (mm)
* For Non-Direct Vent (1-Pipe) system, orient elbow so that its
opening faces down.
** For Non-Direct Vent (1-Pipe) system, orient elbow so that its
opening faces sideways.
† An external trap kit (see furnace product data sheet) must be used.
††
Bottom combustion-air not allowed for non-direct vent
A05092
CASING WIDTH
17---1/2 (445)
21(533)
24---1/2 (622)
A
8---1/2 ±1/2 (216 ± 13)
10---1/2 ±1/2 (267 ± 13)
12 ±1/2 (318 ± 13)
Fig. 35 -- Combustion-Air and Vent Pipe Connections
Assembly of Combustion Air Pipe (Non-Direct Vent/1-Pipe
System ONLY)
1. Permanently
install
perforated
disk
assembly
(factory-supplied in loose parts bag) in combustion-air
elbow using RTV or by cementing, as shown in Fig. 36.
For 120,000 Btuh size units only: separate the 2 halves of
perforated disk assembly and use only the shouldered disk
half.
2. Determine the length of straight portion of combustion-air
inlet pipe from Fig. 36.
3. Cut field-supplied 2-in. (51 mm) diameter PVC pipe to
length as determined per Fig. 36.
4. Permanently attach elbow/perforated disk assembly to
straight portion of pipe using RTV or by cementing as
shown in Fig. 36.
Assembly of Combustion Air Pipe (Direct Vent -- 2-Pipe
System ONLY)
1. Using Table 11, individually determine the diameter of the
combustion air and vent pipe allowed. If different, pick the
larger of these two diameters and use this diameter for
both combustion--air and vent pipes.
2. When installing vent systems of short pipe length, use the
smallest allowable pipe diameter. Do not use pipe size
greater than required or incomplete combustion, flame
disturbance, or flame sense lockout may occur.
NOTE: Do not count elbows or pipe sections in terminations or
within furnace (All elbows shown in Fig. 42 and Fig. 43 are not
to be counted).
-- 36 --
Fig. 36 -- Combustion-Air Inlet Pipe Assembly
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in incomplete
combustion, flame disturbance, or flame sense lockout.
When installing combustion air and vent system of short pipe
length, the smallest allowable pipe diameter must be used.
NOTE: A 2-in. (51 mm) diameter pipe must be used within
furnace casing. Make all pipe diameter transitions outside furnace
casing per Fig. 39.
3. If required per Table 11, insert perforated disk assembly
(factory-supplied in loose parts bag) in intake housing
where combustion air pipe will be connected. If half disk
set is required, install only shouldered disk half.
Attachment of Combustion Air Pipe
1. Determine location of combustion air intake pipe
connection to combustion air intake housing as shown in
Fig. 35 for application.
2. Reposition combustion air intake housing plug fitting in
appropriate unused intake housing connection.
3. Install pipe support (factory-supplied in loose parts bag)
into selected furnace casing combustion-air pipe hole. Pipe
support should be positioned at bottom of casing hole.
4. Insert assembled combustion air inlet pipe into intake
housing as shown in Fig. 35.
58MCB
5. Drill a 1/8-in. (3 mm) hole in 2-in. (51 mm) combustion
air pipe using the hole in intake housing as a guide.
6. Install a field-supplied No. 6 or No. 8 sheet metal screw
into combustion air pipe.
7. Install casing hole filler cap (factory-supplied in loose
parts bag) in unused combustion air pipe casing hole.
NOTE: Do not attach combustion air intake pipe permanently to
combustion air intake housings since it may be necessary to
remove pipe for service of igniter or flame sensor.
COUPLING MAY BE REMOVED
FOR EASIER INSTALLATION
INDUCER OUTLET
RESTRICTOR
A09328
Fig. 37 -- Outlet Restrictor Installation
60,000 BTUH Models only. See Table 12.
A09329
Fig. 38 -- Illustration of an Installed Outlet Restrictor
60,000 BTUH Models only. See Table 12.
-- 37 --
Table 11 – Maximum Allowable Pipe Length -- Ft (M)
ALTITUDE
FT (M)
UNIT SIZE
(BTUH)
40,000
60,000
58MCB
80,000
0 to 2000
(0 to 610)
100,000
120,000
140,000
ALTITUDE
FT (M)
2001 to 3000
(610 to 914)
UNIT SIZE
(BTUH)
DIRECT VENT (2-PIPE) ONLY
TERMINATION
TYPE
2 Pipe or 2-in
Concentric
2 Pipe or 2-in
Concentric
2 Pipe or 2-in
Concentric
2 Pipe or 3-in
Concentric
2 Pipe or 3-in.
Concentric
2 Pipe or 3-in.
Concentric
40,000
2 Pipe or 2-in
Concentric
60,000
2 Pipe or 2-in
Concentric
80,000
2 Pipe or 2-in
Concentric
100,000
2 Pipe or 3-in
Concentric
120,000
140,000
2 Pipe or 3-in.
Concentric
2 Pipe or 3-in.
Concentric
NUMBER OF 90° ELBOWS
PIPE DIA
IN. (mm)*
PIPE DIA
IN. (mm)*
1
2
3
4
5
6
1 (25)
1 (25)
5
(1.5)
NA
NA
NA
NA
NA
1-1/2 (38)
1-1/2 (38)
70
(21.3)
70
(21.3)
65
(19.8)
60
(18.3)
60
(18.3)
55
(16.8)
2 (51)
2 (51)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
1-1/2 (38)
1-1/2 (38)
20
(6.1)
15
(4.6)
10
(3.0)
5
(1.5)
NA
NA
2 (51)
2 (51)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
1-1/2 (38)
1-1/2 (38)
10
(3.0)
NA
NA
NA
NA
NA
2 (51)
2 (51)
55
(16.8)
50
(15.2)
35
(10.7)
30
(9.1)
30
(9.1)
20
(6.1)
2-1/2 (64)
2-1/2 (64)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
2 (51)
2 (51)
5
(1.5)
NA
NA
NA
NA
NA
2-1/2 (64)
2-1/2 (64)
40
(12.2)
30
(9.1)
20
(6.1)
20
(6.1)
10
(3.0)
NA
3 (76)
3 (76)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
2-1/2 (64)
one disk
2-1/2 (64)
10
(3.0)
NA
NA
NA
NA
NA
3 (76)†
NA
45
(13.7)
40
(12.2)
35
(10.7)
30
(9.1)
25
(7.6)
20
(6.1)
3 (76) † no disk
3 (76)†
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
2-1/2 (64)
one disk
NA
5
(1.5)
NA
NA
NA
NA
NA
3 (76)†
NA
40
(12.1)
35
(10.6)
30
(9.1)
25
(7.6)
20
(6.1)
15
(4.6)
3 (76) † no disk
NA
60
(18.3)
56
(17.0)
52
(15.8)
48
(14.6)
44
(13.4)
40
(12.2)
4 (102) † no
disk
NA
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
DIRECT VENT (2-PIPE) ONLY
TERMINATION
TYPE
NON-DIRECT
VENT (1-PIPE)
ONLY
NON-DIRECT
VENT (1-PIPE)
ONLY
NUMBER OF 90° ELBOWS
PIPE DIA
IN. (mm)*
PIPE DIA
IN. (mm)*
1
2
3
4
5
6
1-1/2 (38)
1-1/2 (38)
67
(20.4)
62
(18.9)
57
(17.4)
52
(15.8)
52
(15.8)
47
(14.3)
2 (51)
2 (51)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
1-1/2 (38)
1-1/2 (38)
17
(5.2)
12
(3.7)
7
(2.1)
NA
NA
NA
2 (51)
2 (51)
70
(21.3)
67
(20.4)
66
(20.1)
61
(18.6)
61
(18.6)
61
(18.6)
2 (51)
2 (51)
49
(14.9)
44
(13.4)
30
(9.1)
25
(7.6)
25
(7.6)
15
(4.6)
2-1/2 (64)
2-1/2 (64)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
2-1/2 (64)
2-1/2 (64)
35
(10.7)
26
(7.9)
16
(4.9)
16
(4.9)
6
(1.8)
NA
3 (76)
3 (76)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
66
(20.1)
61
(18.6)
3 (76)
NA
14
(4.3)
9
(2.7)
NA
NA
NA
NA
NA
3 (76)†
63
(19.2)
62
(18.9)
62
(18.9)
61
(18.6)
61
(18.6)
61
(18.6)
3 (76)† no disk
NA
70
(21.3)
70
(21.3)
63
(19.2)
56
(17.1)
50
(15.2)
43
(13.1)
4 (102)† no
disk
4 (102)† no disk
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
3 (76) one
disk†
NA
20
(6.1)
15
(4.6)
10
(3.0)
5
(1.5)
NA
NA
3 (76)† no disk
NA
39
(11.8)
35
(10.6)
31
(11.9)
27
(8.2)
23
(7.0)
19
(5.8)
4 (102)† no
disk
NA
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
See notes at end of table.
-- 38 --
Table 11—Maximum Allowable Pipe Length -- Ft (M) (Continued)
3001 to 4000
(914 to 1219)
UNIT SIZE
(BTUH)
DIRECT VENT (2-PIPE) ONLY
TERMINATION
TYPE
40,000
2 Pipe or 2-in
Concentric
60,000
2 Pipe or 2-in
Concentric
80,000
2 Pipe or 2-in
Concentric
100,000
2 Pipe or 3-in
Concentric
120,000
2 Pipe or 3-in.
Concentric
4† no disk
140,000
ALTITUDE
FT (M)
4001 to 5000‡
(1219 to 1524)
UNIT SIZE
(BTUH)
2 Pipe or 3-in.
Concentric
40,000
2 Pipe or 2-in
Concentric
60,000
2 Pipe or 2-in
Concentric
80,000
2 Pipe or 2-in
Concentric
100,000
2 Pipe or 3-in
Concentric
120,000
140,000
2 Pipe or 3-in.
Concentric
2 Pipe or 3-in.
Concentric
NUMBER OF 90° ELBOWS
PIPE DIA --IN (mm)*
PIPE DIA --IN (mm)*
1
2
3
4
5
6
1-1/2 (38)
1-1/2 (38)
64
(19.5)
59
(18.0)
54
(16.5)
49
(14.9)
48
(14.6)
43
(13.1)
2 (51)
2 (51)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
1-1/2 (38)
1-1/2 (38)
16
(4.9)
11
(3.4)
6
(1.8)
NA
NA
NA
2 (51)
2 (51)
68
(20.7)
63
(19.2)
62
(18.9)
57
(17.4)
57
(17.4)
56
(17.1)
2 (51)
2 (51)
46
(14.0)
41
(12.5)
28
(8.5)
23
(7.0)
22
(6.7)
13
(4.0)
2-1/2 (64)
2-1/2 (64)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
2-1/2 (64)
2-1/2 (64)
33
(10.1)
24
(7.3)
15
(4.6)
14
(4.3)
5
(1.5)
NA
3 (76)
3 (76)
70
(21.3)
70
(21.3)
70
(21.3)
66
(20.1)
61
(18.6)
56
(17.1)
3 (76)† no disk
NA
65
(19.8)
58
(17.7)
51
(15.5)
44
(13.4)
38
(11.6)
31
(9.4)
NA
3 (76)†
59
(18.0)
59
(18.0)
58
(17.7)
57
(17.4)
57
(17.4)
56
(17.1)
4 (102)† no
disk
4 (102) † no disk
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
3 (76) one
disk†
NA
11
(3.4)
6
(1.8)
NA
NA
NA
NA
3 (76)† no disk
NA
30
(9.1)
26
(7.9)
22
(6.7)
18
(5.5)
14
(4.3)
10
(3.0)
4 (102)† no
disk
NA
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
DIRECT VENT (2-PIPE) ONLY
TERMINATION
TYPE
NON-DIRECT
VENT (1-PIPE)
ONLY
PIPE DIA
IN. (mm)*
NON-DIRECT
VENT (1-PIPE)
ONLY
NUMBER OF 90° ELBOWS
PIPE DIA
IN. (mm)*
1
2
3
4
5
6
1-1/2 (38)
1-1/2 (38)
60
(18.3)
55
(16.8)
50
(15.2)
45
(13.7)
44
(13.4)
39
(11.9)
2 (51)
2 (51)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
1-1/2 (38)
1-1/2 (38)
15
(4.6)
10
(3.0)
5
(1.5)
NA
NA
NA
2 (51)
2 (51)
64
(19.5)
59
(18.0)
58
(17.7)
53
(16.2)
52
(15.8)
52
(15.8)
2 (51)
2 (51)
44
(13.4)
39
(11.9)
26
(7.9)
21
(6.4)
20
(6.1)
11
(3.4)
2-1/2 (64)
2-1/2 (64)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
2-1/2 (64)
2-1/2 (64)
31
(9.4)
22
(6.7)
13
(4.0)
12
(3.7)
NA
NA
3 (76)
3 (76)
70
(21.3)
70
(21.3)
67
(20.4)
62
(18.9)
57
(17.4)
52
(15.8)
3 (76)†
no disk
NA
53
(16.2)
46
(14.0)
40
(12.2)
33
(10.1)
26
(7.9)
20
(6.1)
NA
3 (76)†
56
(17.1)
55
(16.8)
54
(16.5)
53
(16.2)
52
(15.8)
52
(15.8)
4 (102)† no
disk
4 (102)† no disk
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
3 (76)† no disk
NA
21
(6.4)
17
(5.1)
13
(3.9)
9
(2.7)
5
(1.5)
NA
4 (102)† no
disk
NA
69
(21.0)
64
(19.5)
59
(17.9)
54
(16.4)
49
(15.0)
44
(13.4)
See notes at end of table.
-- 39 --
58MCB
ALTITUDE
FT (M)
Table 11—Maximum Allowable Pipe Length -- Ft (M) (Continued)
58MCB
ALTITUDE
FT (M)
5001 to 6000‡
(1524 to 1829)
UNIT SIZE
(BTUH)
2 Pipe or 2-in
Concentric
60,000
2 Pipe or 2-in
Concentric
80,000
2 Pipe or 2-in
Concentric
100,000
2 Pipe or 3-in
Concentric
140,000
6001 to 7000‡
(1829 to 2134)
TERMINATION
TYPE
40,000
120,000
ALTITUDE
FT (M)
DIRECT VENT (2-PIPE) ONLY
UNIT SIZE
(BTUH)
2 Pipe or 3-in.
Concentric
2 Pipe or 3-in.
Concentric
40,000
2 Pipe or 2-in
Concentric
60,000
2 Pipe or 2-in
Concentric
80,000
2 Pipe or 2-in
Concentric
100,000
2 Pipe or 3-in
Concentric
120,000
2 Pipe or 3-in.
Concentric
140,000
2 Pipe or 3-in.
Concentric
NUMBER OF 90° ELBOWS
PIPE DIA
IN. (mm)*
PIPE DIA
IN. (mm)*
1
2
3
4
5
6
1-1/2 (38)
1-1/2 (38)
57
(17.4)
52
(15.8)
47
(14.3)
42
(12.8)
40
(12.2)
35
(10.7)
2 (51)
2 (51)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
1-1/2 (38)
1-1/2 (38)
14
(4.3)
9
(2.7)
NA
NA
NA
NA
2 (51)
2 (51)
60
(18.3)
55
(16.8)
54
(16.5)
49
(14.9)
48
(14.6)
47
(14.3)
2 (51)
2 (51)
41
(12.5)
36
(11.0)
23
(7.0)
18
(5.5)
17
(5.2)
8
(2.4)
2-1/2 (64)
2-1/2 (64)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
2-1/2 (64)
2-1/2 (64)
29
(8.8)
21
(6.4)
12
(3.7)
11
(3.4)
NA
NA
3 (76)
3 (76)
70
(21.3)
67
(20.4)
62
(18.9)
57
(17.4)
52
(15.8)
47
(14.3)
3 (76)†
no disk
NA
42
(12.8)
35
(10.7)
29
(8.8)
22
(6.7)
15
(4.6)
9
(2.7)
NA
3 (76)†
53
(16.2)
52
(15.8)
50
(15.2)
49
(14.9)
48
(14.6)
47
(14.3)
4 (102)† no
disk
4 (102)† no disk
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
70
(21.3)
3 (76)† no disk
NA
12
(3.6)
8
(2.4)
NA
NA
NA
NA
NA
42
(12.8)
37
(11.2)
32
(9.7)
27
(8.2)
22
(6.7)
17
(5.1)
4 (102)† no
disk
DIRECT VENT (2-PIPE) ONLY
TERMINATION
TYPE
NON-DIRECT
VENT (1-PIPE)
ONLY
NON-DIRECT
VENT (1-PIPE)
ONLY
NUMBER OF 90° ELBOWS
PIPE DIA
IN. (mm)*
PIPE DIA
IN. (mm)*
1
2
3
4
5
6
1-1/2 (38)
1-1/2 (38)
53
(16.2)
48
(14.6)
43
(13.1
38
(11.6)
37
(11.3)
32
(9.8)
2 (51)
2 (51)
70
(21.3)
70
(21.3)
68
(20.7)
67
(20.4)
66
(20.1)
64
(19.5)
1-1/2 (38)
1-1/2 (38)
13
(4.0)
8
(2.4)
NA
NA
NA
NA
2 (51)
2 (51)
57
(17.4)
52
(15.8)
50
(15.2)
45
(13.7)
44
(13.4)
43
(13.1)
2 (51)
2 (51)
38
(11.6)
33
(10.1)
21
(6.4)
16
(4.9)
15
(4.6)
6
(1.8)
2-1/2 (64)
2-1/2 (64)
70
(21.3)
70
(21.3)
68
(20.7)
67
(20.4)
66
(20.1)
64
(19.5)
2-1/2 (64)
2-1/2 (64)
27
(8.2)
19
(5.8)
10
(3.0)
9
(2.7)
NA
NA
3 (76)
3 (76)
68
(20.7)
63
(19.2)
58
(17.7)
53
(16.2)
48
(14.6)
43
(13.1)
3 (76)†
no disk
NA
31
(9.4)
24
(7.3)
18
(5.5)
11
(3.4)
NA
NA
NA
3 (76)†
49
(14.9)
48
(14.6)
47
(14.3)
45
(13.7)
44
(13.4)
43
(13.1)
4 (102)† no
disk
NA
17
(5.1)
12
(3.6)
7
(2.1)
NA
NA
NA
See notes at end of table.
-- 40 --
Table 11—Maximum Allowable Pipe Length -- Ft (M) (Continued)
UNIT SIZE
(BTUH)
DIRECT VENT (2-PIPE) ONLY
TERMINATION
TYPE
40,000
2 Pipe or 2-in
Concentric
60,000
2 Pipe or 2-in
Concentric
80,000
2 Pipe or 2-in
Concentric
100,000
2 Pipe or 3-in
Concentric
7001 to 8000‡
(2134 to 2438)
120,000
2 Pipe or 3-in.
Concentric
NON-DIRECT
VENT (1-PIPE)
ONLY
PIPE DIA
IN. (mm)*
PIPE DIA
IN. (mm)*
1
2
3
4
5
6
1-1/2 (38)
1-1/2 (38)
49
(14.9)
44
(13.4)
39
(11.9)
34
(10.4)
33
(10.1)
28
(6.5)
2 (51)
2 (51)
66
(20.1)
65
(19.8)
63
(19.2)
62
(18.9)
60
(18.3)
59
(18.0)
1-1/2 (38)
1-1/2 (38)
12
(3.7)
7
(2.1)
NA
NA
NA
NA
2 (51)
2 (51)
53
(16.2)
48
(14.6)
46
(14.0)
41
(12.5)
40
(12.2)
38
(11.6)
2 (51)
2 (51)
36
(11.0)
31
(9.4)
19
(5.8)
14
(4.3)
12
(3.7)
NA
2-1/2 (64)
2-1/2 (64)
66
(20.1)
65
(19.8)
63
(19.2)
62
(18.9)
60
(18.3)
59
(18.0)
2-1/2 (64)
2-1/2 (64)
25
(7.6)
17
(5.2)
8
(2.4)
7
(2.1)
NA
NA
3 (76)
3 (76)
63
(19.2)
58
(17.7)
53
(16.2)
48
(14.6)
43
(13.1)
38
(11.6)
3 (76)† no disk
NA
20
(6.1)
13
(4.0)
7
(2.1)
NA
NA
NA
NA
3 (76)†
46
(14.0)
44
(13.4)
43
(13.1)
41
(12.5)
40
(12.2)
38
(11.6)
4 (102)† no
disk
4 (102)† no disk
61
(18.6)
56
(17.1)
51
(15.5)
46
(14.0)
41
(12.5)
36
(11.0)
140,000
ALTITUDE
FT (M)
UNIT SIZE
(BTUH)
NA
DIRECT VENT (2-PIPE) ONLY
TERMINATION
TYPE
8001 to 9000‡
(2438 to 2743)
40,000
2 Pipe or 2-in
Concentric
60,000
2 Pipe or 2-in
Concentric
80,000
2 Pipe or 2-in
Concentric
100,000
2 Pipe or 3-in
Concentric
120,000
NUMBER OF 90° ELBOWS
2 Pipe or 3-in.
Concentric
NON-DIRECT
VENT (1-PIPE)
ONLY
NUMBER OF 90° ELBOWS
PIPE DIA
IN. (mm)*
PIPE DIA
IN. (mm)*
1
2
3
4
5
6
1-1/2 (38)
1-1/2 (38)
46
(14.0)
41
(12.5)
36
(11.0)
31
(9.4)
29
(8.8)
24
(7.3)
2 (51)
2 (51)
62
(18.9)
60
(18.3)
58
(17.7)
56
(17.1)
55
(16.8)
53
(16.2)
1-1/2 (38)
1-1/2 (38)
11
(3.4)
6
(1.8)
NA
NA
NA
NA
2 (51)
2 (51)
49
(14.9)
44
(13.4)
42
(12.8)
37
(11.3)
35
(10.7)
34
(10.4)
2 (51)
2 (51)
33
(10.1)
28
(8.5)
17
(5.2)
12
(3.7)
10
(3.0)
NA
2-1/2 (64)
2-1/2 (64)
62
(18.9)
60
(18.3)
58
(17.7)
56
(17.1)
55
(16.8)
53
(16.2)
2-1/2 (64)
2-1/2 (64)
23
(7.0)
15
(4.6)
7
(2.1)
5
(1.5)
NA
NA
3 (76)
3 (76)
59
(18.0)
54
(16.5)
49
(14.9)
44
(13.4)
39
(11.9)
34
(10.4)
3 (76)† no disk
NA
10
(3.0)
NA
NA
NA
NA
NA
NA
3 (76)†
43
(13.1)
41
(12.5)
39
(11.9)
37
(11.3)
35
(10.7)
34
(10.4)
4 (102)† no
disk
4† no disk
35
(10.7)
30
(9.1)
25
(7.6)
20
(6.1)
15
(4.6)
10
(3.0)
140,000
NA
See notes at end of table.
-- 41 --
58MCB
ALTITUDE
FT (M)
Table 11—Maximum Allowable Pipe Length -- Ft (M) (Continued)
ALTITUDE
FT (M)
UNIT SIZE
(BTUH)
NON-DIRECT
VENT (1-PIPE)
ONLY
NUMBER OF 90° ELBOWS
TERMINATION
TYPE
PIPE DIA
IN. (mm)*
PIPE DIA
IN. (mm)*
1
2
3
4
5
6
2 Pipe or 2-in
1-1/2 (38)
1-1/2 (38)
42
(12.8)
37
(11.3)
32
(9.8)
27
(8.2)
25
(7.6)
20
(6.1)
Concentric
2 (51)
2 (51)
57
(17.4)
55
(16.8)
53
(16.2)
51
(15.5)
49
(14.9)
47
(14.3)
60,000
2 Pipe or 2-in
Concentric
2 (51)
2 (51)
45
(13.7)
40
(12.2)
38
(11.6)
33
(10.1)
31
(9.4)
29
(8.8)
2 (51)
2 (51)
30
(9.1)
25
(7.6)
14
(4.3)
9
(2.7)
7
(2.1)
NA
80,000
2 Pipe or 2-in
Concentric
2-1/2 (64)
2-1/2 (64)
57
(17.4)
55
(16.8)
53
(16.2)
51
(15.5)
49
(14.9)
47
(14.3)
2-1/2 (64)
2-1/2 (64)
21
(6.4)
13
(4.0)
5
(1.5)
NA
NA
NA
100,000
2 Pipe or 3-in
Concentric
3 (76)
3 (76)
54
(16.5)
49
(14.9)
44
(13.4)
39
(11.9)
34
(10.4)
29
(8.8)
NA
3 (76)†
120,000
2 Pipe or 3-in.
Concentric
39
(11.9)
37
(11.3)
35
(10.7)
33
(10.1)
31
(9.4)
29
(8.8)
4 (102)† no
disk
4 (102)† no disk
10
(3.0)
5
(1.5)
NA
NA
NA
NA
40,000
9001 to 10,000‡
(2743 to 3048)
58MCB
DIRECT VENT (2-PIPE) ONLY
140,000
NA
* Disk usage-Unless otherwise specified, use perforated disk assembly (factory-supplied in loose parts bag).
# If one disk is stated, separate 2 halves of perforated disk assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box.
† Wide radius elbow.
‡ Vent sizing for Canadian installations over 4500 ft (1370 M) above sea level are subject to acceptance by the local authorities having jurisdiction. NA-Not Allowed;
pressure switch will not make.
NOTES:
1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.
2. Size both the combustion-air and vent pipe independently, then use the larger diameter for both pipes.
3. Assume two 45° elbows equal one 90° elbow. Wide radius elbows are desirable and may be required in some cases.
4. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.
5. The minimum pipe length is 5 ft (1.5 M) for all applications.
6. Use 3-in. (76 mm) diameter vent termination kit for installations requiring 4-in (102 mm) diameter pipe.
Table 12 – Vent Length for Outlet Restrictor Usage (60,000 btu model only) -- Ft (M)}
ALTITUDE --- FT (M)
0 --- 2000 (0 --- 610)
2001 --- 3000 (610 --- 914)
3001 --- 4000 (914 --- 1219)
4001 --- 5000 (1219 --- 1524)
5001 --- 6000 (1524 --- 1829)
6001 --- 7000 (1829 --- 2134)
7001 --- 8000 (2134 --- 2438)
8001 --- 9000 (2438 --- 2743)
9001 --- 10000 (2743 --- 3048)
UNIT SIZE
60,000
DIRECT VENT
(2---PIPE)
PIPE DIA.
(IN / mm)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
NON---DIRECT
VENT
(1---PIPE ONLY)
PIPE DIA.
(IN / mm)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
2---in. (51)
NO. OF 90_ ELBOWS
1
2
3
4
28 (8.5)
24 (7.3)
21 (6.4)
17 (5.1)
14 (4.2)
10 (3)
6 (1.8)
20 (6)
17 (5.1)
13 (3.9)
10 (3)
6 (1.8)
15 (4.2)
12 (3.6)
8 (2.4)
5 (1.5)
10 (3)
7 (2.1)
5
}Discard outlet restrictor if vent lengths or elbows exceed the above table Discard restrictor if using 11/2---in. (38mm) diameter pipe. See Fig. 37 and 38 for
proper installation.
-- 42 --
COMBUSTION – AIR
INTAKE HOUSING
3/8 ID TUBE
BURNER
BOX
COMBUSTION-AIR
PIPE (DIRECT
VENT/2 PIPE)
FURNACE
3/16
DRILL
NOT IN
HORIZONTAL
SECTION
TRAP
PIPE DIAMETER
TRANSITION IN
VERTICAL SECTION
COMBUSTION-AIR
PIPE (NON-DIRECT
VENT/1-PIPE)
4″MIN
(102 mm)
TO OPEN
DRAIN
A93034
A05093
Attachment of Combustion Air Intake Housing
Plug Fitting
The combustion-air intake plug fitting must be installed in unused
combustion air intake housing. This fitting must be attached by
using RTV sealant, or by drilling a 1/8-in. (3 mm) hole in fitting,
using hole in intake housing as a guide. Install a field-supplied
No. 6 or No. 8 sheet metal screw.
NOTE: DO NOT OVERTIGHTEN SCREW. Breakage of intake
housing or fitting may cause air leakage to occur.
A plugged drain connection has been provided on this fitting for
use when moisture is found in combustion air intake pipe and
combustion box. If use of this drain connection is desired, drill
out fitting’s tap plug with 3/16-in. (5 mm)drill and connect a
field-supplied 3/8-in. (10 mm) tube. This tube should be routed to
open condensate drain for furnace and A/C (If used), and should
be trapped, as shown in Fig. 40.
NOTE:
(Direct Vent/2-Pipe System ONLY) Moisture in
combustion air intake may be a result of improper termination.
Ensure combustion air pipe termination is similar to those as
shown in Fig. 42 so that it will not be susceptible to area where
light snow or other sources of moisture could be pulled in.
VENT PIPE
General
Furnace vent connection must be attached as shown in Fig. 35.
!
WARNING
CARBON MONOXIDE POISONING AND PROPERTY
DAMAGE HAZARD
Failure to follow this warning could result in property damage,
personal injury, or death.
Vent pipes must be airtight.
NOTE: A 2-in. (51 mm) diameter pipe must be used within the
furnace casing. Make all pipe diameter transitions outside furnace
casing per Fig. 39.
The minimum vent pipe length for these furnaces is 5 ft. Short
pipe lengths (5 -- 8 ft) may discharge condensate droplets. These
condensate droplets may be undesirable. A 12-in. (305 mm)
minimum offset pipe section is recommended to reduce excessive
condensate droplets from exiting vent pipe outlet. (See Fig. 41)
Attachment of Vent Pipe
1. Determine vent pipe diameter and maximum pipe lengths
Using Table 11.
NOTE: (Direct Vent/2-Pipe ONLY) vent pipe system has the
same diameter and same length as combustion air pipe as
mentioned in section “Assembly of Combustion Air Pipe (Direct
Vent/2-Pipe system ONLY).”
Fig. 40 -- Air Intake Housing Plug Fitting Drain
NOTE: Do not count elbows or pipe sections in terminations or
within furnace (all elbows shown in Fig. 42 and Fig. 43 are not
be counted).
2. Determine location of vent pipe connection to inducer
housing as shown in Fig. 35 for application.
3. Reposition elastomeric (rubber) inducer housing outlet cap
and clamp to appropriate unused inducer housing
connection. Tighten clamp.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit
component damage.
Inducer housing outlet cap must be installed and fully seated
against inducer housing. Clamp must be tightened to prevent
any condensate leakage.
4. Install pipe support (factory-supplied in loose parts bag)
into selected furnace casing vent pipe hole. Pipe support
should be positioned at bottom of casing hole.
5. Be certain that mating surfaces of inducer housing
connection elastomeric (rubber) coupling, and 2-in. (51
mm) diameter vent pipe are clean and dry. Assemble the
elastomeric (rubber) vent coupling (with 2 loose clamps)
onto inducer housing connection. Insert the 2-in. (51 mm)
diameter vent pipe through the elastomeric (rubber)
coupling and fully into inducer housing connection until it
touches a stop inside the inducer housing outlet. Tighten
the screws on both clamps to 15-in-lb. of torque. pipe to
inducer housing. Tighten the clamp screws to 15-in-lb. of
torque.
NOTE: Starting at furnace, slope vent pipe a minimum of 1/4-in.
(6 mm) per linear ft with no sags between hangers.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit
component damage.
Vent pipe must be installed and fully seated against inducer
housing internal stop. Clamp must be tightened to prevent
any condensate leakage.
6. Install casing hole filler cap (factory-supplied in loose
parts bag) in unused vent pipe casing hole.
-- 43 --
58MCB
Fig. 39 -- Combustion--Air and Vent Pipe Diameter
Transition Location and Elbow Configuration
COMBUSTION AIR
PIPE (DIRECT VENT
/2-PIPE)
COMBUSTION AIR
PIPE (NON-DIRECT
VENT/1-PIPE)
COMBUSTION AIR
PIPE (NON-DIRECT
VENT/1-PIPE)
12″ MIN
(305 mm)
12″ MIN
(305 mm)
VENT PIPE
VENT PIPE
COMBUSTION AIR
PIPE (DIRECT
VENT/2-PIPE)
58MCB
HORIZONTAL TO ROOF
HORIZONTAL TO SIDEWALL
COMBUSTION AIR
PIPE (DIRECT VENT
/2-PIPE)
COMBUSTION AIR
PIPE (NON-DIRECT
VENT/1-PIPE)
COMBUSTION AIR
PIPE (DIRECT VENT
/2-PIPE)
VENT PIPE
COMBUSTION AIR
PIPE (NON-DIRECT
VENT/1-PIPE)
12″ MIN
(305 mm)
12″ MIN
(305 mm)
VENT PIPE
VERTICAL TO ROOF
VERTICAL TO SIDEWALL
NOTE: A 12-in. (305 mm) minimum offset pipe section is recommended with
short (5-ft. to 8-ft (1.5 to 2.4 M)) vent systems. This recommendation is
to reduce excessive condensate droplets from exiting the vent pipe
.
A05094
Fig. 41 -- Short Vent (5 to 8 ft) System
Attachment of Vent Extension Pipe
Furnaces with 100,000 Btuh and larger input are supplied with a
PVC vent extension pipe (2-in. (51 mm) diameter by 12-in. (305
mm) long). This pipe has a built-in channel to assist vent
condensate disposal. When this vent extension pipe is supplied, it
MUST be used to connect the field vent pipe to furnace inducer
housing on ALL upflow and downflow applications.
NOTE: See label on vent extension pipe for proper installation.
This pipe may be shortened if an elbow is used to connect vent
extension tube to field-installed vent pipe.
Installation Guidelines for Combustion Air Pipe and
Vent Pipe
It is recommended that all pipes be cut, prepared, and
pre-assembled before permanently cementing any joint.
1. Attach combustion air pipe and vent pipe per instructions
in sections “Combustion Air Pipe” and “Vent Pipe.”
2. Working from furnace to outside, cut pipe to required
length(s).
3. Deburr inside and outside of pipe.
4. Chamfer outside edge of pipe for better distribution of
primer and cement.
5. Clean and dry all surfaces to be joined.
6. Check dry fit of pipe and mark insertion depth on pipe.
7. After pipes have been cut and preassembled, apply
generous layer of cement primer to pipe fitting socket and
-- 44 --
8.
9.
10.
11.
12.
13.
14.
end of pipe to insertion mark. Quickly apply approved
cement to end of pipe and fitting socket (over primer).
Apply cement in a light, uniform coat on inside of socket
to prevent buildup of excess cement. Apply second coat.
While cement is still wet, twist pipe into socket with 1/4
turn. Be sure pipe is fully inserted into fitting socket.
Wipe excess cement from joint. A continuous bead of
cement will be visible around perimeter of a properly
made joint.
Handle pipe joints carefully until cement sets.
Horizontal portions of the venting system shall be
supportive to prevent sagging support. Support
combustion air piping (if applicable) and vent piping a
minimum of every 5 ft (1.5 M) (3 ft (0.9 M) for SDR--21
or --26 PVC) using perforated metal hanging strap.
Slope combustion air piping (if applicable) and vent piping
downward towards furnace a minimum of 1/4--in. (6 mm)
per linear ft with no sags between hangers.
Horizontal portions of the venting system shall be installed
so as to prevent the accumulation of condensate.
Use appropriate methods to seal openings where
combustion air pipe (if applicable) and vent pipe pass
through roof or sidewall.
Roof Te rmination (Preferred)
At least 36 in.
(914mm)
Concentric Vent and Combustion Air
Roof Termination (preferred)
A
Vertical separation
between combustion
air and vent
8 3/4 in. (222mm)for 3 in. (76mm)ki t
6 3/4 in. (172mm)for 2 in. (51mm) ki t 18 in. maximum (457mm)
A
At least
36 in.
(914mm)
Maintain 12 in. (305mm)min
.
clearance above
highest anticipated
snow level
Maximum of 24 in.(614mm)
above roof
Maintain 12 in. (305mm)
min. clearance above
highest anticipated
snow level, maximum of
24 in. above roof
1 in. (25mm) maximum (typ) from wall to inlet
Abandoned masonry
used as raceway
(per code)
12 in. (305mm) minimum from
overhang or roof
(914mm)
At
le
36 ast
in
.
12 in. min from
overhang or roof
(typ)
A
Maintain 12 in. (305mm)
min. clearance above
highest anticipated
snow level or grade
whichever is greater
58MCB
Note: "A" denotes 0 to < 2 in. (51mm)
Between the first 2 vents
Third vent must be > 36 in. away
Concentric Vent
and Combustion - Air
Side Te rmination
A
At least 36 in.
(914mm)
12 in. (305mm)
separation between
bottom ofcombustion air and
bottom of vent (typ)
90°
A
Side wall termination
of less than 12 in. (305mm) above highest snow level
Maintain 12 in. (305mm)
min. clearance above
highest anticipated
snow level or grade
whichever is greater (typ)
6 in.
ast 3
At le mm)
(914
A05090
Fig. 42 -- Combustion Air and Vent Pipe Termination for Direct Vent (2-pipe) System
Roof Termination (Preferred)
Vent
Maintain 12 in (305mm)
.
minimum clearance
above highest anticipated
snow level maximum of
24 in. (610mm) above. roof
Abandoned masonry
used as raceway
(per code)
12 in. min. (305 mm)from
overhang or roof
6 in. (152mm) minimum clearance
between wall and end of vent pipe.
10 in. (254mm) maximum pipe length
Maintain 12 in. (305mm)
minimum clearance
above highest anticipated
snow level or grade
whichever is greater
12 in. (305 mm) min. from
overhang or roof
Sidewall Termination
with Straight Pipe (preferred)
90°
Maintain 12 in. (305mm)
minimum clearance
above highest anticipated
snow level or grade
whichever is greater.
Side wall termination
with 2 elbows (preferred)
A05091
Fig. 43 -- Vent Pipe Termination for Non-Direct Vent (1-pipe) System
-- 45 --
58MCB
Table 13 – Vent Termination Kit for Direct Vent/2-Pipe System
DIRECT VENT (2-PIPE) TERMINATION KIT
TERMINATION SYSTEM
2-in. (51 mm) Concentric Vent Kit
3-in. (76 mm)Concentric Vent Kit
2-in. (51 mm)Termination Bracket Kit
3-in. (76 mm) Termination Bracket Kit
Single Penetration of Wall or Roof
Single Penetration of Wall or Roof
2---Pipe Termination System
2---Pipe Termination System
EXAMPLE:
An 080--12 size furnace located in Indianapolis, elevation
650 ft (198 M) above sea level, could be installed as either a
direct vent/2-pipe system that requires 3 elbows and 32 ft
(9.8 M) of vent pipe, along with 5 elbows and 34 ft (10.4 M)
of combustion-air pipe OR a non-direct vent/1-pipe system
that requires 3 elbows and 32 (9.8 M) ft vent pipe.
For a direct vent/2-pipe system, Table 11 indicates this
application would allow a 2-in. (51 mm) diameter vent pipe,
but require a 2-1/2 in. (64 mm) diameter combustion air
pipe. According to Table 11, 2-in. (51 mm) diameter pipe is
good for 35 ft (10.7 M) with 3 elbows, but only 30 ft (9.1 M)
with 5 elbows. Therefore, 2-1/2 in. (64 mm) diameter pipe
must be used for both vent and combustion-air pipe since
larger required diameter must always be used for both pipes.
For a non-direct vent/1-pipe system, Table 11 indicates that
this application would allow a 2-in. (51 mm) diameter vent
pipe. If same installations were in Albuquerque, elevation
5250 ft (1600 M) above sea level:
For a direct vent/2-pipe system, Table 11 indicates that
2-1/2--in. (64 mm) diameter vent pipe and combustion-air
pipe are required.
For a non-direct vent/1-pipe system, Table 11 indicates that
2-1/2-in. (64 mm) diameter vent pipe is required.
If same applications are to be installed at 5001 to 6000 ft
(1524 to 1829 M) elevation:
For a direct vent/2-pipe system, 2-in. (51 mm) pipe is only
good for 23 ft (7.0 M) (with 3 elbows) and 17 ft (5.2
M)(with 5 elbows). Therefore, 2-1/2 in. (51 mm) diameter
combustion air and vent pipe must be used.
For a non-direct vent/1-pipe system, a 2-in. (51 mm)
diameter pipe is only good for 23 ft (7.0 M) with 3 elbows.
A 2-1/2-in. (64 mm) diameter vent pipe must be used.
VENT TERMINATION
General
Combustion-air (direct vent/2-pipe system only) and vent pipe
must terminate outside structure, either through sidewall or roof.
For vent termination clearance, refer to Table 8 for Direct
Vent/2-Pipe system and Table 9 for Non-direct Vent/1-Pipe
system. For exterior piping arrangements, refer to Fig. 42 for
Direct Vent/2-Pipe system and Fig. 43 for Non-Direct/
1-Pipe system.
Roof termination is preferred since it is less susceptible to
damage or contamination, and it has less visible vent vapors.
Sidewall termination require sealing or shielding of building
surfaces with a corrosive resistance material due to corrosive
combustion products of vent system.
NOTE: (Direct Vent/2-Pipe system ONLY) A factory accessory
termination kit MUST be used. See section “Vent Termination Kit
(Direct Vent/2--Pipe System Only)” in this instruction.
When determining appropriate location for termination, consider
the following guidelines:
-- 46 --
DIAM. OF COMBUSTION AIR AND VENT
PIPES --- IN (mm)
1, 1---1/2, 2, or 2---1/2 (25, 38, 51, 64 mm)
2---1/2, 3 or 4 (64, 76, 102 mm)
1, 1---1/2 or 2 (25, 38, 51mm)
2---1/2, 3 or 4 (64, 76, 102 mm)
1. Comply with all clearance requirements stated in Table 8
or Table 9 per application.
2. Termination or termination kit should be positioned where
vent vapors will not damage plants/shrubs or air
conditioning equipment.
3. Termination or termination kit should be positioned so that
it will not be affected by wind eddy, such as inside
building corners, nor by recirculation of flue gases,
airborne leaves, or light snow.
4. Termination or termination kit should be positioned where
it will not be damaged by or subjected to foreign objects
such as stones, balls, etc.
5. Termination or termination kit should be positioned where
vent vapors are not objectionable.
Extended Exposed Sidewall Pipes
Sidewall combustion air pipe termination (direct vent/2-pipe
system only) and vent pipe termination may be extended beyond
area shown in Fig. 42 or in Fig. 43 per application in outside
ambient by insulating pipe as indicated in Table 10.
1. Determine combustion air pipe diameter (direct
vent/2-pipe system only) and vent pipe diameter, as stated
above, using total pipe length and number of elbows.
2. Using winter design temperature (used in load
calculations), find appropriate temperature for your
application and furnace model.
3. Determine required insulation thickness for exposed
pipe length(s).
NOTE: Pipe length (ft) specified for maximum pipe lengths
located in unconditioned spaces cannot exceed total allowable
pipe length as specified in Table 11.
Vent Termination Kit (Direct Vent/2-Pipe System Only)
NOTE: Always refer to the instructions in termination kit for the
latest version.
Combustion air and vent pipes MUST terminate outside structure.
A factory accessory termination kit must be installed as shown in
Table 13. There are four options of vent/combustion air
termination kits available as shown in Table 13.
NOTE: Combustion air pipe must have the same diameter as
vent pipe.
Concentric Vent/Combustion Air Termination Kit (Direct
Vent/ 2-Pipe System Only)
Determine an appropriate location for termination kit using the
guidelines provided in section “Vent Termination: General” in
this instruction.
1. Cut one 4-in. (102 mm) diameter hole for 2-in. (51 mm)
kit, or one 5-in. (127 mm) diameter hole for 3-in. (76 mm)
kit.
2. Loosely assemble concentric vent/combustion air
termination components together using instructions in kit.
3. Slide assembled kit with rain shield REMOVED through
hole.
NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole.
OPEN STAND
PIPE FOR
A/C OR
HUMIDIFIER
DRAIN
TEE
TO OPEN
DRAIN
A94054
Fig. 44 -- Example of Field Drain Attachment
Furnace condensate is mildly acidic, typically in the pH range of
3.2 to 4.5. Due to corrosive nature of this condensate, a
condensate pH neutralizing filter may be desired. Check with
local authorities to determine if a pH neutralizer is required.
APPLICATION
The furnace, A/C, and humidifier drains may be combined and
drained together. The A/C drain must have an external, fieldsupplied trap prior to the furnace drain connection. All drain
connections (furnace, A/C, or humidifier) must be terminated into
an open or vented drain as close to the respective equipment as
possible to prevent siphoning of the equipment’s drain.
See Fig. 44 for example of possible field drain attachment using
1/2-in. (13 mm) CPVC or PVC tee for vent and A/C or humidifier
drain connection.
Outdoor draining of the furnace is permissible if allowed by local
codes. Caution should be taken when freezing. Ambient may
freeze drain pipe and prohibit draining.
!
Step 11 -- Condensate Drain
GENERAL
Condensate trap is shipped installed in the blower shelf and
factory connected for UPFLOW applications. Condensate trap
must be RELOCATED for use in DOWNFLOW and
HORIZONTAL applications.
Condensate trap MUST be used for all applications.
An external trap is not required when connecting the field drain
to this condensate trap.
The field drain connection (condensate trap or drain tube
coupling) is sized for 1/2-in. (13 mm) CPVC, 1/2-in. (13 mm)
PVC, or 5/8 in. (16 mm) ID tube connection.
Drain pipe and fittings must conform to ANSI standards and
ASTM D1785, D2466 or D2846. CPVC or PVC cement must
conform to ASTM D2564 or F493. Primer must conform to
ASTM F656. In Canada, use CSA or ULC listed schedule 40
CPVC or PVC drain pipe, fittings, and cement.
When a condensate pump is required, select a pump which is
approved for condensing furnace applications. To avoid
condensate spillage, select a pump with an overflow switch.
58MCB
Roof terminations -- Locate assembly through roof to
appropriate height as shown in Fig. 42.
Sidewall terminations -- Locate assembly through side wall with
rain shield positioned no more than 1-in. (25 mm) from wall as
shown in Fig. 42.
4. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.
5. Check required dimensions as shown in Fig. 42.
Two-Pipe Termination Kit (Direct Vent/2-Pipe System Only
Determine an appropriate location for termination kit using the
guidelines provided in section “Vent Termination: General” in
this instruction.
1. Cut 2 holes, 1 for each pipe, of appropriate size for pipe
size being used.
2. Loosely install elbow in bracket and place assembly on
combustion-air pipe.
Roof terminations -- Loosely install pipe coupling on
properly cut vent pipe. Coupling must be positioned so
bracket will mount as shown in Fig. 42.
For applications using combustion-air pipe option,
indicated by dashed lines in Fig. 42, install 90° street
elbow into 90° elbow, making a U-fitting. A 180° U-fitting
may be used.
Sidewall terminations -- Install bracket as shown in
Fig. 42.
For applications using vent pipe option indicated by
dashed lines in Fig. 42, rotate vent elbow 90° from
position shown in Fig. 42.
3. Disassemble loose pipe fittings. Clean and cement using
same procedures as used for system piping.
4. Check required dimensions as shown in Fig. 42.
Multi--venting and Vent Terminations
When 2 or more 58MCB Furnaces are vented near each other,
each furnace must be individually vented. NEVER common vent
or breach vent 58MCB furnaces.
(Direct Vent/2-Pipe System ONLY) -- When 2 or more 58MCB
furnaces are vented near each other, 2 vent terminations may be
installed as shown in Fig. 42, but next vent termination must be at
least 36 in. (914 mm) away from first 2 terminations. It is
important that vent terminations be made as shown in Fig. 42 to
avoid recirculation of flue gases.
WARNING
PERSONAL INJURY HAZARD
Caution should be taken to prevent draining where slippery
conditions may cause personal injuries.
Excessive condensate draining may cause saturated soil
conditions which could result in damage to plants.
CONDENSATE DRAIN PROTECTION
Freezing condensate left in condensate trap and drain line may
cause cracks, and possible water damage may occur. If freeze
protection is required, use condensate freeze protection accessory
or equivalent 3 to 6 watt per ft at 120v and 40°F (4°C)
self-regulating, shielded, and waterproof heat tape. See
Installation Instructions supplied with accessory or heat tape
manufacturer’s recommendations.
1. Fold heat tape in half and wrap on itself 3 times.
2. Locate heat tape between sides of condensate trap back.
(See Fig. 45.)
-- 47 --
3. Use wire ties to secure heat tape in place. Wire ties can be
positioned in notches of condensate trap sides.
4. Wrap field drain pipe with remaining heat tape,
approximately 1 wrap per ft.
5. When using field-supplied heat tape, follow heat tape
manufacturer’s instructions for all other installation
guidelines.
START-UP, ADJUSTMENT AND SAFETY
CHECK
58MCB
Step 1 -- General
1. Furnace must have a 115-v power supply properly
connected and grounded. Proper polarity must be
maintained for correct operation.
NOTE:
Proper polarity and proper grounding must be
maintained for 115-v wiring. If polarity is incorrect, control
center LED status indicator light will flash rapidly and furnace
will not operate.
2. Thermostat wire connections at terminals R, W, G, and Y
must be made at 24-v terminal block on furnace
control center.
3. Natural gas service pressure must not exceed 0.5 psig
(14-in. wc), but must be no less than 0.16 psig
(4.5-in. wc).
4. Blower access panel must be in place to complete 115-v
electrical circuit to furnace.
!
CAUTION
Step 2 -- Prime Condensate Trap with Water
!
CAUTION
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent
unit operation.
Condensate trap must be PRIMED or proper draining may
not occur. The condensate trap has 2 internal chambers
which can ONLY be primed by pouring water into the
inducer drain side of condensate trap.
1. Remove upper inducer housing drain connection cap.
(See Fig. 46.)
2. Connect field-supplied 1/2-in. (13 mm) ID tube to upper
inducer housing drain connection.
3. Insert field-supplied funnel into tube.
4. Pour 1 quart of water into funnel/tube. Water should run
through inducer housing, overfill condensate trap, and
flow into open field drain. (See Fig. 47.)
5. Remove funnel and tube from inducer housing and replace
drain connection cap and clamp.
Step 3 -- Purge Gas Lines
!
WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in a fire, explosion,
personal injury, or death.
Never purge a gas line into a combustion chamber. Never test
for gas leaks with an open flame. Use a commercially
available soap solution made specifically for the detection of
leaks to check all connections.
UNIT MAY NOT OPERATE
Failure to follow this caution may result in intermittent
unit operation.
These furnaces are equipped with a manual reset limit switch
in burner box. This switch will open and shut power to gas
valve if an overheat condition (flame rollout) occurs in
burner enclosure. Correct inadequate combustion-air supply
or improper venting condition and reset switch. DO NOT
jumper this switch.
If not previously done, purge lines after all connections have been
made and check for leaks.
Step 4 -- Sequence of Operation
Before operating furnace, check flame rollout manual reset
switch for continuity. If necessary, press button to reset switch.
!
CAUTION
FURNACE MAY NOT OPERATE
Failure to follow this caution may result in furnace operation
stopping and water pipes freezing during cold weather.
CONDENSATE TRAP
Furnace control must be grounded for proper operation, or
control will lock out. Control is grounded through
green/yellow wire routed to gas valve and burner box screw.
Using schematic diagram, follow sequence of operation through
different modes. (See Fig. 33.) Read and follow wiring diagram
carefully.
NOTE: If a power interruption occurs during a call for heat (W),
the control will start a 90-second blower-only ON period two
seconds after power is restored, if the thermostat is still calling
for gas heating. The red LED light will flash code 12 during the
90-second period, after which the LED will be ON continuous, as
long as no faults are detected. After the 90-second period, the
furnace will respond to the thermostat normally.
The blower door must be installed for power to be conducted
through the blower door interlock switch ILK to the furnace
control CPU, transformer TRAN, inducer motor IDM, blower
motor BLWM, hot-surface igniter HSI, and gas valve GV.
WIRE TIE(S)
HEAT TAPE
(3 WRAPS MINIMUM)
Fig. 45 -- Condensate Trap Heat Tape
A93036
-- 48 --
(See Fig. 30 for thermostat connections.)
The wall thermostat “calls for heat”, closing the R to W
circuit. The furnace control performs a self-check, verifies
the pressure switch contacts PRS are open, and starts the
inducer motor IDM.
a. Inducer Prepurge Period -- As the inducer motor
IDM comes up to speed, the pressure switch contacts
PRS close, 24 vac power is supplied for a field
installed humidifier at the HUM terminal and the
control begins a 15-second prepurge period.
b. Igniter Warm-Up -- At the end of the prepurge period,
the Hot-Surface Igniter HIS is energized for a
17-second igniter warm-up period.
c. Trial-for-Ignition Sequence -- When the igniter warm
up period is completed the main gas valve relay
contacts GVR close to energize the gas valve GV, the
gas valve opens. The gas valve GV permits gas flow to
the burners where it is ignited by the Hot Surface
Igniter HSI. Five seconds after the GVR closes, a
2-second flame period begins. The HSI igniter will
remain energized until the flame is sensed or until the
2-second flame proving period begins.
d. Flame-Proving -- When the burner flame is proved at
the flame-proving sensor electrode FSE, the furnace
control CPU begins the blower-ON delay period and
continues to hold the gas valve GV open. If the burner
flame is not proved within two seconds, the control
CPU will close the gas valve GV, and the control CPU
will repeat the ignition sequence for up to three more
Trials-For-Ignition before going to Ignition-Lockout.
Lockout will be reset automatically after three hours,
by momentarily interrupting 115 vac power to the
furnace, or by interrupting 24 vac power at SEC1 or
SEC2 to the furnace control CPU (not at W,G,R, etc.)
If flame is proved when flame should not be present,
the furnace control CPU will lock out of Gas-Heating
mode and operate the inducer motor IDM until flame
is no longer proved.
e. Blower-On Delay -- If the burner flame is proven, the
blower motor is energized on HEAT speed 66 seconds
(040 through 120 sizes) or 45 seconds (140 size) after
the gas valve GV is energized.
Simultaneously, the electronic air cleaner terminal
EAC--1 is energized and remains energized as long as
the blower motor BLWM is energized.
f. Blower-Off Delay -- When the thermostat is satisfied,
the R-to-W circuit is opened, de-energizing the gas
valve GV, stopping gas flow to the burners, and
de-energizing the humidifier terminal HUM. The
inducer motor IDM will remain energized for a
15-second (040 through 120 sizes) or 5-second (140
size) post-purge period. The blower motor BLWM and
air cleaner terminal EAC--1 will remain energized for
90, 120, 150, or 180 seconds (depending on the
blower-OFF delay selection). The furnace control CPU
is factory-set for a 120-second blower-OFF delay.
COOLING MODE
(See Fig. 30 for thermostat connections)
The thermostat closes the R-to-G-and-Y circuits. The R-to-Y
circuit starts the outdoor unit, and the R-to-G and Y circuits start
the furnace blower motor BLWM on COOL speed.
The electronic air cleaner terminal EAC--1 is energized with
115 vac when the blower motor BLWM is operating.
When the thermostat is satisfied, the R-to-G-and-Y circuits are
opened. The outdoor unit will stop, and the furnace blower motor
BLWM will continue operating on the COOL speed for an
additional 90 seconds. Cut jumper J2 to reduce the cooling
off-delay to 5 seconds.
CONTINUOUS BLOWER MODE
When the R-to-G circuit is closed by the thermostat, the blower
motor BLWM will operate on continuous-blower speed (same as
HEAT speed). Terminal EAC--1 is energized as long as the
blower motor BLWM is energized.
During a “call for heat,” the blower BLWM will stop during
igniter warm-up (17 seconds), ignition (7 seconds), and
blower-ON delay (66 or 45 seconds for 040 through 120 sizes or
for 140 size), allowing the furnace heat exchangers to heat up
more quickly, then restarts at the end of the blower-ON delay
period at HEAT speed. In heating, the furnace control CPU will
continue running the blower motor BLWM at HEAT speed after
the selected blower-OFF delay period is completed.
When the thermostat “calls for cooling”, the blower motor
BLWM will operate at COOL speed. When the thermostat is
satisfied, the blower motor BLWM will operate an additional
90 seconds on COOL speed before reverting back to HEAT
speed. Jumper J2 can be cut to reduce the cooling off-delay to 5
seconds. (See Fig. 33.) When the R-to-G circuit is opened, the
blower motor BLWM will continue operating for an additional
5 seconds, if no other function requires blower motor BLWM
operation.
HEAT PUMP MODE
When installed with a heat pump, the furnace control
automatically changes the timing sequence to avoid long blower
off times during demand defrost cycles. When the R-to-W-and-Y
or R-to-W-and-Y-and-G circuits are energized the furnace control
CPU will continue to turn on the blower motor BLWM at HEAT
speed, and begin a heating cycle. The blower motor BLWM will
remain on until the end of the prepurge period, then shut off for
24 seconds then come back on at HEAT speed. When the W input
signal disappears, the furnace control begins a normal inducer
post-purge period and the blower switches to COOL speed after a
3 second delay. If the R-to-W-and-Y-and-G signals disappear at
the same time, the blower motor BLWM will remain on for the
selected blower-OFF delay period. If the R-to-W-and-Y signals
disappear, leaving the G signal, the blower motor BLWM will
continue running the blower motor BLWM at HEAT speed after
the selected blower-OFF delay period is completed.
Control initiates a 90-sec blower only on period before starting
another heat pump cycle if there is a power interruption. Anytime
control senses false flame, control locks out of heating mode.
This reaction occurs because control ignores W input due to false
flame signal and, as a result, sees only Y input and goes into
cooling mode blower off delay. All other control functions remain
in standard format.
NOTE: EAC--1 terminal is energized whenever blower operates.
HUM terminal is only energized when gas valve is energized.
COMPONENT TEST
NOTE:
The furnace control component test allows all
components to run for a short time; except the gas valve and
humidifier terminal HUM are not energized for safety reasons.
The EAC--1 terminal is energized when the blower is energized.
This feature helps diagnose a system problem in case of a
component failure. The component test feature will not operate if
any thermostat signal is present at the control and not until all
time delays are completed.
-- 49 --
58MCB
HEATING MODE
is shut off by either method, the status code will be lost because
the code is not stored while power is removed for any reason.
To Begin Component Self-Test:
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Blower access panel door switch opens 115-v power to control
center. No component operation can occur. Caution must be
taken when manually closing this switch for service purposes.
58MCB
1.
2.
3.
4.
A99118
Fig. 46 -- Inducer Housing Drain Tube Cap
Remove blower access door.
Disconnect the thermostat R lead from furnace control.
Manually close blower door switch.
For approximately 2 sec, short (jumper) the COM-24v
terminal on control to the TEST/TWIN 3/16-in. (5 mm)
quick-connect terminal on control until the LED goes out.
Remove jumper from terminals. (See Fig. 34.)
NOTE: If TEST/TWIN and COM-24v terminals are jumpered
longer than 2 sec, LED will flash rapidly and ignore component
test request.
Component test sequence is as follows:
a. LED will display previous status code 4 times.
b. Inducer motor starts and continues to run until Step g
of component test sequence.
c. After 7 seconds the hot surface igniter is energized for
15 sec., then off.
d. Blower motor operates on Continuous-FAN speed for
10 sec.
e. Blower motor operates on HEAT speed for 10 sec.
f. Blower motor operates on COOL speed for 10 sec.
g. Inducer motor stops.
5. Reconnect R lead to furnace control, remove tape from
blower door switch, and re-install blower door.
6. Operate furnace per instruction on outer door.
7. Verify furnace shut down by lowering thermostat setting
below room temperature.
8. Verify that furnace restarts by raising thermostat setting
above room temperature.
Step 5 -- Adjustments
SET GAS INPUT RATE
A99119
Fig. 47 -- Filling Condensate Trap
NOTE: Record the status code BEFORE opening the blower
access door and before shutting off power to the furnace.
Opening the blower access door will open the blower door switch
and shut off power within the furnace. When power to the furnace
-- 50 --
Furnace gas input rate on rating plate is for installations at
altitudes up to 2000 ft. (610 M).
In the U.S.A., the input ratings for altitudes above 2000 ft (610
M) must be reduced by 2 percent for each 1000 ft (305 M) above
sea level.
In Canada, the input ratings must be derated by 5 percent for
altitudes of 2000 ft to 4500 ft (610 to 1372 M) above sea level.
Furnace input rate must be within ±2 percent of input on furnace
rating plate adjusted for altitude.
1. Determine natural gas orifice size and manifold pressure
for correct input.
a. Obtain average yearly gas heat value (at installed
altitude) from local gas supplier.
b. Obtain average yearly gas specific gravity from local
gas supplier.
c. Verify furnace model. Table 14 can only be used for
model 58MCB furnaces with heating sizes of 040
through 120. Table 15 can only be used for model
58MCB furnaces with a heating size of 140.
EXAMPLE:
(0 -- 2000 ft (0 -- 610 M) altitude using Table 14)
Heating value = 1050 Btu/cu ft
Specific gravity = 0.62
Therefore:
Orifice No. 45
Manifold pressure 3.6-in. wc
* Furnace is shipped with No. 45 orifices. In this example
all main burner orifices are the correct size and do not need
to be changed to obtain the proper input rate.
Check and verify burner orifice size in furnace. NEVER
ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY.
2. Adjust manifold pressure to obtain input rate.
NOTE: Manifold pressure must always be measured with burner
enclosure front REMOVED. Gas meter must always be clocked
with burner enclosure front INSTALLED.
a. Remove burner enclosure front.
b. Remove cap that conceals adjustment screw for gas
valve regulator. (See Fig. 48.)
c. Jumper R and W thermostat connections on control to
start furnace.
d. Turn adjusting screw, counterclockwise (out) to
decrease manifold pressure or clockwise (in) to
increase manifold pressure.
NOTE: This furnace has been approved for a manifold pressure
of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft
(610 M). For altitudes above 2000 ft (610 M), the manifold
pressure can be adjusted from 2.0 in. wc to 3.8 in. wc. If manifold
pressure is outside this range, change burner orifices to obtain
pressure in this range.
!
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in component damage
due to flame impingement of burners and heat exchangers.
DO NOT redrill orifices. Improper drilling (burrs,
out-of-round holes, etc.) can cause excessive burner noise
and misdirection of burner flames. (See Fig. 49.)
g. Look through sight glass in burner enclosure and
check burner flame. Burner flame should be clear blue,
almost transparent. (See Fig. 50.)
h. Remove jumper from R and W.
3. Verify natural gas input rate by clocking gas meter.
NOTE: Be sure all pressure tubing, combustion-air and vent
pipes, and burner enclosure front are in place when checking
input by clocking gas meter.
a. Calculate high-altitude adjustment (if required).
UNITED STATES
At altitudes above 2000 ft (610 M), this furnace has
been approved for a 2% derate for each 1000 ft (305 M)
above sea level. See Table 16 for derate multiplier
factor.
EXAMPLE: 100,000 BTUH INPUT FURNACE INSTALLED AT
4300 FT.
Furnace Input Rate
X
Derate
=
Furnace Input
Multiplier
Rate at
at Sea Level
Factor
Installation
Altitude
100,000
X
0.91
=
91,000
CANADA
At installation altitudes from 2001 to 4500 ft (610 to
1372 M), this furnace must be derated 5% by an
authorized Gas Conversion Station or Dealer. To
determine correct input rate for altitude, see example
above and use 0.95 as derate multiplier factor.
b. Reinstall burner box cover.
c. Gas valve regulator seal cap MUST be on.
CAUTION
d. Turn off all other gas appliances and pilots.
e. Start furnace and let operate for 3 minutes.
UNIT DAMAGE HAZARD
f. Measure time (in sec) for gas meter test dial to
complete 1 revolution.
Failure to follow this caution may result in reduced
furnace life.
g. Refer to Table 17 for cu ft of gas per hr.
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.
h. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft)
using natural gas heating value from local gas
utility/supplier.
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.
e. Replace gas valve regulator adjustment screw cap.
f. Replace burner enclosure front and verify adjusted gas
input rate using method outlined in item 3.
-- 51 --
58MCB
d. Find installation altitude in Table 14 or 15.
NOTE: For Canada altitudes of 2001 to 4500 ft, use U.S.A.
altitudes of 2001 to 3000 ft (610 to 914 M) in Table 14 or 15.
e. Find closest natural gas heat value and specific gravity
on Table 14 or 15.
f. Follow heat value and specific gravity lines to point of
intersection to find orifice size and manifold pressure
settings for proper operation.
Table 14 – Model 58MCB Orifice Size and Manifold Pressure for Correct Input
58MCB
FOR USE WITH
A08606A
Percents of derate are based on midpoint of U.S. altitude ranges.
-- 52 --
Table 14 -- Model 58MCB Orifice Size and Manifold Pressure for Correct Input (Continued)
58MCB
FOR USE WITH
A08606B
Percents of derate are based on midpoint of U.S. altitude ranges.
-- 53 --
Table 15 – Model 58MCB Orifice Size and Manifold Pressure for Correct Input
58MCB
FOR USE WITH
A08607A
Percents of derate are based on midpoint of U.S. altitude ranges.
-- 54 --
Table 15 -- Model 58MCB Orifice Size and Manifold Pressure for Correct Input (Continued)
58MCB
FOR USE WITH
A08607B
Percents of derate are based on midpoint of U.S. altitude ranges.
-- 55 --
EXAMPLE: (0 -- 2000 ft (0 -- 610 M) altitude)
Furnace input from rating plate is 100,000 Btuh.
Btu heating input = Btu/cu ft X cu ft/hr
Heating value of gas = 975 Btu/cu ft
Time for 1 revolution of 2-cu ft dial = 70 sec
Gas rate = 103 cu ft/hr (from Table 17)
Btu heating input = 103 X 975 = 100,425 Btuh
In this example, the orifice size and manifold pressure
adjustment is within ±2 percent of the furnace input rate.
Regulator Seal Cap
ON/OFF Switch
Regulator Adjustment
Under Cap
½ “ NPT Inlet
1/8 NPT Inlet
Pressure Tap
½” NPT Outlet
SET TEMPERATURE RISE
1/8” NPT Manifold
Pressure Tap
CAUTION
!
A07536
Fig. 48 -- Redundant Automatic Gas Valve
58MCB
UNIT DAMAGE HAZARD
Failure to follow this caution may result in overheating the
heat exchangers or condensing flue gases in heat exchanger
areas not designed for condensate.
Temperature rise must be within limits specified on unit
rating plate. Recommended operation is at midpoint of rise
range or slightly above.
Determine and adjust air temperature rise as follows:
1. Place thermometers in return and supply ducts as close to
furnace as possible. Be sure thermometers do not see heat
exchanger so that radiant heat does not affect
readings. This practice is particularly important with
straight-run ducts.
BURNER
ORIFICE
Table 17 – Gas Rate (Cu Ft/Hr)
A93059
Fig. 49 -- Orifice Holes
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Table 16 – Altitude Derate Multiplier for U.S.A.
ALTITUDE
FT (M)
0–2000
(305 --- 610)
2001–3000
(610 --- 914)
3001–4000
(914 --- 1219)
4001–5000
(1219 --- 1524)
5001–6000
1524 --- 1829)
6001–7000
(1829 --- 2134)
7001–8000
2134 --- 2438)
8001–9000
2438 --- 2743
9001–10,000
2743 --- 3048
PERCENT OF
DERATE
DERATE MULTIPLIER
FACTOR*
0
1.00
4---6
0.95
6---8
0.93
8---10
0.91
10---12
0.89
12---14
0.87
14---16
0.85
16---18
0.83
18---20
0.81
SECONDS
FOR 1
REVOLUTION
* Derate multiplier factor is based on midpoint altitude for altitude range.
-- 56 --
SIZE OF TEST DIAL
1
cu ft
2
cu ft
5
cu ft
360
327
300
277
257
240
225
212
200
189
180
171
164
157
150
144
138
133
129
124
120
116
113
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
73
720
655
600
555
514
480
450
424
400
379
360
343
327
313
300
288
277
267
257
248
240
232
225
218
212
206
200
195
189
185
180
176
172
167
164
160
157
153
150
147
1800
1636
1500
1385
1286
1200
1125
1059
1000
947
900
857
818
783
750
720
692
667
643
621
600
581
563
545
529
514
500
486
474
462
450
439
429
419
409
400
391
383
375
367
SECONDS
FOR 1
REVOLUTION
50
51
52
53
54
55
56
57
58
59
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
116
120
124
SIZE OF TEST DIAL
1
cu ft
2
cu ft
5
cu ft
72
71
69
68
67
65
64
63
62
61
60
58
56
54
53
51
50
48
47
46
45
44
43
42
41
40
39
38
38
37
36
35
35
34
33
33
32
31
30
29
144
141
138
136
133
131
129
126
124
122
120
116
112
109
106
103
100
97
95
92
90
88
86
84
82
80
78
76
75
74
72
71
69
68
67
65
64
62
60
58
360
355
346
340
333
327
321
316
310
305
300
290
281
273
265
257
250
243
237
231
225
220
214
209
205
200
196
192
188
184
180
178
173
170
167
164
161
155
150
145
BURNER
MANIFOLD
A89020
Fig. 50 -- Burner Flame
SPEED
Black
Yellow (When Present)
Blue
Red
White
High
Medium High
Medium Low
Low
Common
FACTORY
SHIPPED
CONNECTION
Cool
Spare
Heat
Spare
Com
ADJUST BLOWER OFF DELAY (HEAT MODE)
The blower off delay has 4 adjustable settings from 90 sec to
180 sec. (See Table 19.) The blower off delay jumpers are located
on the furnace control board. (See Fig. 34.) To change the blower
off delay setting, move the jumper from one set of pins on the
control board to the pins used for the desired blower off delay.
Factory blower off delay setting is 120 sec.
PINS
Time (in sec)
1 AND 2
90
2 AND 3
120
3 AND 4
150
4 AND 5
180
SET THERMOSTAT HEAT ANTICIPATOR
HOOK-AROUND
VOLT/AMMETER
When using a nonelectronic thermostat, the thermostat heat
anticipator must be set to match the amp draw of the electrical
components in R--W circuit. Accurate amp draw readings can be
obtained at thermostat subbase terminals R and W. Fig. 51
illustrates the easy method of obtaining actual amp draw. The
amp reading should be taken after blower motor has started and
furnace is heating. Connect ammeter wires as shown in Fig. 51.
The thermostat anticipator should NOT be in the circuit while
measuring current. If thermostat has no subbase, the thermostat
must be disconnected from R and W wires during current
measurement. See thermostat manufacturer’s instructions for
adjusting heat anticipator and for varying heating cycle length.
For an electronic thermostat, set cycle rate for 3 cycles per hour.
R Y W G
10 TURNS
Step 6 -- Check Safety Controls
FROM UNIT 24-VOLT
TERMINAL BLOCK
= 0.5 AMPS FOR THERMOSTAT SETTING
A80201
Fig. 51 -- Amp Draw Check with Ammeter
2. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine air
temperature rise.
3. Adjust temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise.
Decrease blower speed to increase temperature rise.
!
COLOR
Table 19 – Blower Off Delay Setup Position
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
Table 18 – Speed Selector
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Disconnect 115--v electrical power before changing speed tap.
4. To change blower motor speed selections for heating
mode, remove blower motor lead from control center
HEAT terminal. (See Fig. 34.) Select desired blower motor
speed lead from 1 of the other motor leads and relocate it
to HEAT terminal. See Table 18 for lead color
identification. Reconnect original lead on SPARE terminal.
This section covers the safety controls that must be checked
before the installation is complete. The flame sensor, gas valve,
and pressure switch were all checked in the Start-up procedure
section as part of normal operation.
CHECK PRIMARY LIMIT CONTROL
This control shuts off gas control system and energizes
air-circulating blower motor if furnace overheats. Recommended
method of checking this 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 control has shut off burners, return-air
opening should be unblocked to permit normal air circulation. By
using this method to check limit control, it can be established that
limit is functioning properly and operates if there is a restricted
return-air duct or motor failure. If limit control does not function
during this test, cause must be determined and corrected.
CHECK PRESSURE SWITCH
This control proves operation of draft inducer. Check switch
operation as follows:
1. Turn off 115-v power to furnace.
2. Remove main furnace door and disconnect inducer motor
lead wires from wire harness.
3. Turn on 115-v power to furnace.
4. Set thermostat to call for heat and wait 1 minute. When
pressure switch is functioning properly, hot surface igniter
should NOT glow, and control status code LED flashes a
Status Code 31. If hot surface igniter glows when inducer
-- 57 --
58MCB
;;
;;
Follow this same procedure for proper selection of COOL
speed selection.
BURNER FLAME
motor is disconnected, shut furnace down immediately.
Determine reason pressure switch did not function
properly and correct condition.
5. Turn off 115-v power to furnace.
6. Reconnect inducer motor leads, reinstall main furnace
door, and turn on 115-v power supply.
58MCB
CHECKLIST
1. Put away tools and instruments. Clean up debris.
2. Verify flame rollout manual reset switch has continuity.
3. Verify that blower and main access doors are properly
installed.
4. Cycle test furnace with room thermostat.
5. Check operation of accessories per manufacturer’s
instructions.
6. Review User’s Guide with owner.
7. Leave literature packet near furnace.
-- 58 --
CHECKLIST -- DIRECT VENT (2-PIPE) INSTALLATION
LOAD CALCULATION
Condensate Drain
________________
Heating Load (Btuh)
________________
Unit Level or Pitched Forward
________________
Cooling Load (Btuh)
________________
________________
Furnace Model Selection
Internal Tubing Connections Free of
Kinks and traps
________________
External Drain Connection Leak Tight
and sloped
________________
Condensate Trap Primed before Start--Up
________________
Heat Tape Installed if Required
Termination Location
________________
Roof or Sidewall
________________
Termination Kit -- 2 Pipe or Concentric
________________
Combustion-Air Pipe Length
________________
Combustion-Air Pipe Elbow Quantity
________________
CHECKLIST -- START--UP
________________
Gas Input Rate (Set Within 2 percent of
Rating Plate)
Vent Pipe Length
________________
Temperature Rise Adjusted
________________
Vent Pipe Elbow Quantity
Thermostat Anticipator
________________
Pipe Diameter Determined from
Sizing Table
________________
Anticipator Setting Adjusted or
________________
Pipe Sloped To Furnace
________________
Cycle Rate (3 Cycles per Hr) Selected
Safety Controls Check Operation
Pipe Insulation
________________
Over Ceilings
________________
Low-Ambient Exposed Pipes
________________
Primary Limit
________________
Pressure Switch
CHECKLIST -- NON DIRECT VENT (1--PIPE) INSTALLATION
LOAD CALCULATION
Condensate Drain
________________
Heating Load (Btuh)
________________
Unit Level or Pitched Forward
________________
Cooling Load (Btuh)
________________
________________
Furnace Model Selection
Internal Tubing Connections Free of
Kinks and Traps
________________
External Drain Connection Leak Tight
and Sloped
________________
Condensate Trap Primed before Start-Up
________________
Heat Tape Installed if Required
VENT PIPING
Termination Location
________________
Roof or Sidewall
________________
Vent Pipe Length
________________
Vent Pipe Elbow Quantity
________________
Pipe Diameter Determined from Sizing
Table
________________
Pipe Sloped To Furnace
Pipe Insulation
________________
Over Ceilings
________________
Low--Ambient Exposed Pipes
CHECKLIST -- START--UP
________________
Gas Input Rate (Set Within 2 percent of
Rating Plate)
________________
Temperature Rise Adjusted
Thermostat Anticipator
________________
Anticipator Setting Adjusted or
Cycle Rate (3 Cycles per Hr) Selected
Safety Controls Check Operation
________________
Primary Limit
________________
Pressure Switch
-- 59 --
58MCB
COMBUSTION AIR AND VENT PIPING
58MCB
Copyright 2009 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 09/09
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
-- 60 --
Catalog No: 58MCB --- 4SI
Replaces: 58MCB---3SI
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