58MCA
4-Way Multipoise Fixed-Capacity
Direct-Vent Condensing Gas Furnace
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Installation, Start-Up, and Operating Instructions
→ For Sizes 040—140, Series 131
ama
®
CANADIAN GAS ASSOCIATION
A PP R O VED
R
A93040
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index
As an ENERGY STARSM
Partner, Carrier Corporation has determined that
this product meets the ENERGY STAR guidelines
for energy efficiency.
CERTIFICATION OF MANUFACTURING SITE
Page
DIMENSIONAL DRAWING........................................................2
SAFETY CONSIDERATIONS .....................................................3
Clearances to Combustibles......................................................3
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ....3-4
INTRODUCTION ..........................................................................4
APPLICATIONS ......................................................................4-11
General ......................................................................................4
Upflow Applications..............................................................4-7
Downflow Applications.........................................................7-8
Horizontal Left (Supply-Air Discharge) Applications .........8-9
Horizontal Right (Supply-Air Discharge) Applications...10-11
LOCATION ............................................................................11-13
General...............................................................................11-12
Furnace Location Relative to Cooling Equipment ................12
Hazardous Locations...............................................................13
INSTALLATION....................................................................13-17
Leveling Legs (If Desired) .....................................................13
Installation In Upflow and Downflow Applications ........13-15
Installation In Horizontal Applications ..................................15
Filter Arrangement..................................................................16
Bottom Closure Panel.............................................................16
Gas Piping...............................................................................17
ELECTRICAL CONNECTIONS...........................................17-20
115-v Wiring......................................................................17-18
24-v Wiring........................................................................18-20
Wiring Diagram ......................................................................19
Accessories..............................................................................20
DIRECT VENTING ...............................................................21-29
Removal of Existing Furnaces from
Common Vent Systems.....................................................21
Combustion-Air and Vent Piping .....................................21-27
Concentric Vent and Combustion-Air Termination
Kit Installation..............................................................27-29
Multiventing and Vent Termination.......................................29
CONDENSATE DRAIN ........................................................29-31
General ....................................................................................29
Application.........................................................................29-31
Condensate Drain Protection ..................................................31
AIRFLOW
UPFLOW
HORIZONTAL
LEFT
HORIZONTAL
RIGHT
DOWNFLOW
AIRFLOW
AIRFLOW
AIRFLOW
Fig. 1—Multipoise Orientations
A93041
SEQUENCE OF OPERATION..............................................31-33
Heating Mode ....................................................................31-32
Cooling Mode .........................................................................32
Continuous Blower Mode.......................................................32
Heat Pump Mode ....................................................................32
Component Test.................................................................32-33
START-UP PROCEDURES ..................................................33-41
General ....................................................................................33
Prime Condensate Trap With Water ......................................33
Purge Gas Lines......................................................................33
Adjustments .......................................................................33-41
Set Gas Input Rate ............................................................33-41
Set Temperature Rise..............................................................41
Blower Off Delay (Heat Mode) .............................................41
Set Thermostat Heat Anticipator............................................41
CHECK SAFETY CONTROLS..................................................42
Check Primary Limit Control.................................................42
Check Pressure Switch ...........................................................42
CHECKLIST...........................................................................42-43
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 565-874
Printed in U.S.A.
Form 58MCA-4SI
Pg 1
12-96
Replaces: 58MCA-3SI
Tab 6a 8a
2
11⁄4"
1"
14 1⁄2"
TYP
26 15⁄16"
1⁄2-IN.
26 15⁄16" TYP
23 1⁄4" TYP
SIDE INLET
SIDE INLET
DIA THERMOSTAT
ENTRY
22 11⁄16"
2-IN. VENT CONN
DIA
GAS CONN
1⁄2-IN.
2-IN. COMBUSTIONAIR CONN
22 5⁄16"
24 1⁄2"
26 1⁄4"
17
UNIT SIZE
040-08
040-12
060-08
060-12
060-16
080-12
080-16
080-20
100-16
100-20
120-20
140-20
E
INLET
OUTLET
D
11/16"
D
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
19-3/8
19-3/8
19-3/8
22-7/8
22-7/8
Fig. 2—Dimensional Drawing
A
17-1/2
17-1/2
17-1/2
17-1/2
17-1/2
17-1/2
17-1/2
21
21
21
24-1/2
24-1/2
Dimensions (In.)
18 1⁄4"
TYP
9⁄16"
DIMPLE LOCATORS
FOR HORIZONTAL
HANGING
CONDENSATE
DRAIN LOCATION
(UPFLOW)
30
1⁄2"
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL RIGHT)
OR ALTERNATE
1⁄2-IN. DIA GAS CONN
13/16"
NOTES: Minimum return-air opening at furnace:
1. For 800 CFM--16-In. round or 14 1/2 x 12-In. rectangle.
2. For 1200 CFM--20-In. round or 14 1/2 x 19 1/2-In. rectangle.
3. For 1600 CFM--22-In. round or 14 1/2 x 23 1/4-In. rectangle.
4. For airflow requirements above 1800 CFM, use both side inlets, a
combination of 1 side inlet and the bottom, or the bottom only.
11/16"
33 1⁄4"
TYP
32 5⁄8"
TYP
30 13⁄16"
29 11⁄16"
TYP
27 5⁄8"
27 9⁄16"
TYP
24 1⁄2"
5⁄16"
CONDENSATE
DRAIN LOCATION
(UPFLOW)
9
TYP
7⁄16"
CONDENSATE
DRAIN TRAP
LOCATION
(ALTERNATE
UPFLOW)
DIA
ACCESSORY
POWER ENTRY
7⁄8-IN.
DIA
POWER CONN
7⁄8-IN.
CONDENSATE DRAIN
TRAP LOCATION
(DOWNFLOW &
HORIZONTAL LEFT)
13/16"
A
AIRFLOW
E
16
16
16
16
16
16
16
19-1/2
19-1/2
19-1/2
23
23
24
BOTTOM INLET
3⁄16"
22 1⁄4" TYP
SIDE INLET
22 11⁄16"
2-IN. VENT CONN
DIA
THERMOSTAT ENTRY
1⁄2-IN.
DIA
POWER CONN
7⁄8-IN.
DIA
GAS CONN
1⁄2-IN.
2-IN. COMBUSTIONAIR CONN
OUTLET
19"
22 5⁄16"
26 1⁄4"
28 1⁄2"
26 15⁄16"
A93023
11⁄16"
7⁄16"
1"
39 7⁄8"
5⁄16"
5⁄8"
13⁄16"
SAFETY CONSIDERATIONS
identify unsafe practices which would result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained
personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating
equipment, observe precautions in literature, on tags, and on labels
attached to or shipped with unit and other safety precautions that
may apply.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
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.
→ Follow
all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA No.
54-1996/ANSI Z223.1-1996 and the Installation Standards, Warm
Air Heating and Air Conditioning Systems (NFPA 90B)
ANSI/NFPA 90B. In Canada, refer to the current edition of the
National Standard of Canada CAN/CGA-B149.1- and .2-M95
Natural Gas and Propane Installation Codes (NSCNGPIC). Wear
safety glasses and work gloves. Have fire extinguisher available
during start-up and adjustment procedures and service calls.
1. Disconnect all power to the furnace. DO NOT TOUCH THE
CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on unit or in instructions and manuals,
be alert to potential for personal injury.
2. Firmly touch a clean, unpainted, metal surface of the furnace
chassis which is close to the control. Tools held in a person’s
hand during grounding will be satisfactorily discharged.
Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies 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
3. After touching the chassis you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch ungrounded
objects, etc.).
This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m),
except 140 size Furnaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m).
An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be
required for some natural gas applications.
This direct-vent, forced-air furnace is for indoor installation in a building constructed on site or in a
manufactured (mobile) home when using factory authorized kit, see rating plate.
This furnace may be installed on combustible flooring in alcove or closet at minimum clearance from
combustible material.
This appliance requires a special venting system. Refer to the installation instructions for parts list and
method of installation. This furnace is for use with schedule-40 PVC, PVC-DWV, or ABS-DWV pipe, and
must not be vented in common with other gas-fired appliances. Construction through which vent/air intake
pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including
roofing materials).
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
TOP / PLENUM
1
1
1
BOTTOM
0
†
0Ø
SIDES
0
0
1§
BACK
FRONT
0 ††
0 ††
0 ††
3*
3*
3*
VENT
INSTALLATION
0
0
0
UPFLOW
DOWNFLOW
HORIZONTAL
†
For Installation on combustible floors only when installed on special base No. KGASB0201ALL,
Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.
§
Clearance shown is for air inlet and air outlet end.
Horizontal position: Line contact is permissible only between lines formed by intersections
of top and two sides of furnace jacket, and building joists, studs, or framing.
Ø 120 and 140 size Furnaces require 1 inch bottom clearance to combustible materials.
*
Minimum front clearance for service 30 inches (762mm).
††
140 size Furnaces require 1 inch back clearance to combustible materials.
323855-101 REV. A (LIT)
A96313
→ Fig. 3—Clearances to Combustibles
3
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching
control or wires.
National Fire Protection Association Inc., Batterymarch Park,
Quincy, MA 02269; American Gas Association, 1515 Wilson
Boulevard, Arlington, VA 22209; or from Literature Distribution.
5. Use this procedure for installed and uninstalled (ungrounded)
furnaces.
Before installing the furnace in Canada, refer to the current edition
of the NSCNGPIC. Contact Standards Department of Canadian
Gas Association, 55 Scarsdale Road, Don Mills, Ontario, Canada
M3B 2R3.
6. Before removing a new control from its container, discharge
your body’s electrostatic charge to ground to protect the
control from damage. If the control is to be installed in a
furnace, follow items 1 through 5 before bringing the control
or yourself into contact with the furnace. Put all used AND
new controls into containers before touching ungrounded
objects.
Installations must comply with regulations of serving gas supplier
and local building, heating, plumbing, or other codes in effect in
area in which installation is made. In absence of local codes,
installation must conform with NFGC.
Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction.
7. An ESD service kit (available from commercial sources) may
also be used to prevent ESD damage.
These instructions cover minimum requirements for a safe installation and conform to existing national standards and safety codes.
In some instances, these instructions exceed certain local codes
and ordinances, especially those that may not have kept pace with
changing residential construction practices. We require these
instructions as a minimum for a safe installation.
INTRODUCTION
→ The 58MCA Multipoise Condensing Gas-Fired Furnaces are
A.G.A./C.G.A. design certified for natural and propane gases and
for installation in alcoves, attics, basements, closets, utility rooms,
crawlspaces, and garages. The furnace is factory-shipped for use
with natural gas. An A.G.A./C.G.A. listed gas conversion kit is
required to convert furnace for use with propane gas. The 58MCA
040 through 120 size units are A.G.A./C.G.A. approved for use in
manufactured (mobile) homes when factory accessory conversion
kit is used. The 140 size unit is NOT approved for use in
manufactured (mobile) homes. These furnaces are suitable for
installation in a residence built on site or a manufactured residence
completed at final site. The design of this furnace line is NOT
A.G.A./C.G.A. certified for installation in recreation vehicles or
outdoors.
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. Improper
installation or misapplication of furnace can require excessive
servicing or cause premature component failure.
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. CD5 or CK5, or when Coil
Box Part No. KCAKC is used.
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. Failure
to follow this warning could result in electrical shock, fire,
personal injury, or death.
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.
For accessory installation details, refer to applicable installation
literature.
These furnaces are shipped with the following materials to assist in
proper furnace installation. These materials are shipped in the main
blower compartment.
APPLICATIONS
Step 1—General
Installer Packet includes:
Installation, Start-Up, 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
Combustion-air pipe perforated disk assembly
1
Vent Pipe Extension
1*
* ONLY supplied with some furnaces.
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. 5. 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.
CONDENSATE TRAP LOCATION (FACTORY-SHIPPED
ORIENTATION)
The condensate trap is factory installed in the blower shelf and
factory connected for UPFLOW applications. A factory-supplied
tube is used to extend the condensate trap drain connection to the
desired furnace side for field drain attachment. See Condensate
Trap Tubing (Factory-Shipped Orientation) section for drain tube
extension details.
Before installing the furnace in the United States, refer to the
current edition of the NFGC and the NFPA 90B. For further
information, the NFGC and the NFPA 90B are available from
4
FURNACE
DOOR
BLOWER SHELF
CONDENSATE
TRAP
CONDENSATE
TRAP (INSIDE)
FURNACE
DOOR
FURNACE
SIDE
4 78
FURNACE
SIDE
4
534
534
4
FIELD
DRAIN
CONN
ALTERNATE DRAIN
TUBE LOCATION
26 1 4
26 1 4
11 2
SIDE VIEW
CONDENSATE TRAP
DRAIN TUBE LOCATION
FRONT VIEW
END VIEW
SLOT FOR SCREW
HORIZONTAL
APPLICATION
(OPTIONAL)
FRONT VIEW
HORIZONTAL
APPLICATIONS
DOWNFLOW AND ALTERNATE
EXTERNAL UPFLOW APPLICATIONS
UPFLOW APPLICATIONS
34
FIELD
DRAIN
CONN
1⁄4
OD
COLLECTOR BOX TO
TRAP RELIEF PORT
11 2
1⁄2
OD
INDUCER HOUSING
DRAIN CONNECTION
34
5⁄8
OD
COLLECTOR BOX
DRAIN CONNECTION
71 8
SCREW HOLE FOR
UPFLOW OR DOWNFLOW APPLICATIONS
(OPTIONAL)
13 4
78
WIRE TIE
GUIDES
(WHEN USED)
21 4
FRONT VIEW
1⁄2-IN.
PVC OR CPVC
SIDE VIEW
A93026
Fig. 4—Condensate Trap
CONDENSATE TRAP TUBING (FACTORY-SHIPPED
ORIENTATION)
d. Slide drain tube coupling (factory-supplied in loose parts
bag) through grommet ensuring long end of coupling faces
blower.
NOTE: See Fig. 5 or tube routing label on main furnace door to
confirm location of these tubes.
e. Cement 2 factory-supplied 1/2-in. street CPVC elbows to
the rigid drain tube connection on the condensate trap. (See
Fig. 5.) These elbows must be cemented together and
cemented to condensate trap drain connection.
NOTE: Failure to use CPVC elbows may allow drain to kink and
prevent draining.
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).
f. Connect larger diameter drain tube and clamp (factorysupplied in loose parts bag) to condensate trap and clamp
securely.
g. Route tube to coupling and cut to appropriate length.
2. Condensate Trap Drain Tube
h. Attach tube to coupling and clamp securely.
The condensate trap drain connection must be extended for
field attachment by doing the following:
CONDENSATE TRAP LOCATION (ALTERNATE UPFLOW
ORIENTATION)
a. Determine location of field drain connection. (See Fig. 2 or
5.)
An alternate location for the condensate trap is the left-hand side
of casing. (See Fig. 2 and 6.)
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.
NOTE: If internal filter is used, drain tube should be located to
opposite side of casing of return duct attachment to assist in filter
removal.
b. Remove and discard casing drain hole plug button from
desired side.
To relocate condensate trap to the left-hand side, perform the
following:
c. Install drain tube coupling grommet (factory-supplied in
loose parts bag) in selected casing hole.
1. Remove 3 tubes connected to condensate trap.
5
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
PLUG
CAP
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
COLLECTOR BOX
DRAIN TUBE (BLUE)
COLLECTOR BOX
TUBE (GREEN)
CONDENSATE
TRAP
COLLECTOR BOX
DRAIN TUBE (BLUE)
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
CONDENSATE
TRAP
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED
1⁄2-IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
INDUCER
HOUSING
DRAIN TUBE
(VIOLET)
A96194
→ Fig. 5—Factory-Shipped Upflow Tube
Configuration
(Shown With Blower Access Panel Removed)
A96195
→ Fig. 6—Alternate Upflow Tube Configuration and
Trap Location
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. Connect relief port tube (green label) to condensate trap.
→ b. Extend this tube (if required) by splicing to small diameter
tube (factory-supplied in loose parts bag).
c. Determine appropriate length, cut, and connect tube.
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. 5 or 6 or tube routing label on main furnace door
to check for proper connections.
2. Remove trap from blower shelf by gently pushing tabs inward
and rotating trap.
3. Remove casing hole filler cap from casing hole. (See Fig. 2 or
6.)
4. Install casing hole filler cap into blower shelf hole where trap
was removed.
5. Install condensate trap into left-hand side casing hole by
inserting tube connection stubs through casing hole and
rotating until tabs snap into locking position.
CONDENSATE TRAP TUBING (ALTERNATE UPFLOW
ORIENTATION)
NOTE: See Fig. 6 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.
NOTE: On 17-1/2-in. 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.
6
UPPER COLLECTOR BOX AND INDUCER HOUSING (UNUSED) DRAIN CONNECTIONS
2. Remove trap from blower shelf by gently pushing tabs inward
and rotating trap.
Upper Collector Box Drain Connection
3. Remove casing hole filler cap from casing hole. (See Fig. 2, 7,
or 8.)
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.
4. Install casing hole filler cap into blower shelf hole where trap
was removed.
5. Install condensate trap into desired casing hole by inserting
tube connection stubs through casing hole and rotating until
tabs snap into locking position.
NOTE: See Fig. 5 or 6 or tube routing label on main furnace door
to check for proper connections.
Upper Inducer Housing Drain Connection
CONDENSATE TRAP TUBING
Attached to the UPPER (unused) inducer housing drain connection
is a cap and clamp. This cap is used to prevent condensate leakage
in this application. Ensure this connection is capped.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace door
to check for proper connections.
NOTE: See Fig. 5 or 6 or tube routing label on main furnace door
to check for proper connections.
a. Remove factory-installed plug from LOWER collector box
drain tube (blue and white striped label).
CONDENSATE TRAP FREEZE PROTECTION
Refer to Condensate Drain Protection section for recommendations and procedures.
b. Install removed clamp and plug into UPPER collector box
drain tube (blue label) which was connected to condensate
trap.
Step 3—Downflow Applications
c. Connect LOWER collector box drain connection to condensate trap.
1. Collector Box Drain Tube
A downflow furnace application is where furnace blower is located
above combustion and controls section of furnace, and conditioned
air is discharged downwards.
(1.) 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.
CONDENSATE TRAP LOCATION
(b.) Clamp tube to prevent any condensate leakage.
The condensate trap must be removed from the factory-installed
blower shelf location and relocated in selected application location
as shown in Fig. 2, 7, or 8.
(2.) 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.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
1. Remove 3 tubes connected to condensate trap.
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)
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
A96196
A96197
→ Fig. 7—Downflow Tube Configuration (Left-Hand
Trap Installation)
→ Fig. 8—Downflow Tube Configuration
(Right-Hand Trap Installation)
7
→
(b.) Connect larger diameter drain tube (factorysupplied 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. 8.
(d.) Determine appropriate length and cut.
6. Determine appropriate length, cut, and connect tube.
(e.) Connect to condensate trap.
7. Clamp tube to relief port connection.
CONDENSATE TRAP FREEZE PROTECTION
2. Inducer Housing Drain Tube
Refer to Condensate Drain Protection section for recommendations and procedures.
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
Step 4—Horizontal Left (Supply-Air Discharge)
Applications
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to condensate
trap.
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.
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 factorysupplied in loose parts bag) to connect LOWER inducer
housing drain connection to the condensate trap.
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.
e. Connect inducer housing drain connection to condensate
trap.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC and/or local codes.
(1.) Condensate Trap Located on Left Side of Casing
(a.) Determine appropriate length and cut.
NOTE: The auxiliary junction box (J-Box) MUST be relocated to
opposite side of furnace casing. (See Fig. 9.) See Electrical
Connection section for J-Box relocation.
(b.) Connect tube to condensate trap.
(c.) Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
CONDENSATE TRAP LOCATION
(a.) Route inducer housing drain tube (violet label)
directly from inducer housing to condensate trap
as shown in Fig. 8.
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 9.
(b.) Determine appropriate length and cut.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
(c.) Connect tube to condensate trap.
(d.) Clamp tube to prevent any condensate leakage.
1. Remove 3 tubes connected to condensate trap.
3. Relief Port Tube
2. Remove trap from blower shelf by gently pushing tabs inward
and rotating trap.
Refer to Pressure Switch Tubing section for connection
procedure.
CONDENSATE TRAP FIELD DRAIN ATTACHMENT
3. Remove casing hole filler cap from casing hole. (See Fig. 2 or
9.)
Refer to Condensate Drain section for recommendations and
procedures.
4. Install casing hole filler cap into blower shelf hole where trap
was removed.
PRESSURE SWITCH TUBING
5. Install condensate trap into casing hole by inserting tube
connection stubs through casing hole and rotating until tabs
snap into locking position.
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.
CONDENSATE TRAP TUBING
NOTE: See Fig. 9 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.
NOTE: See Fig. 7 or 8 or tube routing label on main furnace door
to check for proper connections.
b. Connect large diameter drain tube and clamp (factorysupplied in loose parts bag) to drain tube coupling, extending collector box drain tube.
Relocate tubes as described below.
1. Disconnect collector box pressure tube (pink label) attached to
pressure switch.
→
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.
(f.) Clamp tube to prevent any condensate leakage.
→
3. Connect collector box pressure tube (green label) to pressure
switch connection labeled COLLECTOR BOX.
c. Route extended tube (blue label) to condensate trap and cut
to appropriate length.
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).
d. Clamp tube to prevent any condensate leakage.
2. Inducer Housing Drain Tube
8
PLUG
CAP
AUXILIARY "J" BOX
RELOCATED HERE
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)
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)
A96198
→ Fig. 9—Horizontal Left Tube Configuration
1. Disconnect collector box pressure tube (pink label) attached to
pressure switch.
a. Remove and discard LOWER (molded) inducer housing
drain tube which was previously connected to condensate
trap.
2. Use smaller diameter tube (factory-supplied in loose parts
bag) to extend tube disconnected in item 1.
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.
3. Route extended tube:
a. Behind inducer housing.
c. Determine appropriate length, cut, and connect tube.
b. Between blower shelf and inducer housing.
d. Clamp tube to prevent any condensate leakage.
c. Behind inducer motor bracket.
3. Relief Port Tube
→
d. Between inducer motor and pressure switch.
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).
4. Determine appropriate length, cut, and reconnect tube to
pressure switch connection labeled COLLECTOR BOX.
CONDENSATE TRAP FREEZE PROTECTION
b. Route extended collector box pressure tube to relief port
connection on the condensate trap.
c. Determine appropriate length, cut, and connect tube.
Refer to Condensate Drain Protection section for recommendations and procedures.
d. Clamp tube to prevent any condensate leakage.
CONSTRUCT A WORKING PLATFORM
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 10.)
CONDENSATE TRAP FIELD DRAIN ATTACHMENT
Refer to Condensate Drain section for recommendations and
procedures.
The condensate trap MUST be installed below furnace. See
Fig. 4 for dimensions. The drain connection to condensate
trap must also be properly sloped to an open drain.
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.
NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 6.)
NOTE: A 12-in. minimum offset pipe section is recommended
with short (5 to 8 ft) vent systems. This recommendation is to
reduce excessive condensate droplets from exiting the vent pipe.
(See Fig. 10 or 28.)
NOTE: See Fig. 9 or tube routing label on main furnace door to
check for proper connections.
Modify tube as described below.
9
COMBUSTION – AIR
INTAKE
VENT
30″ MIN
WORK AREA
5 3⁄4″
MANUAL
SHUTOFF
GAS VALVE
A 12-IN. MIN HORIZONTAL PIPE
SECTION IS RECOMMENDED WITH
SHORT (5 TO 8 FT) VENT SYSTEMS
TO REDUCE EXCESSIVE
CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.
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. 10—Attic Location and Working Platform
Step 5—Horizontal Right (Supply-Air Discharge)
Applications
CONDENSATE TRAP TUBING
NOTE: See Fig. 11 or tube routing label on main furnace door to
check for proper connections.
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.
1. Collector Box Drain Tube
a. Remove factory-installed plug from LOWER collector box
drain tube (blue and white striped label).
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.
b. Install removed clamp and plug into UPPER collector box
drain tube (blue label) which was previously connected to
condensate trap.
NOTE: In Canada, installations shall be in accordance with
current NSCNGPIC Installation Codes and/or local codes.
c. Connect LOWER collector box drain tube (blue and white
striped label) to condensate trap. Tube does not need to be
cut.
CONDENSATE TRAP LOCATION
d. Clamp tube to prevent any condensate leakage.
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 11.
2. Inducer Housing Drain Tube
a. Remove factory-installed cap and clamp from LOWER
inducer housing drain connection.
To relocate condensate trap from the blower shelf to desired
location, perform the following:
b. Remove and discard UPPER (molded) inducer housing
drain tube which was previously connected to condensate
trap.
1. Remove 3 tubes connected to condensate trap.
2. Remove trap from blower shelf by gently pushing tabs inward
and rotating trap.
c. Install cap and clamp on UPPER inducer housing drain
connection where molded drain tube was removed.
3. Remove casing hole filler cap from casing hole. (See Fig. 2 or
11.)
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.
4. Install casing hole filler cap into blower shelf hole where trap
was removed.
e. Determine appropriate length, cut, and connect tube to
condensate trap.
5. Install condensate trap into casing hole by inserting tube
connection stubs through casing hole and rotating until tabs
snap into locking position.
f. Clamp tube to prevent any condensate leakage.
10
CAP
COLLECTOR BOX DRAIN TUBE (BLUE)
COLLECTOR BOX TUBE (GREEN)
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX TUBE (PINK)
PLUG
CONDENSATE
TRAP
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
INDUCER HOUSING
DRAIN TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
A96199
→ Fig. 11—Horizontal Right Tube Configuration
6. Route this extended tube (pink label) to condensate trap relief
port connection.
3. Relief Port Tube
Refer to Pressure Switch Tubing section for connection
procedure.
7. Determine appropriate length, cut, and connect tube.
8. Clamp tube to relief port connection.
CONDENSATE TRAP FIELD DRAIN ATTACHMENT
CONDENSATE TRAP FREEZE PROTECTION
Refer to Condensate Drain section for recommendations and
procedures.
Refer to Condensate Drain Protection section for recommendations and procedures.
PRESSURE SWITCH TUBING
CONSTRUCT A WORKING PLATFORM
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.
Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 10.)
The condensate trap MUST be installed below furnace. See
Fig. 4 for dimensions. The drain connection to condensate
trap must also be properly sloped to an open drain.
NOTE: See Fig. 11 or tube routing label on main furnace door to
check for proper connections.
NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 6.)
Relocate tubes as described below:
NOTE: A 12-in. minimum offset pipe section is recommended
with short (5 to 8 ft) vent systems. This recommendation is to
reduce excessive condensate droplets from exiting the vent pipe.
(See Fig. 10 or 28.)
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).
LOCATION
Step 1—General
3. Route extended collector box pressure tube behind inducer
motor bracket then between inducer motor and pressure
switch.
When a furnace is installed so that supply ducts carry air to areas
outside the space containing the furnace, return air must also be
handled by ducts sealed to furnace casing. The ducts terminate
outside the space containing the furnace to ensure there will not be
a negative pressure condition within equipment room or space.
Furnace may be located in a confined space without special
provisions for dilution or ventilation air. This furnace must be
installed so electrical components are protected from water.
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.
11
FRONT
LEVEL (0″)
TO
1⁄2″ MAX
FRONT
LEVEL (0″)
TO
1⁄2″ MAX
UPFLOW OR DOWNFLOW
FRONT
B
A
C
K
HORIZONTAL
BACK
A93025
NOTE: For proper furnace operation, install furnace so that it is
level or pitched forward within 1/2 in. to ensure proper condensate
drainage from secondary heat exchangers.
FRONT
A93043
Do not install furnace on its back. Safety control operation
will be adversely affected. Never connect return-air ducts to
back of furnace. Failure to follow this warning could result in
fire, personal injury, or death.
FRONT
°F
°F
RETURN
AIR
MAX 85°F
MIN 55°F
32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
A93042
NOTE: These furnaces are designed for a minimum continuous
return-air temperature of 60°F or intermittent operation down to 55°F
such as when used with a night setback thermostat. Return-air
temperature must not exceed a maximum of 85°F. Failure to follow
these return-air temperature limits may affect reliability of heat
exchangers, motors, and controls.
Locate furnace as close to center of air distribution system as
possible.
Locate furnace so combustion-air pipe maximum lengths are not
exceeded. Refer to Table 6.
A93058
If these furnaces are installed in an unconditioned space
where ambient temperatures may be 32°F or lower, freeze
protection measures must be taken.
If these furnaces are used during construction when adhesives, sealers, and/or new carpets are being installed, make
sure all combustion and circulating air requirements are
followed. If operation of furnace is required during construction, use clean outside air for combustion and ventilation.
Compounds of chlorine and fluorine, when burned with
combustion air, form acids which will cause corrosion of heat
exchangers. Some of these compounds are found in paneling,
dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in construction
process.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
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 must 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.
Provide ample space for servicing and cleaning. Always comply
with minimum fire protection clearances shown on unit’s clearance to combustibles label. (See Fig. 3.) Locate furnace where
available electric power and gas supplies meet specifications on
furnace rating plate.
12
Step 3—Hazardous Locations
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.
→ Step 2—Installation in Upflow or Downflow
Applications
18-IN. MINIMUM
TO BURNERS
NOTE: For downflow applications, this furnace is approved for
use on combustible flooring when special base (available from
manufacturer) Part No. KGASB0201ALL is used. Special base in
not required when this furnace is installed on manufacturer’s Coil
Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is
used.
A93044
1. Determine application being installed from Table 1.
2. Construct hole in floor per dimensions specified in Table 1
and Fig. 13.
When furnace is installed in a residential garage, it must be
installed so that burners and ignition sources are located a
minimum of 18 in. above floor. The furnace must be located
or protected to avoid physical damage by vehicles. When
furnace is installed in a public garage, airplane hangar, or
other building having a hazardous atmosphere, unit must be
installed in accordance with requirements of National Fire
Protection Association, Inc.
3. Construct plenum to dimensions specified in Table 1 and Fig.
13.
4. If downflow subbase (KGASB) is used, install as shown in
Fig. 14.
If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No.
KCAKC is used, install as shown in Fig. 15.
NOTE: Remove furnace perforated, discharge duct flanges when
they interfere with mating flanges on coil on downflow subbase.
To remove furnace perforated, discharge duct flange, use wide
duct pliers or duct flange tool to bend flange back and forth until
it breaks off. Be careful of sharp edges. (See Fig. 16.)
INSTALLATION
Step 1—Leveling Legs (If Desired)
When furnace is used in upflow position with side inlet(s), leveling
legs may be desired. (See Fig. 12.) Install field-supplied,
corrosion-resistant 5/16-in. machine bolts and nuts.
Do not bend duct flanges inward as shown in Fig. 16. 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. 16.
5⁄16″
5⁄16″
NOTE: For 140 size unit when installed in downflow orientation,
cut the white jumper wire off between terminals PL1-6 and PL1-9.
Refer to Fig. 24 for location of jumper. Cut jumper close to
connector and remove wire to avoid a short circuit.
1 3⁄4″
1 3⁄4″
5⁄16″
5⁄16″
1 3⁄4″
1 3⁄4″
A89014
Fig. 12—Leveling Legs
NOTE: The maximum length of bolt should not exceed 1-1/2 in.
1. Position furnace on its back. Locate and drill a 5/16-in.
diameter hole in each bottom corner of furnace. (See Fig. 12.)
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.)
13
A
PLENUM
OPENING
D
B
FLOOR
OPENING
C
A96283
Fig. 13—Floor and Plenum Opening Dimensions
FURNACE
(OR COIL CASING
WHEN USED)
FURNACE
CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX
COMBUSTIBLE
FLOORING
COMBUSTIBLE
FLOORING
DOWNFLOW
SUBBASE
SHEET METAL
PLENUM
SHEET METAL
PLENUM
FLOOR
OPENING
FLOOR
OPENING
A96284
A96285
Fig. 15—Furnace, Plenum, and Coil
Fig. 14—Furnace, Plenum, and Subbase
Assembly or Coil Box Installed
Installed on a Combustible Floor
on a Combustible Floor
Table 1—Opening Dimensions (In.)
FURNACE
CASING
WIDTH
17-1/2
21
24-1/2
PLENUM OPENING
APPLICATION
Upflow Applications
Downflow Applications on Non-Combustible Flooring
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box
Downflow Applications on Combustible Flooring NOT Using KGASB Subbase
Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box
Upflow Applications
Downflow Applications on Non-Combustible Flooring
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box
Downflow Applications on Combustible Flooring NOT Using KGASB Subbase
Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box
Upflow Applications
Downflow Applications on Non-Combustible Flooring
Downflow Applications on Combustible Flooring Using KGASB Subbase
Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box
Downflow Applications on Combustible Flooring NOT Using KGASB Subbase
Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box
14
FLOOR OPENING
A
B
C
D
16
15-7/8
24-1/8
19
16-5/8
16-1/2
24-3/4
19-5/8
15-1/8
19
16-3/4
20-3/8
15-1/2
19
16-1/2
20
19-1/2
19-3/8
24-1/8
19
20-1/8
20
24-3/4
19-5/8
18-5/8
19
20-1/4
20-3/8
19
19
20
20
23
22-7/8
24-1/8
19
23-5/8
23-1/2
24-3/4
19-5/8
22-1/8
19
23-3/4
20-3/8
22-1/2
19
23-1/2
20
Step 3—Installation in Horizontal Applications
→ These
PERFORATED
DISCHARGE DUCT
FLANGE
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. 17.) Cut hanger bolts (4 each 3/8-in.
all-thread rod) to desired length. Use 1 X 3/8-in. flat washers,
3/8-in. lockwashers, and 3/8-in. nuts on hanger rods as shown in
Fig. 17. Dimples are provided for hole locations. (See Fig. 2.)
NO
YES
→
210°
MIN
YES
Fig. 16—Duct Flanges
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.
A93029
3⁄8-IN.
ANGLE
IRON OR
EQUIVALENT
ROD
5 3⁄4″
ALTERNATE SUPPORT
LOCATION 4-IN. MIN
8-IN. 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) ALTERNATE ROD LOCATION
(A)
(B)
13/16-IN.
MAX
ALTERNATE SUPPORT
LOCATION FROM BACK
NOTES: 1. A 1 In. clearance minimum between top of
furnace and combustible material.
2. The entire length of furnace must be
supported when furnace is used in horizontal
position to ensure proper drainage.
A93304
Fig. 17—Crawlspace Horizontal Application
15
Step 4—Filter Arrangement
171⁄2-IN. WIDE
CASINGS ONLY:
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
Never operate unit without a filter or with blower access
panel removed.
Factory-supplied washable framed filters are shipped in blower
compartment. Determine location for filter and relocate filter
retaining wire if necessary. See Table 2 to determine correct filter
size for desired filter location. Table 2 indicates filter size,
location, and quantity shipped with this furnace. See Fig. 2 for
location and size of bottom and side return-air openings.
241⁄2-IN. WIDE
CASINGS ONLY:
CUT AND FOLD
FACTORY-PROVIDED
FILTERS AS SHOWN
TO DESIRED SIZE.
3″
24 1/2″
1″
Table 2—Filter Information
FURNACE
FILTER SIZE (IN.)*
FILTER TYPE
CASING
FRAMED
Side Return
Bottom Return
WIDTH (IN.)
17-1/2
(1) 16 X 25 X 1† (1) 16 X 25 X 1
Cleanable
21
(1) 16 X 25 X 1 (1) 20 X 25 X 1†
Cleanable
24-1/2
(2) 16 X 25 X 1† (1) 24 X 25 X 1
Cleanable
* Filters can be field modified by cutting frame as marked and folding to desired
size. Alternate sizes can be ordered from your distributor or dealer.
† Factory-provided with furnace.
Air delivery above 1800 CFM requires that both sides, a
combination of 1 side and bottom, or bottom only of furnace
be used for return air.
WASHABLE
FILTER
NOTE: Side return-air openings can ONLY be used in UPFLOW
configurations. Install filter(s) as shown in Fig. 18.
WASHABLE
FILTER
FILTER
RETAINER
FILTER
SUPPORT
FILTER
RETAINER
A96030
Fig. 19—Bottom Filter Arrangement
A93045
Fig. 18—Filter Installed for Side Inlet
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. 19.
NOTE: Remove and discard bottom closure panel when bottom
inlet is used.
Step 5—Bottom Closure Panel
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.
FRONT FILLER
PANEL
To remove bottom closure panel, perform following:
1. Tilt or raise furnace and remove 2 screws holding front filler
panel. (See Fig. 20.)
A93047
Fig. 20—Removing Bottom Closure Panel
2. Rotate front filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall front filler panel and screws.
16
Step 6—Gas Piping
GAS
SUPPLY
Gas piping must be installed in accordance with national and local
codes. Refer to current edition of NFGC. 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
3 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. Joint
compound (pipe dope) should be applied sparingly and only to
male threads of joints. Pipe dope must be resistant to propane gas.
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
Connect gas pipe to furnace using a backup wrench to avoid
damaging gas controls.
A93324
Fig. 21—Typical Gas Pipe Arrangement
Gas valve shutoff switch MUST be facing forward or tilted
upward. Failure to follow this warning could result in
property damage or death.
plugged tapping, accessible for test gage connection, MUST be
installed immediately upstream of gas supply connection to
furnace and downstream of manual shutoff valve.
NOTE: The gas valve inlet press tap connection is suitable to use
as test gage connection providing test pressure DOES NOT exceed
maximum 0.5 psig (14-in. wc) stated on gas valve. (See Fig. 44.)
Piping should be pressure tested in accordance with local and
national plumbing and gas codes before furnace is attached. In
Canada, refer to current edition of NSCNGPIC. If pressure
exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected
from furnace and capped before pressure test. If test pressure is
equal to or less than 0.5 psig (14-in. wc), turn off electric shutoff
switch located on gas valve before test. It is recommended that
ground joint union be loosened before pressure testing. After all
connections have been made, purge lines and check for leakage.
Never purge a gas line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition for
purpose of checking leakage. Use a soap-and-water solution
to check for leakage. Failure to follow this warning could
result in fire, explosion, personal injury, or death.
Use proper length of pipe to avoid stress on gas control
manifold. Failure to follow this warning could result in a gas
leak resulting in fire, explosion, personal injury, or death.
ELECTRICAL CONNECTIONS
Table 3—Maximum Capacity of Pipe*
NOMINAL
IRON
PIPE
SIZE
(IN.)
1/2
3/4
1
1-1/4
1-1/2
See Fig. 22 for field wiring diagram showing typical field 115-v
and 24-v wiring. Check all factory and field electrical connections
for tightness.
LENGTH OF PIPE (FT)
INTERNAL
DIAMETER
(IN.)
10
20
30
40
50
0.622
0.824
1.049
1.380
1.610
175
360
680
1400
2100
120
250
465
950
1460
97
200
375
770
1180
82
170
320
660
990
73
151
285
580
900
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. Failure to follow
this warning could result in personal injury or death.
→ * Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and
a pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas).
Ref: Table 10-2 NFPA 54-1996.
Furnace control must be grounded for proper operation or
control will lock out. Control is grounded through green wire
routed to gas valve and burner box screw.
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. 21.)
Step 1—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 utility
is sufficient to handle load imposed by this equipment. Refer to
rating plate or Table 4 for equipment electrical specifications.
If a flexible connector is required or allowed by authority
having jurisdiction, black iron pipe shall be installed at gas
valve and extend a minimum of 2 in. outside furnace casing.
Make all electrical connections in accordance with National
Electrical Code (NEC) ANSI/NFPA 70-1996 and any local codes
or ordinances that might apply. For Canadian installations, all
electrical connections must be made in accordance with Canadian
Electrical Code CSA C22.1 or subauthorities having jurisdiction.
An accessible manual shutoff valve MUST be installed upstream
of furnace gas controls and within 6 ft of furnace. A 1/8-in. NPT
17
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
NOTE 2
W
FIVE
WIRE
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATINGONLY
BLK
BLK
W
WHT
WHT
R
GND
GND
208/230- OR
460-VOLT
THREE
PHASE
G
115-VOLT FUSED AUXILIARY
J-BOX
C
DISCONNECT
CONTROL
SWITCH
Y
BOX
(WHEN
REQUIRED)
24-VOLT
TERMINAL
BLOCK
FURNACE
GND
NOTE 1
208/230VOLT
SINGLE
PHASE
CONDENSING
UNIT
TWO
WIRE
NOTES: 1. Connect Y-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A96415
→ Fig. 22—Heating and Cooling Application Wiring Diagram
J-Box Relocation
1. Remove 2 screws holding auxiliary J-box. (See Fig. 23.)
2. Rotate J-box 180° and attach box to right side, using holes
provided.
ELECTRIC
DISCONNECT
SWITCH
COPPER
WIRE ONLY
FACTORY
INSTALLED
LOCATION
ALUMINUM
WIRE
ALTERNATE
FIELD
LOCATION
A93033
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
Use a separate, fused branch electrical circuit containing a properly
sized fuse or circuit breaker for this furnace. See Table 4 for wire
size and fuse specifications. A disconnecting means must be
located within sight from and readily accessible to furnace.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control center LED status indicator light will
flash rapidly and furnace will NOT operate.
A93051
Fig. 23—Relocating J-Box
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.
The cabinet MUST have an uninterrupted or unbroken ground
according to NEC ANSI/NFPA 70-1996 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal
injury if an electrical fault should occur. This may consist of
electrical wire or conduit approved for electrical ground when
installed in accordance with existing electrical codes. Do not
use gas piping as an electrical ground. Failure to follow this
warning could result in electrical shock, fire, or death.
Step 2—24-v Wiring
Make field 24-v thermostat connections at 24-v terminal block on
control center. For proper cooling operation, Y wire from thermostat MUST be connected to Y terminal on control center, as shown
in Fig. 22. The 24-v terminal board is marked for easy connection
of field wiring. (See Fig. 24.) The 24-v circuit contains a 3-amp,
automotive-type fuse located on control center. (See Fig. 25.) Any
electrical shorts of 24-v wiring during installation, service, or
18
19
120 VAC
L1 PR1
GV
GVR
HI/LO
HSI
HSIR
HUM
IDM
IDR
ILK
JB
LED
LGPS
LS
OL
PCB
BLWR
BLWM
CAP
CPU
EAC-1
EAC-2
FRS
FSE
FU1
FU2
HSI
2
1
2
3
BLK
GRN
WHT
1 2 3 PL4
BRN
PR2
M
OL
IDM
BRN
AUX
CAP -2
EAC-2
C OM
HEAT SPARE-2
EAC-1
COOL SPARE-1
24 VAC-3A
FUSE
RED
WHT (COM)
RED (LO)
BLU (MED LO)
NOTE #8
YEL (MED HI)
BLK (HI)
WHT
ORN
BLOWER MOTOR RELAY, SPST-(N.O.)
BLOWER MOTOR
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
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)
GAS VALVE-REDUNDANT OPERATORS
GAS VALVE RELAY, DPST-(N.O.)
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
HOT SURFACE IGNITOR (115 VAC)
HOT SURFACE IGNITOR RELAY, SPST-(N.O.)
24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)
INDUCED DRAFT MOTOR
INDUCED DRAFT RELAY, SPST-(N.O.)
BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
JUNCTION BOX
LIGHT-EMITTING DIODE FOR STATUS CODES
LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LIMIT SWITCH, AUTO RESET, SPST(N.C.)
AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.
PRINTED CIRCUIT BOARD
LEGEND
1
1
2
PL3
L2
BLOWER
SPEED
SELECT
LED
G
R
Y
W
C OM
HUM
SEC-2
6 5 4
9 8 7
3 2 1
SEC-1
FU1
WHT
PL1
TEST/TWIN
HI/LO
RELAY
BLWR
PL5
PL2
IDR
BLK
GVR
225 SEC
180 SEC
135 SEC
90 SEC
BLOWER OFF DELAY
SELECTION CHART
BLK
BLK
HSIR
BLK
SEE NOTE #10
(NOT ON ALL MODELS)
WHT
SW2
BLOWER
OFF
DELAY
SW1
1.5 AMP
PCB
GRN
WHT
WHT
ILK
BLK
OL
RED
BLU
PL1
PL2
PL3
PL4
PL5
PRS
SW1 & 2
TEST/TWIN
TRAN
WHT
LS
RED
PRS
JB
BRN
NOTE #5
2-C
GV
3-P
GRN
BLK
WHT
FU2
L1
NEUTRAL
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
NOTE #4
CAP -1
WHT (COM)
GRN
WHT
YEL
L1
IDR
HSIR
HSIR
IDR
CPU
BLWR
GVR-2
SEC-1
TRAN
PR1
EAC-2
2
1
HI/LO
PR2
PL5
GVR-1
GVR
SEC-2
24VAC
115VAC
PL2
2
1
FRS
9
6
5
8
2
3
4
1
7
PL1
M
1-M
3-P
NOTE #6
PRS
LS
FSE
NOTE #5
2-C
GV
(WHEN USED)
CAP -2
BRN
IDM
CAP-1
AUX
OL
BLWM
START
BRN
PL4
LGPS
2
3
3
2
1
PL3
HSI
OL
1
SPARE-1
NOTE #8
COOL
COM
COM
LO
MED LO
MED HI
HI
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
L2
A95087
322854-101 REV. C
1. IF ANY OF THE ORIGINAL EQUIPMENT WIRE IS REPLACED USE WIRE RATED FOR 105°C.
2. INDUCER (IDM) AND BLOWER (BLWM) MOTORS CONTAIN INTERNAL
AUTO-RESET THERMAL OVERLOAD SWITCHES (OL).
3. BLOWER MOTOR SPEED SELECTIONS ARE FOR AVERAGE CONDITIONS, SEE INSTALLATION
INSTRUCTIONS FOR DETAILS ON OPTIMUM SPEED SELECTION.
4. USE ONLY COPPER WIRE BETWEEN THE DISCONNECT SWITCH AND THE
FURNACE JUNCTION BOX (JB).
5. THIS WIRE MUST BE CONNECTED TO FURNACE SHEETMETAL FOR CONTROL TO PROVE
FLAME.
6. FACTORY CONNECTED WHEN LGPS NOT USED.
7. REPLACE ONLY WITH A 3 AMP FUSE.
8. YELLOW LEAD NOT ON ALL MOTORS.
9. BLOWER-ON DELAY, GAS HEATING 60 SECONDS, COOLING OR HEAT PUMP 2 SECONDS.
10. BLOWER-OFF DELAY, GAS HEATING 90, 135, 180 OR 225 SECONDS, COOLING OR
HEAT PUMP 90 SECONDS. (135 SECONDS ONLY ON SOME MODELS)
11. IGNITION-LOCKOUT WILL OCCUR AFTER FOUR CONSECUTIVE UNSUCCESSFUL
TRIALS-FOR-IGNITION. CONTROL WILL AUTO-RESET AFTER THREE HOURS.
12. SOME MODELS MAY HAVE SPADE QUICK CONNECT TERMINALS.
COM
G
Y
W
R
NOTE #12
HUM
HI/LO
SPARE-2
HEAT
EQUIPMENT GROUND
EAC-1
NOTE #7
BLWR
NEUTRAL
TEST/TWIN FU1
ILK
L1
TO 115VAC FIELD DISCONNECT
NOTE #4
NOTES:
Fig. 24—Wiring Diagram
PLUG RECEPTACLE
FIELD SPLICE
EQUIPMENT GROUND
FIELD GROUND
FIELD WIRING TERMINAL
CONDUCTOR ON PCB
FIELD WIRING (24VAC)
FIELD WIRING (115VAC)
FACTORY WIRING (24VAC)
FACTORY WIRING (115VAC)
PCB TERMINAL
UNMARKED TERMINAL
JUNCTION
9-CIRCUIT CONNECTOR
2-CIRCUIT PCB CONNECTOR
3-CIRCUIT IDM CONNECTOR
3-CIRCUIT IDM EXTENSION CONNECTOR
2-CIRCUIT HSI/PCB CONNECTOR
PRESSURE SWITCH, SPST-(N.O.)
BLOWER OFF DELAY
COMPONENT TEST & TWIN TERMINAL
TRANSFORMER-115VAC/24VAC
GRN
BLWM
START
BRN
GRN
1-M
BLU
BLK
FSE
RED
FRS
NOTE #6
(WHEN USED)
LGPS
TRAN
Table 4—Electrical Data
UNIT
SIZE
VOLTS—
HERTZ—
PHASE
040-08
040-12
060-08
060-12
060-16
080-12
080-16
080-20
100-16
100-20
120-20
→140-20
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
115—60—1
OPERATING
VOLTAGE RANGE
Max*
Min*
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
127
104
MAX
UNIT
AMPS
UNIT
AMPACITY†
MIN
WIRE
SIZE
MAX WIRE
LENGTH
(FT)‡
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
37
44
38
29
36
28
31
27
30
30
30
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 fuse is recommended.
maintenance may cause fuse to blow. If fuse replacement is
required, use only a fuse of identical size (3 amp).
2. Humidifier (HUM)
A quick-connect terminal (HUM) and screw terminal (COM)
are provided for 24-v humidifier connection. (See Fig. 24.)
HUM terminal is energized with 24v (0.5-amp maximum)
after inducer motor prepurge period.
NOTE: Use AWG No. 18 color-coded copper thermostat wire for
lengths up to 100 ft. For wire lengths over 100 ft, use AWG No.
16 wire.
NOTE: A field-supplied, 115-v controlled relay connected to
EAC terminals may be added if humidifier operation is desired
during blower operation.
Step 3—Accessories
1. Electronic Air Cleaner (EAC)
24V
TEST/TWIN
COM W Y R G
Two quick-connect terminals marked EAC-1 and EAC-2 are
provided for EAC connection. (See Fig. 25.) These terminals
are energized with 115v (1.5-amp maximum) during blower
motor operation.
HUM
24-V THERMOSTAT
TERMINALS
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX)
LED OPERATION &
DIAGNOSTIC LIGHT
HARNESS CONNECTOR
SEC-1
3-AMP FUSE
COOL
HEAT
24-V TRANSFORMER SEC-2
SPARE-1
BLOWER SPEED
SELECTION TERMINALS
SPARE-2
EAC-1
EAC-ELECTRONIC AIR CLEANER
TERMINALS (115-VAC 1.5 AMP MAX)
115-VAC (L1)
POWER SUPPLY
HOT SURFACE
IGNITOR CONNECTOR
EAC-2
115-VAC (L2) NEUTRAL
CONNECTION
INDUCER MOTOR
CONNECTOR
A95086
Fig. 25—Control Center
20
NOTE: Furnace combustion-air and vent pipe connections are
sized for 2-in. pipe. Any pipe size change should be made outside
furnace casing in vertical pipe. (See Fig. 26.) This allows proper
drainage of vent condensate.
DIRECT VENTING
The 58MCA Furnaces require a dedicated (one 58MCA furnace
only) direct-vent system. In a direct-vent system, all air for
combustion is taken directly from outside atmosphere, and all flue
products are discharged to outside atmosphere.
Step 1—Removal of Existing Furnaces from
Common Vent Systems
FURNACE
If furnace being replaced was connected to a common vent system
with other appliances, the following steps shall be followed with
each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system
are not in operation:
NOT IN
HORIZONTAL
SECTION
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and horizontal pitch
as required in the National Fuel Gas Code, ANSI Z223.1 or
the CAN/CGA B149 Installation Codes and these instructions.
Determine that there is no blockage or restriction, leakage,
corrosion, and other deficiencies which could cause an unsafe
condition.
PIPE DIAMETER
TRANSITION IN
VERTICAL SECTION
A93034
Fig. 26—Combustion-Air and Vent Pipe Diameter
Transition Location and Elbow Configuration
3. In so far as is 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. 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 shall
operate at maximum speed. Do not operate a summer exhaust
fan. Close fireplace dampers.
Combustion-air and vent pipes must terminate together in same
atmosphere pressure zone, either through roof or sidewall (roof
termination preferred), using accessory termination kit. See Table
5 for required clearances.
Table 5—Combustion-Air and Vent Pipe
Termination Clearances
4. Follow the lighting instructions. Place the appliance being
inspected in operation. Adjust thermostat so appliance shall
operate continuously.
LOCATION
5. Test for draft hood equipped appliance spillage at the draft
hood relief opening after 5 minutes of main burner operation.
Use the flame of a match or candle.
Above grade level or above anticipated snow depth
Dryer vent
From plumbing vent stack
From any mechanical fresh air intake
For furnaces with an input capacity
less than 100,000 Btuh—from any nonmechanical air supply (windows or
doors which can be opened) or
combustion-air opening
For furnaces with an input capacity
greater than 100,000 Btuh—from any
non-mechanical air supply (windows
or doors which can be opened) or
combustion-air opening
From service regulator vent, electric
and gas meters, and relief equipment
Above grade when adjacent to public
walkway
6. 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-burning appliance to their previous
conditions of use.
7. If improper venting is observed during any of above tests, the
venting system must be corrected.
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.
Step 2—Combustion-Air and Vent Piping
CLEARANCE (FT)
U.S.A.
Canada
1
1†
3
3
1
3
3
6
1
1
1
3
4*
6‡
7
7
* Horizontal distance.
† 18 in. above roof surface in Canada.
‡ 36 in. to electric meter in Canada only.
NOTES:
1. If installing 2 adjacent 58MCA Furnaces, refer to Multiventing and Vent
Terminations section for proper vent configurations.
2. When locating combustion-air and vent terminations, consideration must be
given to prevailing winds, location, and other conditions which may cause
recirculation of the appliance’s own flue products or the flue products of
adjacent vents. Recirculation can cause poor combustion, inlet condensate
problems, and accelerated corrosion of heat exchangers.
GENERAL
Combustion-air and vent pipe fittings must conform to American
National Standards Institute (ANSI) standards and American
Society for Testing and Materials (ASTM) standards D1785
(schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and
SDR-26 PVC), D2661 (ABS-DWV), F628 (schedule-40 ABS), or
F891 (PVC-DWV cellular core). Pipe cement and primer must
conform to ASTM standards D2564 (PVC) or D2235 (ABS). See
Table 6 for maximum pipe lengths and Fig. 30, 31, 32, 33, and 34
for exterior piping arrangements.
Furnace combustion-air and vent pipe connections must be attached as shown in Fig. 27. Combustion-air intake plug fitting and
inducer housing alternate vent cap may need to be relocated in
some applications.
In Canada construct all combustion-air and vent pipes for this unit
of CSA or ULC certified schedule-40 PVC, PVC-DWV or
ABS-DWV pipe and pipe cement. SDR pipe is NOT approved in
Canada.
NOTE: Slope combustion-air and vent pipes a minimum of 1/4
in. per linear ft with no sags between hangers.
21
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
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. Failure to follow this warning could result in fire,
property damage, personal injury, or death.
VENT
VENT
VENT
VENT
COMBUSTIONAIR
UPFLOW
COMBUSTIONAIR
AIR
FLOW
All combustion-air and vent pipes must be airtight and
watertight. Pipes must also terminate exactly as shown in Fig.
30, 31, 32, 33, or 34. Failure to follow this warning could
result in property damage, personal injury, or death.
COMBUSTIONAIR
DOWNFLOW
NOTE: The minimum combustion-air and vent pipe length (each)
for these furnaces is 5 ft. Short pipe lengths (5-8 ft) may discharge
water droplets. These droplets may be undesirable, and a 12-in.
minimum offset pipe section is recommended, as shown in Fig. 28,
to reduce excessive droplets from exiting vent pipe outlet.
COMBUSTIONAIR
VENT
VENT
AIR
FLOW
COMBUSTION-AIR AND VENT PIPE DIAMETER
AIR
FLOW
Determine combustion-air and vent pipe diameter.
1. Using Table 6, individually determine the combustion-air and
vent pipe diameters. Pick the larger of these 2 pipe diameters
and use this diameter for both combustion-air and vent pipes.
HORIZONTAL-LEFT DISCHARGE
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. See shaded areas in Fig. 30, 31, 32, 33, and 34.
HORIZONTAL-RIGHT DISCHARGE
A96187
Fig. 27—Combustion-Air and Vent Pipe
Connections
EXAMPLE:
An 080-12 size furnace located in Indianapolis, elevation
650 ft above sea level, could be installed in an application
requiring 3 elbows and 32 ft of vent pipe, along with 5
elbows and 34 ft of combustion-air pipe. Table 6 indicates
this application would allow a 2-in. diameter vent pipe, but
require a 2-1/2 in. diameter combustion air pipe (2-in. pipe
is good for 35 ft with 3 elbows, but only 30 ft with 5
elbows). Therefore, 2-1/2 in. diameter pipe must be used
for both vent and combustion-air pipes since larger required
diameter must always be used for both pipes. If same
installation were in Albuquerque, elevation 5250 ft above
sea level, installation would require 2-1/2 in. vent pipe and
combustion-air pipe. At 5001- to 6000-ft elevation, 2-in.
pipe is only good for 17 ft with 5 elbows, and 2-1/2 in. pipe
is good for 70 ft with 5 elbows.
When combustion-air pipe is installed above a suspended
ceiling, pipe must be insulated with 3/8-in. thick Armaflextype insulation. Combustion-air pipe should also be insulated
when it passes through warm, humid space.
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 7 with Armaflex-type insulation.
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.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
COMBUSTION-AIR AND VENT PIPE ATTACHMENT
NOTE: All pipe joints must be watertight except attachment of
combustion-air pipe to inlet housing connection, since it may be
necessary to remove pipe for servicing.
1. Attach combustion-air pipe as follows:
a. Determine location of combustion-air intake pipe connection to combustion-air intake housing as shown in Fig. 27
for application.
→
22
b. Reposition combustion-air intake housing plug fitting in
appropriate unused intake housing connection.
c. If required, insert perforated disk assembly (factorysupplied in loose parts bag) in intake housing where
combustion-air intake pipe will be connected. If half disk
set is required, install with shoulder of disk against stop in
combustion-air inlet.
12″ MIN
12″ MIN
VENT PIPE
VENT PIPE
COMBUSTION-AIR PIPE
HORIZONTAL TO ROOF
COMBUSTION-AIR PIPE
HORIZONTAL TO SIDEWALL
COMBUSTION-AIR PIPE
VENT PIPE
COMBUSTION-AIR PIPE
12″ MIN
12″ MIN
VENT PIPE
VERTICAL TO ROOF
VERTICAL TO SIDEWALL
NOTE: A 12 In. minimum offset pipe section is recommended with
short (5 to 8 ft) vent systems. This recommendation is to reduce
excessive condensate droplets from exiting the vent pipe.
A96230
→ Fig. 28—Short Vent (5 to 8 Ft) System
A plugged drain connection has been provided on this fitting
for use when moisture is found in combustion-air intake pipe
and combustion box.
NOTE: Moisture in combustion-air intake may be result of
improper termination. Ensure combustion-air intake pipe is similar
to that shown in Fig. 30, 31, 32, 33, or 34 so it will not be
susceptible to areas where light snow or other sources of moisture
could be pulled in.
If use of this drain connection is desired, drill out fitting’s tap
plug with a 3/16-in. drill and connect a field-supplied 3/8-in.
tube. This tube should be routed to open condensate drain for
furnace and A/C (if used), and should be trapped. (See Fig.
29.)
2. Attach vent pipe as follows:
a. Determine location of vent pipe connection to inducer
housing as shown in Fig. 27 for application.
b. Reposition neoprene inducer housing outlet cap and clamp
to appropriate unused inducer housing connection. Tighten
clamp.
d. 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.
e. Insert 2-in. diameter pipe into intake housing.
NOTE: A 2-in. diameter pipe must be used within the furnace
casing. Make all pipe diameter transitions outside furnace casing.
f. Drill a 1/8-in. hole in 2-in. combustion-air pipe using hole
in intake housing as a guide.
g. Install a field-supplied No. 6 or No. 8 sheet metal screw
into combustion-air pipe.
NOTE: DO NOT OVERTIGHTEN SCREW. Breakage to intake
housing or fitting may cause air leakage to occur.
NOTE: Do not attach combustion-air intake pipe permanently to
combustion-air intake housing since it may be necessary to remove
pipe for service of ignitor or flame sensor.
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. 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 to intake
housing or fitting may cause air leakage to occur.
23
Table 6—Maximum Allowable Pipe Length (Ft)
ALTITUDE
0 to 2000
ALTITUDE
ALTITUDE
3001 to 4000
NUMBER OF 90° ELBOWS
2
3
4
5
NA
NA
NA
NA
70
65
60
60
70
70
70
70
6
NA
55
70
1-1/2
20
15
NA
2
70
70
70
70
70
70
1-1/2
2
2-1/2
2
2-1/2
3
2-1/2 one disk
3†
3† no disk
4† no disk
2-1/2 one disk
3† one disk
3† no disk
4† no disk
10
55
70
5
40
70
10
45
70
70
5
40
60
70
NA
50
70
NA
30
70
NA
40
70
70
NA
35
56
70
NA
35
70
NA
20
70
NA
35
70
70
NA
30
52
70
NA
30
70
NA
20
70
NA
30
70
70
NA
25
48
70
NA
30
70
NA
10
70
NA
25
70
70
NA
20
44
70
NA
20
70
NA
NA
70
NA
20
70
70
NA
15
40
70
1
67
70
2
62
70
NUMBER OF 90° ELBOWS
3
4
5
57
52
52
70
70
70
6
47
70
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
060-08
060-12
060-16
2 Pipe or 2-In.
Concentric
10
5
NA
080-12
080-16
080-20
2 Pipe or 2-In.
Concentric
100-16
100-20
2 Pipe or 3-In.
Concentric
→120-20
2 Pipe or 3-In.
Concentric
→140-20
2 Pipe or 3-In.
Concentric
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
1-1/2
2
2 Pipe or 2-In.
Concentric
1-1/2
17
12
7
NA
NA
NA
2
70
67
66
61
61
61
2 Pipe or 2-In.
Concentric
2
49
44
30
25
25
15
2-1/2
70
70
70
70
70
70
2-1/2
3
3
3† no disk
4† no disk
3† one disk
3† no disk
4† no disk
35
70
14
70
70
20
39
70
26
70
9
70
70
15
35
70
16
70
NA
63
70
10
31
70
16
70
NA
56
70
5
27
70
6
66
NA
50
70
NA
23
70
NA
61
NA
43
70
NA
19
70
1
64
70
2
59
70
NUMBER OF 90° ELBOWS
3
4
5
54
49
48
70
70
70
6
43
70
060-08
060-12
060-16
080-12
080-16
080-20
2001 to 3000
1
1-1/2
2
1
5
70
70
TERMINATION
TYPE
UNIT SIZE
100-16
100-20
2 Pipe or 3-In.
Concentric
→120-20
2 Pipe or 3-In.
Concentric
→140-20
2 Pipe or 3-In.
Concentric
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
1-1/2
2
2 Pipe or 2-In.
Concentric
1-1/2
16
11
6
NA
NA
NA
2
68
63
62
57
57
56
060-08
060-12
060-16
080-12
080-16
080-20
2 Pipe or 2-In.
Concentric
100-16
100-20
2 Pipe or 3-In.
Concentric
→120-20
2 Pipe or 3-In.
Concentric
→140-20
2 Pipe or 3-In.
Concentric
2
46
41
28
23
22
13
2-1/2
70
70
70
70
70
70
2-1/2
3
3† no disk
4† no disk
3† one disk
3† no disk
4† no disk
33
70
65
70
11
30
70
24
70
58
70
6
26
70
15
70
51
70
NA
22
70
14
66
44
70
NA
18
70
5
61
38
70
NA
14
70
NA
56
31
70
NA
10
70
See notes on page 26.
24
Table 6—Maximum Allowable Pipe Length (Ft)
ALTITUDE
4001 to 5000‡
ALTITUDE
5001 to 6000‡
ALTITUDE
6001 to 7000‡
ALTITUDE
7001 to 8000‡
1-1/2
2
1
60
70
NUMBER OF 90° ELBOWS
2
3
4
5
55
50
45
44
70
70
70
70
6
39
70
2 Pipe or 2-In.
Concentric
1-1/2
15
10
5
NA
NA
NA
2
64
59
58
53
52
52
2 Pipe or 2-In.
Concentric
2
44
39
26
21
20
11
2-1/2
70
70
70
70
70
70
31
70
53
70
21
69
22
70
46
70
17
64
13
67
40
70
13
59
12
62
33
70
9
54
NA
57
26
70
5
49
NA
52
20
70
NA
44
2
52
70
NUMBER OF 90° ELBOWS
3
4
5
47
42
40
70
70
70
6
35
70
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
060-08
060-12
060-16
080-12
080-16
080-20
Continued
100-16
100-20
2 Pipe or 3-In.
Concentric
→120-20
2 Pipe or 3-In.
Concentric
→140-20
2 Pipe or 3-In.
Concentric
2-1/2
3
3† no disk
4† no disk
3† no disk
4† no disk
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
1-1/2
2
1
57
70
2 Pipe or 2-In.
Concentric
1-1/2
14
9
NA
NA
NA
NA
2
60
55
54
49
48
47
2 Pipe or 2-In.
Concentric
2
41
36
23
18
17
8
2-1/2
70
70
70
70
70
70
29
70
42
70
12
42
21
67
35
70
8
37
12
62
29
70
NA
32
11
57
22
70
NA
27
NA
52
15
70
NA
22
NA
47
9
70
NA
17
2
48
70
NUMBER OF 90° ELBOWS
3
4
5
43
38
37
68
67
66
6
32
64
8
060-08
060-12
060-16
080-12
080-16
080-20
100-16
100-20
2 Pipe or 3-In.
Concentric
→120-20
2 Pipe or 3-In.
Concentric
→140-20
2 Pipe or 3-In.
Concentric
2-1/2
3
3† no disk
4† no disk
3† no disk
4† no disk
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
1-1/2
2
1
53
70
2 Pipe or 2-In.
Concentric
1-1/2
13
2
57
52
2 Pipe or 2-In.
Concentric
2
38
33
2-1/2
70
70
68
67
66
64
2-1/2
3
3† no disk
4† no disk
27
68
31
70
19
63
24
70
10
58
18
70
9
53
11
70
NA
48
NA
67
NA
43
NA
62
17
12
7
NA
NA
NA
2
44
65
NUMBER OF 90° ELBOWS
3
4
5
39
34
33
63
62
60
6
28
59
060-08
060-12
060-16
080-12
080-16
080-20
NA
NA
NA
NA
50
45
44
43
21
16
15
6
100-16
100-20
2 Pipe or 3-In.
Concentric
→120-20
2 Pipe or 3-In.
Concentric
→140-20
2 Pipe or 3-In.
Concentric
4† no disk
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
1-1/2
2
1
49
66
2 Pipe or 2-In.
Concentric
1-1/2
12
7
NA
NA
NA
NA
2
53
48
46
41
40
38
2 Pipe or 2-In.
Concentric
2
36
31
19
14
12
NA
2-1/2
66
65
63
62
60
59
2-1/2
3
3† no disk
4† no disk
25
63
20
61
17
58
13
56
8
53
7
51
7
48
NA
46
NA
43
NA
41
NA
38
NA
36
060-08
060-12
060-16
080-12
080-16
080-20
100-16
100-20
2 Pipe or 3 In.
Concentric
→120-20
2 Pipe or 3-In.
Concentric
→140-20
NA
See notes on page 26.
25
Table 6—Maximum Allowable Pipe Length (Ft)
ALTITUDE
8001 to 9000‡
NUMBER OF 90° ELBOWS
2
3
4
5
41
36
31
29
60
58
56
55
6
24
53
11
6
NA
NA
NA
NA
49
44
42
37
35
34
33
28
17
12
10
NA
2-1/2
62
60
58
56
55
53
2-1/2
3
3† no disk
4† no disk
23
59
10
35
15
54
NA
30
7
49
NA
25
5
44
NA
20
NA
39
NA
15
NA
34
NA
10
NUMBER OF 90° ELBOWS
3
4
5
32
27
25
53
51
49
6
20
47
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
1-1/2
2
2 Pipe or 2-In.
Concentric
1-1/2
2
2 Pipe or 2-In.
Concentric
2
060-08
060-12
060-16
080-12
080-16
080-20
100-16
100-20
2 Pipe or 3-In.
Concentric
→120-20
2 Pipe or 3-In.
Concentric
1
46
62
→140-20
ALTITUDE
9001 to 10,000‡
NA
UNIT SIZE
TERMINATION
TYPE
PIPE DIA
(IN.)*
040-08
040-12
2 Pipe or 2-In.
Concentric
2 Pipe or 2-In.
Concentric
060-08
060-12
060-16
080-12
080-16
080-20
Continued
1-1/2
2
1
42
57
2
37
55
2
45
40
38
33
31
29
9
7
NA
2 Pipe or 2-In.
Concentric
2
30
25
14
2-1/2
57
55
53
51
49
47
100-16
100-20
2 Pipe or 3-In.
Concentric
2-1/2
3
21
54
13
49
5
44
NA
39
NA
34
NA
29
→120-20
2 Pipe or 3-In.
Concentric
4† no disk
10
5
NA
NA
NA
NA
→140-20
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. Long radius elbows are desirable and may be required in some cases.
4. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.
5. The minimum pipe length is 5 ft for all applications.
6. Use 3-in. diameter vent termination kit for installations requiring 4-in diameter pipe.
COMBUSTION – AIR
INTAKE HOUSING
3/8" ID TUBE
BURNER
BOX
3/16"
DRILL
TRAP
Inducer housing outlet cap must be installed and fully seated
against inducer housing. Clamp must be tightened to prevent
any condensate leakage. Failure to follow this warning could
result in electrical shock, fire, personal injury, or death.
c. 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.
d. Insert 2-in. diameter pipe into inducer housing through
neoprene coupling and clamp in inducer housing. Tighten
clamp.
COMBUSTION –
AIR PIPE
4″
MIN
TO OPEN
DRAIN
Vent pipe must be installed and fully seated against inducer
housing. Clamp must be tightened to prevent any condensate
leakage. Failure to follow this warning could result in
electrical shock, fire, personal injury, or death.
A93035
Fig. 29—Intake Housing Plug Fitting Drain
NOTE: A 2-in. diameter pipe must be used within the furnace
casing. Make all pipe diameter transitions outside furnace casing.
26
→
31.) Sidewall termination may require sealing or shielding of
building surfaces with a corrosive resistance material due to
corrosive combustion products of vent system.
VENT EXTENSION PIPE
Furnaces with 100,000 Btuh and larger inputs are supplied
with a PVC vent extension pipe (2-in. diameter by 12-in.
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.
EXTENDED EXPOSED SIDEWALL PIPES
Sidewall combustion-air and vent pipe terminations may be
extended beyond area shown in Fig. 33 or 34 in outside ambient by
insulating pipes as indicated in Table 7.
1. Determine combustion-air and vent pipe diameters, 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. Working from furnace to outside, cut pipe to required
length(s).
4. Deburr inside and outside of pipe.
3. Determine required insulation thickness for exposed pipe
lengths.
5. Chamfer outside edge of pipe for better distribution of primer
and cement.
NOTE: Pipe length (ft) specified for maximum pipe lengths
located in unconditioned spaces cannot exceed total allowable pipe
length as specified in Table 6.
6. Clean and dry all surfaces to be joined.
7. Check dry fit of pipe and mark insertion depth on pipe.
NOTE: It is recommended that all pipes be cut, prepared, and
preassembled before permanently cementing any joint.
TWO-PIPE TERMINATION KIT
1. Determine location for termination.
8. After pipes have been cut and preassembled, apply generous
layer of cement primer to pipe fitting socket and end of pipe
to insertion mark. Quickly apply approved cement to end of
pipe and fitting socket (over primer). Apply cement in a light,
uniform coat on inside of socket to prevent buildup of excess
cement. Apply second coat.
Consideration of the following should be made when determining an appropriate location for termination kit.
a. Comply with all clearance requirements as stated in Table
5.
b. Termination kit should be positioned where vent vapors
will not damage plants/shrubs or air conditioning equipment.
9. While cement is still wet, twist pipe into socket with 1/4 turn.
Be sure pipe is fully inserted into fitting socket.
11. Handle pipe joints carefully until cement sets.
c. Termination kit should be positioned so that it will not be
affected by wind eddy (such as inside building corners) or
allow recirculation of flue gases, airborne leaves, or light
snow.
12. Support combustion-air and vent piping a minimum of every
5 ft (3 ft for SDR-21 or -26 PVC) using perforated metal
hanging strap.
d. Termination kit should be positioned where it will not be
damaged by or subjected to foreign objects, such as stones,
balls, etc.
13. Slope combustion-air and vent pipes toward furnace a minimum of 1/4 in. per linear ft with no sags between hangers.
e. Termination kit should be positioned where vent vapors are
not objectionable.
14. Use appropriate methods to seal openings where vent and
combustion-air pipes pass through roof or side wall.
2. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size
being used.
Step 3—Concentric Vent and Combustion-Air
Termination Kit Installation
NOTE: If these instructions differ from those packaged with
termination kit, follow kit instructions.
3. Loosely install elbow in bracket and place assembly on
combustion-air pipe.
10. Wipe excess cement from joint. A continuous bead of cement
will be visible around perimeter of a properly made joint.
Roof terminations—Loosely install pipe coupling on properly cut vent pipe. Coupling must be positioned so bracket will
mount as shown in Fig. 30.
Combustion-air and vent pipes must terminate outside structure. A
factory accessory termination kit must be installed in 1 of the
installations shown in Fig. 30, 31, 32, 33, or 34. Four termination
kits are available.
→
→
For applications using combustion-air pipe option, indicated
by dashed lines in Fig. 30, install 90° street elbow into 90°
elbow, making U-fitting. A 180° U-fitting may be used.
1. The 2-in. termination bracket kit is for 1-in., 1-1/2 in., and
2-in. diameter 2-pipe termination systems.
Sidewall terminations—Install bracket as shown in Fig. 33 or
34.
2. The 3-in. termination bracket kit is for 2-1/2 in., 3-in., and
4-in. diameter 2-pipe termination systems.
For applications using vent pipe option indicated by dashed
lines in Fig. 33, rotate vent elbow 90° from position shown in
Fig. 33.
3. The 2-in. concentric vent/air termination kit is for 1-in., 1-1/2
in., 2-in., and 2-1/2 in. diameter pipe systems when single
penetration of wall or roof is desired.
4. Disassemble loose pipe fittings. Clean and cement using same
procedures as used for system piping.
4. The 3-in. concentric vent/air termination kit is for 2-1/2 in.,
3-in., and 4-in. diameter pipe systems when single penetration
of wall or roof is desired.
NOTE: Shaded parts in Fig. 30, 31, 32, 33, and 34 are considered
to be termination. These components should NOT be counted
when determining pipe diameter. Roof termination is preferred
since it is less susceptible to damage, has reduced chances to take
in contaminants, and has less visible vent vapors. (See Fig. 30 or
5. Check required dimensions as shown in Fig. 30, 33, or 34.
CONCENTRIC VENT/AIR TERMINATION KIT
1. Determine location for termination.
Consideration of the following should be made when determining an appropriate location for termination kit.
a. Comply with all clearance requirements as stated in Table
5.
27
ROOF
18″ MAXIMUM
BRACKET
COUPLING
COMBUSTION
AIR
VERTICAL SEPARATION
BETWEEN COMBUSTION
AIR AND VENT
8 3/4″ FOR 3″ KIT
6 3/4″ FOR 2″ KIT
VENT
MAINTAIN 12 IN. MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL.
MAXIMUM OF 24 IN. ABOVE ROOF.
A87224
Fig. 30—Roof Termination (Preferred)
OVERHANG OR ROOF
12″ MINIMUM
1″ MAXIMUM
VENT
COMBUSTION-AIR
VENT
COMBUSTION
AIR
MAINTAIN 12 IN.
CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
WHICHEVER IS
GREATER.
MAINTAIN 12 IN.
(18 IN. FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24 IN. ABOVE ROOF.
A93055
A93054
Fig. 32—Concentric Vent and Combustion-Air Side
Termination
Fig. 31—Concentric Vent and Combustion-Air Roof
Termination (Preferred)
OVERHANG OR ROOF
OVERHANG OR ROOF
12″ MINIMUM
12″ MINIMUM
VENT
VENT
90°
90°
BRACKET
COUPLING
BRACKET
12 IN. SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR AND
BOTTOM OF VENT
MAINTAIN 12 IN.
CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
COMBUSTION-AIR WHICHEVER IS
GREATER.
COMBUSTION-AIR
(ELBOW PARALLEL
TO WALL)
A87225
12 IN. SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR AND
BOTTOM OF VENT
MAINTAIN 12 IN.
CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL OR GRADE,
WHICHEVER IS
GREATER.
A87226
Fig. 33—Sidewall Termination of 12 in. or More
Fig. 34—Sidewall Termination of Less than 12 in.
28
→ Table 7—Maximum Allowable Exposed Vent Pipe Length (Ft) With and Without Insulation
in Winter Design Temperature Ambient*
UNIT
SIZE
040
060
080
100
120
140
WINTER DESIGN
TEMPERATURE
(°F)
20
0
-20
20
0
-20
20
0
-20
20
0
-20
20
0
-20
20
0
-20
MAX PIPE
DIAMETER
(IN.)
1-1/2
1-1/2
1-1/2
2
2
2
2-1/2
2-1/2
2-1/2
3
3
3
4
4
4
4
4
4
WITHOUT
INSULATION
WITH 3/8-IN. OR
THICKER INSULATION†
51
28
16
65
35
20
70
47
28
70
50
28
70
48
23
70
57
30
70
70
70
70
70
70
70
70
70
70
70
70
70
70
70
70
70
70
* 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 6.
† Insulation thickness based on R value of 3.5 per in.
b. Termination kit should be positioned where vent vapors
will not damage plants/shrubs or air conditioning equipment.
gases. Dimension "A" in Fig. 35, 36, 37, 38, and 39 represents
distance between pipes or rain shields, as touching or 2-in.
maximum separation.
c. Termination kit should be positioned so it will not be
affected by wind eddy (such as inside building corners) or
that may allow recirculation of flue gases, airborne leaves,
or light snow.
CONDENSATE DRAIN
Step 1—General
d. Termination kit should be positioned where it will not be
damaged by or subjected to foreign objects, such as stones,
balls, etc.
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.
e. Termination kit should be positioned where vent vapors are
not objectionable.
Condensate trap MUST be used for all applications.
An external trap is not required when connecting the field drain to
this condensate trap.
2. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in. diameter
hole for 3-in. kit.
The field drain connection (condensate trap or drain tube coupling)
is sized for 1/2-in. CPVC, 1/2-in. PVC, or 5/8-in. ID tube
connection.
3. Loosely assemble concentric vent/air termination components
together using instructions in kit.
4. Slide assembled kit with rain shield REMOVED through hole.
Roof terminations—Locate assembly through roof to appropriate height as shown in Fig. 31.
Drain pipe and fittings must conform to ANSI standards and
ASTM D1785 or D2846. CPVC or PVC cement and primer must
conform to ASTM D2564 or F493. In Canada, use CSA or ULC
certified schedule 40 CPVC or PVC drain pipe, fittings, and
cement.
Sidewall terminations—Locate assembly through sidewall
with rain shield positioned no more than 1-in. from wall as
shown in Fig. 32.
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.
5. Disassemble loose pipe fittings. Clean and cement using same
procedures as used for system piping.
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.
NOTE: Do not allow insulation or other materials to accumulate
inside of pipe assembly when installing it through hole.
6. Check required dimensions as shown in Fig. 31 or 32.
Step 4—Multiventing and Vent Terminations
Step 2—Application
When 2 or more 58MCA Furnaces are vented near each other, each
furnace must be individually vented. NEVER common vent or
breach vent 58MCA furnaces. When 2 or more 58MCA furnaces
are vented near each other, 2 vent terminations may be installed as
shown in Fig. 35, 36, 37, 38, or 39, but next vent termination must
be at least 36 in. away from first 2 terminations. It is important that
vent terminations be made as shown to avoid recirculation of flue
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.
29
A
A96128
→ Fig. 35—Rooftop Termination
(Dimension "A" is Touching or 2-In. Maximum Separation)
1″ MAXIMUM
(TYP)
VENT
VENT
A
COMBUSTION AIR
VENT
COMBUSTION
AIR
A
VENT
A93056
A93057
Fig. 36—Concentric Vent and Combustion-Air
Roof Termination
(Dimension "A" is Touching or 2-In. Maximum Separation)
Fig. 37—Concentric Vent and Combustion-Air
Side Termination
(Dimension "A" is Touching or 2-In.
Maximum Separation)
VENT
VENT
COMBUSTION AIR
COMBUSTION AIR
COMBUSTION AIR
COMBUSTION AIR
A
A
A96129
A96130
→ Fig. 38—Sidewall Termination of 12 in. or Less
(Dimension "A" is Touching or 2-In.
Maximum Separation)
→ Fig. 39—Sidewall Termination of More Than 12 in.
(Dimension "A" is Touching or 2-In.
Maximum Separation)
30
Caution should be taken to prevent draining where slippery
conditions may cause personal injuries. Excessive condensate
draining may cause saturated soil conditions which may result
in damage to plants.
Step 3—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 self-regulating,
shielded, and waterproof heat tape. See Installation Instructions
supplied with accessory or heat tape manufacturer’s recommendations.
32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
1. Fold heat tape in half and wrap on itself 3 times.
2. Locate heat tape between sides of condensate trap back. (See
Fig. 41.)
3. Use wire ties to secure heat tape in place. Wire ties can be
positioned in notches of condensate trap sides. (See Fig. 41.)
A93058
4. Wrap field drain pipe with remaining heat tape, approximately
1 wrap per ft.
Unit must not be installed, operated, and then turned off and
left in an unoccupied structure during cold weather when
temperature drops to 32°F and below unless drain trap and
drain line have adequate freeze protection. See Service and
Maintenance Instructions for winterizing procedure.
5. When using field-supplied heat tape, follow heat tape manufacturer’s instructions for all other installation guidelines.
CONDENSATE TRAP
See Fig. 40 for example of possible field drain attachment using
1/2-in. CPVC or PVC tee for vent and A/C or humidifier drain
connection.
WIRE TIE(S)
HEAT TAPE
(3 WRAPS MINIMUM)
OPEN STAND
PIPE FOR
A/C OR
HUMIDIFIER
DRAIN
Fig. 41—Condensate Trap Heat Tape
A93036
SEQUENCE OF OPERATION
TEE
Furnace control must be grounded for proper operation, or
control will lock out. Control is grounded through green wire
routed to gas valve and burner box screw.
TO OPEN
DRAIN
Using schematic diagram, follow sequence of operation through
different modes. (See Fig. 24.) Read and follow wiring diagram
carefully.
NOTE: If 115-v power supply to furnace or blower access panel
switch is interrupted during a call for heat, blower operates for 90
sec when power is restored before heating cycle is resumed.
A94054
Fig. 40—Example of Field Drain Attachment
Step 1—Heating Mode
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.
When wall thermostat calls for heat, R-W circuit closes. Furnace
control performs a self-check, verifies pressure switch contacts are
open, and starts inducer motor.
31
Step 4—Heat Pump Mode
1. Prepurge period—As inducer motor comes up to speed,
pressure switch contacts close to begin a 15-sec prepurge
period.
When installed with a heat pump, furnace control automatically
changes blower on delay timing sequence to avoid no blower
operation time during demand defrost cycles. When R-W and R-Y
or R-W, R-Y, and R-G thermostat inputs are received at the same
time at furnace control center, control starts blower in heating
speed. Then a gas heat mode begins. Blower remains operating at
heating speed for 15 sec or until end of prepurge period, then
blower shuts off until end of ignitor warm up and trial for ignition
periods (a total of 24 sec). Blower restarts at heating speed.
2. Ignitor warm up—At end of prepurge period, ignitor is
energized for a 17-sec ignitor warm-up period.
3. Ignition sequence—When ignitor warm-up period is completed, gas valve opens, permitting gas flow to burners where
it is ignited. After 5 sec, ignitor is de-energized and a 2-sec
flame-sensing period begins.
HUM terminal on control center is energized with gas valve.
See Accessories — Humidifier section.
→ When R-W thermostat call disappears, control completes inducer
post-purge period of 15 sec (5 sec if jumper has been cut for 140
size unit in downflow orientation) and changes to cooling speed
after a 2-sec delay.
4. Flame sensing—When burner flame is sensed, control begins
blower on delay period and continues holding gas valve open.
If burner flame is not sensed, control center de-energizes gas
valve and ignition sequence is repeated.
→ If
R-W, R-Y, and R-G thermostat signals should disappear
simultaneously, blower remains on for heating blower off delay
period of 135, and the inducer goes through 15 sec post-purge
period (5 sec if jumper has been cut for 140 size unit in downflow
orientation). If R-W and R-Y thermostat signals should disappear,
leaving R-G thermostat signal, blower remains on in heating speed
and inducer remains on for 15 sec to complete post-purge period (5
sec if jumper has been cut for 140 size unit in downflow
orientation).
NOTE: Ignition sequence repeats 3 additional times before a
lockout occurs. Lockout automatically resets after 3 hr or can be
manually reset by turning off 115v (not at thermostat) for 3 sec
minimum, then turning it on again.
→
5. Blower on delay—Sixty sec after burner flame is proven (40
sec if jumper has been cut for 140 size unit in downflow
orientation), blower motor is energized on heating speed.
Simultaneously, electronic air cleaner terminal EAC-1 is
energized.
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.
6. Blower off delay—When thermostat is satisfied, circuit between R-W is opened, de-energizing gas valve (stopping gas
flow to burners) and humidifier. Blower motor and electronic
air cleaner remain energized for 135 sec.
→
7. Post purge—Inducer motor remains energized 15 sec after
burners are extinguished (5 sec if jumper has been cut for 140
size unit in downflow orientation).
NOTE: EAC-1 terminal is energized whenever blower operates.
HUM terminal is only energized when gas valve is energized.
Step 5—Component Test
Step 2—Cooling Mode
COMPONENT TEST SEQUENCE
When thermostat calls for cooling, R-G and R-Y circuits close.
R-Y circuit starts outdoor condensing unit, and combined R-Y and
R-G circuit starts furnace blower motor on cooling speed. Electronic air cleaner EAC-1 terminal is energized with 115v whenever
blower is operating.
NOTE: All components are functionally operated except the gas
valve.
When component test is initiated, the following sequence of events
occurs:
1. LED flashes a status code 4 times.
When thermostat is satisfied, R-G and R-Y circuits are opened,
furnace blower continues operating on cooling speed for an
additional 90 sec.
2. Inducer motor starts and continues to run for remainder of
component test.
3. Hot surface ignitor is energized for 15 sec, then de-energized.
Step 3—Continuous Blower Mode
4. Main blower operates at cooling speed for 10 sec, then turns
off.
When R-G circuit is made, blower motor operates on heating
speed.
5. Main blower operates at heating speed for 10 sec, then turns
off.
NOTE: Electronic air cleaner EAC-1 terminal is energized with
115v whenever blower is operating.
6. Inducer motor stops.
→ If a call for heat (R-W) occurs while thermostat is in continuous
Component test can be initiated by one of the following procedures.
blower mode, blower stops to allow furnace heat exchangers to
heat up more quickly, then restarts at end of blower on delay
period of 60 sec (40 sec if jumper has been cut for 140 size unit in
downflow orientation).
INITIATING COMPONENT TEST BY REMOVING MAIN
LIMIT SWITCH WIRE
NOTE: NO thermostat signal may be present at control center
and all blower time delay off periods must be completed.
Blower reverts to continuous operation after heating cycle is
completed.
1. Leave 115-v power to furnace turned on.
If a call for cooling (R-Y) occurs while thermostat is in continuous
blower mode, blower changes from continuous blower speed
(heating speed) to cooling speed.
2. Remove main furnace door.
3. Look into blower access panel sight glass for current LED
status.
When thermostat cooling call is satisfied, R-Y opens and blower
operates an additional 90 sec at cooling speed before reverting
back to continuous operation (heating speed).
NOTE: Leave blower access panel installed to maintain power to
control center to view current LED status.
32
4. BRIEFLY remove either wire from the main limit switch until
the LED goes out, then reconnect it.
These furnaces are equipped with a manual reset limit switch
in burner box. This switch will open if an overheat condition
(rollout) occurs in burner enclosure. Correct inadequate
combustion-air supply or improper venting condition and
reset switch. DO NOT jumper this switch.
Make sure limit switch wire does not contact any metallic
component such as the gas valve. If wire is shorted, 3-amp
fuse on control center will blow.
Before operating furnace, check each manual reset switch for
continuity. If necessary, press button to reset switch.
NOTE: If wire to main limit is disconnected longer than 4 sec, the
control senses limit circuit is open. Main blower will start and
status retrieval request will be ignored.
Step 2—Prime Condensate Trap with Water
5. When above items have been completed, the component test
sequence will occur as described in the Component Test
Sequence section above.
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.
NOTE: Be sure to record the status code which is flashed 4 times
at start of component test for further troubleshooting.
6. After component test is completed and LED is ON continuously indicating the furnace is ready to operate when a signal
from the thermostat is received, replace main furnace door.
1. Remove upper inducer housing drain connection cap. (See
Fig. 42.)
INITIATING COMPONENT TEST BY JUMPERING CONTROL TEST TERMINAL
2. Connect field-supplied 1/2-in. ID tube to upper inducer
housing drain connection.
1. Remove main furnace door.
3. Insert field-supplied funnel into tube.
2. Remove blower access panel.
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. 43.)
3. Manually close blower access panel door switch. Use a piece
of tape to hold switch closed.
5. Remove funnel and tube from inducer housing and replace
drain connection cap and clamp.
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. Failure to follow this warning could result in
electrical shock, personal injury, or death.
Step 3—Purge Gas Lines
If not previously done, purge lines after all connections have been
made and check for leaks.
4. BRIEFLY short (jumper) TEST, 1/4-in. quick-connect terminal on control center (adjacent to the LED diagnostic light)
and the COM terminal on thermostat connection block. (See
Fig. 25.)
Never purge a gas line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition for
purpose of checking leakage. Use a soap-and-water solution
to check for leakage. Failure to follow this warning could
result in fire, explosion, personal injury, or death.
NOTE: If TEST to COM terminals are jumpered longer than 2 sec,
LED will flash rapidly, and retrieval request will be ignored.
5. When above items have been completed, the component test
sequence will occur as described in the Component Test
Sequence section above.
NOTE: Be sure to record the status code which is flashed 4 times
at start of component test for further troubleshooting.
6. After component test is completed and furnace is operating
properly, release blower access panel door switch, replace
blower access panel, and replace main furnace door.
START-UP PROCEDURES
Step 1—General
Step 4—Adjustments
SET GAS INPUT RATE
Furnace gas input rate on rating plate is for installations at altitudes
up to 2000 ft.
→ In the U.S.A., the input ratings for altitudes above 2000 ft must be
reduced by 2 percent for each 1000 ft above sea level.
→ In
Canada, the input ratings must be derated by 5 percent for
altitudes of 2000 ft to 4500 ft above sea level.
→ Furnace input rate must be within ±2 percent of input on furnace
rating plate adjusted for altitude.
1. Furnace must have a 115-v power supply properly connected
and grounded. Proper polarity must be maintained for correct
operation.
1. Determine natural gas orifice size and manifold pressure for
correct input.
NOTE: Proper polarity 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 control center.
a. Obtain average yearly heat value (at installed altitude) from
local gas supplier.
→
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 24-v
electrical circuit to furnace.
→
33
b. Obtain average yearly specific gravity from local gas
supplier.
c. Verify furnace model. Table 8 can only be used for model
58MCA furnaces with heating sizes of 040 through 120.
Table 9 can only be used for model 58MCA furnaces with
a 140 heating size.
d. Find installation altitude in Table 8 or 9.
A94208
A94209
Fig. 42—Inducer Housing Drain Tube
Fig. 43—Filling Condensate Trap
→ NOTE:
→
NOTE: This furnace has been approved for a manifold pressure
of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft.
For altitudes above 2000 ft, the manifold pressure can be adjusted
from 2.0 in. wc to 3.8 in. wc.
For Canada altitudes of 2000 to 4500 ft, use U.S.A.
altitudes of 2001 to 3000 ft in Table 8 or 9.
e. Find closest natural gas heat value and specific gravity on
Table 8 or 9.
f. Follow heat value and specific gravity lines to point of
intersection to find orifice size and manifold pressure
settings for proper operation.
ON AND
OFF SWITCH
GAS
PRESSURE
REGULATOR
ADJUSTMENT
EXAMPLE: (0—2000 ft altitude using Table 8)
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.
BURNER
ENCLOSURE
REFERENCE
PRESSURE
TAP
Check and verify burner orifice size in furnace. NEVER ASSUME
ORIFICE SIZE; ALWAYS CHECK AND VERIFY.
INLET
PRESSURE TAP
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.
MANIFOLD
PRESSURE TAP
A95622
Fig. 44—Redundant Automatic Gas Valve
a. Remove burner enclosure front.
b. Remove cap that conceals adjustment screw for gas valve
regulator. (See Fig. 44.)
c. Turn adjusting screw, counterclockwise (out) to decrease
manifold pressure or clockwise (in) to increase manifold
pressure.
34
→ Table 8—Model 58MXA Orifice Size and Manifold Pressure for Correct Input
For Use with 040 through 120 Size Furnaces Only
(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
0
to
2000
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2000
to
4500
U.S.A. Only
ALTITUDE
RANGE
(FT)
3001
to
4000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
850
875
900
925
950
975
1000
1025
1050
1075
1100
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
775
800
825
850
875
900
925
950
975
1000
1025
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
750
775
800
825
850
875
900
925
950
975
1000
0.58
Orifice
Manifold
No.
Pressure
43
3.7
43
3.5
44
3.7
44
3.5
44
3.4
44
3.2
45
3.7
45
3.5
45
3.3
45
3.2
47
3.6
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.8
42
3.2
42
3.3
43
3.6
43
3.7
43
3.8
43
3.4
43
3.5
43
3.6
44
3.7
44
3.8
43
3.4
44
3.5
44
3.6
44
3.7
44
3.3
44
3.4
44
3.5
45
3.8
44
3.2
44
3.4
45
3.6
45
3.7
44
3.2
45
3.4
45
3.6
45
3.7
45
3.3
45
3.4
45
3.5
47
3.7
45
3.2
45
3.4
Orifice
No.
42
42
43
43
44
44
44
44
45
45
45
0.66
Manifold
Pressure
3.4
3.2
3.7
3.5
3.8
3.6
3.5
3.3
3.8
3.6
3.5
0.58
Orifice
Manifold
No.
Pressure
43
3.8
43
3.5
44
3.8
44
3.6
44
3.4
44
3.2
45
3.7
45
3.5
45
3.3
45
3.1
45
3.0
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.2
42
3.3
42
3.4
43
3.7
43
3.8
42
3.2
43
3.4
43
3.6
43
3.7
44
3.7
44
3.8
43
3.5
44
3.5
44
3.6
44
3.7
44
3.3
44
3.4
44
3.5
45
3.8
44
3.2
44
3.3
45
3.6
45
3.7
45
3.8
45
3.4
45
3.5
45
3.6
45
3.2
45
3.4
45
3.5
45
3.1
45
3.2
45
3.3
Orifice
No.
42
42
43
43
43
44
44
44
45
45
45
0.66
Manifold
Pressure
3.5
3.3
3.8
3.6
3.4
3.6
3.4
3.3
3.8
3.6
3.4
0.58
Orifice
Manifold
No.
Pressure
43
3.7
43
3.5
44
3.7
44
3.5
44
3.3
45
3.8
45
3.6
45
3.4
45
3.2
45
3.0
45
2.9
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.8
42
3.3
42
3.4
43
3.6
43
3.7
43
3.8
43
3.4
43
3.5
43
3.6
44
3.6
44
3.8
43
3.4
44
3.4
44
3.5
44
3.7
44
3.2
44
3.3
44
3.5
45
3.7
45
3.8
44
3.3
45
3.5
45
3.6
45
3.7
45
3.3
45
3.4
45
3.5
45
3.2
45
3.3
45
3.4
45
3.0
45
3.1
45
3.2
Orifice
No.
42
42
43
43
44
44
44
44
45
45
45
0.66
Manifold
Pressure
3.5
3.2
3.7
3.5
3.8
3.6
3.4
3.2
3.7
3.5
3.3
35
→ Table 8—Model 58MXA Orifice Size and Manifold Pressure for Correct Input Continued
For Use with 040 through 120 Size Furnaces Only
(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)
U.S.A. Only
ALTITUDE
RANGE
(FT)
4001
to
5000
U.S.A. Only
ALTITUDE
RANGE
(FT)
5001
to
6000
U.S.A. Only
ALTITUDE
RANGE
(FT)
6001
to
7000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
725
750
775
800
825
850
875
900
925
950
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
700
725
750
775
800
825
850
875
900
925
950
975
1000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
650
675
700
725
750
775
800
825
850
875
0.58
Orifice
Manifold
No.
Pressure
43
3.7
43
3.4
44
3.7
44
3.5
44
3.2
45
3.7
45
3.5
45
3.3
45
3.1
45
3.0
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.8
42
3.2
42
3.3
43
3.5
43
3.7
43
3.8
44
3.8
43
3.4
43
3.5
44
3.6
44
3.7
44
3.8
44
3.4
44
3.5
44
3.6
45
3.8
44
3.3
44
3.4
45
3.6
45
3.7
44
3.2
45
3.4
45
3.5
45
3.6
45
3.2
45
3.3
45
3.4
45
3.1
45
3.2
45
3.3
Orifice
No.
42
42
43
43
44
44
44
45
45
45
0.66
Manifold
Pressure
3.4
3.2
3.7
3.4
3.7
3.5
3.3
3.8
3.6
3.4
0.58
Orifice
Manifold
No.
Pressure
43
3.6
43
3.4
44
3.6
44
3.4
44
3.2
45
3.6
45
3.4
45
3.2
45
3.0
45
2.9
45
2.7
45
2.6
45
2.5
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
43
3.7
42
3.2
42
3.3
43
3.5
43
3.6
43
3.7
44
3.7
43
3.4
43
3.5
44
3.5
44
3.6
44
3.7
44
3.3
44
3.4
44
3.5
45
3.7
44
3.2
44
3.3
45
3.5
45
3.6
45
3.8
45
3.3
45
3.4
45
3.6
45
3.1
45
3.3
45
3.4
45
3.0
45
3.1
45
3.2
45
2.8
45
2.9
45
3.0
45
2.7
45
2.8
45
2.9
45
2.5
45
2.6
45
2.7
Orifice
No.
42
43
43
43
44
44
44
45
45
45
45
45
45
0.66
Manifold
Pressure
3.4
3.8
3.6
3.4
3.6
3.4
3.2
3.7
3.5
3.3
3.1
2.9
2.8
0.58
Orifice
Manifold
No.
Pressure
42
3.2
43
3.6
44
3.8
44
3.6
44
3.3
45
3.8
45
3.5
45
3.3
45
3.1
45
3.0
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.3
42
3.4
42
3.5
43
3.7
43
3.8
42
3.2
43
3.4
43
3.6
43
3.7
44
3.7
44
3.8
43
3.4
44
3.4
44
3.6
44
3.7
44
3.2
44
3.3
44
3.4
45
3.7
45
3.8
44
3.2
45
3.4
45
3.6
45
3.7
45
3.2
45
3.4
45
3.5
45
3.1
45
3.2
45
3.3
Orifice
No.
42
42
43
43
44
44
44
45
45
45
0.66
Manifold
Pressure
3.6
3.3
3.8
3.5
3.8
3.5
3.3
3.8
3.6
3.4
36
→ Table 8—Model 58MXA Orifice Size and Manifold Pressure for Correct Input Continued
For Use with 040 through 120 Size Furnaces Only
(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)
U.S.A. Only
ALTITUDE
RANGE
(FT)
7001
to
8000
U.S.A. Only
ALTITUDE
RANGE
(FT)
8001
to
9000
U.S.A. Only
ALTITUDE
RANGE
(FT)
9001
to
10,000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
625
650
675
700
725
750
775
800
825
850
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
600
625
650
675
700
725
750
775
800
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
575
600
625
650
675
700
725
750
775
0.58
Orifice
Manifold
No.
Pressure
43
3.8
43
3.5
44
3.8
44
3.5
44
3.3
45
3.7
45
3.5
45
3.3
45
3.1
45
2.9
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.3
42
3.4
42
3.5
43
3.7
43
3.8
42
3.2
43
3.4
43
3.5
43
3.6
44
3.6
44
3.8
43
3.4
44
3.4
44
3.5
44
3.6
45
3.8
44
3.3
44
3.4
45
3.6
45
3.7
45
3.8
45
3.4
45
3.5
45
3.6
45
3.2
45
3.3
45
3.4
45
3.0
45
3.1
45
3.2
Orifice
No.
42
42
43
43
44
44
44
45
45
45
0.66
Manifold
Pressure
3.6
3.3
3.7
3.5
3.7
3.5
3.3
3.7
3.5
3.3
0.58
Orifice
Manifold
No.
Pressure
43
3.8
43
3.5
44
3.7
44
3.5
44
3.2
45
3.6
45
3.4
45
3.2
45
3.0
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.3
42
3.4
42
3.5
43
3.6
43
3.8
42
3.2
43
3.4
43
3.5
43
3.6
44
3.6
44
3.7
44
3.8
44
3.3
44
3.4
44
3.6
45
3.8
44
3.2
44
3.3
45
3.5
45
3.6
45
3.8
45
3.3
45
3.4
45
3.5
45
3.1
45
3.2
45
3.3
Orifice
No.
42
42
43
43
44
44
44
45
45
0.66
Manifold
Pressure
3.6
3.3
3.7
3.4
3.7
3.4
3.2
3.6
3.4
0.58
Orifice
Manifold
No.
Pressure
43
3.8
43
3.5
44
3.7
44
3.4
45
3.8
45
3.6
45
3.3
45
3.1
45
2.9
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
42
3.2
42
3.3
42
3.5
43
3.6
43
3.7
42
3.2
44
3.8
43
3.5
43
3.6
44
3.5
44
3.7
44
3.8
44
3.3
44
3.4
44
3.5
45
3.7
45
3.8
44
3.3
45
3.4
45
3.6
45
3.7
45
3.2
45
3.3
45
3.4
45
3.0
45
3.1
45
3.2
Orifice
No.
42
42
43
43
44
44
45
45
45
0.66
Manifold
Pressure
3.6
3.3
3.7
3.4
3.6
3.4
3.8
3.5
3.3
37
→ Table 9—Model 58MXA Orifice Size and Manifold Pressure for Correct Input
For Use with 140 Size Furnaces Only
(Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
0
to
2000
U.S.A. and Canada
ALTITUDE
RANGE
(FT)
U.S.A.
Altitudes
2001
to
3000
or
Canada
Altitudes
2001
to
4500
U.S.A. Only
ALTITUDE
RANGE
(FT)
3001
to
4000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
850
875
900
925
950
975
1000
1025
1050
1075
1100
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
775
800
825
850
875
900
925
950
975
1000
1025
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
750
775
800
825
850
875
900
925
950
975
1000
0.58
Orifice
Manifold
No.
Pressure
41
3.6
42
3.8
42
3.5
42
3.4
42
3.2
43
3.7
43
3.5
43
3.3
43
3.2
44
3.5
44
3.3
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.7
41
3.8
40
3.6
41
3.5
41
3.6
41
3.7
42
3.7
42
3.8
41
3.5
42
3.5
42
3.6
42
3.7
42
3.3
42
3.4
42
3.5
43
3.8
42
3.2
42
3.3
43
3.6
43
3.7
42
3.2
43
3.4
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
44
3.6
43
3.2
43
3.3
44
3.4
44
3.5
43
3.2
Orifice
No.
40
41
41
42
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.8
3.8
3.6
3.8
3.6
3.4
3.3
3.8
3.6
3.4
3.3
0.58
Orifice
Manifold
No.
Pressure
41
3.7
42
3.8
42
3.6
42
3.4
42
3.2
43
3.7
43
3.5
43
3.3
43
3.1
43
3.0
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.8
40
3.6
40
3.7
41
3.6
41
3.7
41
3.8
42
3.7
41
3.5
41
3.6
42
3.5
42
3.6
42
3.7
42
3.3
42
3.4
42
3.5
43
3.8
42
3.2
42
3.3
43
3.6
43
3.7
42
3.2
43
3.4
43
3.5
43
3.7
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
2.9
43
3.0
43
3.1
Orifice
No.
39
40
41
41
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.6
3.6
3.7
3.5
3.6
3.4
3.3
3.8
3.6
3.4
3.2
0.58
Orifice
Manifold
No.
Pressure
41
3.6
42
3.8
42
3.5
42
3.3
43
3.8
43
3.6
43
3.4
43
3.2
43
3.1
43
2.9
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.8
40
3.6
40
3.7
41
3.5
41
3.6
41
3.7
42
3.7
42
3.8
41
3.5
42
3.4
42
3.6
42
3.7
42
3.2
42
3.4
42
3.5
43
3.7
42
3.2
42
3.3
43
3.5
43
3.6
43
3.8
43
3.3
43
3.5
43
3.6
43
3.2
43
3.3
43
3.4
43
3.0
43
3.1
43
3.2
43
2.9
43
3.0
43
3.0
Orifice
No.
40
40
41
42
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.8
3.6
3.6
3.8
3.6
3.4
3.2
3.7
3.5
3.3
3.1
38
→ Table 9—Model 58MXA Orifice Size and Manifold Pressure for Correct Input Continued
For Use with 140 Size Furnaces Only
(Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)
ALTITUDE
RANGE
(FT)
U.S.A. Only
4001
to
5000
U.S.A. Only
ALTITUDE
RANGE
(FT)
5001
to
6000
ALTITUDE
RANGE
(FT)
U.S.A. Only
6001
to
7000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
725
750
775
800
825
850
875
900
925
950
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
700
725
750
775
800
825
850
875
900
925
950
975
1000
AVG GAS
HEAT VALUE
AT ALTITUDE
(BTU/CU FT)
650
675
700
725
750
775
800
825
850
875
0.58
Orifice
Manifold
No.
Pressure
41
3.6
42
3.7
42
3.5
42
3.3
43
3.7
43
3.5
43
3.3
43
3.1
43
3.0
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.7
41
3.8
40
3.6
42
3.8
41
3.6
41
3.7
42
3.6
42
3.7
42
3.8
42
3.4
42
3.5
42
3.6
42
3.2
42
3.3
42
3.4
43
3.6
43
3.8
42
3.2
43
3.4
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
2.9
43
3.0
43
3.1
Orifice
No.
40
41
41
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.8
3.8
3.6
3.7
3.5
3.3
3.8
3.6
3.4
3.2
0.58
Orifice
Manifold
No.
Pressure
41
3.5
42
3.7
42
3.4
42
3.2
43
3.7
43
3.5
43
3.3
43
3.1
43
2.9
43
2.7
43
2.6
43
2.5
43
2.3
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
41
3.7
41
3.8
40
3.6
42
3.8
41
3.5
41
3.6
42
3.5
42
3.7
42
3.8
42
3.3
42
3.4
42
3.5
43
3.8
42
3.2
42
3.3
43
3.6
43
3.7
43
3.8
43
3.4
43
3.5
43
3.6
43
3.2
43
3.3
43
3.4
43
3.0
43
3.1
43
3.2
43
2.8
43
2.9
43
3.0
43
2.7
43
2.8
43
2.9
43
2.6
43
2.6
43
2.7
43
2.4
43
2.5
43
2.6
Orifice
No.
40
41
41
42
42
42
43
43
43
43
43
43
43
0.66
Manifold
Pressure
3.7
3.8
3.5
3.7
3.4
3.2
3.7
3.5
3.3
3.1
3.0
2.8
2.7
0.58
Orifice
Manifold
No.
Pressure
41
3.8
41
3.5
42
3.6
42
3.4
43
3.8
43
3.6
43
3.4
43
3.2
43
3.0
43
2.8
SPECIFIC GRAVITY OF NATURAL GAS
0.60
0.62
0.64
Orifice
Manifold
Orifice
Manifold
Orifice
Manifold
No.
Pressure
No.
Pressure
No.
Pressure
40
3.6
40
3.7
40
3.8
41
3.6
41
3.7
40
3.6
42
3.7
41
3.5
41
3.6
42
3.5
42
3.6
42
3.7
42
3.3
42
3.4
42
3.5
43
3.7
43
3.8
42
3.3
43
3.5
43
3.6
43
3.7
43
3.3
43
3.4
43
3.5
43
3.1
43
3.2
43
3.3
43
2.9
43
3.0
43
3.1
Orifice
No.
39
40
41
42
42
42
43
43
43
43
0.66
Manifold
Pressure
3.7
3.7
3.7
3.8
3.6
3.4
3.8
3.6
3.4
3.2
39
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, this furnace has been approved
for a 2% derate for each 1000 ft above sea level. See Table
10 for derate multiplier factor.
DO NOT bottom out gas valve regulator adjusting screw.
This can result in unregulated manifold pressure and result in
excess overfire and heat exchanger failures.
NOTE: If orifice hole appears damaged or it is suspected to have
been redrilled, check orifice hole with a numbered drill bit of
correct size. Never redrill an orifice. A burr-free and squarely
aligned orifice hole is essential for proper flame characteristics.
Table 10—Altitude Derate Multiplier for U.S.A.
ALTITUDE
(FT)
0—2000
2001—3000
3001—4000
4001—5000
5001—6000
6001—7000
7001—8000
8001—9000
9001—10,000
BURNER
ORIFICE
% OF
DERATE
0
4—6
6—8
8—10
10—12
12—14
14—16
16—18
18—20
DERATE MULTIPLIER
FACTOR FOR U.S.A.*
1.00
0.95
0.93
0.91
0.89
0.87
0.85
0.83
0.81
* Derate multiplier factor is based on midpoint altitude for altitude range.
EXAMPLE:
100,000 Btuh input furnace installed at 4300 ft.
A93059
DO NOT redrill orifices. Improper drilling (burrs, out-ofround holes, etc.) can cause excessive burner noise and
misdirection of burner flames. This can result in flame
impingement of burners and heat exchangers causing failures.
Furnace Input
Rate at
Sea Level
X
Derate
Multiplier
Factor
=
Furnace Input Rate
at Installation
Altitude
100,000
X
0.91
=
91,000
→
d. Replace gas valve regulator adjustment screw cap.
e. Replace burner enclosure front and verify adjusted gas
input rate using method outlined in item 3.
f. Look through sight glass in burner enclosure and check
burner flame. Burner flame should be clear blue, almost
transparent. (See Fig. 45.)
b.
c.
d.
BURNER FLAME
BURNER
e.
f.
MANIFOLD
A89020
Fig. 45—Burner Flame
40
CANADA
At installation altitudes from 2000 to 4500 ft, 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.
Turn off all other gas appliances and pilots.
Start furnace and let operate for 3 minutes.
Measure time (in sec) for gas meter test dial to complete 1
revolution.
Refer to Table 11 for cu ft of gas per hr.
Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft) using
natural gas heating value from local gas utility/supplier.
Table 11—Gas Rate (Cu Ft/Hr)
3. Adjust temperature rise by adjusting blower speed. Increase
blower speed to reduce temperature rise. Decrease blower
speed to increase temperature rise.
SIZE OF TEST DIAL
SIZE OF TEST DIAL
SECONDS
SECONDS
FOR 1
FOR 1
1
2
5
1
2
5
REVOLUTION cu ft cu ft
cu ft REVOLUTION cu ft
cu ft
cu ft
10
11
12
13
14
360
327
300
277
257
720
655
600
555
514
1800
1636
1500
1385
1286
50
51
52
53
54
72
71
69
68
67
144
141
138
136
133
360
355
346
340
333
15
16
17
18
19
240
225
212
200
189
480
450
424
400
379
1200
1125
1059
1000
947
55
56
57
58
59
65
64
63
62
61
131
129
126
124
122
327
321
316
310
305
20
21
22
23
24
180
171
164
157
150
360
343
327
313
300
900
857
818
783
750
60
62
64
66
68
60
58
56
54
53
120
116
112
109
106
300
290
281
273
265
25
26
27
28
29
144
138
133
129
124
288
277
267
257
248
720
692
667
643
621
70
72
74
76
78
51
50
48
47
46
103
100
97
95
92
257
250
243
237
231
30
31
32
33
34
120
116
113
109
106
240
232
225
218
212
600
581
563
545
529
80
82
84
86
88
45
44
43
42
41
90
88
86
84
82
225
220
214
209
205
35
36
37
38
39
103
100
97
95
92
206
200
195
189
185
514
500
486
474
462
90
92
94
96
98
40
39
38
38
37
80
78
76
75
74
200
196
192
188
184
40
41
42
43
44
90
88
86
84
82
180
176
172
167
164
450
439
429
419
409
100
102
104
106
108
36
35
35
34
33
72
71
69
68
67
180
178
173
170
167
BLOWER OFF DELAY (HEAT MODE)
45
46
47
48
49
80
78
76
75
73
160
157
153
150
147
400
391
383
375
367
110
112
116
120
33
32
31
30
65
64
62
60
164
161
155
150
SET THERMOSTAT HEAT ANTICIPATOR
Disconnect 115-v electrical power before changing speed tap.
Failure to follow this warning could result in personal injury.
4. To change blower motor speed selections for heating mode,
remove blower motor lead from control center HEAT terminal. (See Fig. 25.) Select desired blower motor speed lead
from 1 of the other terminals and relocate it to HEAT terminal.
See Table 12 for lead color identification. Reconnect original
lead on SPARE terminal.
Follow this same procedure for proper selection of COOL
speed selection.
Table 12—Speed Selector
COLOR
SPEED
Black
Yellow (When Present)
Blue
Red
White
High
Medium High
Medium Low
Low
Common
FACTORYSHIPPED
CONNECTION
Cool
Spare
Heat
Spare
Com
The main blower off time delay period is factory-set at 135 sec and
is not field-adjustable.
Thermostat heat anticipator must be set to match amp draw of
components in R-W circuit. Accurate amp draw measurements can
be obtained at thermostat subbase terminals R and W.
Fig. 46 illustrates an easy method of obtaining these measurements. Amp reading should be taken after blower motor has
started. See thermostat manufacturer’s instructions for adjusting
heat anticipator and for varying heating cycle length.
EXAMPLE: (0—2000 ft 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 11)
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.
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
HOOK-AROUND
VOLT/AMMETER
SET TEMPERATURE RISE
R Y W G
Temperature rise must be within limits specified on unit
rating plate. Recommended operation is at midpoint of rise or
above. Failure to follow this caution may result in condensing
or overheating the heat exchangers.
10 TURNS
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.
FROM UNIT 24-VOLT
TERMINAL BLOCK
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
2. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.
= 0.5 AMPS FOR THERMOSTAT SETTING
A80201
Fig. 46—Amp Draw Check with Ammeter
41
CHECK SAFETY CONTROLS
Step 1—Check Primary Limit Control
should NOT glow, and control center diagnostic light flashes
a Status Code 31. If hot surface ignitor glows when inducer
motor is disconnected, shut furnace down immediately. Determine reason pressure switch did not function properly and
correct condition.
This control shuts off combustion 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 supply or motor failure. If limit control does not function
during this test, cause must be determined and corrected.
5. Turn off 115-v power to furnace.
6. Reconnect inducer motor leads, reinstall main furnace door,
and turn on 115-v power supply.
CHECKLIST
1. Put away tools and instruments. Clean up debris.
Step 2—Check Pressure Switch
2. Verify manual reset switch has continuity.
This control proves operation of draft inducer. Check switch
operation as follows:
3. Verify that blower and control access doors are properly
installed.
1. Turn off 115-v power to furnace.
4. Cycle test furnace with room thermostat.
2. Remove main furnace door and disconnect inducer motor lead
wires from wire harness.
5. Check operation of accessories per manufacturer’s instructions.
3. Turn on 115-v power to furnace.
6. Review User’s Guide with owner.
4. Set thermostat to call for heat and wait 1 minute. When
pressure switch is functioning properly, hot surface ignitor
7. Leave literature packet near furnace.
42
CHECKLIST—INSTALLATION
LOAD CALCULATION
Condensate Drain
____________
Heating Load (Btuh)
____________
Cooling Load (Btuh)
____________
Furnace Model Selection
COMBUSTION AND VENT PIPING
Termination Location
________
Roof or Sidewall
________
Termination Kit — 2 Pipe or Concentric
________
Combustion-Air Pipe Length
________
Combustion-Air Pipe Elbow Quantity
________
Vent Pipe Length
________
Vent Pipe Elbow Quantity
________
Pipe Diameter Determined from Sizing Table
________
Pipe Sloped To Furnace
________
Unit Level or Pitched Forward
________
Internal Tubing Connections Free of Kinks
and Traps
________
External Drain Connection Leak Tight and
Sloped
________
Condensate Trap Primed before Start-Up
________
Heat Tape Installed if Required
CHECKLIST—START-UP
________
Gas Input Rate
(Set Within 2 percent of Rating Plate)
________
Temperature Rise Adjusted
Thermostat Anticipator
________
Anticipator Setting Adjusted or
________
Cycle Rate (3 Cycles per Hr) Selected
Safety Controls Check Operation
Pipe Insulation
________
Over Ceilings
________
Low-Ambient Exposed Pipes
43
________
Primary Limit
________
Pressure Switch
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization
• Maintenance
• Installation Overview
• Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training
[ ] Classroom Service Training
A94328
Copyright 1996 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
58mca4si
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 565-874
Printed in U.S.A.
Form 58MCA-4SI
Pg 44
12-96
Replaces: 58MCA-3SI
Tab 6a 8a
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