Carrier INDUCED COMBUSTION FURNACES 58GFA Operating instructions

58GFA
Upflow Induced-Combustion Furnaces
Installation, Start-Up, and Operating Instructions
Sizes 065-150, Series 130
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index
Page
SAFETY CONSIDERATIONS ................................................. 1
INTRODUCTION ................................................................... 1-2
Clearance From Combustible Materials ..................................1
Dimensional Drawing ...............................................................2
LOCATION ..............................................................................2-3
General .................................................................................2-3
Location Relative to Cooling Equipment ................................3
Hazardous Locations.................................................................3
AIR FOR COMBUSTION AND VENTILATION...................3-4
Unconfined Space .....................................................................3
Confined Space......................................................................3-4
FILTER ARRANGEMENT .......................................................4-5
LEVELING LEGS ....................................................................5-6
GAS PIPING ................................................................................6
ELECTRICAL CONNECTIONS .............................................6-7
115-v Wiring ...........................................................................6
24-v Wiring...............................................................................7
Accessory ..................................................................................7
VENTING ....................................................................................7
START-UP, ADJUSTMENT, AND SAFETY CHECK.........7-13
Sequence Of Operation.............................................................8
Heating Mode............................................................................8
Cooling Mode ...........................................................................8
Continuous Blower Mode.........................................................8
Start-up Procedures..............................................................8-10
Adjustments .......................................................................10-12
Check Safety Controls.......................................................12-13
Checklist..................................................................................13
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code NFPA No. 541992/ANSI Z223.1-1992 (NFGC). In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1and .2-M95 Natural Gas and Propane Gas Installation Codes
(NSCNGPIC). Wear safety glasses and work gloves. Have fire
extinguisher available during start-up and adjustment procedures
and service calls.
®
ama
CANADIAN GAS ASSOCIATION
A PP R O VED
R
Recognize safety information. This is the safety-alert symbol
.
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal word DANGER, WARNING, or CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage.
NOTE is used to highlight suggestions which will result in
enhanced installation, reliability, or operation.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing residential construction practices. We require these instructions as a
minimum for a safe installation.
INTRODUCTION
model 58GFA Series 130 Furnaces are available in sizes
65,000 through 150,000 Btuh input capacities.
→ The
The design of the upflow gas-fired furnace is A.G.A./C.G.A.
certified for natural and propane gas and for installation on
combustible flooring, in alcoves, attics, basements, closets, or
utility rooms. The design of this furnace line is not A.G.A./C.G.A.
certified for installation in mobile homes, recreation vehicles, or
outdoors.
Table 1—Minimum Clearances From Combustible
Materials (In.)
UNIT SIZE
Sides
Back
Top of Plenum
Vent
Front
Single-Wall Vent
Type B-1 Double-Wall Vent
Single-Wall Vent
Type B-1 Double-Wall Vent
Single-Wall Vent
Type B-1 Double-Wall Vent
Service
065
1
0
0
1
6
1
6
3
30
086-150
0
0
0
1
6
1
6
3
30
NOTES:
1. Provide 30-in. front clearance for servicing. An open door in front of the
furnace can meet this requirement.
2. A minimum clearance of 3 in. must be provided in front of the furnace for
combustion air and proper operation.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-809
Printed in U.S.A.
Form 58GF-4SI
Pg 1
10-95
Replaces: 58GF-3SI
Tab 6a 8a
AIRFLOW
28 1⁄2″
2 1⁄16″
FLUE COLLAR
DIA HOLE
POWER ENTRY
7⁄8-IN. DIA
ACCESSORY
5 3⁄8″
12 5⁄16″
2 11⁄16″
5 13⁄16″
5 13⁄16″
2 3⁄8″
1 3⁄4-IN. DIA HOLE
GAS ENTRY
7⁄8-IN.
DIA
POWER ENTRY
1 1⁄2-IN. DIA
R.H. GAS ENTRY
7⁄8-IN.
DIA ACCESSORY
1⁄2-IN.
DIA THERMOSTAT
WIRE ENTRY
2 3⁄8″
DIA HOLE
THERMOSTAT
WIRE ENTRY
13⁄16″
OUTLET
1″
5 3⁄8″
1⁄2-IN.
19″
13⁄16″
1″
7⁄8-IN.
39 7⁄8″
2 1⁄16″
A
D
SIDE INLET
SIDE INLET
141⁄2″
TYP 1″
1 3⁄4″
11⁄16″
24 5⁄16″
AIR INLET
3″
11⁄16″
E
11⁄16″
5⁄8″
TYP
1″
231⁄4″
SIDE RETURN
DUCT LOCATION
NOTE: 2 additional 7⁄8 In. Dia knockouts are located in the top plate.
NOTES: Minimum return-air opening at furnace:
1. For 800 CFM–16-In. round or 141⁄2 x 12-In. rectangle.
2. For 1200 CFM–20-In. round or 141⁄2 x 191⁄2-In. rectangle.
3. For 1600 CFM–22-In. round or 141⁄2 x 231⁄4-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.
A88367
Table 2—Dimensions (In.)
UNIT SIZE
065-08
065-12
086-14
086-16
105-12
105-16
105-22
130-16
130-20
150-20
A
14-3/16
14-3/16
17-1/2
21
17-1/2
21
24-1/2
21
24-1/2
24-1/2
D
12-9/16
12-9/16
15-7/8
19-3/8
15-7/8
19-3/8
22-7/8
19-3/8
22-7/8
22-7/8
E
12-11/16
12-11/16
16
19-1/2
16
19-1/2
23
19-1/2
23
23
VENT CONN
4
4
4
4
4
4
4
5
5
5
SHIP. WT
126
128
143
147
153
159
176
171
186
196
Fig. 1—Dimensional Drawing
Before installing the furnace, refer to the current edition of the
NFGC. Canadian installations must be installed in accordance with
NSCNGPIC and all authorities having jurisdiction. For further
information, the National Fuel Gas Code is available from National Fire Protection Association Inc., Batterymarch Park,
Quincy, MA 02269, American Gas Association, 1515 Wilson
Boulevard, Arlington, VA 22209, or from Literature Distribution.
Installation must conform to the regulations of the serving gas
supplier and the local building, heating, and plumbing codes in
effect in the area in which the installation is made, or in the
absence of local codes with the requirements of the NFGC.
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 can cause electrical shock, fire,
personal injury, or death.
For accessory installation details, refer to the applicable instruction
literature.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, and unit sizing. Improper installation or
misapplication of the furnace can require excessive servicing
or cause premature component failure.
NOTE: Remove all shipping brackets and materials before
operating the furnace.
Step 1—Location
GENERAL
This furnace is designed for a minimum continuous return-air
temperature of 60°F db or an intermittent operation down to 55°F
db such as when used with a night setback thermostat. Return-air
temperature must not exceed a maximum of 85°F db.
Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.
2
Do not use this furnace during construction when adhesives,
sealers, and/or new carpets are being installed. If the furnace
is required during construction, use clean outside air for
combustion and ventilation. Compounds of chlorine and
fluorine when burned with combustion air form acids which
will cause corrosion of the heat exchangers and metal vent
system. Some of these compounds are found in paneling and
dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction process.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, or fireplaces could create a NEGATIVE
PRESSURE condition at the furnace. Makeup air MUST be
provided for the ventilation devices, in addition to that
required by the furnace.
Combustion air requirements are determined by whether the
furnace is in an UNCONFINED or CONFINED space.
UNCONFINED SPACE — An unconfined space must have at
least 50 cu ft for each 1000 Btuh of input for all the appliances
(such as furnaces, clothes dryer, water heaters, etc.) in the space.
For Example:
This furnace must be installed so the electrical components are
protected from water. Locate the furnace close to the chimney/vent
and as near the center of the air distribution system as possible.
The furnace should be installed level.
58GFA FURNACE
INPUT BTUH
63,000
84,000
105,000
126,000
147,000
When a furnace is installed so that the supply ducts carry air to
areas outside the space containing the furnace, the return air must
also be handled by a duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
MINIMUM SQ FT
WITH
7-1/2 FT CEILING
420
560
700
840
980
If the unconfined space is of unusually tight construction, air for
combustion and ventilation MUST come from either the outdoors
or spaces freely communicating with the outdoors. Combustion
and ventilation openings must be sized the same as for a confined
space. A minimum opening with a total of not less than 1 sq in. per
5000 Btuh of total input rating for all equipment must be provided.
Return air must not be taken from the room unless an equal or
greater amount of air is supplied to the room.
Provide ample space for servicing and cleaning. Always comply
with the minimum fire protection clearances shown on the unit
rating plate. This furnace shall not be installed directly on
carpeting, tile, or any combustible material other than wood
flooring.
LOCATION RELATIVE TO COOLING EQUIPMENT — The
cooling coil must be installed parallel with or on the downstream
side of the furnace to avoid condensation in the heat exchangers.
When installed parallel with a furnace, dampers or other means
used to control the flow of air must prevent chilled air from
entering the unit. If the dampers are manually operated, they must
be equipped with means to prevent operation of either unit unless
the damper is in the full-heat or full-cool position.
CONFINED SPACE — A confined space is one whose volume is
less than 50 cu ft per 1000 Btuh of the total output rating for all
appliances installed in that space. A confined space MUST have 2
permanent openings, 1 within 12 in. of the ceiling, and the other
within 12 in. of the floor. (See Fig. 2.)
NOTE: In determining the free area of an opening, the blocking
effect of the louvers, grilles, and screens must be considered. If the
free area of a louver or grille design is unknown, it may be
assumed that wood louvers have a 20 percent free area and metal
louvers or grilles have a 60 percent free area. Screens, when used,
must not be smaller than 1/4-in. mesh. Louvers and grilles must be
constructed so they cannot be closed.
The size of the openings depends upon whether the air comes from
inside or outside of the structure.
1. All air from inside the structure:
Each opening MUST have at least 1 sq in. of free area per
1000 Btuh of the total input for all equipment within the
confined space, but not less than 100 sq in. per opening. (See
Fig. 2.)
For Example:
HAZARDOUS LOCATIONS — When the furnace is installed in
a residential garage, it must be installed so that the burners and
ignition source are located at least 18 in. above the floor. The
furnace should be protected from physical damage by vehicles.
When a furnace is installed in public garages, airplane hangars, or
other buildings having hazardous atmospheres, the unit must be
installed in accordance with the recommended good practice
requirements of the National Fire Protection Association, Inc.
Step 2—Air for Combustion and Ventilation
Provisions for adequate combustion and ventilation air must be
provided in accordance with Section 5.3, Air for Combustion and
Ventilation, of the NFGC or applicable provisions of the local
building codes.
Canadian installations must be in accordance with NSCNGPIC.
58GFA FURNACE
INPUT BTUH
63,000
84,000
105,000
126,000
147,000
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and
other household products.
FREE AREA PER
OPENING (SQ IN.)
100
100
105
126
147
If the building is constructed unusually tight, a permanent opening
directly communicating with the outdoors should be provided.
This opening shall have a minimum free area of 1 sq in. per 5000
Btuh of total input rating for all equipment in the enclosure.
All fuel-burning equipment must be supplied with air for combustion of the fuel. Sufficient air MUST be provided to ensure there
will not be a negative pressure in the equipment room or space. In
addition, a positive seal MUST be made between the furnace
cabinet and the return-air duct to prevent air from being pulled
from the burner area and draft safeguard opening.
3
For Example:
SUPPLY
AIR
58GFA FURNACE
INPUT BTUH
63,000
84,000
105,000
126,000
147,000
VENT THROUGH ROOF
CONFINED
SPACE
12″ MAX
INTERIOR
HEATED
SPACE
FREE AREA PER
OPENING (SQ IN.)
31.5
42.0
52.5
63.0
73.5
ROUND PIPE
(IN. DIA)
7
8
9
9
10
When ducts are used, they must be of the same cross-sectional area
as the free area of the openings to which they connect. The
minimum dimension of rectangular ducts must not be less than 3
in. (See Fig. 3.)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
UNCONFINED
SPACE
1 SQ IN.
PER 4000
BTUH*
DUCTS
TO
OUTDOORS
6″ MIN
(FRONT) †
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
12″ MAX
1 SQ IN.
PER 2000
BTUH*
A
D
VENT
THROUGH
SUPPLY ROOF
AIR
12″
MAX
F
1 SQ IN.
PER
4000
BTUH*
CONFINED
SPACE
RETURN AIR
DUCTS
TO
OUTDOORS
* Minimum opening size is 100 square in. with
minimum dimensions of 3-In.
† Minimum of 3-In. when type-B1 vent is used.
OUTDOORS
12″ MAX
1 SQ IN.
PER
4000
BTUH*
A89012
Fig. 2—Air for Combustion and Ventilation
(Inside Air)
1 SQ IN.
PER 2000
BTUH*
12″ MAX
G
12″
MAX
C
12″ MAX
If the furnace is installed on a raised platform to provide a returnair plenum, and return air is taken directly from the hallway or
space adjacent to the furnace, all air for combustion must come
from outdoors.
RETURN AIR
2. All air from outside the structure:
a. If combustion air is taken from outdoors through vertical
ducts, the openings and ducts MUST have at least 1 sq in.
of free area per 4000 Btuh of the total input for all
equipment within the confined space. (See Fig. 3.)
DUCT
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
*Minimum dimensions of 3-In.
NOTE: Use any of the following
combinations of openings:
A&B C&D D&E F&G
A89013
For Example:
58GFA FURNACE
INPUT BTUH
63,000
84,000
105,000
126,000
147,000
E
B
FREE AREA PER
OPENING (SQ IN.)
16.0
21.0
26.5
31.5
37.0
Fig. 3—Air for Combustion and Ventilation
(Outside Air)
ROUND PIPE
(IN. DIA)
5
6
6
7
7
Do not install the furnace on its back; safety control operation
will be adversely affected. Never connect return-air ducts to
the back of the furnace. Failure to follow this warning can
cause a fire, personal injury, or death.
b. If combustion air is taken from the outdoors through
horizontal ducts, the openings and ducts MUST have at
least 1 sq in. of free area per 2000 Btuh of the total input
for all equipment within the confined space.
Step 3—Filter Arrangement
The factory-supplied filter(s) is shipped in the blower compartment. Determine location for the filter and move filter retaining
hardware, if necessary, before attaching the return-air duct. After
the return-air duct has been connected to the furnace, install the
filter(s) inside the furnace blower compartment. See Fig. 4 for side
return application and Fig. 5 for bottom return application.
4
A bottom closure panel is factory installed in the bottom of the
furnace. When bottom return inlet is desired, remove and discard
the enclosure panel.
3″
Filter retaining brackets, supports, and retainers are factory assembled and shipped installed for side return application, with 1
set of all required hardware provided. (See Fig. 4.) For bottom
return applications, remove the brackets (front and back) and
supports from each side. The back bracket(s) are installed in the
rear of the furnace casing. Dimples are provided to mark mounting
screw locations.
24 1/2″
1″
FIELD-SUPPLIED
FILTER FILLER
STRIP FOR
171⁄ 2-IN. WIDE
CASINGS ONLY.
INSTALL UNDER
FILTER.
The front bracket(s) are installed on the bottom front plate as
shown in Fig. 5, once the bottom enclosure has been removed.
Rotate filter supports 180° so filter will rest on support, and
reinstall. (Do not reinstall in 17-1/2 in. casing.) Install the filter
retaining rod (small U-shaped end) in the rear bracket, and the
front of the filter retainer rod as shown in Fig. 5. Two sets of
hardware are needed for furnaces in 24-1/2 in. casings using 1
filter for bottom return. All hardware is provided for filter
installation.
WASHABLE
FILTER
WASHABLE
FILTER
FILTER
RETAINER
FILTER
SUPPORT
FILTER
RETAINER
A93321
Fig. 5—Bottom Filter Arrangement
A93045
Fig. 4—Side Filter Arrangement
5⁄16″
Never operate unit without a filter or with filter access door
removed. Failure to follow this warning can cause fire,
personal injury, or death.
5⁄16″
1 3⁄4″
Table 3—Filter Information (In.)
FURNACE CASING
WIDTH
14-3/16
17-1/2
21
24-1/2
FILTER QUANTITY AND SIZE*
FILTER TYPE
Side Return
Bottom Return
(1) 16 X 25 X 1† (1) 14 X 25 X 1
Cleanable
(1) 16 X 25 X 1† (1) 16 X 25 X 1
Cleanable
(1) 16 X 25 X 1 (1) 20 X 25 X 1†
Cleanable
(2) 16 X 25 X 1† (1) 24 X 25 X 1
Cleanable
* Filter can be field modified by cutting to the desired size. Alternate sizes can
be ordered from your distributor or dealer.
† Factory provided with the furnace.
1 3⁄4″
5⁄16″
Step 4—Leveling Legs (If Required)
When the furnace is used with side inlet(s) and leveling legs are
required, refer to Fig. 6, and install field-supplied, corrosionresistant 5/16-in. machine bolts and nuts.
NOTE: The maximum length of the bolt should not exceed 1-1/2
in.
5⁄16″
1 3⁄4″
1 3⁄4″
1. Lay furnace on its back. Locate and drill 5/16-in. diameter
hole in each bottom corner of furnace as shown in Fig. 6.
A89014
Fig. 6—Leveling Leg Installation
2. Install nut on bolt and install bolt and nut in hole. (Install flat
washer if desired.)
5
3. Install another nut on other side of furnace base. (Install flat
washer if desired.)
4. Adjust outside nut to provide desired height, and tighten inside
nut to secure arrangement.
Step 5—Gas Piping
Gas piping must be installed in accordance with national and local
codes. Refer to the current edition of the NFGC. Canadian
installations must be installed in accordance with NSCNGPIC and
all authorities having jurisdiction.
The gas supply line should be a separate line running directly from
the gas meter to the furnace, if possible. Refer to Table 4 for the
recommended gas pipe size. Risers must be used to connect to the
furnace and the meter.
Table 4—Maximum Capacity of Pipe*
NOMINAL IRON
INTERNAL
PIPE SIZE (IN.) DIAMETER (IN.)
1/2
3/4
1
1-1/4
1-1/2
0.622
0.824
1.049
1.380
1.610
LENGTH
10
20
175 120
360 250
680 465
1400 950
2100 1460
OF PIPE (FT)
30
40 50
97
82 73
200 170 151
375 320 285
770 660 580
1180 990 900
A89417
Fig. 7—Typical Gas Pipe Arrangement
* 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
C-2 NFPA 54-1992.
Use the proper length of pipes to avoid stress on the gas
control manifold. Failure to follow this warning can cause a
gas leak resulting in fire, explosion, personal injury, or death.
If a flexible connector is required or allowed by the authority
having jurisdiction, black iron pipe shall be installed at the
gas valve and extend a minimum of 2 in. outside the furnace
casing.
Connect the gas pipe to the furnace using a backup wrench to
avoid damaging gas controls.
Piping should be pressure tested in accordance with local and
national plumbing and gas codes before the furnace has been
attached. If the pressure exceeds 0.5 psig (14-in. wc), the gas
supply pipe must be disconnected from the furnace and capped
before the pressure test. If the test pressure is equal to or less than
0.5 psig (14-in. wc), close the manual shut-off valve located on the
gas valve before the test. It is recommended that the ground joint
union be loosened before pressure testing. After all connections
have been made, purge the lines and check for leakage with
regulated gas supply pressure.
Step 6— Electrical Connections
Install a sediment trap in the riser leading to the furnace. The trap
can be installed by connecting a tee to the riser leading from the
furnace. Connect a capped nipple into the lower end of the tee. The
capped nipple should extend below the level of the gas controls.
(See Fig. 7.)
Make all electrical connections in accordance with the National
Electrical Code ANSI/NFPA 70-1990 and local codes or ordinances that might apply. For Canadian installations, all electrical
connections must be made in accordance with Canadian Electrical
Code CSA C22.1 or authorities having jurisdiction.
115-V WIRING — Refer to the unit rating plate or Table 5 for
equipment electrical requirements. The control system requires an
earth ground for proper operation.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
Apply joint compound (pipe dope) sparingly and only to the male
threads of each joint. The compound must be resistant to the action
of propane gas.
The cabinet MUST have an uninterrupted or unbroken ground
according to National Electrical Code ANSI/NFPA 70-1990
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.
Never purge a line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition for the
purpose of checking leakage. Use a soap-and-water solution
to check for leakage. Failure to follow this warning can cause
fire, explosion, personal injury, or death.
The auxiliary junction box can be moved to the right-hand side of
the furnace when a right side power supply is desired. Remove the
2 screws holding the auxiliary junction box. Mount the junction
box on the right-hand side of the furnace (holes have been
predrilled in casing). The blower door interlock switch must also
be moved to the right-hand side of the furnace due to the length of
the wiring harness. When moved, tuck the wiring harness behind
the clip provided to keep extra wire lengths out of the way.
Install accessible manual shut-off valve upstream of the furnace
gas controls and within 72 in. of the furnace. A 1/8-in. NPT
plugged tapping, accessible for test gage connection, must be
installed immediately upstream of the gas supply connection to the
furnace and downstream of the manual shut-off valve. Place
ground joint union between the gas control manifold and the
manual shut-off valve.
6
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
115-VOLT FIELD- AUXILIARY
J-BOX
SUPPLIED
CONTROL
FUSED
BOX
DISCONNECT
208/230- OR
460-VOLT
THREE
PHASE
G
C
GND
NOTE 1
CONDENSING
UNIT
Y
24-VOLT
TERMINAL
BLOCK
FURNACE
208/230VOLT
SINGLE
PHASE
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.
A95241
→
Table 5—Electrical Data
UNIT SIZE
VOLTS—
HERTZ—
PHASE
065-08
065-12
086-14
086-16
105-12
105-16
105-22
130-16
130-20
150-20
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
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
MAX UNIT AMPS
MIN WIRE GAGE
MAX WIRE LENGTH
(FT)‡
MAX FUSE OR
HACR-TYPE CKT
BKR AMPS†
7.1
8.7
9.0
10.4
8.0
10.1
14.4
10.1
13.3
13.7
14
14
14
14
14
14
12
14
12
12
41
34
33
28
37
29
33
29
36
35
15
15
15
15
15
15
20
15
20
20
* Permissible limits of the voltage range at which the unit will operate satisfactorily.
† Time-delay fuse is recommended.
‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
Fig. 8—Heating and Cooling Application Wiring Diagram
system shall maintain a minimum of 1/4-in. upward slope per
linear ft and it shall be rigidly supported every 5 ft or less with
hangers or straps to ensure that there will be no movement after
installation.
Step 8—Start-Up, Adjustment, and Safety Check
24-V WIRING — Make field 24-v connections at the 24-v terminal strip. (See Fig. 8 and 9.) Connect terminal Y as shown in Fig.
8 for proper cooling operation. Use only AWG No. 18, colorcoded copper thermostat wire.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the main control board. Any direct shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3-amp fuse of identical size.
GENERAL — The furnace must have a 115-v power supply
properly connected and grounded. Thermostat wire connections at
R, W, C, and Y must be made at the 24-v terminal block on the
control board. The gas service pressure must not exceed 0.5 psig
(14-in. wc), but must be no less than 0.16 psig (4.5-in. wc).
→ ACCESSORY
Electronic air cleaner (EAC)
Two terminals (EAC-1 and EAC-2) are provided for EAC
connection. The terminals are energized with 115-v, 1-amp
maximum during blower motor operation.
Step 7—Venting
Refer to the enclosed Installation Instructions, GAMA Venting
Tables for Category I Furnaces and venting tables for Category I
Fan-Assisted Furnaces. The horizontal portion of the venting
7
115-VAC
NEUTRAL
TERMINALS
This furnace is equipped with a fuse link in the gas control
area. The fuse link will open and shut off power to the gas
valve if a flame rollout or overheating condition occurs in the
gas control area. DO NOT bypass the fuse link. Call your
service dealer to correct inadequate combustion-air supply
problem and replace fuse link.
115-VAC
LINE
VOLTAGE
HEATING
SPEED TAP
TERMINAL
115-VAC
TRANSFORMER
1
COM
PR-2
EAC-2
L2
CFR
L1
HFR
PR-1
LO
Before operating the furnace, check each manual reset switch for
continuity. If necessary, press the button to reset the switch.
1
4
7
2
5
8
3
6
9
PL-1
3
HI
EAC-1
9-PIN
CONNECTOR
The blower compartment door must be in place to complete the
115-v circuit to the furnace.
IDR
SPARE-1
SEQUENCE OF OPERATION — Using the schematic diagram
show in Fig. 10, follow the sequence of operation through the
different modes.
ELECTRONIC
AIR-CLEANER
TERMINALS
NOTE: When the blower door is in place, 115v is supplied
through blower door interlock switch ILK to heating fan relay
HFR, induced draft relay IDR, and transformer TRAN. Transformer TRAN energizes the safety circuit containing fuse link FL
and limit switch LS to energize R.
W
24-VAC COMMON
COOLING
SPEED TAP
TERMINAL
SPARE-2
Y1
R
SEC-2
24-VAC POWER
C
SEC-1
FU
G
3-AMP
FUSE
GROUND
SCREW
REQUIRED
CES0110074-01
The furnace pilot must be lit so the thermocouple energizes the
thermal magnet circuit of gas valve GV, which permits gas flow to
the remaining portion of the valve.
24VAC
COMMON
BLOWER
OFF-DELAY
24-VAC
THERMOSTAT
TERMINALS
24-VAC FUSE
3-AMP ONLY
1. Heating mode
BLOWER
OFF-TIME
ADJUSTMENT
a. When the wall thermostat "calls for heat" the R-W circuit
closes. This closed circuit supplies power to the 24-v safety
circuit containing automatic reset limit switch LS and fuse
link FL.
→
b. The inducer-motor relay coil IDR is energized. Inducer
motor relay contacts in the 115-v circuit close, starting
inducer motor IDM. Simultaneously, another set of contacts in inducer-motor relay IDR close in the 24-v circuit
and lock-in until the R-W circuit or safety opens.
A95463
Fig. 9—Control Center
the furnace skips the blower on delay and immediately starts the
blower.
2. Cooling mode
When the wall thermostat "calls for cooling" the R, G, and Y
circuits close. Simultaneously, the R-Y circuit starts the
outdoor condensing unit, the R-G circuit energizes cooling
relay coil CFR, and heating fan relay coil HFR. The normally
open contact of heating fan relay HFR and the normally open
contact of cooling relay CFR closes, energizing the cooling
speed of blower motor BLWM. The EAC terminals are
energized with 115v when the blower is operating on either
heating or cooling speed.
3. Continuous blower mode
When the R-G circuit is made, the blower motor operates on
cooling speed. During a "call for heat", the blower stops,
allowing the furnace heat exchangers to heat up more quickly.
When the blower motor comes back on it runs on heating
speed. The blower reverts to continuous operation after the
heating cycle blower off delay is completed.
c. As inducer motor IDM comes up to speed, pressure switch
PRS actuates and supplies power through manual reset
draft safeguard switch DSS. Both solenoid coils in gas
valve GV are energized, causing the valve to open and
permitting gas flow to the main burners, where it is ignited
by the pilot.
d. Simultaneously, solid-state time-delay circuit in the blower
control center is energized. Approximately 45 sec after the
R-W circuit is closed, heating fan relay coil HFR is
energized, closing the 115-v contacts of heating fan relay
HFR, and starting blower motor BLWM on heating speed.
EAC terminals energize with 115v when the blower is
operating on either heating or cooling speed.
e. When the thermostat is satisfied, the R-W circuit is broken,
de-energizing both solenoid coils of gas valve GV and the
solid-state time-delay circuit for the heating fan relay HFR.
The gas flow to the main burners immediately stops.
Approximately 120 sec (or 180 sec depending on the
blower off time selected) after main burners are extinguished, heating fan relay HFR is de-energized and blower
motor BLWM stops. The blower off delay can be permanently changed to 180 sec by cutting the resistor. (See Fig.
9.)
START-UP PROCEDURES — Check to be sure that all connections have been properly made, then light the pilot using the
procedure outlined on the lighting/operation instructions label
attached to the furnace. However, when lighting the pilot for the
first time, perform the following additional steps:
1. Purge gas lines after all connections have been made and
check for leaks.
f. If the pilot flame is extinguished, the thermocouple no
longer energizes the thermal magnet circuit of gas valve
GV. Gas flow to the pilot and main burners ceases until the
pilot is manually relit.
NOTE: When gas valve GV is energized, R-W circuit is closed.
After a power interruption, the gas valve closes within 7 sec and
8
GV
CONNECTION DIAGRAM
DSS
MGV
TH
TR
PRS
L1
NO
BRN
L2
TO 115V AC FIELD DISCONNECTIONS
ILK
C
SCHEMATIC
DIAGRAM
NOTE #4
NC
EQUIPMENT GROUND
PILOT
L1
LS
FL
ALS
SPARE-1
NOTE #9
IDM
(WHEN USED)
NOTE #6
PL1-3
RED
BLU
WHT
115V AC
LS
FL
ALS
GRN
CAP
BRN
PR2 L2
START
YEL
WHT
RED
RED
BLU
BRN
ORN
BLK
BLU
RED
BLK
PL1 1 4 7
2 5 8
3 6 9
L1 PR1
CFR
HFR
EAC-1
HFR
LOGIC
PL1-9
TIME
DELAY
MGV
DSS
BLK (HI)
GV
SPARE-1
YEL (MED HI)
SPARE-2
Y
IDR
NOTE #9
NO
NC
SEC-2
SEC-1
RED (LO)
Y
R
C
G
PCB
3AMP
FUSE
NOTE #7
NOTE #8
PILOT
PL1-2
PL1-6
IDR
GROUND
SCREW
REQUIRED
W
IDR
CFR
NOTE #1
G
LEGEND
AUXILIARY LIMIT SWITCH, OVERTEMP.
-MANUAL RESET, SPST-(N.C.)
BLWM BLOWER MOTOR
CAP
CAPACITOR
CFR
COOLING FAN RELAY, SPDT
DSS
DRAFT SAFEGUARD SWITCH, SPST-(N.C.),
MANUAL RESET
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC)
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FL
FUSIBLE LINK
FU1
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE
FU2
FUSE FIELD INSTALLED
GV
GAS VALVE-REDUNDANT OPERATORS
HFR
HEATING FAN RELAY, SPST (N.O.)
IDM
INDUCED DRAFT MOTOR
IDR
INDUCED DRAFT RELAY, SPST-(N.O.)
ILK
BLOWER ACCESS PANEL INTERLOCK SWITCH,
SPST-(N.O.)
JB
JUNCTION BOX
LS
LIMIT SWITCH, AUTO RESET, SPST(N.C.)
OL
AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.
PCB
PRINTED CIRCUIT BOARD (FURNACE CONTROL)
PL1
9-CIRCUIT CONNECTOR (PCB1)
PR5
PRESSURE SWITCH, SPDT
TRAN TRANSFORMER (115V AC/24V AC)
C
PL1-8
TR
TH
PRS
RED
BLU
W
→
SEC-2
R
FU1
ALS
PR-2
HI
BLU (MED LO)
BRN
(WHEN USED)
NOTE #6
TRAN
24V AC
3A
FUSE SEC-1
NOTE #7
LO
WHT (COM)
OL
PL1-7
COM
JB
EAC-2
BLWM
BLK
WHT
WHT
FU1 PR-1
PL1-4
BLK
GRN
IDM
PL1-1
TRAN
NOTE #4
ILK
GRN
BLWM
EAC-1
EAC-2
IDR
BLK
WHT
CAP
COM
COM
BLK
FU2
START
OL
COOL
WHT
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
L1
LO
MED LO
MED HI
HI
SPARE-2
HEAT
CFR
HFR
NOTE #9
C
JUNCTION
UNMARKED TERMINAL
NOTES:
PCB TERMINAL
FACTORY POWER WIRING (120 AC)
FACTORY CONTROL WIRING (120 AC)
FIELD POWER WIRING (120 AC)
CONDUCTOR ON PCB
FIELD WIRING SCREW TERMINAL
FIELD GROUND
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE
1. Internally connected to equipment ground through mounting screw.
2. If any of the original equipment wire is replaced, use wire rated for 105°C.
3. Blower motor (BLWM) & Inducer motor (IDM) contain auto-reset
thermal overload switch.
4. Use only copper wire between the disconnect switch and the furnace
junction box (JB).
5. Symbols are electrical representations only6.
6. Auxiliary limit switch (ALS) used on downflow models only.
7. The transformer 24VAC winding is protected by a 3 AMP automotive
blade type fuse on the control board. A 24VAC short to ground during
installation, checkout, operation, service or maintenance could cause
this fuse to open. Do not replace the 3 AMP fuse with any other size fuse.
8. Blower motor (BLWM) adjustable OFF-DELAY. Factory set: 120 seconds
cut resistor: 180 seconds.
9. When CFR relay is energized, HFR relay is also energized.
322876-101 REV. A
A95464
Fig. 10—Unit Wiring Diagram
never come in contact with any other part of the thermocouple
or its lead wire. The flame should extend above the carryover
part of the burner and merge with the carryover flame. If the
pilot flame requires adjustment:
a. Locate adjustment screw on top of the main gas valve right
next to the pilot tube. (See Fig. 11.)
b. Remove capscrew and turn adjustment screw clockwise
(in) to decrease pilot gas flow and counterclockwise (out)
to increase pilot gas flow.
c. When proper adjustment is obtained, replace capscrew.
3. Allow 5 minutes for the pilot to establish a draft before
operating furnace.
Never purge a line into a combustion chamber. Never use
matches, candles, flame or other sources of ignition for the
purpose of checking leakage. Use a soap-and-water solution
to check for leakage. Failure to follow this warning can cause
fire, explosion, personal injury, or death.
2. Allow 5 minutes to elapse after purging gas lines, then light
pilot in accordance with lighting/operating instructions label
on the furnace.
The pilot flame should be soft blue in color and surround 3/8
to 1/2 in. of the thermocouple element tip. The flame must
9
Table 6—Model 58GFA Orifice Size and Manifold Pressure for Correct Input Rate
(Tabulated Data Based on Altitude Up to 2000 Ft and 21,000 Btuh Per Burner)
GAS HEAT VALUE
0.54
(BTU/CU FT)
Orf Mnfld
No. Press.
43
3.8
860
—
—
—
—
43
3.7
875
—
—
—
—
43
3.5
890
—
—
—
—
43
3.4
905
—
—
—
—
43
3.3
920
44
3.8
—
—
43
3.2
935
44
3.7
—
—
44
3.6
950
—
—
—
—
44
3.4
965
—
—
—
—
44
3.3
980
—
—
—
—
44
3.2
995
—
—
—
—
45
3.8
1010
—
—
—
—
45
3.7
1025
—
—
—
—
45
3.6
1040
46
3.8
—
—
45
3.5
1055
46
3.7
—
—
45
3.4
1070
46
3.6
—
—
45
3.3
1085
46
3.5
—
—
45
3.2
1100
46
3.4
47
3.8
0.56
Orf Mnfld
No. Press.
42
3.2
—
—
—
43
3.8
—
—
—
—
43
3.7
—
—
—
—
43
3.6
—
—
—
—
43
3.4
—
—
—
—
43
3.3
44
3.8
—
—
43
3.2
44
3.7
—
—
44
3.6
—
—
—
—
44
3.5
—
—
—
—
44
3.4
—
—
—
—
44
3.3
—
—
—
—
44
3.2
45
3.8
—
—
45
3.7
—
—
—
—
45
3.6
46
3.8
—
—
45
3.5
46
3.7
—
—
45
3.4
46
3.6
—
—
45
3.3
46
3.5
—
—
0.58
Orf Mnfld
No. Press.
42
3.3
—
—
—
—
42
3.2
—
—
—
—
43
3.8
—
—
—
—
43
3.7
—
—
—
—
43
3.6
—
—
—
—
43
3.4
—
—
—
—
43
3.3
44
3.8
—
—
43
3.2
44
3.7
—
—
44
3.6
—
—
—
—
44
3.5
—
—
—
—
44
3.4
—
—
—
—
44
3.3
—
—
—
—
44
3.2
—
—
—
—
45
3.8
—
—
—
—
45
3.7
46
3.8
—
—
45
3.6
46
3.7
—
—
45
3.5
46
3.6
—
—
SPECIFIC GRAVITY
0.60
0.62
Orf Mnfld Orf Mnfld
No. Press. No. Press.
42
3.5
41
3.2
—
—
42
3.6
—
—
—
—
42
3.3
42
3.4
—
—
—
—
—
—
—
—
42
3.2
42
3.3
—
—
—
—
—
—
—
—
43
3.8
42
3.2
—
—
—
—
—
—
—
—
43
3.7
43
3.8
—
—
—
—
—
—
—
—
43
3.6
43
3.7
—
—
—
—
—
—
—
—
43
3.5
43
3.6
—
—
—
—
—
—
—
—
43
3.3
43
3.5
44
3.8
—
—
—
—
—
—
43
3.2
43
3.4
44
3.7
44
3.8
—
—
—
—
44
3.6
43
3.3
—
—
44
3.7
—
—
—
—
44
3.5
43
3.2
—
—
44
3.6
—
—
—
—
44
3.4
44
3.5
—
—
—
—
—
—
—
—
44
3.3
44
3.4
—
—
—
—
—
—
—
—
44
3.2
44
3.3
—
—
—
—
—
—
—
—
45
3.8
44
3.2
—
—
—
—
—
—
—
—
45
3.7
45
3.8
—
—
—
—
—
—
—
—
45
3.6
45
3.7
46
3.8
—
—
—
—
—
—
4. To operate furnace, follow procedures on the lighting instructions label on the furnace.
OF NATURAL GAS
0.64
0.66
Orf Mnfld Orf Mnfld
No. Press. No. Press.
41
3.3
40
3.2
42
3.7
41
3.4
—
—
42
3.8
41
3.2
41
3.3
42
3.6
42
3.7
—
—
—
—
42
3.4
41
3.2
—
—
42
3.5
—
—
—
—
42
3.3
42
3.4
—
—
—
—
—
—
—
—
42
3.2
42
3.3
—
—
—
—
—
—
—
—
43
3.8
42
3.2
—
—
—
—
—
—
—
—
43
3.7
43
3.8
—
—
—
—
—
—
—
—
43
3.6
43
3.7
—
—
—
—
—
—
—
—
43
3.5
43
3.6
—
—
—
—
—
—
—
—
43
3.4
43
3.5
44
3.8
—
—
—
—
—
—
43
3.3
43
3.4
44
3.7
44
3.8
—
—
—
—
43
3.2
43
3.3
44
3.6
44
3.7
—
—
—
—
44
3.5
43
3.2
—
—
44
3.6
—
—
—
—
44
3.4
44
3.5
—
—
—
—
—
—
—
—
44
3.3
44
3.4
—
—
—
—
—
—
—
—
44
3.2
44
3.3
—
—
—
—
—
—
—
—
45
3.8
44
3.2
—
—
—
—
—
—
—
—
0.68
0.70
Orf Mnfld Orf Mnfld
No. Press. No. Press.
40
3.3
40
3.3
41
3.5
41
3.6
—
—
—
—
41
3.4
40
3.2
42
3.8
41
3.5
—
—
—
—
41
3.3
41
3.4
42
3.7
42
3.8
—
—
—
—
41
3.2
41
3.3
42
3.5
42
3.6
—
—
—
—
42
3.4
41
3.2
—
—
42
3.5
—
—
—
—
42
3.3
42
3.4
—
—
—
—
—
—
—
—
42
3.2
42
3.3
—
—
—
—
—
—
—
—
43
3.8
42
3.2
—
—
—
—
—
—
—
—
43
3.7
43
3.8
—
—
—
—
—
—
—
—
43
3.6
43
3.7
—
—
—
—
—
—
—
—
43
3.5
43
3.6
—
—
—
—
—
—
—
—
43
3.4
43
3.5
44
3.8
—
—
—
—
—
—
43
3.3
43
3.4
44
3.7
44
3.8
—
—
—
—
43
3.2
43
3.3
44
3.6
44
3.7
—
—
—
—
44
3.5
43
3.2
—
—
44
3.6
—
—
—
—
44
3.4
44
3.5
—
—
—
—
—
—
—
—
44
3.3
44
3.4
—
—
—
—
—
—
—
—
0.72
Orf Mnfld
No. Press.
39
3.2
40
3.4
41
3.7
40
3.3
41
3.6
—
—
40
3.2
41
3.5
—
—
41
3.4
42
3.7
—
—
41
3.3
42
3.6
—
—
41
3.2
42
3.5
—
—
42
3.4
—
—
—
—
42
3.3
—
—
—
42
3.2
—
—
—
—
43
3.8
—
—
—
—
43
3.7
—
—
—
—
43
3.6
—
—
—
—
43
3.5
—
—
—
—
43
3.4
44
3.8
—
—
43
3.3
44
3.7
—
—
43
3.2
44
3.6
—
—
44
3.5
—
—
—
—
The gas valve regulator has been nominally set at 3.5-in. wc
for natural gas. When adjusting input rate, do not set manifold
pressure above 3.8-in. wc or below 3.2-in. wc.
5. With furnace operating, set thermostat below room temperature and observe that the furnace goes off. Set thermostat
above room temperature and observe that the furnace restarts.
a. Check gas input rate using Table 6.
(1.) Obtain average yearly heat value for local gas supply.
(2.) Obtain average yearly specific gravity for local gas
supply.
ADJUSTMENTS
1. Set gas input rate.
(3.) Verify furnace model. Table 6 can only be used for
model 58GFA Furnaces.
There are 2 methods of adjusting the gas input rate. The
preferred method is by using Table 6 and following instructions in item a. The second is by clocking the gas meter and
following instructions in item b.
(4.) Check and verify orifice size in furnace. NEVER
ASSUME THE ORIFICE SIZE. ALWAYS CHECK
AND VERIFY.
10
REGULATOR
ADJUSTMENT
SEAL CAP
INLET
PRESSURE
TAP
Table 7—Gas Rate Cu Ft/Hr
MANUAL
ON/OFF
KNOB
ON
OFF
PILOT
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
MANIFOLD
PRESSURE
TAP
PILOT TUBE
CONNECTION
PILOT
ADJUSTMENT
SCREW
THERMOCOUPLE
CONNECTION
A89171
Fig. 11—Redundant Automatic Gas Control Valve
DO NOT redrill burner orifices. Improper drilling (burrs,
out-of-round holes, etc.) can cause excessive burner noise and
misdirection of burner flames. This can result in flame
impingement of the burners and heat exchangers, causing
failure.
NOTE: If orifice hole appears damaged or is suspected to have
been redrilled, check the orifice hole with the correct size
numbered drill bit. Never redrill an orifice. A burr-free and
squarely aligned orifice hole is essential for proper flame characteristics.
(5.) Find natural gas heat value and specific gravity in
Table 6.
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
100
947
55
56
57
58
59
65
64
63
62
61
131
129
126
124
122
327
321
316
310
305
20
21
22
23
24
180
171
164
157
150
360
343
327
313
300
900
857
818
783
750
60
62
64
66
68
60
58
56
54
53
120
116
112
109
106
300
290
281
273
265
25
26
27
28
29
144
138
133
129
124
288
277
267
257
248
720
692
667
643
621
70
72
74
76
78
51
50
48
47
46
103
100
97
95
92
257
250
243
237
231
30
31
32
33
34
120
116
113
109
106
240
232
225
218
212
600
581
563
545
529
80
82
84
86
88
45
44
43
42
41
90
88
86
84
82
225
220
214
209
205
35
36
37
38
39
103
100
97
95
92
206
200
195
189
185
514
500
486
474
462
90
92
94
96
98
40
39
38
38
37
80
78
76
75
74
200
196
192
188
184
40
41
42
43
44
90
88
86
84
82
180
176
172
167
164
450
439
429
419
409
100
102
104
106
108
36
35
35
34
33
72
71
69
68
67
180
178
173
170
167
45
46
47
48
49
80
78
76
75
73
160
157
153
150
147
400
391
383
375
367
110
112
116
120
33
32
31
30
65
64
62
60
164
161
155
150
Multiply gas rate (cu ft/hr) by heating value (Btu/cu ft).
EXAMPLE:
Btu heating input = Btu/cu ft X cu ft/hr
Heating value of gas = 1070 Btu/cu ft
Time for 1 revolution of 2 cu ft dial = 72 sec
Gas rate 100 X 1070 = 107,000 Btuh
(6.) Follow heat value and specific gravity lines to point of
intersection. Find orifice size and manifold pressure
settings for proper operation at given natural gas
conditions.
EXAMPLE:
Heat value = 1070 Btu/cu ft
Btu/cu ft specific gravity = 0.58
Therefore; Orifice = No. 45 *
Manifold pressure = 3.7-in. wc
* The furnace is shipped with No. 44 orifices. Therefore, in
this example all main burner orifices must be changed and
manifold pressure must be adjusted.
(6.) Measured gas input should not exceed gas input on
unit rating plate.
(7.) Proceed to item c. to adjust manifold pressure.
c. Adjust gas input.
(1.) Remove regulator adjustment seal cap. (See Fig. 11.)
(2.) Turn adjusting screw counterclockwise to decrease
input. Turn screw clockwise to increase input. DO
NOT set manifold pressure less than 3.2-in. wc or
more than 3.8-in. wc for natural gas. Make any major
adjustments by changing main burner orifices.
(7.) Proceed to item c. to adjust manifold pressure.
b. Check gas input rate by clocking gas meter.
(1.) Obtain average yearly heat value for local gas supply.
(1.) When correct input is obtained, replace regulator seal
cap. Main burner flame should be clear blue, almost
transparent. (See Fig. 12.)
NOTE: Be sure heating valve of gas used for calculations is
correct for your altitude. Consult local gas utility for altitude
adjustments of gas heating value.
d. High altitude—In the United States, gas input on rating
plate is for altitudes up to 2000 ft. Ratings for altitudes over
2000 ft must be 4 percent less for each 1000 ft above sea
level. To obtain the adjusted altitude rating, adjust the
manifold pressure, item c., and replace the main burner
orifices as needed. Refer to NFGC Appendix F Table F-4
for proper orifice sizing at high altitudes.
(2.) Turn off all other gas appliances and pilots.
(3.) Start furnace and let run for 3 minutes.
(4.) Measure time (in sec) for gas meter to complete 1
revolution.
(5.) Refer to Table 7 for cu ft of gas per hr.
11
e. Canadian installations only—The Canadian ratings are
approved for altitudes up to 2000 ft for natural and propane
gases. High-altitude ratings are from 2001 ft to 4500 ft
above sea level. High-altitude rating includes a 10 percent
derate as required by Canadian standards. (See Table 8.)
PILOT FLAME
→
BURNER FLAME
BURNER
Table 9—Speed Selector
COLOR
SPEED
Black
Yellow (When
present)
Blue
Red
White
High
FACTORY
ATTACHED TO
Cool
Medium-High
Spare
Medium-Low
Low
Common
Heat
Spare
COM
Recheck the temperature rise. It must be within the limits
specified on the unit rating plate. Recommended operation at
midpoint of rise or above.
3. Set thermostat heat anticipator.
The thermostat heat anticipator must be set to match the amp
draw of the electrical components in the R-W circuit. Accurate
amp draw readings can be obtained at thermostat subbase
terminals R and W. Fig. 13 illustrates an easy method of
obtaining the actual amp draw. The amp reading should be
taken after the blower motor has started. See the thermostat
manufacturer’s instructions for adjusting the heat anticipator
and for varying the heating cycle length.
NOTE: When using an electronic thermostat, set the cycle rate for
3 cycles per hr.
MANIFOLD
THERMOSTAT SUBBASE
TERMINALS WITH
THERMOSTAT REMOVED
A84076
Fig. 12—Burner Flame
HOOK-AROUND
VOLT/AMMETER
Table 8—Canadian Orifice Size
GAS
Natural
Propane
SEA LEVEL
0—2000
44
54
HIGH ALTITUDE
2001—4500 FT
45
55
R Y W G
2. Set temperature rise.
Do not exceed the temperature rise range specified on the unit
rating plate. Determine the air temperature rise as follows:
10 TURNS
a. Place duct thermometers in return and supply ducts as near
furnace as possible. Be sure thermometers do not "see" heat
exchangers so that radiant heat will not affect thermometer
readings. This is particularly important with straight-run
ducts.
FROM UNIT 24-VOLT
TERMINAL BLOCK
EXAMPLE: 5.0 AMPS ON AMMETER
10 TURNS AROUND JAWS
b. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine temperature rise.
= 0.5 AMPS FOR THERMOSTAT SETTING
A80201
Fig. 13—Amp Draw Check With Ammeter
c. Adjust air temperature rise by adjusting blower speed.
Increase blower speed to reduce temperature rise. Decrease
blower speed to increase temperature rise.
CHECK SAFETY CONTROLS
1. Check operation of gas shut-off control for 100 percent
shutoff.
NOTE: The furnace pilot must be lit to cause the thermocouple to
energize the thermal magnet circuit of gas valve GV, which
permits gas flow to the remaining portion of the valve. If the pilot
flame is extinguished, the thermocouple will no longer energize
the thermal magnet circuit of the gas valve GV. Gas flow to the
pilot and the main burners will cease until the pilot is manually
relit.
d. To change blower motor speed selections for heating mode,
remove blower motor lead from control board HEAT
terminal. (See Fig. 10) Select desired blower motor speed
lead from 1 of the other terminals and relocate it to HEAT
terminal. See Table 9 for lead color identification. Reconnect original lead on SPARE terminal.
a. With furnace operating, unscrew pilot thermocouple lead
from gas valve. The pilot and main burner gas must shut
off. No gas should flow through valve.
Disconnect the electrical power before changing the speed
tap. Failure to follow this warning can cause personal injury.
12
b. After valve is found to operate satisfactorily, reconnect
thermocouple to gas valve (finger-tight position only).
d. Remove blockage and reconnect vent pipe to furnace outlet
collar.
c. Tighten thermocouple connection 1/4-turn with a wrench.
e. Wait 5 minutes and then reset draft safeguard switch.
d. Relight the pilot following lighting instructions on furnace.
4. Check pressure switch.
2. Check primary limit control.
This control proves operation of draft inducer blower.
This control shuts off the combustion control system and
energizes the circulating-air blower motor if the furnace
overheats.
a. Turn off 115-v power to furnace.
The preferred method of checking the limit control is to
gradually block off the return air after the furnace has been
operating for a period of at least 5 minutes. As soon as the
limit has shut off the burners, the return-air opening should be
unblocked. By using this method to check the limit control, it
can be established that the limit is functioning properly and
will operate if there is a motor failure.
c. Turn on 115-v power to furnace.
b. Remove control door and disconnect inducer motor lead
wires from wire harness.
d. Close thermostat switch as if making normal furnace start.
If the burners do not light, the pressure switch is functioning properly.
e. Turn off 115-v power to furnace.
f. Reconnect inducer motor wires, replace control door, and
turn on 115-v power.
3. Check draft safeguard switch.
CHECKLIST
The purpose of this control is to permit the safe shutdown of
the furnace during certain blocked vent conditions.
1. Put away tools and instruments, and clean up debris.
a. Disconnect power to furnace and remove vent connector
from furnace outlet collar. Be sure to allow time for vent
pipe to cool down before removing.
2. Verify manual reset switches have continuity.
3. Ensure blower and control access doors are properly installed.
4. Cycletest furnace with room thermostat.
b. Set room thermostat above room temperature and restore
power to furnace.
5. Check operation of accessories per manufacturer’s instructions.
c. After normal start-up, allow furnace to operate for 2
minutes, then block 50 percent of flue outlet. Furnace
should cycle off within 3 minutes.
6. Review User’s Manual with owner.
7. Leave literature packet near furnace.
13
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 1995 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
58gf4si
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-809
Printed in U.S.A.
Form 58GF-4SI
Pg 14
10-95
Replaces: 58GF-3SI
Tab 6a 8a