Carrier GAS FURNACE 58MXA Operating instructions

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Carrier GAS FURNACE 58MXA Operating instructions | Manualzz

58MXA

Deluxe 4-Way Multipoise Fixed-Capacity

Direct-Vent Condensing Gas Furnace

Visit www.carrier.com

Installation, Start-Up, and Operating Instructions

For Sizes 040—140, Series 130 (LIMITED)

ama

CERTIFIED

A93040

NOTE: Read the entire instruction manual before starting the installation.

Index Page

DIMENSIONAL DRAWING........................................................2

SAFETY CONSIDERATIONS .....................................................3

Clearances to Combustibles......................................................3

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........4

INTRODUCTION ..........................................................................4

APPLICATIONS ......................................................................5-12

General ......................................................................................5

Upflow Applications..............................................................5-7

Downflow Applications.........................................................7-8

Horizontal Left (Supply-Air Discharge) Applications .......8-10

Horizontal Right (Supply-Air Discharge) Applications ...10-12

LOCATION ............................................................................12-13

General ....................................................................................12

Furnace Location Relative to Cooling Equipment ................13

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..........................................................................16-17

AIR DUCTS............................................................................17-18

General Requirements.............................................................17

Ductwork Acoustical Treatment.............................................18

Supply Air connections ..........................................................18

Return Air Connections ..........................................................18

ELECTRICAL CONNECTIONS...........................................18-19

115-v Wiring......................................................................18-19

24-v Wiring.............................................................................19

Accessories..............................................................................19

DIRECT VENTING ...............................................................19-28

Removal of Existing Furnaces from

Common Vent Systems................................................19-21

Combustion-Air and Vent Piping .....................................21-27

Concentric Vent and Combustion-Air Termination

Kit Installation..............................................................27-28

Multiventing and Vent Termination.......................................28

CONDENSATE DRAIN ........................................................28-31

General...............................................................................28-30

As an ENERGY STAR®

Partner, Carrier Corporation has determined that this product meets the EN-

ERGY STAR® guidelines for energy efficiency.

AIRFLOW

HORIZONTAL

LEFT

REGISTERED QUALITY SYSTEM

AIRFLOW

UPFLOW

DOWNFLOW

HORIZONTAL

RIGHT

AIRFLOW

AIRFLOW

Fig. 1—Multipoise Orientations

A93041

Application ..............................................................................30

Condensate Drain Protection.............................................30-31

SEQUENCE OF OPERATION..............................................32-36

Heating Mode..........................................................................32

Cooling Mode ....................................................................32-33

Continuous Blower Mode.......................................................33

Continuous Blower Speed Selection from Thermostat .........33

Heat Pump Mode ....................................................................33

Component Test.................................................................33-36

START-UP PROCEDURES ..................................................36-45

General ....................................................................................36

Prime Condensate Trap With Water ......................................37

Purge Gas Lines......................................................................37

Adjustments .......................................................................37-45

Set Gas Input Rate ............................................................37-38

Set Temperature Rise ........................................................38-44

Adjust Blower Off Delay (Heat Mode) .................................45

Set Thermostat Heat Anticipator............................................45

CHECK SAFETY CONTROLS..................................................45

Check Primary Limit Control.................................................45

Check Pressure Switch ...........................................................45

CHECKLIST ................................................................................45

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4

Tab 6a 8a

PC 101 Catalog No. 535-759 Printed in U.S.A.

Form 58MXA-10SI Pg 1 1-00 Replaces: New

2

INSTALLATION

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 furnace is for indoor installation in a building constructed on site. This furnace may be installed in a manufactured (mobile) home when stated on rating plate and using factory authorized kit.

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, CPVC 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).

Furnace must be installed level, or pitched forward within 1/2 inch of level for proper drainage. Failure will result in equipment or property damage. See Installation Manual for IMPORTANT unit support details on horizontal applications

LEVEL (0")

TO

1/2" MAX

UPFLOW OR

DOWNFLOW

FRONT

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

LEVEL (0")

TO

1/2" MAX

FRONT

HORIZONTAL

This furnace is approved for UPFLOW, DOWNFLOW and

HORIZONTAL installations.

1"

ALL POSITIONS:

*

††

Mimimum front clearance for service 30 inches (762mm).

140 size furnaces require 1 inch back clearance to combustible materials.

DOWNFLOW POSITIONS:

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.

HORIZONTAL POSITIONS:

Line contact is permissible only between lines formed by intersections of top and two sides of furnace jacket, and building joists, studs, or framing.

§

Clearance shown is for air inlet and air outlet end.

Ø

120 and 140 size Furnaces require 1 inch bottom clearance to combustible materials.

324999-201 REV. B (LIT)

††

0"

B

A

C

K

§

0"

S I

D E

Clearance in inches

S I

D E

F U

R N

A C

O N

T

F R

E

F

R

O

N

T

3"

S

E

R V

I

C

E

§

0"

*

MIN

0"

Ø

Vent clearance to combustibles 0”.

A99230

Fig. 3—Clearances to Combustibles

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 literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply.

Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA

54-1999/ANSI Z223.1-1999 and the Installation Standards, Warm

Air Heating and Air Conditioning Systems (NFPA 90B)

ANSI/NFPA 90B. In Canada, refer to the current edition of the

CAN/CGA-B149.1- and .2-M95 National Standard of Canada,

Natural Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls.

Recognize safety information. This is the safety-alert symbol .

When you see this symbol on unit or in instructions and manuals, be alert to potential for personal injury.

Understand the signal words DANGER, WARNING, and CAU-

TION. These words are used with the safety-alert symbol. DAN-

GER 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 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.

3

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.

1. Disconnect all power to the furnace. DO NOT TOUCH THE

CONTROL OR ANY WIRE CONNECTED TO THE CON-

TROL PRIOR TO DISCHARGING YOUR BODY’S ELEC-

TROSTATIC CHARGE TO GROUND.

2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity (for example; DO

NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).

4. If you touch ungrounded objects (recharge your body with static electricity), firmly touch furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 5 before bringing the control or yourself into contact with the furnace. Put all used AND new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

INTRODUCTION

The 58MXA Multipoise Condensing Gas-Fired Series 130 Limited

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 58MXA 040 through 120 sizes are

A.G.A./C.G.A. approved for use in manufactured (mobile) homes when factory accessory conversion kit is used. The 140 size 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.

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.

These furnaces are shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main blower compartment.

4

Installer Packet includes:

Installation, Start-Up, and Operating Instructions

Service and Maintenance Instructions

User’s Information Manual

Warranty Certificate

Loose Parts Bag includes:

Pressure tube extension

Collector box or condensate trap extension tube

Inducer housing drain tube

1/2-in. CPVC street elbow

Drain tube coupling

Drain tube coupling grommet

Vent and combustion-air pipe support

Combustion-air pipe perforated disk assembly

Vent Pipe Extension

* ONLY supplied with some furnaces.

Quantity

1

1

1

1

1*

1

2

2

1

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.

This furnace must be installed with a direct-vent (combustion air and flue) system and a factory accessory termination kit. In a direct-vent system, all air for combustion is taken directly from the outside atmosphere and all flue products are discharged to the outside atmosphere. See furnace and factory accessory termination kit instructions for proper installation.

Before installing the furnace in the United States, refer to the current edition of the NFGC and the NFPA 90B. For copies of the

NFGC and NFPA 90B contact the National Fire Protection

Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC contact the American Gas Association, 400 N.

Capitol St., NW, Wahington DC 20001.

Before installing the furnace in Canada, refer to the current edition of the NSCNGPIC. Contact Standard Sales CSA International, 178

Rexdale Boulevard, Etobicoke, (Toronto) Ontario, Canada M9W

1R3, Canada.

Installation must comply with regulations of serving gas supplier and local building, heating, plumbing or other codes in effect in the area in which installation is made. In absence of local codes, installation must comply with the NFGC in the United States and the NSCNGPIC in Canada..

These instructions cover minimum requirements for a safe installation and conform to existing national standards and safety codes.

In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept pace with changing residential construction practices. We require these instructions as a minimum for a safe installation.

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.

BLOWER SHELF

CONDENSATE

TRAP (INSIDE)

FURNACE

DOOR

CONDENSATE

TRAP

FURNACE

SIDE

FURNACE

DOOR FURNACE

SIDE

ALTERNATE DRAIN

TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

4

78

FIELD

DRAIN

CONN

26

1 4

SIDE VIEW

1 1 2

FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

4

5

3 4

5

3 4

4

26

1 4

FIELD

DRAIN

CONN

END VIEW

3 4

FRONT VIEW

HORIZONTAL

APPLICATIONS

3 4

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

1

1 2

1

3 4

7

1 8

1 ⁄

4

OD

COLLECTOR BOX TO

TRAP RELIEF PORT

1 ⁄

2

OD

INDUCER HOUSING

DRAIN CONNECTION

5 ⁄

8

OD

COLLECTOR BOX

DRAIN CONNECTION

SCREW HOLE FOR

UPFLOW OR DOWN-

FLOW APPLICATIONS

(OPTIONAL)

1 ⁄

2

-IN. PVC OR CPVC

WIRE TIE

GUIDES

(WHEN USED)

7 8

2

1 4

FRONT VIEW SIDE VIEW

A93026

APPLICATIONS

Fig. 4—Condensate Trap

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.

For accessory installation details, refer to applicable installation literature.

Step 1—General

Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 1. All drain and pressure tubes are connected as shown in Fig. 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.

CONDENSATE TRAP TUBING (FACTORY-SHIPPED

ORIENTATION)

NOTE: See Fig. 5 or tube routing label on main furnace door to confirm location of these tubes.

1. Collector Box Drain, Inducer Housing Drain, Relief Port, and

Pressure Switch Tubes

These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications. These tubes can be identified by their connection location and also by a color label on each tube. These tubes are identified as follows: collector box drain tube (blue label), inducer housing drain tube (violet label or molded), relief port tube (green label), and pressure switch tube (pink label).

2. Condensate Trap Drain Tube

The condensate trap drain connection must be extended for field attachment by doing the following: a. Determine location of field drain connection. (See Fig. 2 or

5.)

5

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

CONDENSATE

TRAP

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

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)

A94163

Fig. 5—Factory-Shipped Upflow Tube

Configuration

(Shown With Blower Access Panel Removed)

CONDENSATE

TRAP

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

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.

c. Install drain tube coupling grommet (factory-supplied in loose parts bag) in selected casing hole.

d. Slide drain tube coupling (factory-supplied in loose parts bag) through grommet ensuring long end of coupling faces blower.

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.

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.

h. Attach tube to coupling and clamp securely.

6

A94164

Fig. 6—Alternate Upflow Tube Configuration and

Trap Location

CONDENSATE TRAP LOCATION (ALTERNATE UPFLOW

ORIENTATION)

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.

To relocate condensate trap to the left-hand side, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. 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.

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.

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections.

UPPER COLLECTOR BOX AND INDUCER HOUSING (UN-

USED) DRAIN CONNECTIONS

Upper Collector Box Drain Connection

Attached to the UPPER collector box drain connection is a factory-installed corrugated, plugged tube (blue and white striped label). This tube is plugged to prevent condensate leakage in this application. Ensure this tube is plugged.

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections.

Upper Inducer Housing Drain Connection

Attached to the UPPER (unused) inducer housing drain connection is a cap and clamp. This cap is used to prevent condensate leakage in this application. Ensure this connection is capped.

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

Step 3—Downflow Applications

A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, and conditioned air is discharged downwards.

CONDENSATE TRAP LOCATION

The condensate trap must be removed from the factory-installed blower shelf location and relocated in selected application location as shown in Fig. 2, 7, or 8.

To relocate condensate trap from the blower shelf to desired location, perform the following:

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE

TRAP

INDUCER HOUSING

DRAIN TUBE (VIOLET)

Fig. 7—Downflow Tube Configuration

(Left-Hand Trap Installation)

A94165

7

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

INDUCER HOUSING

DRAIN TUBE

(VIOLET)

CONDENSATE

TRAP

COLLECTOR BOX

EXTENSION

DRAIN TUBE

DRAIN TUBE

COUPLING

Fig. 8—Downflow Tube Configuration

(Right-Hand Trap Installation)

A94166

1. Remove 3 tubes connected to condensate trap.

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, 7, or 8.)

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.

CONDENSATE TRAP TUBING

NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections.

1. Collector Box Drain Tube a. Remove factory-installed plug from LOWER collector box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was connected to condensate trap.

c. Connect LOWER collector box drain connection to condensate trap.

(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.

(b.) Clamp tube to prevent any condensate leakage.

(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.

(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.

(e.) Connect to condensate trap.

(f.) Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed.

d. Use inducer housing drain tube (violet label and factorysupplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap.

e. Connect inducer housing drain connection to condensate trap.

(1.) Condensate Trap Located on Left Side of Casing

(a.) Determine appropriate length and cut.

(b.) Connect tube to condensate trap.

(c.) Clamp tube to prevent any condensate leakage.

8

(2.) Condensate Trap Located on Right Side of Casing

(a.) Route inducer housing drain tube (violet label) directly from inducer housing to condensate trap as shown in Fig. 8.

(b.) Determine appropriate length and cut.

(c.) Connect tube to condensate trap.

(d.) Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection procedure.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and procedures.

PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections.

Relocate tubes as described below.

1. Disconnect collector box pressure tube (pink label) attached to pressure switch.

2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in loose parts bag).

3. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.

4. Extend collector box pressure tube (pink label) which was previously connected to pressure switch by splicing to remaining small diameter tube (factory-supplied in loose parts bag).

5. Route this extended tube (pink label) to condensate trap relief port connection.

6. Determine appropriate length, cut, and connect tube.

7. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

Step 4—Horizontal Left (Supply-Air Discharge)

Applications

A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace, and conditioned air is discharged to the left.

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.

NOTE: In Canada, installations shall be in accordance with current NSCNGPIC and/or local codes.

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.

PLUG

AUXILIARY " J " BOX

RELOCATED HERE

CAP

COLLECTOR BOX

DRAIN TUBE

(BLUE AND WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040, 060, AND 080 HEATING INPUT FURNACES

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

DRAIN TUBE (BLUE)

A93302

Fig. 9—Horizontal Left Tube Configuration

CONDENSATE TRAP LOCATION

The condensate trap must be removed from the factory-installed blower shelf location and relocated in selected application location as shown in Fig. 2 or 9.

To relocate condensate trap from the blower shelf to desired location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2 or

9.)

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap.

c. Determine appropriate length, cut, and connect tube.

d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube a. Extend collector box tube (green label) which was previously connected to the condensate trap by splicing to small diameter tube (factory-supplied in loose parts bag).

b. Route extended collector box pressure tube to relief port connection on the condensate trap.

c. Determine appropriate length, cut, and connect tube.

d. Clamp tube to prevent any condensate leakage.

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.

b. Connect large diameter drain tube and clamp (factorysupplied in loose parts bag) to drain tube coupling, extending collector box drain tube.

c. Route extended tube (blue label) to condensate trap and cut to appropriate length.

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 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.

9

COMBUSTION – AIR

INTAKE

VENT

30

MIN

WORK AREA

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.

5 3 ⁄ 4

MANUAL

SHUTOFF

GAS VALVE

ACCESS OPENING

FOR TRAP

SEDIMENT

TRAP

DRAIN

CONDENSATE

TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

FURNACE AND CONDENSATE TRAP WHEN A CONDENSING

FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.

A93031

Fig. 10—Attic Location and Working Platform

NOTE: See Fig. 9 or tube routing label on main furnace door to check for proper connections.

Modify tube as described below.

1. Disconnect collector box pressure tube (pink label) attached to pressure switch.

2. Use smaller diameter tube (factory-supplied in loose parts bag) to extend tube disconnected in item 1.

3. Route extended tube: a. Behind inducer housing.

b. Between blower shelf and inducer housing.

c. Behind inducer motor bracket.

d. Between inducer motor and pressure switch.

4. Determine appropriate length, cut, and reconnect tube to pressure switch connection labeled COLLECTOR BOX.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

CONSTRUCT A WORKING PLATFORM

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: 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 31.)

Step 5—Horizontal Right (Supply-Air Discharge)

Applications

A horizontal right furnace application is where furnace blower is located to the left of combustion and controls section of furnace, and conditioned air is discharged to the right.

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in attic application or over a finished ceiling.

NOTE: In Canada, installations shall be in accordance with current NSCNGPIC Installation Codes and/or local codes.

CONDENSATE TRAP LOCATION

The condensate trap must be removed from the factory-installed blower shelf location and relocated in selected application location as shown in Fig. 2 or 11.

To relocate condensate trap from the blower shelf to desired location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2 or

11.)

10

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

CONDENSATE

TRAP

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 11—Horizontal Right Tube Configuration

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

CONDENSATE TRAP TUBING

NOTE: See Fig. 11 or tube routing label on main furnace door to check for proper connections.

1. Collector Box Drain Tube a. Remove factory-installed plug from LOWER collector box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was previously connected to condensate trap.

c. Connect LOWER collector box drain tube (blue and white striped label) to condensate trap. Tube does not need to be cut.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed.

d. Use inducer housing drain extension tube (violet label and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to condensate trap.

e. Determine appropriate length, cut, and connect tube to condensate trap.

f. Clamp tube to prevent any condensate leakage.

A93303

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection procedure.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and procedures.

PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 11 or tube routing label on main furnace door to check for proper connections.

Relocate tubes as described below:

1. Disconnect collector box pressure tube (pink label) attached to pressure switch.

2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in loose parts bag).

3. Route extended collector box pressure tube behind inducer motor bracket then between inducer motor and pressure switch.

4. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.

5. Use remaining smaller diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch.

11

6. Route this extended tube (pink label) to condensate trap relief port connection.

7. Determine appropriate length, cut, and connect tube.

8. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

CONSTRUCT A WORKING PLATFORM

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.

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.)

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 31.)

LOCATION

Step 1—General

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.

FRONT

°F °F

RETURN

AIR

MAX 85°F MIN 55°F

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.

FRONT

B

A

C

K

BACK

LEVEL (0

)

TO

1 ⁄

2

MAX

FRONT FRONT

LEVEL (0

)

TO

1 ⁄

2

MAX

UPFLOW OR DOWNFLOW HORIZONTAL

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.

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.

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.

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.

12

32

°

F MINIMUM INSTALLED

AMBIENT OR FREEZE

PROTECTION REQUIRED

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.

5 ⁄

16

5 ⁄

16

1 3 ⁄

4

1 3 ⁄

4

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.

5 ⁄

16

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.

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.

Step 3—Hazardous Locations

18-IN. MINIMUM

TO BURNERS

A93044

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.

13

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.)

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

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.

1. Determine application being installed from Table 1.

2. Construct hole in floor per dimensions specified in Table 1 and Fig. 13.

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

B

A

PLENUM

OPENING

D

FLOOR

C

OPENING

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96283

Fig. 13—Floor and Plenum Opening Dimensions

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 14—Furnace, Plenum, and Subbase

Installed on a Combustible Floor

Table 1—Opening Dimensions (In.)

A96284

Fig. 15—Furnace, Plenum, and Coil

Assembly or Coil Box Installed on a Combustible Floor

FURNACE

CASING

WIDTH

APPLICATION

PLENUM OPENING

A

16

15-7/8

B

24-1/8

19

FLOOR OPENING

C

16-5/8

16-1/2

D

24-3/4

19-5/8

17-1/2

21

24-1/2

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

15-1/8

15-1/2

19-1/2

19-3/8

18-5/8

19

23

22-7/8

22-1/8

22-1/2

19

19

24-1/8

19

19

19

24-1/8

19

19

19

16-3/4

16-1/2

20-1/8

20

20-1/4

20

23-5/8

23-1/2

23-3/4

23-1/2

20-3/8

20

24-3/4

19-5/8

20-3/8

20

24-3/4

19-5/8

20-3/8

20

PERFORATED

DISCHARGE DUCT

FLANGE

210°

MIN

Fig. 16—Duct Flanges

NO

YES

YES

A93029 duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 16.)

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.

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.

Step 3—Installation in Horizontal Applications

These furnaces can be installed horizontally in either horizontal left or right discharge position. In a crawlspace, furnace can either be hung from floor joist or installed on suitable blocks or pad.

Furnace can be suspended from each corner by hanger bolts and angle iron supports. (See Fig. 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.)

3 ⁄

8

-IN. ROD

ANGLE

IRON OR

EQUIVALENT

5 3 ⁄

4

(B)

(A)

(B) DRAIN

(A) ROD LOCATION

USING DIMPLE

LOCATORS

(SEE DIMENSIONAL

DWG FOR

LOCATIONS)

3 /

8

-IN. HEX NUT

& WASHER (4)

REQD PER ROD

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

(A) (B)

(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.

ALTERNATE SUPPORT

LOCATION 4-IN. MIN

8-IN. MAX

A93304

Fig. 17—Crawlspace Horizontal Application

15

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.

Step 4—Filter Arrangement

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.

Table 2—Filter Information

FURNACE

CASING

WIDTH (IN.)

17-1/2

21

24-1/2

FILTER SIZE (IN.)*

Side Return

(1) 16 X 25 X 1†

(1) 16 X 25 X 1

(2) 16 X 25 X 1†

Bottom Return

(1) 16 X 25 X 1

(1) 20 X 25 X 1†

(1) 24 X 25 X 1

FILTER TYPE

FRAMED

Cleanable

Cleanable

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.

17 1 ⁄

2

-IN. WIDE

CASINGS ONLY:

INSTALL FIELD-SUPPLIED

FILTER FILLER STRIP

UNDER FILTER.

3 ″

24 1 /

2

1

24 1 ⁄

2

-IN. WIDE

CASINGS ONLY:

CUT AND FOLD

FACTORY-PROVIDED

FILTERS AS SHOWN

TO DESIRED SIZE.

WASHABLE

FILTER

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.

NOTE: Side return-air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 18.

WASHABLE

FILTER

FILTER

RETAINER

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

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.

16

FILTER

SUPPORT

FILTER

RETAINER

A96030

Fig. 19—Bottom Filter Arrangement

To remove bottom closure panel, perform following:

1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 20.)

2. Rotate front filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall front filler panel and screws.

Step 6—Gas Piping

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.

Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls.

GAS

SUPPLY

MANUAL

SHUTOFF

VALVE

(REQUIRED)

SEDIMENT

TRAP

UNION

BOTTOM

CLOSURE

PANEL

FRONT FILLER

PANEL

A93047

Fig. 20—Removing Bottom Closure Panel

Fig. 21—Typical Gas Pipe Arrangement

A93324

Gas valve shutoff switch MUST be facing forward or tilted upward. Failure to follow this warning could result in property damage or death.

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. A 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.

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.

An accessible manual shutoff valve MUST be installed upstream of furnace gas controls and within 6 ft of furnace. A 1/8-in. NPT 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. 45.)

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.

Table 3—Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE

SIZE

(IN.)

1/2

3/4

1

1-1/4

1-1/2

INTERNAL

DIAMETER

(IN.)

0.622

0.824

1.049

1.380

1.610

10

175

360

680

1400

LENGTH OF PIPE (FT)

20

120

250

465

950

30

97

200

375

770

40

82

170

320

660

50

73

151

285

580

2100 1460 1180 990 900

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas).

Ref: Table 10-2 NFPA 54-1999.

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.)

17

AIR DUCTS

Step 1—General Requirements

The duct system should be designed and sized according to accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA) or

American Society of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE). Or consult factory The Air Systems Design

Guidelines reference tables available from your local distributor.

The duct system should be sized to handle the required system design CFM at the design static pressure.

When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

Secure ductwork with proper fasteners for type of ductwork used.

Seal supply- and return-duct connections to furnace with code approved tape or duct sealer.

Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1-in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See

NFPA 90B or local code for further requirements.

Step 2—Ductwork Acoustical Treatment

Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take-off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of

SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA

90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Step 3—Supply Air Connections

Connect supply-air duct to 3/4-in. flange on furnace supply-air outlet. The supply-air duct attachment must ONLY be connected to furnace supply-/outlet-air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

1. DOWNFLOW FURNACES

Connect supply-air duct to supply-air opening on furnace. The supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used), when installed on non-combustible material. When installed on combustible material, supply-air duct attachment must ONLY be connected to an accessory subbase or factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories

MUST be connected external to furnace main casing.

2. HORIZONTAL FURNACES

Connect supply-air duct to supply air opening on furnace. The supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

Step 4—Return Air Connections

1. UPFLOW FURNACES

The return-air duct must be connected to bottom , sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 1. Bypass humidifier may be attached into unused side return air portion of the furnace casing. DO NOT connect any portion of return-air duct to back of furnace casing.

2. DOWNFLOW AND HORIZONTAL FURNACES

The return-air duct must be connected to return-air opening provided as shown in Fig. 1. DO NOT cut into casing sides or back to attach any portion of return-air duct. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

ELECTRICAL CONNECTIONS

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.

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.

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.

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.

FIELD 24-V WIRING

FIELD 115-, 208/230-, 460-V WIRING

FACTORY 24-V WIRING

FACTORY 115-V WIRING

NOTE 2

FIVE WIRE

THREE-WIRE

HEATING-ONLY

W C R G Y

THERMOSTAT

TERMINALS FIELD-SUPPLIED

DISCONNECT

BLOWER DOOR SWITCH

208/230- OR

460-V

THREE

PHASE

BLK BLK

W

WHT

GND

115-V FIELD-

SUPPLIED

DISCONNECT

WHT

GND

AUXILIARY

J-BOX

R

O

L

C

O

N

T

R

G

COM

Y/Y2

GND

208/230-V

SINGLE

PHASE

NOTE 1

CONDENSING

UNIT

24-V

TERMINAL

BLOCK

TWO

WIRE

FURNACE

NOTES: 1.

2.

3.

Connect Y-terminal in furnace as shown for proper blower operation.

Some thermostats require a "C" terminal connection as shown.

If any of the original wire, as supplied, must be replaced, use same type or equivalent wire.

A99440

Fig. 22—Standard Heating and Cooling Application Wiring Diagram

18

Make all electrical connections in accordance with National

Electrical Code (NEC) ANSI/NFPA 70-1999 and any local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with Canadian

Electrical Code CSA C22.1 or subauthorities having jurisdiction.

FACTORY

INSTALLED

LOCATION

ALTERNATE

FIELD

LOCATION

ELECTRIC

DISCONNECT

SWITCH

COPPER

WIRE ONLY

ALUMINUM

WIRE

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.

The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-1999 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electrical shock, fire, or death.

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.

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.

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/Y2 terminal on control center, as shown in Fig. 22. The 24-v terminal board is marked for easy connection of field wiring. (See Fig. 25.) 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 maintenance may cause fuse to blow. If fuse replacement is required, use only a fuse of identical size (3 amp).

19

A93051

Fig. 23—Relocating J-Box

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.

Step 3—Accessories

1. Electronic Air Cleaner (EAC)

Two quick-connect terminals, marked EAC-1 and EAC-2, are provided for EAC connection (See Fig. 25). These terminals are energized with 115v (1.0-amp maximum) during blower motor operation.

2. Humidifier (HUM)

Quick connect terminal (HUM) and screw terminal (Com) are provided for 24-v humidifier connection. (See Fig. 25.) HUM terminal is energized with 24v (0.5-amp maximum) after inducer motor prepurge period.

NOTE: A field-supplied, 115-v controlled relay connected to

EAC terminals may be added if humidifier operation is desired during blower operation.

DIRECT VENTING

The 58MXA Furnaces require a dedicated (one 58MXA 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

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:

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.

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.

N TRA

WHT

RED

WHT

GRN

WHT

YEL

11 0 91 8 7 6 5 4 3 2 1

L2

L COO T HEA

HSI

20

Table 4—Electrical Data

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

VOLTS—

HERTZ—

PHASE

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

OPERATING

VOLTAGE RANGE

Max*

127

127

127

127

127

127

127

127

127

127

127

127

Min*

104

104

104

104

104

104

104

104

104

104

104

104

MAX

UNIT

AMPS

6.1

7.3

6.1

7.1

9.5

7.6

10.0

14.1

10.2

14.8

14.6

14.3

UNIT

AMPACITY†

8.4

10.0

8.4

9.8

12.8

10.4

13.4

18.4

13.5

19.3

19.1

18.8

MIN

WIRE

SIZE

14

14

14

14

14

14

14

12

14

12

12

12

MAX WIRE

LENGTH

(FT)‡

44

37

44

38

29

36

28

31

27

30

30

30

MAX FUSE

OR CKT BKR

AMPS**

15

15

15

15

15

15

15

20

15

20

20

20

* Permissible limits of voltage range at which unit will operate satisfactorily.

† Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load amps.

‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

** Time-delay type is recommended.

4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously.

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.

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 NSC-

NGPIC.

Step 2—Combustion-Air and Vent Piping

GENERAL

Combustion-air and vent pipe fittings must conform to American

National Standards Institute (ANSI) standards and American

BLOWER OFF DELAY

JUMPER SELECT

90

135

180

225

1

2

3

4

5

J1

24-V THERMOSTAT

TERMINALS

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX)

24-V TRANSFORMER SEC-2

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC (L2) NEUTRAL

CONNECTION

TEST/TWIN

HUM

3-AMP FUSE

SEC-1

EAC-2

HARNESS CONNECTOR

COOL

HEAT

BLOWER SPEED

SELECTION TERMINALS

SPARE-1

FAN

SPARE-2

HOT SURFACE

IGNITOR CONNECTOR

PRI

115-VAC (L1)

POWER SUPPLY

INDUCER MOTOR

CONNECTOR

EAC-1 ELECTRONIC AIR CLEANER

TERMINALS (115-VAC 1.0 AMP MAX)

Fig. 25—Control Center

21

A99417

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 or F493 (PVC or CPVC) or

D2235 (ABS). See Table 6 for maximum pipe lengths and Fig. 30,

31, 32, 33, and 34 for exterior piping arrangements.

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: 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.

FURNACE

Table 5—Combustion-Air and Vent Pipe

Termination Clearances

LOCATION

CLEARANCE (FT)

U.S.A.

Canada

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

From service regulator vent, electric and gas meters, and relief equipment

Above grade when adjacent to public walkway

* Horizontal distance.

† 18 in. above roof surface in Canada.

‡ 36 in. to electric meter in Canada only.

NOTES:

1

3

3

1

1

4*

Note 3

1†

3

3

6

1

6‡

Note 3

1. If installing 2 adjacent 355MAV 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.

3. Vent termination can not terminate less than 2 ft horizontal and 7 ft above public walkway or where condensate vapor or droplets may be a hazard.

NOT IN

HORIZONTAL

SECTION

PIPE DIAMETER

TRANSITION IN

VERTICAL SECTION

A93034

Fig. 26—Combustion-Air and Vent Pipe Diameter

Transition Location and Elbow Configuration

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.

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.

NOTE: Slope combustion-air and vent pipes a minimum of 1/4 in. per linear ft with no sags between hangers.

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.

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.

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.

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.

22

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.

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,

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

COMBUSTION-

AIR

AIR

FLOW

COMBUSTION-

AIR

VENT

VENT

VENT

VENT

UPFLOW

COMBUSTION-

AIR

VENT

AIR

FLOW

COMBUSTION-

AIR

AIR

FLOW

COMBUSTION-

AIR

DOWNFLOW

COMBUSTION-

AIR

VENT

AIR

FLOW

HORIZONTAL-LEFT DISCHARGE HORIZONTAL-RIGHT DISCHARGE

Fig. 27—Combustion-Air and Vent Pipe

Connections

A96187 to reduce excessive droplets from exiting vent pipe outlet.

COMBUSTION-AIR AND VENT PIPE DIAMETER

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.

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.

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.

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.

23

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.

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.

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.

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 elastomeric (rubber) inducer housing outlet cap and clamp to appropriate unused inducer housing connection. Tighten clamp.

VENT PIPE

12

MIN

COMBUSTION-AIR PIPE

VENT PIPE

12

MIN

COMBUSTION-AIR PIPE

HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL

COMBUSTION-AIR PIPE

VENT PIPE

COMBUSTION-AIR PIPE

12

MIN

12

MIN

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.

Fig. 28—Short Vent (5 to 8 Ft) System

VENT PIPE

A96230

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. Be certain that mating surfaces of inducer housing connection, elastomeric coupling, and 2-in. diameter vent pipe are clean and dry. Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps) onto inducer housing connection. Insert the 2-in. diameter vent pipe through the elastomeric (rubber) coupling and fully into inducer housing connection until it bottoms on the internal stop. Tighten both clamps to secure the pipe to inducer housing. Tighten the clamp screws to 15 in.-lb. of torque.

24

Vent pipe must be installed and fully seated against inducer housing internal stop. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

NOTE: A 2-in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing.

VENT EXTENSION PIPE

Furnaces with 100,000 Btuh or 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.

3. Working from furnace to outside, cut pipe to required length(s).

4. Deburr inside and outside of pipe.

5. Chamfer outside edge of pipe for better distribution of primer and cement.

6. Clean and dry all surfaces to be joined.

ALTITUDE

0 to 2000

ALTITUDE

2001 to 3000

ALTITUDE

3001 to 4000

See notes on page 26.

UNIT SIZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

UNIT SIZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

120-20

140-20

140-20

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

2-1/2

2-1/2

3

3

3† no disk

4† no disk

3† one disk

3† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

3† one disk

3† no disk

4† no disk

PIPE DIA

(IN.)*

1

1-1/2

2

1-1/2

2

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

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

Table 6—Maximum Allowable Pipe Length (Ft)

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

1

64

70

16

68

46

70

70

11

30

70

33

70

65

1

67

70

17

70

49

70

35

70

14

70

70

20

39

70

70

45

70

70

5

40

60

70

10

55

70

5

40

70

10

1

5

70

70

20

2

NUMBER OF 90° ELBOWS

3 4 5

NA

70

70

NA

65

70

NA

60

70

NA

60

70

15 10 5 NA

70

40

70

70

NA

35

56

70

NA

50

70

NA

30

70

NA

70

35

70

70

NA

30

52

70

NA

35

70

NA

20

70

NA

2

62

70

NUMBER OF 90° ELBOWS

3 4 5

57

70

52

70

52

70

12 7 NA NA

70

30

70

70

NA

25

48

70

NA

30

70

NA

20

70

NA

70

25

70

70

NA

20

44

70

NA

30

70

NA

10

70

NA

67

44

66

30

61

25

61

25

41

70

70

6

26

70

24

70

58

70

26

70

9

70

70

15

35

70

70

16

70

NA

63

70

10

31

70

70

16

70

NA

56

70

5

27

70

2

59

70

NUMBER OF 90° ELBOWS

3 4 5

54

70

49

70

48

70

11 6 NA NA

70

6

66

NA

50

70

NA

23

70

63 62 57 57

28

70

15

70

51

70

NA

22

70

23

70

14

66

44

70

NA

18

70

22

70

5

61

38

70

NA

14

70

6

47

70

NA

61

15

70

NA

61

NA

43

70

NA

19

70

70

20

70

70

NA

15

40

70

NA

20

70

NA

NA

70

NA

6

NA

55

70

NA

6

43

70

NA

56

13

70

NA

56

31

70

NA

10

70

25

ALTITUDE

4001 to 5000‡

ALTITUDE

5001 to 6000‡

ALTITUDE

6001 to 7000‡

ALTITUDE

7001 to 8000‡

See notes on page 26.

Table 6—Maximum Allowable Pipe Length (Ft) Continued

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

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

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

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

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3 In.

Concentric

2 Pipe or 3-In.

Concentric

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

3† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

3† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

1

53

70

13

57

38

70

27

68

31

70

17

1

60

70

15

64

44

70

31

70

53

70

21

69

1

57

70

14

60

41

70

29

70

42

70

12

42

1

49

66

12

53

36

66

25

63

20

61

52

33

70

19

63

24

70

2

55

NUMBER OF 90° ELBOWS

3 4 5

50 45 44

70 70 70 70

10 5 NA NA

59

39

58

26

53

21

52

20

70

22

70

46

70

17

64

70

13

67

40

70

13

59

70

12

62

33

70

9

54

2

52

70

NUMBER OF 90° ELBOWS

3 4 5

47

70

42

70

40

70

9 NA NA NA

70

NA

57

26

70

5

49

55

36

54

23

49

18

48

17

70

21

67

35

70

8

37

70

12

62

29

70

NA

32

70

11

57

22

70

NA

27

2

48

70

NUMBER OF 90° ELBOWS

3 4 5

43

68

38

67

37

66

8 NA NA NA

70

NA

52

15

70

NA

22

50

21

68

10

58

18

70

45

16

67

9

53

11

70

44

15

66

NA

48

NA

67

12 7 NA NA

NA

65

17

58

13

56

2

44

65

NUMBER OF 90° ELBOWS

3 4 5

39

63

34

62

33

60

7 NA NA NA

48

31

46

19

41

14

40

12

63

8

53

7

51

62

7

48

NA

46

60

NA

43

NA

41

26

6

35

70

NA

47

8

70

NA

47

9

70

NA

17

6

39

70

NA

52

11

70

NA

52

20

70

NA

44

6

32

64

NA

43

6

64

NA

43

NA

62

NA

6

28

59

NA

38

NA

59

NA

38

NA

36

Table 6—Maximum Allowable Pipe Length (Ft) Continued

ALTITUDE

8001 to 9000‡

UNIT SIZE

040-08

040-12

060-08

060-12

060-16

080-12

080-16

080-20

100-16

100-20

120-20

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

4† no disk

1

46

62

11

49

33

62

23

59

10

35

2

41

60

6

44

28

60

15

54

NA

30

NUMBER OF 90° ELBOWS

3 4 5

36

58

NA

42

17

58

7

49

NA

25

31

56

NA

37

12

56

5

44

NA

20

29

55

NA

35

10

55

NA

39

NA

15

6

24

53

NA

34

NA

53

NA

34

NA

10

140-20 NA

ALTITUDE UNIT SIZE

040-08

040-12

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

PIPE DIA

(IN.)*

1-1/2

2

1

42

57

2

37

55

NUMBER OF 90° ELBOWS

3

32

53

4

27

51

5

25

49

6

20

47

9001 to 10,000‡

060-08

060-12

060-16

080-12

080-16

080-20

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2

2

2-1/2

45

30

57

40

25

55

38

14

53

33

9

51

31

7

49

29

NA

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.

3/8" ID TUBE

3/16"

DRILL

TRAP

TO OPEN

DRAIN

4

MIN

COMBUSTION – AIR

INTAKE HOUSING

BURNER

BOX

COMBUSTION –

AIR PIPE

A93035

Fig. 29—Intake Housing Plug Fitting Drain

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.

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.

9. While cement is still wet, twist pipe into socket with 1/4 turn.

Be sure pipe is fully inserted into fitting socket.

10. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint.

11. Handle pipe joints carefully until cement sets.

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.

13. Slope combustion-air and vent pipes toward furnace a minimum of 1/4 in. per linear ft with no sags between hangers.

14. Use appropriate methods to seal openings where vent and combustion-air pipes pass through roof or side wall.

Step 3—Concentric Vent and Combustion-Air

Termination Kit Installation

NOTE: If these instructions differ from those packaged with termination kit, follow kit instructions.

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.

1. The 2-in. termination bracket kit is for 1-in., 1-1/2 in., and

2-in. diameter 2-pipe termination systems.

2. The 3-in. termination bracket kit is for 2-1/2 in., 3-in., and

4-in. diameter 2-pipe termination systems.

27

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. 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

31.) Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system.

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. Determine required insulation thickness for exposed pipe lengths.

NOTE: Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 6.

TWO-PIPE 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.

b. Termination kit should be positioned where vent vapors will not damage plants/shrubs or air conditioning equipment.

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.

d. Termination kit should be positioned where it will not be damaged by or subjected to foreign objects, such as stones, balls, etc.

e. Termination kit should be positioned where vent vapors are not objectionable.

2. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size being used.

3. Loosely install elbow in bracket and place assembly on combustion-air pipe.

Roof terminations—Loosely install pipe coupling on properly cut vent pipe. Coupling must be positioned so bracket will mount as shown in Fig. 30.

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.

Sidewall terminations—Install bracket as shown in Fig. 33 or

34.

For applications using vent pipe option indicated by dashed lines in Fig. 33, rotate vent elbow 90° from position shown in

Fig. 33.

28

4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping.

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.

b. Termination kit should be positioned where vent vapors will not damage plants/shrubs or air conditioning equipment.

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.

d. Termination kit should be positioned where it will not be damaged by or subjected to foreign objects, such as stones, balls, etc.

e. Termination kit should be positioned where vent vapors are not objectionable.

2. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in. diameter hole for 3-in. kit.

3. Loosely assemble concentric vent/air termination components together using instructions in kit.

4. Slide assembled kit with rain shield REMOVED through hole.

NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.

Roof terminations—Locate assembly through roof to appropriate height as shown in Fig. 31.

Sidewall terminations—Locate assembly through sidewall with rain shield positioned no more than 1-in. from wall as shown in Fig. 32.

5. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping.

6. Check required dimensions as shown in Fig. 31 or 32.

Step 4—Multiventing and Vent Terminations

When 2 or more 58MXA Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent 58MXA furnaces. When 2 or more 58MXA 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 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.

Step 1—General

CONDENSATE DRAIN

Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be

RELOCATED for use in DOWNFLOW and HORIZONTAL applications.

Condensate trap MUST be used for all applications.

An external trap is not required when connecting the field drain to this condensate trap.

The field drain connection (condensate trap or drain tube coupling) is sized for 1/2-in. CPVC, 1/2-in. PVC, or 5/8-in. ID tube connection.

VERTICAL SEPARATION

BETWEEN COMBUSTION

AIR AND VENT

8 3/4

FOR 3

KIT

6 3/4

FOR 2

KIT

MAINTAIN 12 IN. MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL.

MAXIMUM OF 24 IN.

ABOVE ROOF.

ROOF

18

MAXIMUM

BRACKET

COUPLING

VENT

Fig. 30—Roof Termination (Preferred)

COMBUSTION

AIR

A87224

OVERHANG OR ROOF

VENT

1

MAXIMUM

12

MINIMUM

COMBUSTION-AIR

VENT

MAINTAIN 12 IN.

(18 IN. FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF.

A93054

Fig. 31—Concentric Vent and Combustion-Air Roof

Termination (Preferred)

OVERHANG OR ROOF

COMBUSTION

AIR

MAINTAIN 12 IN.

CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL OR GRADE,

WHICHEVER IS

GREATER.

A93055

Fig. 32—Concentric Vent and Combustion-Air Side

Termination

OVERHANG OR ROOF

VENT

12

MINIMUM

VENT

12

MINIMUM

BRACKET

90

°

COMBUSTION-AIR

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.

A87225

Fig. 33—Sidewall Termination of 12 in. or More

29

BRACKET

COUPLING

90

°

COMBUSTION-AIR

(ELBOW PARALLEL

TO WALL)

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. 34—Sidewall Termination of Less than 12 in.

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

0

-20

20

-20

20

0

-20

0

-20

20

0

-20

MAX PIPE

DIAMETER

(IN.)

2

2

2

2

2

2

2-1/2

2-1/2

2-1/2

3

3

3

4

4

4

4

4

4

WITHOUT

INSULATION

45

28

10

65

35

20

70

47

28

70

50

28

70

48

23

70

57

30

WITH 3/8-IN. OR

THICKER INSULATION†

70

70

58

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.

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.

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.

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.

Step 2—Application

The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, fieldsupplied trap prior to the furnace drain connection. All drain connections (furnace, A/C, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible to prevent siphoning of the equipment’s drain.

See Fig. 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.

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.

32

°

F MINIMUM INSTALLED

AMBIENT OR FREEZE

PROTECTION REQUIRED

A93058

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.

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

30 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.

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.)

A

A96128

Fig. 35—Rooftop Termination

(Dimension "A" is Touching or 2-In. Maximum Separation)

VENT

A

VENT

1

MAXIMUM

(TYP)

COMBUSTION AIR

VENT

COMBUSTION

AIR

A93056

Fig. 36—Concentric Vent and Combustion-Air

Roof Termination

(Dimension "A" is Touching or 2-In.

Maximum Separation)

VENT

A

A93057

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

A96129

Fig. 38—Sidewall Termination of 12 in. or Less

(Dimension "A" is Touching or 2-In.

Maximum Separation)

31

A

A96130

Fig. 39—Sidewall Termination of More Than 12 in.

(Dimension "A" is Touching or 2-In.

Maximum Separation)

OPEN STAND

PIPE FOR

A/C OR

HUMIDIFIER

DRAIN

TEE

TO OPEN

DRAIN

CONDENSATE TRAP

WIRE TIE(S)

HEAT TAPE

(3 WRAPS MINIMUM)

A94054

Fig. 40—Example of Field Drain Attachment

Fig. 41—Condensate Trap Heat Tape

A93036

4. Wrap field drain pipe with remaining heat tape, approximately

1 wrap per ft.

5. When using field-supplied heat tape, follow heat tape manufacturer’s instructions for all other installation guidelines.

SEQUENCE OF OPERATION

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.

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.

32

Step 1—Heating Mode

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.

1. Prepurge period—As inducer motor comes up to speed, pressure switch contacts close to begin a 15-sec prepurge period.

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.

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.

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.

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 remains energized 90, 135, 180, or 225 sec

(depending on blower off time selection). Furnace is factory shipped set for a 135-sec blower off delay.

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).

Step 2—Cooling Mode

1. Single-Speed Outdoor Unit-See figures 42 and 44.

The thermostat closes the R to G and Y circuits. The R-Y/Y2 circuit starts the outdoor unit, and the R to G and Y/Y2 circuits start furnace blower motor on COOL speed. Electronic air cleaner EAC-1 terminal is energized with 115v whenever blower is operating.

When thermostat is satisfied, R to G and Y/Y2 circuits are opened. The outdoor unit stops and the furnace blower continues operating on COOL speed for an additional 90 sec.

Jumper Y/Y2 to DHUM on the furnace control to reduce cooling off delay to 3 sec from 90. See figure 25.

2. Two-Speed Outdoor Unit without Thermidistat-See figure 46.

The thermostat closes the R to G and Y1 circuits for low cooling and the R to G, Y1 and Y/Y2 circuits for high cooling.

The R to Y1 circuit starts the outdoor unit on low cooling and the R to G and Y1 circuits start the furnace blower on FAN speed. The R to Y1 and Y2 circuits start the outdoor unit on high cooling and the R to G, Y1 and Y2 circuits start the furnace blower on COOL speed.

If the R to Y2 circuit opens with the R to G and Y1 circuits still closed, the outdoor unit will drop to low cooling and the furnace control will drop the blower speed to FAN. When the

R to G and Y1 circuit open, the furnace blower continues

operating on FAN speed for an additional 90 sec. To set the cooling off delay to 3 sec instead of 90, connect a jumper between the Y/Y2 and DHUM thermostat connects on the furnace control.

3. Two-Speed Cooling Unit with Thermidistat-See figures 43 and 45..

The dehumidification output, DHUM, on the Thermidistat should be connected to the furnace control thermostat terminal

DHUM. When there is a dehumidify demand, the DHUM input is activated, which menas 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists and is turned OFF when demand exists. Once 24 vac is detected by the furnace control on the

DHUM input, the control operates in Thermidistat mode.

The thermostat closes the R to G and Y1 circuits for low cooling and the R to G, Y1 and Y/Y2 circuits for high cooling.

The R to Y1 circuit starts the outdoor unit on low cooling and the R to G and Y1 circuits start the furnace blower on FAN speed. The R to Y1 and Y2 circuits start the outdoor unit on high cooling and the R to G, Y1 and Y2 circuits start the furnace blower on COOL speed. If the R to Y2 circuit opens with the R to G and Y1 circuits still closed, the outdoor unit will drop to low cooling and the furnace control will drop the blower speed to FAN. When the thermostat is satisfied, the R to G and Y1 circuits are opened. The outdoor unit stops. When there is a dehumidy demand, the cooling blower off delay is decreased from 90 to 3 sec.

In Two-Speed Cooling with only the R to G and Y1 circuits closed and there is a demand for dehumidification, the furnace control blower speed will remain at FAN speed. In high cooling with a demand for dehumidification, the furnace control will drop the blower speed from COOL to HEAT for a maximum of 10 minutes before reverting back to COOL speed. If there is still a demand for dehumidification after 20 minutes, the control will drop the blower speed back to HEAT speed. This alternating 10-minute cycle will continue as long as there is a call for cooling. If the DHUM input is low for more than 48 hours, the control reverts back to non-

Thermidistat operation.

Step 3—Continuous Blower Mode

When R-G circuit is made, blower motor operates at FAN speed.

NOTE: Electronic air cleaner EAC-1 terminal is energized with

115v whenever blower is operating.

If a call for heat (R-W) occurs while thermostat is in continuous blower mode, blower stops to allow furnace heat exchangers to heat up more quickly, then restarts on HEAT speed at end of blower on delay period of 60 sec (40 sec if jumper has been cut for

140 size unit in downflow orientation).

Blower reverts to FAN speed after heating cycle is completed.

If a call for cooling (R-Y/Y2) occurs while thermostat is in continuous blower mode, blower changes from continuous blower speed (FAN speed) to COOL speed.

When thermostat cooling call is satisfied, R-Y opens and blower operates an additional 90 sec at COOL speed before reverting back to continuous operation (FAN speed).

Step 4—Continuous Blower Speed Selection from Thermostat

To select different continuous blower speeds from the room thermostat, momentarily turn off the FAN switch or pushbutton on the room thermostat for 1-3 seconds after the blower is opersting.

The control will shift the blower speed from factory setting of

FAN to HEAT speed. Momentarily turning off the FAN switch

33 again at the thermostat will shift the continuous blower speed selection from HEAT to COOL. Repeating the procedure will cause the control to shift from COOL to FAN speed. The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption.

Step 5—Heat Pump Mode

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 W-Y1,

W-Y/Y2, W-Y1-G, or W-Y/Y2-G thermostat inputs are received at the same time at furnace control center, control starts blower in

HEAT speed. Then a gas heat mode begins. Blower remains operating at HEAT 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 HEAT speed.

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.

If W-Y1-G or W-Y/Y2-G thermostat signals should disappear simultaneously, blower remains on for selected heating blower off delay period (90, 135, 180, or 225 sec), 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 W-Y1 or W-Y/Y2 thermostat signals should disappear, leaving G thermostat signal, blower remains on in HEAT speed for the selected blower off-dealy period 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). After the blower off-delay is completed, the control switches the blower to FAN speed.

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 Y1 and/or Y/Y2 input and goes into cooling mode blower off delay. All other control functions remain in standard format.

NOTE: EAC-1 terminal is energized whenever blower operates.

HUM terminal is only energized when gas valve is energized.

Step 6—Component Test

COMPONENT TEST SEQUENCE

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.

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.

4. Main blower operates at FAN speed for 10 sec, then turns off.

5. Main blower operates at HEAT speed for 10 sec, then turns off.

6. Main blower operates at COOL speed for 10 sec, then turns off.

7. Inducer motor stops.

Component test can be initiated by one of the following procedures.

THERMIDISTAT

N/A O/W2

N/A Y1/W2

HEAT STAGE 1 W/W1

COOL STAGE 1 Y/Y2

FAN G

24 VAC HOT R

DEHUMIDIFY DHUM

24 VAC COMM C

HUMIDIFY HUM

N/A

OUTDOOR

SENSOR

CONNECTION

B

S1

S2

FURNACE

CONTROL

1-SPEED

AIR CONDITIONER

Y1

W

Y/Y2

G

R

DHUM

COM

HUM

HUMIDIFIER

(24 VAC)

OUTDOOR

SENSOR

Y

C

See notes 5, 7, and 10

Fig. 42—Single-Stage Furnace with 1-Speed Air Conditioner

A99435

THERMIDISTAT

N/A O/W2

COOL STAGE 1 Y1/W2

HEAT STAGE 1 W/W1

COOL STAGE 1 Y/Y2

FAN

24 VAC HOT

G

R

DEHUMIDIFY DHUM

24 VAC COMM C

HUMIDIFY HUM

N/A

OUTDOOR

SENSOR

CONNECTION

B

S1

S2

FURNACE

CONTROL

2-SPEED

AIR CONDITIONER

Y1

W

Y/Y2

G

R

DHUM

COM

HUM

HUMIDIFIER

(24 VAC)

OUTDOOR

SENSOR

Y1

Y2

R

C

See notes 5, 8, and 10

Fig. 43—Single-Stage Furnace with 2-Speed Air Conditioner

A99436

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.

1. Leave 115-v power to furnace turned on.

2. Remove main furnace door.

3. Look into blower access panel sight glass for current LED status.

34

NOTE: Leave blower access panel installed to maintain power to control center to view current LED status.

4. BRIEFLY remove either wire from the main limit switch until the LED goes out, then reconnect it.

THERMIDISTAT

RVS COOLING O/W2

N/A Y1/W2

HEAT STAGE 2

(FURNACE)

HEAT/COOL STAGE 1

(COMPRESSOR)

W/W1

Y/Y2

FAN G

24 VAC HOT R

DEHUMIDIFY DHUM

24 VAC COMM C

HUMIDIFY HUM

N/A

OUTDOOR

SENSOR

CONNECTION

B

S1

S2

FURNACE

CONTROL

Y1

W

Y/Y2

G

R

DHUM

COM

HUM

HUMIDIFIER

(24 VAC)

OUTDOOR

SENSOR

1-SPEED

HEAT PUMP

O

W2

Y

R

C

See notes 1, 4, 6, 7, 9, and 10.

Fig. 44—Single-Stage Furnace with 1-Speed Heat Pump (Dual Fuel)

A99437

THERMIDISTAT

RVS COOLING O/W2

HEAT/COOL STAGE 1

(COMPRESSOR LO)

Y1/W2

HEAT STAGE 3

(FURNACE)

HEAT/COOL STAGE 2

(COMPRESSOR HI)

W/W1

Y/Y2

FAN G

24 VAC HOT R

DEHUMIDIFY DHUM

24 VAC COMM C

HUMIDIFY HUM

N/A

OUTDOOR

SENSOR

CONNECTION

B

S1

S2

FURNACE

CONTROL

Y1

W

Y/Y2

G

R

DHUM

COM

HUM

HUMIDIFIER

(24 VAC)

OUTDOOR

SENSOR

2-SPEED

HEAT PUMP

O

Y1

W2

Y2

W3

R

C

See notes 1, 2, 3, 4, 6, 8, 9, and 10.

Fig. 45—Single-Stage Furnace with 2-Speed Heat Pump (Dual Fuel)

A99438

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.

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.

35

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 LED is ON continuously indicating the furnace is ready to operate when a signal from the thermostat is received, replace main furnace door.

TWO-STAGE

THERMOSTAT

FURNACE

CONTROL

Heat Pump only

O

Y1

W

Y2

2-SPEED

AIR CONDITIONER

OR HEAT PUMP

Y1

W

Y/Y2

Heat Pump only

O

Y1

W2

Y2

G G W3

R R

DHUM

R

C COM

HUM

C

HUMIDIFIER

(24 VAC)

See notes 1, 2, and 9.

A99439

Fig. 46—Single-Stage Furnace with 2-Speed Outdoor Unit

Notes:

1. Heat pump must have a high pressure switch for dual fuel applications.

2. Refer to outdoor equipment Installation Instructions for proper setup.

3. Select the "zone" position on the 2-speed heat pump control.

4. Outdoor air sensor must be attached in all dual fuel applications.

5. Dip switch No. 1 on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.

6. Dip switch No. 1 on Thermidistat should be set in ON position for heat pump installations.

7. Dip switch No. 2 on Thermidistat should be set in OFF position for single-speed compressor operation. This is factory default.

8. Dip switch No. 2 on Thermidistat should be set in ON position for 2-speed compressor operation.

9. Configuration Option No. 10 "Dual Fuel Selection" must be turned ON in all dual fuel applications.

10. No connection should be made to the furnace HUM terminal when using a Thermidistat.

INITIATING COMPONENT TEST BY JUMPERING CON-

TROL TEST TERMINAL

1. Remove main furnace door.

2. Remove blower access panel.

3. Manually close blower access panel door switch. Use a piece of tape to hold switch closed.

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.

4. BRIEFLY short (jumper) TEST, 3/16-in. quick-connect terminal on control center (behind the Y/Y2 terminal) and the

C

OM terminal on thermostat connection block. (See Fig. 25.)

NOTE: If TEST to C

OM 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

1. Furnace must have a 115-v power supply properly connected and grounded. Proper polarity must be maintained for correct operation.

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, Y1 and

Y/Y2 must be made at 24-v terminal block on control center.

3. Natural gas service pressure must not exceed 0.5 psig (14-in.

wc), but must be no less than 0.16 psig (4.5-in. wc).

4. Blower access panel must be in place to complete 24-v electrical circuit to furnace.

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.

Before operating furnace, check each manual reset switch for continuity. If necessary, press button to reset switch.

36

Fig. 47—Inducer Housing Drain Tube

Step 2—Prime Condensate Trap with Water

A99118

Fig. 48—Filling Condensate Trap

A99119

Condensate trap must be PRIMED or proper draining may not occur. The condensate trap has 2 internal chambers which can

ONLY be primed by pouring water into the inducer drain side of condensate trap.

1. Remove upper inducer housing drain connection cap. (See

Fig. 47.)

2. Connect field-supplied 1/2-in. ID tube to upper inducer housing drain connection.

3. Insert field-supplied funnel into tube.

4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 48.)

5. Remove funnel and tube from inducer housing and replace drain connection cap and clamp.

Step 3—Purge Gas Lines

If not previously done, purge lines after all connections have been made and check for leaks.

37

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.

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. Determine natural gas orifice size and manifold pressure for correct input.

a. Obtain average yearly heat value (at installed altitude) from local gas supplier.

b. Obtain average yearly specific gravity from local gas supplier.

c. Verify furnace model and size. Table 8 can only be used for model 58MXA furnaces with heating sizes of 040 through

120. Table 9 can only be used for model 58MXA furnaces with a 140 heating size.

d. Find installation altitude in Table 8 or 9.

NOTE: 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.

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.

Check and verify burner orifice size in furnace. NEVER ASSUME

ORIFICE SIZE; ALWAYS CHECK AND VERIFY.

2. Adjust manifold pressure to obtain input rate.

NOTE: Manifold pressure must always be measured with burner enclosure front REMOVED. Gas meter must always be clocked with burner enclosure front INSTALLED.

a. Remove burner enclosure front.

b. Remove cap that conceals adjustment screw for gas valve regulator. (See Fig. 49.) c. Turn adjusting screw, counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure.

NOTE: This furnace has been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft.

For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 in. wc to 3.8 in. wc.

EXAMPLE:

100,000 Btuh input furnace installed at 4300 ft.

Furnace Input Rate at Sea Level

X

Derate

Multiplier

Factor

=

Furnace Input Rate at Installation

Altitude

100,000 X 0.91

= 91,000

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.

b. Turn off all other gas appliances and pilots.

c. Start furnace and let operate for 3 minutes.

d. Measure time (in sec) for gas meter test dial to complete 1 revolution.

e. Refer to Table 11 for cu ft of gas per hr.

f. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft) using natural gas heating value from local gas utility/supplier.

EXAMPLE: (0—2000 ft altitude)

Furnace input from rating plate is 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.

SET TEMPERATURE RISE

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.

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. 50.)

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.

38

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.

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.

2. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.

3. Adjust temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.

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.

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)*

ALTITUDE

RANGE

(FT)

0 to

2000

ALTITUDE

RANGE

(FT)

U.S.A.

Altitudes

2001 to

3000 or

Canada

Altitudes

2000 to

4500

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

Orifice

No.

43

0.58

Manifold

Pressure

3.7

43

44

44

44

44

45

3.5

3.7

3.5

3.4

3.2

3.7

45

45

45

47

3.5

3.3

3.2

3.6

44

44

44

45

45

45

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

3.8

3.5

3.8

3.6

3.4

3.2

3.7

3.5

3.3

3.1

3.0

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

3001 to

4000

750

775

800

825

850

875

900

925

950

975

1000

*Orifice numbers shown in BOLD are factory installed.

44

45

45

45

45

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.7

3.5

3.7

3.5

3.3

3.8

3.6

3.4

3.2

3.0

2.9

Orifice

No.

43

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

3.8

Orifice

No.

42

Manifold

Pressure

3.2

Orifice

No.

42

Manifold

Pressure

3.3

43

43

44

44

44

45

3.6

3.4

3.7

3.5

3.3

3.8

43

43

44

44

44

44

3.7

3.5

3.8

3.6

3.4

3.2

43

43

43

44

44

44

3.8

3.6

3.4

3.7

3.5

3.4

45

45

45

47

3.6

3.4

3.3

3.7

45

45

45

45

3.7

3.6

3.4

3.2

44

45

45

45

3.2

3.7

3.5

3.4

44

44

44

45

45

45

45

45

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

0.60

Manifold

Pressure

Orifice

No.

0.62

Manifold

Pressure

Orifice

No.

0.64

Manifold

Pressure

42

43

43

3.2

3.7

3.4

42

43

43

3.3

3.8

3.6

42

42

43

3.4

3.2

3.7

3.7

3.5

3.3

3.8

3.6

3.4

3.2

3.1

44

44

44

44

45

45

45

45

3.8

3.6

3.4

3.2

3.7

3.5

3.4

3.2

43

44

44

44

45

45

45

45

3.5

3.7

3.5

3.3

3.8

3.6

3.5

3.3

44

44

45

45

45

45

45

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

43

44

3.8

3.6

3.4

3.6

42

43

43

44

3.3

3.7

3.5

3.8

42

43

43

43

3.4

3.8

3.6

3.4

3.4

3.2

3.7

3.5

3.3

3.2

3.0

44

44

45

45

45

45

45

3.5

3.3

3.8

3.6

3.4

3.3

3.1

44

44

44

45

45

45

45

3.7

3.5

3.3

3.7

3.5

3.4

3.2

Orifice

No.

42

0.66

Manifold

Pressure

3.4

42

43

43

44

44

44

3.2

3.7

3.5

3.8

3.6

3.5

44

45

45

45

3.3

3.8

3.6

3.5

43

43

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

3.5

3.3

3.8

3.6

3.4

3.6

3.4

3.3

3.8

3.6

3.4

44

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.5

3.2

3.7

3.5

3.8

3.6

3.4

3.2

3.7

3.5

3.3

39

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)*

ALTITUDE

RANGE

(FT)

4001 to

5000

ALTITUDE

RANGE

(FT)

5001 to

6000

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

Orifice

No.

43

0.58

Manifold

Pressure

3.7

43

44

44

44

45

45

3.4

3.7

3.5

3.2

3.7

3.5

45

45

45

3.3

3.1

3.0

45

45

45

44

45

45

45

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.6

3.4

3.6

3.4

3.2

3.6

3.4

3.2

3.0

2.9

2.7

2.6

2.5

ALTITUDE

RANGE

(FT)

6001 to

7000

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650

675

700

725

750

775

800

825

850

875

Orifice

No.

0.58

Manifold

Pressure

42

43

44

44

44

45

45

45

45

45

*Orifice numbers shown in BOLD are factory installed.

3.2

3.6

3.8

3.6

3.3

3.8

3.5

3.3

3.1

3.0

Orifice

No.

43

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

3.8

Orifice

No.

42

Manifold

Pressure

3.2

Orifice

No.

42

Manifold

Pressure

3.3

43

44

44

44

45

45

3.5

3.8

3.6

3.4

3.8

3.6

43

43

44

44

44

45

3.7

3.4

3.7

3.5

3.3

3.7

43

43

44

44

44

44

3.8

3.5

3.8

3.6

3.4

3.2

45

45

45

3.4

3.2

3.1

45

45

45

3.5

3.3

3.2

45

45

45

3.6

3.4

3.3

45

45

45

44

45

45

45

45

45

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

44

44

3.7

3.5

3.7

3.5

42

43

43

44

3.2

3.6

3.4

3.6

42

43

43

44

3.3

3.7

3.5

3.7

3.3

3.7

3.5

3.3

3.1

3.0

2.8

2.7

2.5

44

44

45

45

45

45

45

45

45

3.4

3.2

3.6

3.4

3.3

3.1

2.9

2.8

2.6

44

44

45

45

45

45

45

45

45

3.5

3.3

3.8

3.6

3.4

3.2

3.0

2.9

2.7

44

44

44

45

45

45

45

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

0.60

Manifold

Pressure

Orifice

No.

0.62

Manifold

Pressure

Orifice

No.

0.64

Manifold

Pressure

42

43

43

3.3

3.7

3.4

42

43

43

3.4

3.8

3.6

42

42

43

3.5

3.2

3.7

3.7

3.4

3.2

3.7

3.4

3.2

3.1

44

44

44

45

45

45

45

3.8

3.6

3.3

3.8

3.6

3.4

3.2

43

44

44

44

45

45

45

3.4

3.7

3.4

3.2

3.7

3.5

3.3

Orifice

No.

42

0.66

Manifold

Pressure

3.4

42

43

43

44

44

44

3.2

3.7

3.4

3.7

3.5

3.3

45

45

45

3.8

3.6

3.4

45

45

45

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

43

43

43

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

43

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

3.6

3.3

3.8

3.5

3.8

3.5

3.3

3.8

3.6

3.4

40

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)*

ALTITUDE

RANGE

(FT)

7001 to

8000

ALTITUDE

RANGE

(FT)

8001 to

9000

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

Orifice

No.

43

0.58

Manifold

Pressure

3.8

43

44

44

44

45

45

3.5

3.8

3.5

3.3

3.7

3.5

45

45

45

3.3

3.1

2.9

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.8

3.5

3.7

3.5

44

45

45

45

45

3.2

3.6

3.4

3.2

3.0

ALTITUDE

RANGE

(FT)

9001 to

10,000

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

575

600

625

650

675

700

725

750

775

Orifice

No.

43

0.58

Manifold

Pressure

3.8

43

44

44

45

45

45

45

45

3.5

3.7

3.4

3.8

3.6

3.3

3.1

2.9

*Orifice numbers shown in BOLD are factory installed.

Orifice

No.

42

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

3.3

Orifice

No.

42

Manifold

Pressure

3.4

Orifice

No.

42

Manifold

Pressure

3.5

43

43

44

44

45

45

3.7

3.4

3.6

3.4

3.8

3.6

43

43

44

44

44

45

3.8

3.5

3.8

3.5

3.3

3.7

42

43

43

44

44

45

3.2

3.6

3.4

3.6

3.4

3.8

45

45

45

3.4

3.2

3.0

45

45

45

3.5

3.3

3.1

45

45

45

3.6

3.4

3.2

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

42

43

43

44

3.3

3.6

3.4

3.6

42

43

43

44

3.4

3.8

3.5

3.7

42

42

43

44

3.5

3.2

3.6

3.8

44

45

45

45

45

3.3

3.8

3.5

3.3

3.1

44

44

45

45

45

3.4

3.2

3.6

3.4

3.2

44

44

45

45

45

3.6

3.3

3.8

3.5

3.3

Orifice

No.

42

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

3.2

Orifice

No.

42

Manifold

Pressure

3.3

Orifice

No.

42

Manifold

Pressure

3.5

43

44

44

44

45

45

45

45

3.6

3.8

3.5

3.3

3.7

3.4

3.2

3.0

43

43

44

44

45

45

45

45

3.7

3.5

3.7

3.4

3.8

3.6

3.3

3.1

42

43

44

44

44

45

45

45

3.2

3.6

3.8

3.5

3.3

3.7

3.4

3.2

Orifice

No.

42

0.66

Manifold

Pressure

3.6

42

43

43

44

44

44

3.3

3.7

3.5

3.7

3.5

3.3

45

45

45

3.7

3.5

3.3

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.6

3.3

3.7

3.4

44

44

44

45

45

3.7

3.4

3.2

3.6

3.4

Orifice

No.

42

0.66

Manifold

Pressure

3.6

42

43

43

44

44

45

45

45

3.3

3.7

3.4

3.6

3.4

3.8

3.5

3.3

41

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)*

ALTITUDE

RANGE

(FT)

0 to

2000

ALTITUDE

RANGE

(FT)

U.S.A.

Altitudes

2001 to

3000 or

Canada

Altitudes

2001 to

4500

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

Orifice

No.

41

0.58

Manifold

Pressure

3.6

42

42

42

42

43

43

3.8

3.5

3.4

3.2

3.7

3.5

43

43

44

44

3.3

3.2

3.5

3.3

42

42

43

43

43

43

43

43

Orifice

No.

0.58

Manifold

Pressure

41

42

42

3.7

3.8

3.6

3.4

3.2

3.7

3.5

3.3

3.1

3.0

2.8

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

3001 to

4000

750

775

800

825

850

875

900

925

950

975

1000

*Orifice numbers shown in BOLD are factory installed.

43

43

43

43

43

43

43

Orifice

No.

0.58

Manifold

Pressure

41

42

42

42

3.6

3.8

3.5

3.3

3.8

3.6

3.4

3.2

3.1

2.9

2.8

Orifice

No.

41

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

3.7

Orifice

No.

41

Manifold

Pressure

3.8

Orifice

No.

40

Manifold

Pressure

3.6

41

42

42

42

43

43

3.5

3.7

3.5

3.3

3.8

3.6

41

42

42

42

42

43

3.6

3.8

3.6

3.4

3.2

3.7

41

41

42

42

42

42

3.7

3.5

3.7

3.5

3.3

3.2

43

43

44

44

3.4

3.3

3.6

3.4

43

43

43

44

3.6

3.4

3.2

3.5

43

43

43

43

3.7

3.5

3.3

3.2

42

42

43

43

43

43

43

43

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

0.60

Manifold

Pressure

Orifice

No.

0.62

Manifold

Pressure

Orifice

No.

0.64

Manifold

Pressure

41

41

42

3.8

3.6

3.7

40

41

41

3.6

3.7

3.5

40

41

41

3.7

3.8

3.6

3.5

3.3

3.8

3.6

3.4

3.3

3.1

2.9

42

42

42

43

43

43

43

43

3.6

3.4

3.2

3.7

3.5

3.4

3.2

3.0

42

42

42

42

43

43

43

43

3.7

3.5

3.3

3.2

3.7

3.5

3.3

3.1

42

43

43

43

43

43

43

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

41

41

42

42

3.8

3.5

3.7

3.4

40

41

42

42

3.6

3.6

3.8

3.6

40

41

41

42

3.7

3.7

3.5

3.7

3.2

3.7

3.5

3.3

3.2

3.0

2.9

42

42

43

43

43

43

43

3.4

3.2

3.6

3.5

3.3

3.1

3.0

42

42

43

43

43

43

43

3.5

3.3

3.8

3.6

3.4

3.2

3.0

Orifice

No.

40

0.66

Manifold

Pressure

3.8

41

41

42

42

42

42

3.8

3.6

3.8

3.6

3.4

3.3

43

43

43

43

3.8

3.6

3.4

3.3

41

42

42

42

43

43

43

43

Orifice

No.

0.66

Manifold

Pressure

39

40

41

3.6

3.6

3.7

3.5

3.6

3.4

3.3

3.8

3.6

3.4

3.2

42

42

42

43

43

43

43

Orifice

No.

0.66

Manifold

Pressure

40

40

41

42

3.8

3.6

3.6

3.8

3.6

3.4

3.2

3.7

3.5

3.3

3.1

42

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)

4001 to

5000

ALTITUDE

RANGE

(FT)

5001 to

6000

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

Orifice

No.

41

0.58

Manifold

Pressure

3.6

42

42

42

43

43

43

3.7

3.5

3.3

3.7

3.5

3.3

43

43

43

3.1

3.0

2.8

43

43

43

43

43

43

43

43

43

Orifice

No.

0.58

Manifold

Pressure

41

42

42

42

3.5

3.7

3.4

3.2

3.7

3.5

3.3

3.1

2.9

2.7

2.6

2.5

2.3

ALTITUDE

RANGE

(FT)

6001 to

7000

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650

675

700

725

750

775

800

825

850

875

Orifice

No.

0.58

Manifold

Pressure

41

41

42

42

43

43

43

43

43

43

*Orifice numbers shown in BOLD are factory installed.

3.8

3.5

3.6

3.4

3.8

3.6

3.4

3.2

3.0

2.8

Orifice

No.

41

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

3.7

Orifice

No.

41

Manifold

Pressure

3.8

Orifice

No.

40

Manifold

Pressure

3.6

42

42

42

42

43

43

3.8

3.6

3.4

3.2

3.6

3.4

41

42

42

42

43

43

3.6

3.7

3.5

3.3

3.8

3.6

41

42

42

42

42

43

3.7

3.8

3.6

3.4

3.2

3.7

43

43

43

3.3

3.1

2.9

43

43

43

3.4

3.2

3.0

43

43

43

3.5

3.3

3.1

43

43

43

43

43

43

43

43

43

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

41

42

42

42

3.7

3.8

3.5

3.3

41

41

42

42

3.8

3.5

3.7

3.4

40

41

42

42

3.6

3.6

3.8

3.5

3.8

3.6

3.4

3.2

3.0

2.8

2.7

2.6

2.4

42

43

43

43

43

43

43

43

43

3.2

3.7

3.5

3.3

3.1

2.9

2.8

2.6

2.5

42

43

43

43

43

43

43

43

43

3.3

3.8

3.6

3.4

3.2

3.0

2.9

2.7

2.6

42

42

43

43

43

43

43

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

0.60

Manifold

Pressure

Orifice

No.

0.62

Manifold

Pressure

Orifice

No.

0.64

Manifold

Pressure

40

41

42

3.6

3.6

3.7

40

41

41

3.7

3.7

3.5

40

40

41

3.8

3.6

3.6

3.5

3.3

3.7

3.5

3.3

3.1

2.9

42

42

43

43

43

43

43

3.6

3.4

3.8

3.6

3.4

3.2

3.0

42

42

42

43

43

43

43

3.7

3.5

3.3

3.7

3.5

3.3

3.1

Orifice

No.

40

0.66

Manifold

Pressure

3.8

41

41

42

42

42

43

3.8

3.6

3.7

3.5

3.3

3.8

43

43

43

3.6

3.4

3.2

43

43

43

42

42

43

43

43

43

Orifice

No.

0.66

Manifold

Pressure

40

41

41

42

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

42

42

42

43

43

43

43

Orifice

No.

0.66

Manifold

Pressure

39

40

41

3.7

3.7

3.7

3.8

3.6

3.4

3.8

3.6

3.4

3.2

43

ON AND

OFF SWITCH

GAS

PRESSURE

REGULATOR

ADJUSTMENT

BURNER

ENCLOSURE

REFERENCE

PRESSURE

TAP

INLET

PRESSURE TAP

MANIFOLD

PRESSURE TAP

A95622

Fig. 49—Redundant Automatic Gas Valve

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.

BURNER FLAME

BURNER

MANIFOLD

BURNER

ORIFICE

Fig. 50—Burner Flame

A89020

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

% 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.

Table 11—Gas Rate (Cu Ft/Hr)

SECONDS

FOR 1

REVOLUTION

30

31

32

33

34

25

26

27

28

29

15

16

17

18

19

10

11

12

13

14

20

21

22

23

24

40

41

42

43

44

35

36

37

38

39

45

46

47

48

49

90

88

86

84

82

103

100

97

95

92

80

78

76

75

73

120

116

113

109

106

144

138

133

129

124

160

157

153

150

147

180

176

172

167

164

206

200

195

189

185

240

232

225

218

212

180

171

164

157

150

240

225

212

200

189

SIZE OF TEST DIAL SECONDS

1 cu ft

2 cu ft

5 cu ft

FOR 1

REVOLUTION

360

327

300

277

257

720

655

600

555

514

1800

1636

1500

1385

1286

50

51

52

53

54

480

450

424

400

379

360

343

327

313

300

1200

1125

1059

1000

947

900

857

818

783

750

55

56

57

58

59

60

62

64

66

68

288

277

267

257

248

720

692

667

643

621

70

72

74

76

78

600

581

563

545

529

514

500

486

474

462

450

439

429

419

409

400

391

383

375

367

100

102

104

106

108

90

92

94

96

98

80

82

84

86

88

110

112

116

120

33

32

31

30

40

39

38

38

37

45

44

43

42

41

36

35

35

34

33

80

78

76

75

74

90

88

86

84

82

72

71

69

68

67

51

50

48

47

46

SIZE OF TEST DIAL

1 cu ft

2 cu ft

5 cu ft

65

64

63

62

61

72

71

69

68

67

60

58

56

54

53

144

141

138

136

133

131

129

126

124

122

120

116

112

109

106

300

290

281

273

265

327

321

316

310

305

360

355

346

340

333

103

100

97

95

92

257

250

243

237

231

200

196

192

188

184

225

220

214

209

205

180

178

173

170

167

65

64

62

60

164

161

155

150

Follow this same procedure for proper selection of COOL speed selection.

COLOR

Table 12—Speed Selector

Black

Yellow (When Present)

Blue

Red

White

SPEED

High

Medium High

Medium Low

Low

Common

FACTORY-

SHIPPED

CONNECTION

Cool

Spare

Heat

Fan

L2

44

ADJUST BLOWER OFF DELAY (HEAT MODE)

If desired, the main blower off time delay period may be lengthened or shortened when operating in the heating mode to provide greater comfort. Position shunt jumpers as shown in Table

13 and Fig. 25 for location of switches on control center.

Table 13—Blower Off Delay Jumper

Position

DESIRED HEATING

MODE BLOWER OFF

DELAY (SEC)

90

135

180

225

JUMPER POSITION

1-2

2-3

3-4

4-5

SET THERMOSTAT HEAT ANTICIPATOR

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. 51 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.

CHECK SAFETY CONTROLS

Step 1—Check Primary Limit Control

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.

Step 2—Check Pressure Switch

This control proves operation of draft inducer. Check switch operation as follows:

1. Turn off 115-v power to furnace.

2. Remove main furnace door and disconnect inducer motor lead wires from wire harness.

3. Turn on 115-v power to furnace.

THERMOSTAT SUBBASE

TERMINALS WITH

THERMOSTAT REMOVED

HOOK-AROUND

VOLT/AMMETER

R Y W G

10 TURNS

FROM UNIT 24-VOLT

TERMINAL BLOCK

EXAMPLE:

5.0 AMPS ON AMMETER

10 TURNS AROUND JAWS

= 0.5 AMPS FOR THERMOSTAT SETTING

Fig. 51—Amp Draw Check with Ammeter

A80201

4. Set thermostat to call for heat and wait 1 minute. When pressure switch is functioning properly, hot surface ignitor 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.

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.

2. Verify manual reset switch has continuity.

3. Verify that blower and control access doors are properly installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instructions.

6. Review User’s Guide with owner.

7. Leave literature packet near furnace.

45

________

________

________

________

________

________

CHECKLIST—INSTALLATION

LOAD CALCULATION

____________ 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

Condensate Drain

________

________

________

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

Pipe Insulation

________ Over Ceilings

________ Low-Ambient Exposed Pipes

________ Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Check Operation

________

________

Primary Limit

Pressure Switch

46

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:

• Unit Familiarization

• Installation Overview

• Maintenance

• 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

47

Copyright 2000 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58mxa10si

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4

Tab 6a 8a

PC 101 Catalog No. 535-759 Printed in U.S.A.

Form 58MXA-10SI Pg 48 1-00 Replaces: New

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