58PAV

Upflow Induced-Combustion Furnaces

Installation, Start-Up, and Operating Instructions

Sizes 045-155, Series 161

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

This symbol

→ indicates a change since the last issue.

Index Page

SAFETY CONSIDERATIONS .....................................................1

Clearances From Combustible Materials .................................1

Dimensional Drawing ...............................................................2

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE........................................................................2-3

INTRODUCTION ..........................................................................3

LOCATION....................................................................................3

General ......................................................................................3

Location Relative to Cooling Equipment ................................3

Hazardous Locations.................................................................3

AIR FOR COMBUSTION AND VENTILATION ...................3-5

Unconfined Space .....................................................................4

Confined Space......................................................................4-5

FILTER ARRANGEMENT .......................................................5-6

LEVELING LEGS (IF REQUIRED).........................................5-6

GAS PIPING...............................................................................6-7

ELECTRICAL CONNECTIONS ..................................................7

115-v Wiring.............................................................................7

24-v Wiring...............................................................................7

Accessories................................................................................7

VENTING ......................................................................................7

START-UP, ADJUSTMENT, AND SAFETY CHECK .........7-14

General...................................................................................7-8

Sequence Of Operation .......................................................8-11

Heating Mode............................................................................9

Cooling Mode ...........................................................................9

Continuous Blower Mode.........................................................9

Heat Pump Mode.................................................................9-11

Start-Up Procedures ................................................................11

Adjustments .......................................................................11-13

Set Gas Input Rate ............................................................11-12

Set Temperature Rise ........................................................12-13

Set Thermostat Heat Anticipator............................................13

Check Safety Controls ............................................................14

Checklist..................................................................................14

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety

→ precautions that may apply.

Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No.

54-1992/ANSI Z223.1-1992. In Canada, refer to the current

® ama

CANADIAN GAS ASSOCIATION

R

A PP R O VED edition of the National Standard of Canada CAN/CGA-B149.1and .2-M95 Natural Gas and Propane Installation Codes (NSC-

NGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls.

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

When you see this symbol on the furnace and in instructions or manuals, be alert to the 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 the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which

could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We require these instructions as a minimum for a safe installation.

Table 1—Minimum Clearances To

Combustible Materials (In.)

Sides

Back

Plenum Top

Vent

Front

UNIT SIZE

Single-Wall Vent

Type B-1 Double-Wall Vent

Single-Wall Vent

Type B-1 Double-Wall Vent

Single-Wall Vent

Type B-1 Double-Wall Vent

Service

045 AND 070 090-155

1 0

0

0

1

0

0

1

6

1

6

3

30

6

3

6

1

30

NOTES:

1. Provide 30-in. front clearance for servicing. An open door in front of the unit can meet this requirement.

2. A minimum clearance of 3 in. must be provided in front of the unit for combustion air and proper operation.

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

Book 1 4

Tab 6a 8a

PC 101 Catalog No. 565-848 Printed in U.S.A.

Form 58PA-12SI Pg 1 1-96 Replaces: 58PA-11SI

39 7 ⁄

8

″

28 1 ⁄

2

″

FLUE COLLAR

7 ⁄

8

-IN. DIA HOLE

POWER ENTRY

7 ⁄

8

-IN. DIA

ACCESSORY

1 3 ⁄

4

-IN.

DIA HOLE

GAS ENTRY

1 ⁄

2

-IN. DIA HOLE

THERMOSTAT

WIRE ENTRY

2 1 ⁄

16

″

1

″

5 3 ⁄

8

″

5 13 ⁄

16

″

12 5 ⁄

16

″

2 3 ⁄

8

″

A

D

13 ⁄

16

″

5 3 ⁄

8

″

5 13 ⁄

16

″

11 ⁄

16

″

2 3 ⁄

8

″

2 1 ⁄

16

″

AIRFLOW

19

″

1

″ OUTLET

7 ⁄

8

-IN. DIA

POWER ENTRY

1 1 ⁄

2

-IN.

DIA

R.H. GAS ENTRY

7 ⁄

8

-IN. DIA ACCESSORY

1 ⁄

2

-IN. DIA THERMOSTAT

WIRE ENTRY

13 ⁄

16

″

SIDE INLET SIDE INLET

14 1 ⁄

2

″

TYP 1

″

1 3 ⁄

4

″

11 ⁄

16

″

24 5 ⁄

16

″

AIR INLET

3

″

11 ⁄

16

″

E

11 ⁄

16

″

5 ⁄

8

″

TYP

23 1 ⁄

4

″

SIDE RETURN

DUCT LOCATION

1

″

NOTES: 1. Two additional 7 ⁄

8

-in. dia knockouts are located in the top plate.

2. Minimum return-air opening at furnace:

a. For 800 CFM–16-in. round or 14 1

b. For 1200 CFM–20-in. round or 14

⁄

2

1

x 12-in. rectangle.

⁄

2

x 19 1 ⁄

2

-in. rectangle.

c. For 1600 CFM–22-in. round or 14 1 ⁄

2

x 23 1 ⁄

4

-in. rectangle.

d. For airflow requirements above 1800 CFM, use both side inlets,

a combination of 1 side inlet and the bottom, or the bottom only.

A88367

Fig. 1—Dimensional Drawing

UNIT SIZE

045-08

045-12

070-08

070-12

090-14

090-16

111-12

111-16

111-20

135-16

135-20

155-20

A

14-3/16

14-3/16

14-3/16

14-3/16

17-1/2

21

17-1/2

21

24-1/2

21

24-1/2

24-1/2

Table 2—Dimensions (In.)

D

12-9/16

12-9/16

12-9/16

12-9/16

15-7/8

19-3/8

15-7/8

19-3/8

22-7/8

19-3/8

22-7/8

22-7/8

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE

E

12-11/16

12-11/16

12-11/16

12-11/16

16

19-1/2

16

19-1/2

23

19-1/2

23

23

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.

VENT CONN

4

4

4

4

4

4

4

4

4

5

5

5

SHIP. WT (LB)

122

124

132

134

150

154

160

166

184

178

194

204

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.).

2

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 Model 58PAV, Series 161 Furnace is available in sizes 45,000 through 155,000 Btuh input capacities.

The design of the upflow gas-fired furnace is A.G.A./C.G.A.

certified for natural and propane gas and for installation on combustible flooring, in alcoves, attics, basements, closets, or utility rooms. The design of this furnace line is not A.G.A./C.G.A.

certified for installation in mobile homes, recreation vehicles, or outdoors.

Before installing the furnace, refer to the current edition of the

NFGC. Canadian installations must be installed in accordance with

NSCNGPIC and all authorities having jurisdiction. For further information, the NFGC is available from National Fire Protection

Association Inc., Batterymarch Park, Quincy, MA 02269; American Gas Association, 1515 Wilson Boulevard, Arlington, VA

22209; or from Literature Distribution.

Installation must conform to the regulations of the serving gas supplier and the local building, heating, and plumbing codes in effect in the area in which the installation is made, or in the absence of local codes with the requirements of the NFGC.

Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, and unit sizing. Improper installation or misapplication of the furnace can require excessive servicing or cause premature component failure.

This furnace is designed for a minimum continuous return-air temperature of 60°F db or an intermittent operation down to 55°F db such as when used with a night setback thermostat. Return-air temperature must not exceed a maximum of 85°F db.

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this product. Failure to follow this warning can cause electrical shock, fire, personal injury, or death.

For accessory installation details, refer to the applicable instruction literature.

NOTE: Remove all shipping brackets and materials before operating the furnace.

Step 1—Location

GENERAL

Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.

→

Do not use this furnace during construction when adhesives, sealers, and/or new carpets are being installed. If the furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine when burned with combustion air form acids which cause corrosion of the heat exchangers and metal vent system.

Some of these compounds are found in paneling and dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction process.

Excessive exposure to contaminated combustion air will result in safety and performance related problems.

This furnace must be installed so the electrical components are protected from water. This furnace shall not be installed directly on carpeting, tile, or any combustible material other than wood flooring.

Locate furnace as close to the chimney/vent and as near the center of the air distribution system as possible. The furnace should be installed as level as possible.

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.

Provide ample space for servicing and cleaning. Always comply with the minimum fire protection clearances shown on the unit rating plate.

LOCATION RELATIVE TO COOLING EQUIPMENT — The cooling coil must be installed parallel with or on the downstream side of the unit to avoid condensation in the heat exchangers.

When installed parallel with a furnace, dampers or other means used to control the flow of air must prevent chilled air from entering the unit. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full-heat or full-cool position.

HAZARDOUS LOCATIONS — When the furnace is installed in a residential garage, it must be installed so that the burners and ignition source are located at least 18 in. above the floor. The furnace should be protected from physical damage by vehicles.

When a furnace is installed in public garages, airplane hangars, or other buildings having hazardous atmospheres, the unit must be installed in accordance with the recommended good practice requirements of the National Fire Protection Association, Inc.

Step 2—Air For Combustion and Ventilation

Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3 of the NFGC, Air for

Combustion and Ventilation, or applicable provisions of the local building codes.

Canadian installations must be installed in accordance with NSC-

NGPIC and all authorities having jurisdiction.

3

SUPPLY

AIR VENT THROUGH ROOF

Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

All fuel-burning equipment must be supplied with air for combustion of the fuel. Sufficient air MUST be provided to ensure there will not be a negative pressure in the equipment room or space. In addition, a positive seal MUST be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and draft safeguard opening.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, or fireplaces could create a NEGATIVE

PRESSURE CONDITION at the furnace. Make-up air MUST

BE PROVIDED for the ventilation devices, in addition to that required by the furnace.

The requirements for combustion and ventilation air depend upon whether the furnace is located in an unconfined or confined space.

UNCONFINED SPACE — An unconfined space must have at least 50 cubic ft for each 1000 Btuh of input for all the appliances

(such as furnaces, clothes dryer, water heaters, etc.) in the space.

For Example:

58PAV FURNACE

INPUT BTUH

44,000

66,000

88,000

110,000

132,000

154,000

MINIMUM SQ FT WITH

7-1/2 FT CEILING

293

440

587

733

880

1026

If the unconfined space is constructed unusually tight, air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the outdoors. Combustion and ventilation openings must be sized the same as for a confined space. A minimum opening with a total of at least 1 sq in. per 5000

Btuh of total input rating for all equipment must be provided.

Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room.

CONFINED SPACE

A confined space has volume less than 50 cu ft per 1000 Btuh of the total input rating for all appliances installed in that space. A confined space MUST have 2 permanent openings, 1 within 12 in.

of the ceiling and the other within 12 in. of the floor. (See Fig. 2.)

NOTE: In determining the free area of an opening, the blocking effect of the louvers, grilles, and screens must be considered. If the free area of a louver or grille design is unknown, it may be assumed that wood louvers have a 20 percent free area, and metal louvers or grilles have a 60 percent free area. Screens, when used, must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed.

The size of the openings depends upon whether the air comes from inside or outside of the structure.

INTERIOR

HEATED

SPACE

12

″

MAX

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

UNCONFINED

SPACE

6

″

MIN

(FRONT) †

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

12

″

MAX

RETURN AIR

* Minimum opening size is 100 square in. with

minimum dimensions of 3-In.

† Minimum of 3-In. when type-B1 vent is used.

A89012

Fig. 2—Air For Combustion and Ventilation

(Inside Air)

1. All air from inside the structure: a. Each opening MUST have at least 1 sq in. of free area per

1000 Btuh of the total input for all equipment within the confined space, but not less than 100 sq in. per opening.

(See Fig. 2.)

For Example:

58PAV FURNACE

INPUT BTUH

44,000

66,000

88,000

110,000

132,000

154,000

FREE AREA PER OPENING

(SQ IN.)

100

100

100

110

132

154 b. If the building is constructed unusually tight, a permanent opening directly communicating with the outdoors should be provided. This opening shall have a minimum free area of 1 sq in. per 5000 Btuh of total input rating for all equipment in the enclosure.

c. If the furnace is installed on a raised platform to provide a return-air plenum, and return air is taken directly from the hallway or space adjacent to the furnace, all air for combustion must come from outdoors.

4

2. All air from outside the structure: a. If combustion air is taken from outdoors through vertical ducts, the openings and ducts MUST have at least 1 sq in.

of free area per 4000 Btuh of the total input for all equipment within the confined space. (See Fig. 3.)

For Example:

58PAV FURNACE

INPUT BTUH

44,000

66,000

88,000

110,000

132,000

154,000

FREE AREA PER OPENING

(SQ IN.)

11.0

16.5

22.0

27.5

33.0

38.5

ROUND PIPE

(IN. DIA)

4

5

6

6

7

7 b. If combustion air is taken from the outdoors through horizontal ducts, the openings and ducts MUST have at least 1 sq in. of free area per 2000 Btuh of the total input for all equipment within the confined space.

For Example:

58PAV FURNACE

INPUT BTUH

44,000

66,000

88,000

110,000

132,000

154,000

FREE AREA PER OPENING

(SQ IN.)

22.0

33.0

44.0

55.0

66.0

77.0

ROUND PIPE

(IN. DIA)

6

7

8

9

10

10 c. When ducts are used, they must be of the same crosssectional area as the free area of the openings to which they connect. The minimum dimension of rectangular ducts must not be less than 3 in. (See Fig. 3.)

Do not install the furnace on its back; safety control operation will be adversely affected. Never connect return-air ducts to the back of the furnace. A failure to follow this warning can cause a fire, personal injury, or death.

Step 3—Filter Arrangement

The factory-supplied filter(s) is shipped in the blower compartment. Determine location for the filter and relocate filter retaining wire if necessary. See Fig. 4 for side return application and Fig. 5 for bottom return application. See Table 3 to determine correct filter size for desired filter location. Table 3 indicates filter size, location, and quantity shipped with the furnace.

For bottom air-return applications, filter may need to be cut to fit some furnace casing widths. A bottom closure panel is factory installed in the bottom of the furnace. When bottom return inlet is desired, remove and discard the bottom closure panel. Two sets of hardware are needed for furnaces in 24-1/2-in. wide casings using

2 filters for bottom return. All hardware is provided for filter installation.

NOTE: Furnaces with a 17-1/2-in. wide casing require an additional procedure when locating the filter for bottom return-air application. Field fabricate a sheet metal filler strip 1 X 3 X 24-1/2 in. and install it along side of the filter as shown in Fig. 5. Drive

2 screws through the casing side and into the filler strip to secure it in place. Filter should rest on the top of the filler strip when installed.

5

DUCTS

TO

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

12

″

MAX

1 SQ IN.

PER 2000

BTUH*

A

SUPPLY

AIR

D

VENT

THROUGH

ROOF

12

″

MAX

F

1 SQ IN.

PER

4000

BTUH*

DUCTS

TO

OUTDOORS

1 SQ IN.

PER 2000

BTUH*

12

″

MAX

B

E G

C

12

″

MAX

1 SQ IN.

PER

4000

BTUH*

12

″

MAX

RETURN AIR

DUCT

TO

OUTDOORS

*Minimum dimensions of 3-In.

NOTE: Use any of the following combinations of openings:

A & B C & D D & E F & G

1 SQ IN.

PER 4000

BTUH*

A89013

Fig. 3—Air For Combustion and Ventilation

(Outside Air)

WASHABLE

FILTER

FILTER

RETAINER

Fig. 4—Side Filter Arrangement

(Control Removed for Clarity)

A93045

Never operate unit without a filter or with filter access door removed. Failure to follow this warning can cause fire, personal injury, or death.

Step 4—Leveling Legs (If Required)

When the furnace is used with side inlet(s) and leveling legs are required, refer to Fig. 6, and install field-supplied, corrosionresistant 5/16-in. machine bolts and nuts.

5 ⁄

16

″

3

″

5 ⁄

16

″

24 1 /

2

″

1

″

1 3 ⁄

4

″

1 3 ⁄

4

″

FIELD-SUPPLIED

FILTER FILLER

STRIP FOR

17 1 ⁄

2

-IN. WIDE

CASINGS ONLY.

INSTALL UNDER

FILTER.

WASHABLE

FILTER

5 ⁄

16

″

5 ⁄

16

″

1 3 ⁄

4

″

1 3 ⁄

4

″

A89014

Fig. 6—Leveling Leg Installation

Refer to Table 4 for the recommended gas pipe size. Risers must be used to connect to the furnace and the meter.

If a flexible connector is required or allowed by the authority having jurisdiction, black iron pipe shall be installed at the gas valve and extend a minimum of 2 in. outside the furnace casing.

FILTER

SUPPORT

FILTER

RETAINER

Table 4—Maximum Capacity of Pipe*

A93321

Fig. 5—Bottom Filter Arrangement

(Control Removed for Clarity)

Table 3—Filter Information (In.)

FURNACE

CASING WIDTH

14-3/16

17-1/2

21

24-1/2

FILTER SIZE*

Side Return Bottom Return

(1) 16 X 25 X 1† (1) 14 X 25 X 1

(1) 16 X 25 X 1† (1) 16 X 25 X 1

(1) 16 X 25 X 1

(2) 16 X 25 X 1†

(1) 20 X 25 X 1†

(1) 24 X 25 X 1

FILTER TYPE

Cleanable

Cleanable

Cleanable

Cleanable

* Filters can be field modified by cutting to the desired size. Alternate sizes can be ordered from your distributor or dealer.

† Factory-provided with the furnace.

NOTE: The maximum length of the bolt should not exceed 1-1/2 in.

1. Lay furnace on its back. Locate and drill 5/16-in. diameter hole in each bottom corner of furnace as shown in Fig. 6.

2. Install nut on bolt and 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.

Step 5—Gas Piping

Gas piping must be installed in accordance with national and local codes. Refer to the current edition of the NFGC. Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction.

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

LENGTH OF PIPE (FT)

20 30 40 50

175 120 97 82 73

360 250 200 170 151

680 465 375 320 285

1400 950 770 660 580

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 54-1992.

6

→

Piping should be pressure tested in accordance with local and national plumbing and gas codes before the furnace has been attached. If the pressure exceeds 0.5 psig (14-in. wc), the gas supply pipe must be disconnected from the furnace and capped before the pressure test. If the test pressure is equal to or less than

0.5 psig (14-in. wc), turn off electric shutoff switch located on the gas valve before the test. It is recommended that the ground joint union be loosened before pressure testing. After all connections have been made, purge the lines and check for leakage with regulated gas supply pressure.

Install a sediment trap in the riser leading to the furnace. The trap can be installed by connecting a tee to the riser leading from the furnace. Connect a capped nipple into the lower end of the tee. The capped nipple should extend below the level of the gas controls.

(See Fig. 7.)

Apply joint compound (pipe dope) sparingly and only to the male threads of each joint. The compound must be resistant to the action of propane gas.

GAS

SUPPLY

MANUAL

SHUTOFF

VALVE

(REQUIRED)

SEDIMENT

TRAP

UNION

A89417

→

Fig. 7—Typical Gas Pipe Arrangement

→

An accessible manual shutoff valve MUST be installed upstream of the furnace gas controls and within 72 in. of the furnace. A

1/8-in. NPT plugged tapping, accessible for test gage connection,

MUST be installed immediately upstream of the gas supply connection to the furnace and downstream of the manual shutoff valve. Place ground joint union between the gas control manifold and the manual shutoff valve.

Use the proper length of pipes to avoid stress on the gas control manifold. Failure to follow this warning can result in a gas leak, causing fire, explosion, personal injury, or death.

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

Never purge a line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap-and-water solution to check for leakage. Failure to follow this warning can cause a fire, explosion, personal injury, or death.

Step 6—Electrical Connections

115-V WIRING — Refer to the unit rating plate or Table 5 for equipment electrical requirements. The control system requires an earth ground for proper operation.

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.

→

Make all electrical connections in accordance with the National

Electrical Code (NEC) ANSI/NFPA 70-1996 and local codes or ordinances that might apply. For Canadian installations, all elec-

7

→ trical connections must be made in accordance with CSA C22.1

Canadian Electrical Code, or authorities having jurisdiction.

The cabinet MUST have an uninterrupted or unbroken ground according to NEC, ANSI/NFPA 70-1996 and Canadian

Electrical Code, CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electrical shock, fire, or death.

The auxiliary junction box (J-box) can be moved to the left-hand side of the furnace when a left-side power supply is desired.

Remove the 2 screws holding the auxiliary J-box. Mount the J-box on the left-hand side of the furnace (holes have been pre-drilled in casing). When moved, tuck the wiring harness behind the clip provided to keep extra wire lengths out of the way.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control board fault code indicator light will flash rapidly and the furnace will not operate.

24-V WIRING

Make field 24-v connections at the 24-v terminal strip. (See Fig.

9.) Connect terminal Y as shown in Fig. 8 for proper cooling operation. Use only AWG No. 18, color-coded, copper thermostat wire.

The 24-v circuit contains an automotive-type, 3-amp fuse located on the main control board. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp fuse of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC)

Two quick-connect terminals, marked EAC-1 and EAC-2 are provided for EAC connection. (See Fig. 9.) These terminals are energized with 115-v, (1.5-amp maximum) during blower motor operation.

2. Humidifier (HUM)

Quick-connect terminal (HUM) and screw terminal (Com) are provided for 24-v humidifier connection. The terminals are energized with 24-v 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.

→

Step 7— Venting

Refer to the National or Local Installation Code such as; National

Fuel Gas Code Z223.1-1992, or the Canadian Installation Code,

CAN B149.1- and .2-M95, for proper vent sizing and installation requirements. Use the enclosed Venting Tables for Category I

Fan-Assisted Furnaces for a quick, easy reference. The horizontal portion of the venting system shall maintain a minimum of 1/4-in.

upward slope per linear ft and it shall be rigidly supported every 5 ft or less with hangers or straps to ensure that there will be no movement after installation.

Step 8—Start-Up, Adjustment, and Safety Check

GENERAL

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control board fault indicator light will flash rapidly and furnace will not operate.

FIELD 24-VOLT WIRING

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

FACTORY 24-VOLT WIRING

FACTORY 115-VOLT WIRING

BLK

WHT

GND

BLK

WHT

FIVE

WIRE

THREE-WIRE

HEATING-

ONLY

NOTE 2

W C

W

R

R

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

GND

AUXILIARY

J-BOX

CONTROL

BOX

G

C

Y

24-VOLT

TERMINAL

BLOCK

FURNACE

G Y

THERMOSTAT

TERMINALS FIELD-SUPPLIED

FUSED DISCONNECT

208/230- OR

460-VOLT

THREE

PHASE

NOTE 1

NOTES: 1.

2.

3.

208/230-

VOLT

SINGLE

PHASE

GND

TWO

WIRE

CONDENSING

UNIT

Connect Y-terminal as shown for proper 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.

A95241

Fig. 8—Heating and Cooling Application Wiring Diagram

Table 5—Electrical Data

UNIT SIZE

VOLTS—

HERTZ—

PHASE

OPERATING

VOLTAGE RANGE

MAXIMUM

UNIT AMPS

MINIMUM

WIRE GAGE

MAXIMUM

WIRE LENGTH (FT)‡

Maximum* Minimum*

045-08

045-12

070-08

070-12

090-14

090-16

111-12

111-16

111-20

135-16

135-20

155-20

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

127

127

127

127

127

127

127

127

127

127

127

127

104

104

104

104

104

104

104

104

104

104

104

104

6.0

8.3

5.9

8.7

9.0

10.4

8.0

10.1

14.4

10.1

13.3

14.0

14

14

14

14

14

14

14

14

12

14

12

12

* Permissible limits of the voltage range at which the unit operates satisfactorily.

† Time-delay fuse is recommended.

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

31

27

35

28

31

28

47

34

47

32

33

31

The furnace must have a 115-v power supply properly connected and grounded. Proper polarity must be maintained for correct operation. Thermostat wire connections at R, W, C, and Y must be made at the 24-v terminal block on the control board. The gas service pressure must not exceed 0.5 psig (14-in. wc), but must be no less than 0.16 psig (4.5-in. wc).

MAXIMUM

FUSE OR

HACR-TYPE CKT

BKR AMPS†

15

15

15

15

15

15

15

15

20

15

20

20

The blower compartment door must be in place to complete the

115-v circuit to the furnace.

SEQUENCE OF OPERATION

This furnace is equipped with a manual reset limit switch or fuse link in the gas control area. The switch or fuse link opens and shuts off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area. DO NOT bypass the switch. Correct inadequate combustion air supply problem and reset the switch or replace the fuse link.

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

Furnace control must be grounded for proper operation, or control will lockout. Control is grounded through green wire routed to gas valve and burner bracket screw.

Using the schematic diagram shown in Fig. 10, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If there is a power interruption and any thermostat call, the control initiates a 90-sec blower only on period before starting another cycle.

8

24-V THERMOSTAT

TERMINALS

TEST/TWIN

HUM

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX)

LED OPERATION &

DIAGNOSTIC LIGHT

HARNESS CONNECTOR

SEC-1

3-AMP FUSE

COOL

HEAT

24-V TRANSFORMER SEC-2

SPARE-1

BLOWER SPEED

SELECTION TERMINALS

SPARE-2

EAC-1

115-VAC (L1)

POWER SUPPLY

HOT SURFACE

IGNITOR CONNECTOR

EAC-ELECTRONIC AIR CLEANER

TERMINALS (115-VAC 1.5 AMP MAX)

EAC-2

115-VAC (L2) NEUTRAL

CONNECTION

INDUCER MOTOR

CONNECTOR

A95086

Fig. 9—Control Board

1. Heating mode

When the wall thermostat "calls for heat," the R-W circuit closes. The furnace control performs a self-check, verifies the pressure switch contacts are open, and starts inducer motor.

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

b. Ignitor warm-up—At the end of the prepurge period, the ignitor is energized for a 17-sec ignitor warm-up period.

c. Ignition sequence—When the ignitor warm-up period is completed, the gas valve opens, permitting gas flow to the burners where it is ignited. After 5 sec, the ignitor is de-energized and a 2-sec flame-sensing period begins.

d. HUM terminal is energized with the gas valve. See accessories in the Electrical Connections section.

e. Flame-sensing—When burner flame is sensed, the control begins the blower on delay period and continues holding the gas valve open. If burner flame is not sensed, the control closes the gas valve and repeats ignition cycle.

NOTE: Ignition sequence will repeat 3 additional times before a lockout occurs. Lockout automatically resets after 3 hrs, or can be manually reset by turning 115v off (not at thermostat) for 3 sec minimum, then on again.

f. Blower on delay—Forty sec after burner flame is proven, the blower motor is energized on heating speed. Simultaneously, the humidifier and electronic air cleaner terminals

(HUM and Com for humidifier, EAC-1 and EAC-2 for electronic air cleaner) are energized.

g. Blower off delay—When the thermostat is satisfied, the circuit between R-W is broken, de-energizing the gas valve stopping gas flow to the burners. The blower motor and

EAC remain energized for 135 sec.

h. Post-purge—The inducer motor remains energized 5 sec after the burners are extinguished.

2. Cooling mode

When the thermostat "calls for cooling," R-G and R-Y circuits close. The R-Y circuit starts the outdoor condensing unit and the combined R-Y and R-G circuits start the furnace blower motor on cooling speed. The EAC-1 terminal is energized with 115v when the blower is operating on cooling speed.

When the thermostat is satisfied, R-G and R-Y circuits are broken. The furnace blower and EAC continue operating on cooling speed for an additional 90 sec.

3. Continuous blower mode

NOTE: EAC-1 terminal is energized with 115v whenever blower operates.

When the R-G circuit is made, the blower motor operates on heating speed. During a call for heat, the blower stops, allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the 40-sec blower on delay period.

The blower reverts to continuous operation after the heating cycle is completed.

When the thermostat "calls for cooling," the blower operates on cooling speed. When the thermostat is satisfied, the blower operates an additional 90 sec before reverting back to continuous operation on heating speed.

4. Heat pump mode

When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off time during demand defrost cycles. When the W-Y or

9

TRAN

MP 1.5 A

WHT

BLK

BLK

BLK

WHT

10

W-Y-G thermostat inputs are received at the same time, the control changes the blower to heating speed or starts the blower if it was off, and begins a heating cycle. The blower remains on until the end of the prepurge period, then shuts off until the end of the ignition warm-up and trial for ignition periods (a total of 24 sec). The blower then comes back on at heating speed.

When the W input signal disappears, the control begins the normal inducer post-purge period and the blower changes to cooling speed after a 1-sec delay. If the W-Y-G signals disappear at the same time, the blower remains on for the selected heating blower off delay period and the inducer goes through its normal post-purge period. If the W-Y inputs should disappear, leaving the G signal input, the control goes into continuous blower and the inducer remains on for the normal post-purge period.

Anytime the control senses false flame, the control locks out of the heating mode. This occurs because the control cannot sense the W input due to the false flame signal, and as a result, sees only the Y input and goes into cooling mode, blower off delay. All other control functions remain in standard format.

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

HUM terminal is only energized when gas valve is energized

START-UP PROCEDURES

1. Purge gas lines—After all connections have been made, purge the lines and check for leaks.

There are 2 methods of adjusting the gas input rate. The preferred method is by using Table 6 and following the instructions in item a. The second method is by clocking the gas meter and using the instructions in item b.

The gas valve regulator has been nominally set at 3.5-in. wc for natural gas. When adjusting input rate, do not set manifold pressure above 3.8-in. wc or below 3.2-in. wc.

a. Check gas input rate using Table 6.

(1.) Obtain average yearly heat value for local gas supply.

(2.) Obtain average yearly specific gravity for local gas supply.

(3.) Verify furnace model. Table 6 can only be used for model 58PAV Furnaces.

(4.) Check and verify orifice size in furnace. NEVER

ASSUME THE ORIFICE SIZE. ALWAYS CHECK

AND VERIFY.

(5.) Find natural gas heat value and specific gravity in

Table 6.

(6.) Follow heat value and specific gravity lines to point of intersection. Find orifice size and manifold pressure settings for proper operation at given natural gas conditions.

EXAMPLE:

Heat value 1070 Btu/cu ft

Specific gravity 0.58

Therefore; Orifice No. 44*

Manifold pressure 3.3-in. wc

* The furnace is shipped with No. 43 orifices.

Therefore, in this example all main burner orifices must be changed and manifold pressure must be adjusted.

(7.) Proceed to item c to adjust manifold pressure.

b. Check gas input rate by clocking gas meter.

(1.) Obtain average yearly heat value for local gas supply.

(2.) Check and verify orifice size in furnace. NEVER

ASSUME THE ORIFICE SIZE. ALWAYS CHECK

AND VERIFY.

Never purge a line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for the purpose of checking leakage. Use a soap-and-water solution to check for leakage. Failure to follow this warning can cause fire, explosion, personal injury, or death.

2. Component test—The furnace control board allows all components, except gas valve, to be run for a short period of time.

This feature helps diagnose a system problem in case of a component failure. To initiate component test procedure, short

(jumper) the TEST 1/4-in. quick connect terminal on control board (adjacent to diagnostic light) and the Com terminal on thermostat connection block for approximately 2 sec. (See Fig.

9.)

NOTE: Component test feature will not operate if any thermostat signal is present at control board.

Component test sequence is as follows.

a. Momentarily jumper TEST and Com terminals until LED goes off.

b. LED will display previous fault 4 times.

c. Inducer motor operates for 10 sec, then stops.

d. Hot surface ignitor is energized for 15 sec, then deenergized.

e. Blower motor operates on cooling speed for 10 sec, then stops.

f. Blower motor operates on heating speed for 10 sec, then stops.

3. To operate furnace, follow procedures on operating instructions label attached to furnace.

4. With furnace operating, set thermostat below room temperature and observe that furnace goes off. Set thermostat above room temperature and observe that furnace restarts.

ADJUSTMENTS

1. Set gas input rate.

11

DO NOT redrill burner orifices. Improper drilling (burrs, out of round, etc.) can cause excessive burner operating noise and misdirection of burner flames. This could result in flame impingement on burners and heat exchanger surfaces, leading to potential failures.

(3.) Turn off all other gas appliances and pilots.

(4.) Start furnace and let run for 3 minutes.

(5.) Measure time (in sec) for gas meter to complete 1 revolution.

(6.) Refer to Table 7 for cu ft of gas per hr.

(7.) Multiply gas rate (cu ft/hr) by heating value (Btu/cu ft).

EXAMPLE:

Btu heating input = Btu/cu ft X cu ft/hr

Heating value of gas = 1070 Btu/cu ft

Time for 1 revolution of 2 cu ft dial = 72 sec

Gas rate = 100 X 1070 = 107,000 Btuh

(8.) Measured gas input should not exceed gas input on unit rating plate.

GAS HEAT

VALUE

(Btu/cu ft)

860

875

890

905

920

935

950

965

980

995

1010

1025

1040

1055

1070

1085

1100

44

43

44

—

43

—

44

43

44

—

43

—

43

—

43

—

44

—

45

—

45

—

44

—

44

—

Orf

No.

0.56

Mnfld

Press.

41

42

—

42

—

—

42

—

—

42

—

—

3.2

3.6

—

3.4

—

—

3.3

—

—

3.2

—

—

3.4

—

3.3

—

3.2

—

3.8

—

3.7

—

3.4

—

3.8

3.3

3.7

3.2

3.6

—

3.5

—

3.8

—

3.7

—

3.6

—

44

43

44

43

43

—

42

—

44

43

42

—

43

—

43

—

44

—

44

—

45

—

44

—

44

—

Orf

No.

0.58

Mnfld

Press.

41

42

—

41

42

—

42

—

—

42

—

—

3.3

3.7

—

3.2

3.6

—

3.4

—

—

3.3

—

—

3.5

—

3.4

—

3.3

—

3.2

—

3.8

3.4

3.6

—

3.5

—

3.8

3.4

3.7

3.3

3.6

3.2

3.2

—

3.8

—

3.7

—

Table 6—Model 58PAV Orifice Size and Manifold Pressure for Correct Input Rate

(Tabulated Data Based on Altitude Up to 2000 Ft and 22,000 Btuh Per Burner)

43

—

44

43

43

—

43

—

44

43

42

—

42

—

43

—

44

—

44

—

44

—

44

43

44

—

Orf

No.

0.60

Mnfld

Press.

41

42

40

41

42

—

41

42

—

42

—

—

3.4

3.8

3.2

3.3

3.7

—

3.2

3.6

—

3.4

—

—

3.6

3.2

3.5

—

3.4

—

3.3

—

3.2

—

3.7

—

3.6

—

3.5

—

3.8

3.4

3.7

3.3

3.3

—

3.2

—

3.8

—

44

—

44

—

44

—

44

43

44

43

43

—

43

—

43

—

43

—

43

—

3.7

3.3

3.6

3.2

3.5

—

3.4

—

3.4

—

3.8

—

3.7

—

3.6

—

3.5

—

3.4

—

41

42

40

41

42

—

41

42

—

42

—

42

—

42

—

SPECIFIC GRAVITY OF NATURAL GAS

0.62

0.64

0.66

Orf

No.

41

40

—

Mnfld

Press.

3.5

3.3

—

Orf

No.

41

39

40

Mnfld

Press.

3.7

3.2

3.4

Orf

No.

41

39

40

Mnfld

Press.

3.8

3.3

3.5

3.4

3.8

3.2

3.3

3.7

—

3.2

3.6

—

3.4

—

3.3

—

3.2

—

41

40

—

41

42

—

41

42

—

41

42

42

—

42

—

3.5

3.3

—

3.4

3.8

—

3.3

3.7

—

3.2

3.5

3.4

—

3.3

—

41

39

40

41

40

—

41

42

—

41

42

41

42

42

—

3.6

3.2

3.4

3.5

3.2

—

3.4

3.8

—

3.3

3.7

3.2

3.5

3.4

—

44

43

44

—

44

—

43

—

44

43

43

—

43

—

42

—

43

—

43

—

3.4

—

3.8

3.3

3.7

3.2

3.6

—

3.5

—

3.2

—

3.8

—

3.7

—

3.6

—

3.5

—

44

43

44

43

44

—

43

—

43

—

43

—

43

—

42

—

42

—

43

—

3.5

—

3.4

—

3.8

3.3

3.7

2.3

3.6

—

3.3

—

3.2

—

3.8

—

3.7

—

3.6

—

42

—

43

—

42

—

42

—

43

—

41

42

41

42

41

42

43

—

44

43

44

43

43

—

43

—

Orf

No.

0.68

Mnfld

Press.

39

40

—

41

39

40

41

40

—

41

40

—

3.4

3.6

—

3.8

3.3

3.5

3.6

3.3

—

3.5

3.2

—

3.6

—

3.5

—

3.4

—

3.8

3.3

3.7

3.2

3.4

—

3.3

—

3.2

—

3.8

—

3.7

—

3.4

3.8

3.3

3.7

3.2

3.5

42

—

42

—

41

42

42

—

43

—

41

40

41

42

41

42

43

—

43

—

44

43

43

—

43

—

Orf

No.

0.70

Mnfld

Press.

38

39

40

39

40

—

41

39

40

41

40

—

3.2

3.5

3.7

3.3

3.6

—

3.7

3.2

3.4

3.6

3.3

—

3.7

—

3.6

—

3.5

—

3.4

—

3.8

3.3

3.2

3.5

3.4

—

3.3

—

3.2

—

3.8

—

3.5

3.2

3.4

3.8

3.3

3.6

42

—

42

—

41

42

41

42

43

—

41

40

41

40

41

42

43

—

43

—

43

—

43

—

43

—

Orf

No.

0.72

Mnfld

Press.

38

39

40

38

39

40

41

39

40

41

39

40

3.3

3.6

3.8

3.2

3.4

3.7

3.8

3.3

3.5

3.7

3.2

3.4

3.8

—

3.7

—

3.6

—

3.5

—

3.4

—

3.3

3.6

3.2

3.5

3.4

—

3.3

—

3.2

—

3.6

3.3

3.5

3.2

3.4

3.7

(9.) Proceed to item c to adjust manifold pressure.

c. Adjust gas input.

(1.) Remove regulator adjustment seal cap. (See Fig. 11.)

(2.) Turn adjusting screw counterclockwise to decrease input. Turn screw clockwise to increase input. DO

NOT set manifold pressure less than 3.2-in. wc or more than 3.8-in. wc for natural gas. Make any major adjustments by changing main burner orifices.

(3.) When correct input is obtained, replace regulator seal cap. Main burner flame should be clear blue, almost transparent. (See Fig. 12.) d. High altitude—In the United States gas input on rating plate is for altitudes up to 2000 ft. Ratings for altitudes over

2000 ft must be 4 percent less for each 1000 ft above sea level. To obtain the adjusted altitude rating, adjust the manifold pressure (see item c) and replace the main burner orifices as needed. Refer to National Fuel Gas Code

Appendix F, Table F-4 for proper orifice sizing at high altitudes.

e. Canadian installations only—The Canadian ratings are approved for altitudes up to 2000 ft for natural and propane gases. High-altitude ratings are from 2000 ft to 4500 ft above sea level. See Table 8 for nominal burner orifice size. High-altitude rating includes a 10 percent derate as required by Canadian standards.

2. Set temperature rise.

Furnace must operate within range of temperature rise specified on the unit rating plate. Determine the air temperature rise as follows.

a. Place duct thermometers in return and supply ducts as near furnace as possible. Be sure thermometers do not "see" heat exchangers so that radiant heat will not affect thermometer readings. This is particularly important with straight-run ducts.

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

c. Adjust air temperature rise by adjusting blower speed.

Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.

12

Table 7—Gas Rate Cu Ft/Hr

40

41

42

43

44

35

36

37

38

39

45

46

47

48

49

25

26

27

28

29

30

31

32

33

34

20

21

22

23

24

15

16

17

18

19

10

11

12

13

14

SECONDS

FOR 1

REVOLUTION

144

138

133

129

124

120

116

113

109

106

240

225

212

200

189

180

171

164

157

150

90

88

86

84

82

103

100

97

95

92

80

78

76

75

73

SIZE OF

TEST DIAL

1 cu ft

2 cu ft

5 cu ft

360

327

300

277

257

720

655

600

555

514

1800

1636

1500

1385

1286

206

200

195

189

185

180

176

172

167

164

160

157

153

150

147

514

500

486

474

462

450

439

429

419

409

400

391

383

375

367

288

277

267

257

248

240

232

225

218

212

480

450

424

400

379

360

343

327

313

300

720

692

667

643

621

600

581

563

545

529

1200

1125

1059

100

947

900

857

818

783

750

SECONDS

FOR 1

REVOLUTION

110

112

116

120

70

72

74

76

78

80

82

84

86

88

100

102

104

106

108

90

92

94

96

98

60

62

64

66

68

55

56

57

58

59

50

51

52

53

54

51

50

48

47

46

45

44

43

42

41

36

35

35

34

33

40

39

38

38

37

60

58

56

54

53

65

64

63

62

61

SIZE OF

TEST DIAL

1 cu ft

2 cu ft

5 cu ft

72

71

69

68

67

144

141

138

136

133

360

355

346

340

333

103

100

97

95

92

90

88

86

84

82

72

71

69

68

67

80

78

76

75

74

131

129

126

124

122

120

116

112

109

106

257

250

243

237

231

225

220

214

209

205

200

196

192

188

184

180

178

173

170

167

327

321

316

310

305

300

290

281

273

265

33

32

31

30

65

64

62

60

164

161

155

150

ON AND

OFF SWITCH

GAS

PRESSURE

REGULATOR

ADJUSTMENT

BURNER FLAME

BURNER

MANIFOLD

A89020

Fig. 12—Burner Flame

GAS

Table 8—Canadian Orifice Size

Natural

Propane

SEA LEVEL

0—2000 FT

43

54

HIGH ALTITUDE

2000—4500 FT

44

55

Disconnect the electrical power before changing the speed tap. A failure to follow this warning can cause personal injury.

d. To change blower motor speed selections for heating mode, remove blower motor lead from control board HEAT terminal. (See Fig. 9.) Select desired blower motor speed lead from 1 of the other terminals and relocate it to HEAT terminal. See Table 9 for lead color identification. Reconnect original lead on SPARE terminal.

COLOR

Table 9—Speed Selector

Black

Yellow (When present)

Blue

Red

White

SPEED

High

Medium-High

Medium-Low

Low

Common

FACTORY-

ATTACHED TO

COOL

SPARE

HEAT

SPARE

COM

INLET

PRESSURE TAP

MANIFOLD

PRESSURE TAP

→

A95618

Fig. 11—Redundant Automatic Gas Control Valve

13

Recheck temperature rise. It must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise or above.

3. Set thermostat heat anticipator.

The thermostat heat anticipator must be set to match the amp draw of the electrical components in the R-W circuit. Accurate amp draw readings can be obtained at thermostat subbase terminals R and W. Fig. 13 illustrates an easy method of obtaining the actual amp draw. The amp reading should be taken after the blower motor has started. See the thermostat manufacturer’s instructions for adjusting the heat anticipator and for varying the heating cycle length.

NOTE: When using an electronic thermostat, set the cycle rate for

3 cycles per hr.

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. 13—Amp Draw Check With Ammeter

A80201

CHECK SAFETY CONTROLS — The flame sensor, gas valve, and pressure switch were all checked in the Start-Up Procedures section as part of normal operation.

1. Check primary limit control.

This control shuts off the combustion control system and energizes the circulating-air blower motor if the furnace overheats.

The preferred method of checking the limit control is to gradually block off the return air after the furnace has been operating for a period of at least 5 minutes. As soon as the limit has shut off the burners, the return-air opening should be unblocked. By using this method to check the limit control, it can be established that the limit is functioning properly and operates if there is a motor failure.

2. Check draft safeguard switch.

The purpose of this control is to permit the safe shutdown of the furnace during certain blocked vent conditions.

a. Disconnect power to furnace and remove vent connector from furnace outlet collar. Be sure to allow time for vent pipe to cool down before removing.

b. Restore power to furnace and set room thermostat above room temperature.

c. After normal start-up, allow furnace to operate for 2 minutes, then block flue outlet 100 percent. Furnace should cycle off within 2 minutes.

d. Remove blockage and reconnect vent pipe to furnace outlet collar.

e. Wait 5 minutes and then reset draft safeguard switch.

3. Check pressure switch.

This control proves operation of draft inducer blower.

a. Turn off 115-v power to furnace.

b. Remove control door and disconnect inducer motor lead wires from wire harness.

c. Turn on 115-v power to furnace.

d. 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 31 fault. If hot surface ignitor glows when inducer motor is disconnected, shut down furnace immediately.

Determine reason pressure switch did not function properly and correct condition.

e. Turn off 115-v power to furnace.

f. Reconnect inducer motor wires, replace control door, and turn on 115-v power.

CHECKLIST

1. Put away tools, instruments, and clean up debris.

2. Verify manual reset switches have continuity.

3. Ensure 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 Manual with owner.

7. Leave literature packet near furnace.

14

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

15

Copyright 1996 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58pa12si

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. 565-848 Printed in U.S.A.

Form 58PA-12SI Pg 16 1-96 Replaces: 58PA-11SI