Carrier DOWNFLOW HORIZONTAL 2-SPEED, 2-STAGE 58TMA, 58TMA Install And Operation Instructions

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Downflow/Horizontal 2-Speed, 2-Stage,

Induced-Combustion Gas Furnace

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Installation, Start-Up, and Operating Instructions

Sizes 065-125, Series 111

NOTE: Read the entire instruction manual before starting the

installation. This symbol → indicates a change since the last issue.

Index Page

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE ...........................................................................2

INTRODUCTION.......................................................................2-4

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

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

LOCATION....................................................................................4

General ......................................................................................4

Location Relative to Cooling Equipment ................................4

Hazardous Locations.................................................................4

AIR FOR COMBUSTION AND VENTILATION...................4-5

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

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

SUPPLY-AIR PLENUM INSTALLATION

(DOWNFLOW) .....................................................................5-6

Installation On Combustible Floor...........................................6

HORIZONTAL ATTIC INSTALLATION...................................7

HORIZONTAL CRAWLSPACE INSTALLATION....................7

FILTER ARRANGEMENT...........................................................7

GAS PIPING...............................................................................7-9

ELECTRICAL CONNECTIONS ................................................10

115-v Wiring...........................................................................10

24-v Wiring.............................................................................10

Accessories..............................................................................10

VENTING ....................................................................................10

START-UP, ADJUSTMENT, AND SAFETY CHECK.......10-22

General...............................................................................10-12

Sequence of Operation ......................................................12-16

Adaptive Heating Mode ....................................................12-14

Non-Adaptive Heating Mode .................................................14

Cooling Mode....................................................................14-15

Continuous Blower Mode.......................................................15

Heat Pump Mode....................................................................15

Defrost Mode.....................................................................15-16

Start-Up Procedures................................................................16

Adjustments .......................................................................16-22

Set Gas Input Rate ............................................................16-22

Set Temperature Rise ........................................................17-21

Set Thermostat Heat Anticipator ......................................21-22

Check Safety Controls............................................................22

Checklist..................................................................................23

CERTIFICATION OF MANUFACTURING SITE

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, refer to the National Fuel Gas Code (NFGC) NFPA No. 54-1996/ANSI Z223.1-1996. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1- and .2-M95 Natural Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls.

Recognize safety information. This is the safety-alert symbol When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage.

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.

ama

58TMA

CANADIAN GAS ASSOCIATION

APPROVED

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. 535-887 Printed in U.S.A. Form 58TMA-6SI Pg 1 8-97 Replaces: 58TMA-4SI

⁄2″

20″

⁄16″

⁄8″

⁄16″

INLET

⁄8″ DIA

ACCESSORY

⁄4″ DIA HOLE

GAS ENTRY

OUTLET

19″

ADDITIONAL

NOTE:

LOCATED IN THE TOP PLATE AND BOTTOM PLATE

⁄8″ DIA K.O. ARE

VENT CONNECTION

⁄16″

⁄8″

⁄4″

⁄16″

⁄8″

⁄4″

⁄16″

AIRFLOW

⁄2″ DIA

2″

⁄16″

DIMPLES TO DRILL HOLES FOR HANGER BOLTS (4 PLACES) IN HORIZONTAL POSITION

⁄4″

THERMOSTAT  WIRE ENTRY

⁄8″ DIA

ACCESSORY

⁄8″ DIA HOLE

POWER ENTRY

⁄2″ DIA

R.H. GAS ENTRY

⁄8″ DIA

ACCESSORY

⁄16″

⁄8″

″ TYP

⁄8″ TYP

Fig. 1—Dimensional Drawing

Table 1—Dimensions (In.)

UNIT SIZE A D E VENT CONN SHIP. WT

065-08 14-3/16 12-9/16 12-11/16 4 141 065-12 14-3/16 12-9/16 12-11/16 4 145 085-12 17-1/2 15-7/8 16 4 154 085-16 17-1/2 15-7/8 16 4 154 105-16 17-1/2 15-7/8 16 4 171 105-20 21 19-3/8 19-1/2 4 181 125-20 24-1/2 22-7/8 23 5 192

A88324

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE

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 CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC 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.

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INTRODUCTION

The model 58TMA Series 111 Furnace is available in sizes 65,000 through 123,000 Btuh input capacities.

The design of the downflow/horizontal gas-fired furnace is A.G.A./C.G.A. certified for natural and propane gases and for installation on noncombustible flooring. The furnace is factoryshipped for use with natural gas. The manufacturer’s accessory gas conversion kit is required to convert furnace for use with propane gas.

These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, the manufacturer’s 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. This furnace is for installation

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

This forced air furnace is equipped for use with natural gas at

altitudes 0-10,000 ft (0-3,050m).

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 on combustible flooring in alcove or closet at minimum clearance from combustible material.

This furnace may be used with a Type B-1 Vent and may be vented in common with other gas-fired appliances.

For installation on non-combustible floors only.

†

For installation on combustible flooring only when installed on special base, Part No. KGASB0201ALL, Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

For furnaces wider than 14.25 inches (362mm) may be 0 inches.

18 inches front clearance required for alcove.

Indicates supply or return sides when furnace is in the horizontal

position. Line contact only permissible between lines formed by intersections of the Top and two Sides of the furnace jacket, and building joists, studs or framing.

For single wall vent type 6 inches.

For Type B-1 vent type 3 inches.

††

Clearance to Back 0 inches (0 po) in downflow and horizontal (attic/alcove & crawlspace) positions and 3 inches (3 po) in horizontal closet positions.

Clearance arrows do not change with furnace orientation.

††

1" #

Clearance in inches.

TOP / PLENUM

†

BOTTOM

Vent Clearance to combustibles:

For Single Wall vents 6 inches (6 po). For Type B-1 vent type 1 inch (1 po).

30"

MIN

322286-101 REV. D (LIT)

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Fig. 2—Clearances to Combustibles

in alcoves, attics, crawlspaces, 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 and the NFPA 90B. Canadian installations must be installed in accordance NSCNGPIC and all authorities having jurisdiction. For a copy of the NFGC NFPA54/Z223.1, contact International Approval Services U.S. Inc., 8501 E. Pleasant Valley Road, Cleveland, OH 44131 or National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269. For a copy of NFPA 90B, contact National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269.

Before installing the furnace in Canada, refer to the current edition of the NSCNGPIC. Contact Standards Department of Canadian Gas Association, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3.

The duct system should be designed and sized according to accepted national standards published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA). Or consult the Residential Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the maximum CFM capabilities of the equipment at the optimum design static pressure.

A97430

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.

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

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

To aid in installation, troubleshooting, and service, a status code label is located on blower component door. This label explains how to use the LED status indicated on furnace control which is viewed through the sight glass on door.

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, loss of life, 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. A failure to follow this warning could result in electrical shock, fire, personal injury, or death.

For high-altitude installation, the high-altitude conversion kit must be installed at or above 5500 ft above sea level.

For accessory installation details, refer to applicable installation literature.

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

Step 1—Location

GENERAL

DO NOT install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are followed. DO NOT use this furnace during construction when adhesives, sealers, and/or new carpets are being installed and curing. If the furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine when burned in combustion air form acids which will cause corrosion of the heat exchangers and metal vent systems. Some of these compounds are released from 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 electrical components are protected from water.

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

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

Provide ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on unit clearance label. This furnace shall not be installed directly on carpeting, tile, or any combustible material other than wood flooring. The furnace may be installed on combustible flooring when installed with accessory downflow subbase, which is available from your distributor or branch when required.

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with or on downstream side of furnace to avoid condensation in heat exchangers. When installed parallel with furnace, dampers or other means used to control the flow of air must prevent chilled air from entering furnace. If dampers are manually operated, they must be equipped with means to prevent operation of either unit unless damper is in full-heat or full-cooling position.

HAZARDOUS LOCATIONS

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

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

Step 2—Air for Combustion and Ventilation

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Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5.3, Air for Combustion and Ventilation, of the NFGC or applicable provisions of local building codes.

Canadian installations must be in accordance with NSCNGPIC and all authorities having jurisdiction.

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.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, or fireplaces could create a negative air pressure condition at the furnace. Make-up air must be provided for these devices, in addition to that required by the furnace.

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 equipment room or space. In addition, a positive seal MUST be made between furnace cabinet and return-air duct to avoid pulling air from the burner area and draft safeguard opening into circulating air.

The requirements for combustion and ventilation air depend upon whether furnace is located in a CONFINED or UNCONFINED space.

UNCONFINED SPACE

An unconfined space must have at least 50 cu ft for each 1000 Btuh of input for all appliances (such as furnaces, clothes dryer, water heaters, etc.) in the space.

For Example:

58TMA FURNACE HIGH-FIRE INPUT

BTUH 63,000 420 84,000 560

105,000 700 123,000 820

MINIMUM SQ FT

WITH

7-1/2 FT CEILING

If space is constructed unusually tight, air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with outdoors. Combustion and ventilation openings must be sized the same as for a confined space as defined below. Return air must not be taken from the room unless equal or greater amount of air is supplied to the room.

CONFINED SPACE

A confined space is defined as a space whose volume is less than 50 cu ft per 1000 Btuh of total input ratings of all appliances

VENT THROUGH ROOF (CATEGORY I)

DUCTS TO

OUTDOORS

1 SQ IN. PER 4000 BTUH

RETURN

AIR

INTERIOR

HEATED

SPACE

SUPPLY AIR

* Minimum opening size is 100 sq in. with minimum dimensions of 3 in.

†

Minimum of 3 in. when type B-1 vent is used.

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

A93387

Fig. 3—Confined Space: Air for Combustion and

Ventilation from an Unconfined Space

12″ MAX

1 SQ IN. PER 2000 BTUH

DUCTS

TO

OUTSIDE

1 SQ IN. PER 2000 BTUH

12″ MAX

SUPPLY AIR

Minimum dimensions of 3 in.

NOTE:

Use any of the following combinations of openings: A & B C & D D & E F & G

RETURN

AIR

VENT THROUGH ROOF (CATEGORY I)

CONFINED

DUCT

TO

OUTDOORS

SPACE

12″ MAX

12″

MAX

1 SQ IN. PER 4000 BTUH

OUTDOORS

1 SQ IN. PER 4000 BTUH

12″

MAX

1 SQ IN. PER 4000 BTUH

A93388

Fig. 4—Confined Space: Air for Combustion and

Ventilation from Outdoors

installed in that space. A confined space MUST have provisions for supplying air for combustion, ventilation, and dilution of flue gases using 1 of the following methods. (See Fig. 3 and Table 2.)

NOTE: In determining free area of an opening, the blocking effect of louvers, grilles, and screens must be considered. If free area of louver or grille design is unknown, assume 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 air comes from outside of the structure or an unconfined space inside the structure.

1. All air from inside the structure requires 2 openings (for structures not usually tight):

a. Each opening MUST have at least 1 sq in. of free area per

1000 Btuh of total input for all equipment within the confined space, but not less than 100 sq in. per opening. (See Fig. 3 and Table 2.) The minimum dimension of air openings shall not be less than 3 in.

b. If the building is constructed unusually tight, a permanent

opening directly communicating with the outdoors shall be provided. See item 2 below.

c. If furnace is installed on a raised platform to provide a

return-air plenum, and return air is taken directly from hallway or space adjacent to furnace, all air for combustion must come from outdoors.

2. Air from outside the structure requires 1 of the following methods:

a. If combustion air is taken from outdoors through 2 vertical

ducts, the openings and ducts MUST have at least 1 sq in. of free area per 4000 Btuh of total input for all equipment within the confined space. (See Fig. 4 and Table 2.)

b. If combustion air is taken from outdoors through 2 hori-

zontal ducts, the openings and ducts MUST have at least 1 sq in. of free area per 2000 Btuh of total input for all equipment within the confined space. (See Fig. 4 and Table

2.)

c. If combustion air is taken from outdoors through a single

opening or duct (horizontal or vertical) commencing within 12 in. of the top of the confined space, opening and duct MUST have at least 1 sq in. of free area per 3000 Btuh of the total input for all equipment within the confined space and not less than the sum of the areas of all vent connectors in the confined space. (See Fig. 4 and Table 2.) Equipment clearances to the structure shall be at least 1 in. from the sides and back and 6 in. from the front of the appliances.

When ducts are used, they must be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of ducts must not be less than 3 in. (See Fig.

4.)

Step 3—Supply-Air Plenum Installation (Downflow)

DOWNFLOW INSTALLATION

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NOTE: This furnace is approved for use on combustible flooring when manufacturer’s accessory floor base Part No.

Table 2—Free Area Of Combustion Air Opening

58TMA

FURNACE

HIGH-FIRE

INPUT

(BTUH)

63,000 100 15.8 5 31.5 7 21.0 6

84,000 100 21.0 6 42.0 8 28.0 6 105,000 105 26.3 6 52.5 9 35.0 7 123,000 123 30.8 7 61.5 9 41.0 8

AIR UNCONFINED

SPACE FROM

Free Area

of Opening

(Sq In.)

OUTDOOR AIR THROUGH

VERTICAL DUCTS

Free Area of

Opening and Duct

(Sq In.)

Round

Pipe

(In. Dia)

OUTDOOR AIR THROUGH

HORIZONTAL DUCTS

Free Area of

Opening and Duct

(Sq In.)

Round

Pipe

(In. Dia)

OUTDOOR AIR THROUGH

SINGLE DUCT

Free Area of

Opening and Duct

(Sq In.)

Round

Pipe

(In. Dia)

KGASB0201ALL is used. Manufacturer’s accessory floor base is 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 3.

2. Construct hole in floor per dimensions specified in Table 3 and Fig. 5.

3. Construct plenum to dimensions specified in Table 3.

4. If downflow subbase (KGASB) is used, install as shown in Fig. 6.

If coil assembly CD5, CK5, or Coil Box KCAKC is used, install as shown in Fig. 7.

INSTALLATION ON COMBUSTIBLE FLOOR

1. Cut and frame hole in floor per dimensions in Installation Instructions packaged with downflow subbase.

PLENUM

OPENING

FLOOR

OPENING

Fig. 5—Floor and Plenum Opening Dimensions

FURNACE

CASING

WIDTH

14-3/16

17-1/2

24-1/2

Combustible Flooring Using KGASB Subbase 11-13/16 19 13-7/16 20-3/8

Combustible Flooring with CD5 or CK5 Coil Assembly or

Combustible Flooring Using KGASB Subbase 15-1/8 19 16-3/4 20-3/8

Combustible Flooring with CD5 or CK5 Coil Assembly or

Combustible Flooring Using KGASB Subbase 18-5/8 19 20-1/4 20-3/8

Combustible Flooring with CD5 or CK5 Coil Assembly or

Combustible Flooring Using KGASB Subbase 22-1/8 19 23-3/4 20-3/8

Combustible Flooring with CD5 or CK5 Coil Assembly or

APPLICATION

Non-Combustible Flooring 12-11/16 19 13-3/8 19-5/8

KCAKC Coil Box

Non-Combustible Flooring 16 19 16-5/8 19-5/8

KCAKC Coil Box

Non-Combustible Flooring 19-1/2 19 20-1/8 19-5/8

KCAKC Coil Box

Non-Combustible Flooring 23 19 23-5/8 19-5/8

KCAKC Coil Box

A96283

Table 3—Opening Dimensions (In.)

PLENUM OPENING FLOOR OPENING

ABCD

12-5/16 19 13-5/16 20

15-1/2 19 16-1/2 20

19 19 20 20

22-1/2 19 23-1/2 20

FURNACE

(OR COIL CASING

WHEN USED)

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Fig. 6—Furnace, Plenum, and Subbase Installed on

Combustible Floor

2. When completed, downflow subbase, plenum, and furnace (or coil casing when used) should be installed as shown in Fig. 6.

Step 4—Horizontal Attic Installation

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

The furnace can be installed horizontally on either the left-hand (LH) or right-hand (RH) side. A typical attic installation is shown in Fig. 8.

CONSTRUCT WORKING PLATFORM

Construct working platform on location where all required furnace clearances are met. (See Table 1 and Fig. 8.)

INSTALL FURNACE

1. Position furnace in desired location.

2. Connect gas supply pipe. See Fig. 8 for typical piping entry.

3. Connect supply- and return-air ducts.

4. Install field-supplied filter retainers as indicated in Fig. 11 and Table 4 before connecting return-air duct to furnace.

5. Install 24- X 24-in. sheet metal shield on platform in front of louvered control panel as shown in Fig. 8.

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Step 5—Horizontal Crawlspace Installation

The furnace can be installed horizontally with either the LH or RH side up. In a crawlspace, furnace can either be hung from floor joist (see Fig. 9) or installed on suitable blocks or pad. (See Fig.

A96285

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96284

Fig. 7—Furnace, Plenum, and Coil Assembly or Coil

Box Installed on Combustible Floor

10.) The furnace can be suspended from each corner by hanger bolts (4 each 3/8-in. all-thread rod) cut to desired length, 1- X 3/8-in. flat washer, 3/8-in. lockwasher, and 3/8-in. nut. Dimples are provided for hole locations. (See Fig. 1.)

Since horizontal crawlspace installation is very similar to attic installation, refer to Step 4. The installation of a sheet metal shield in front of louvered control panel is covered in Step 4. For a crawlspace installation, this same sheet metal shield must be installed above louvered control panel. Extend sheet metal shield over furnace top far enough to cover gas pipe entry hole.

Step 6—Filter Arrangement

Never operate unit without a filter or with filter access door removed. A failure to follow this warning could result in fire, personal injury, or death.

The 2 factory-supplied filters are shipped in the blower compartment. After return-air duct has been connected to furnace, install filters in a V-formation inside return-air plenum. See Fig. 11 and Table 4 for horizontal applications. Horizontal filter retainers must be field supplied. See Fig. 12 for downflow applications.

Step 7—Gas Piping

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Gas piping must be installed in accordance with national and local codes. Refer to the NFGC NFPA 54-1996/ANSI Z223.1-1996.

Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction.

The gas supply line should be a separate line directly from the meter to the furnace, if possible. Refer to Table 5 for recommended gas pipe sizing. Risers should be used to connect to the furnace and to the meter.

LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS, STUDS, OR FRAMING.

MANUAL SHUTOFF

GAS VALVE

SEDIMENT

TRAP

GAS ENTRY

MIN

″

SHEET METAL

Fig. 8—Typical Attic Installation

TYPE-B VENT

30-IN. MIN WORK AREA

A97516

ANGLE IRON OR EQUIVALENT

(B)

(A)

ROD LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS)

(A) PREFERRED ROD LOCATION  (B) ALTERNATE ROD LOCATION

→ Fig. 9—Horizontal Crawlspace Installation on Hanger Rods

/8-IN. HEX NUT

& WASHER (4)

REQD PER ROD

(B)

(A)

(B)

NOTES:

⁄8-IN. ROD

(A)

(B)

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.

A96633

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;;;;;

;;;;;;

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AIRFLOW

INSTALLATION

POSITION

OF FILTERS

RETURN-AIR

PLENUM

A95235

Fig. 10—Horizontal Installation on Blocks

AIRFLOW

12″

4″

FIELD-SUPPLIED FILTER RETAINERS

Fig. 11—Horizontal Filter Arrangement

Table 4—Filter Retainer (In.)

FURNACE CASING WIDTH FILTERS D

14-3/16 (2) 14 X 20 X 1 14-3/8

17-1/2 (2) 14 X 20 X 1 13-3/8

21 (2) 16 X 20 X 1 11-5/8

24-1/2 (2) 16 X 20 X 1 10-1/4

If 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.

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

Use a backup wrench at furnace gas control when connecting gas pipe to furnace to avoid damaging gas controls or manifold.

Never purge a line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition to check for gas leakage. Use a soap-and-water solution to check for gas leaks. A failure to follow this warning could result in fire, explosion, personal injury, or death.

Joint compounds (pipe dope) should be applied sparingly and only to male threads of joints. This pipe dope must be resistant to action of propane gas.

A82173

ACCESS DOOR

Fig. 12—Downflow Filter Arrangement

A88486

Table 5—Maximum Capacity of Pipe*

NOMINAL

IRON PIPE

SIZE (IN.)

1/2 0.622 175 120 97 82 73 3/4 0.824 360 250 200 170 151

1 1.049 680 465 375 320 285 1-1/4 1.380 1400 950 770 660 580 1-1/2 1.610 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 supply line pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table 10-2, NFPA 54-1996.

Install accessible manual shutoff valve upstream of furnace gas controls and within 72 in. of furnace. A 1/8-in. NPT plugged tapping is provided on gas value for test gage connection. Installation of additional 1/8-in. NPT plugged tapping, accessible for test gage connection, installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve is not required. Place ground joint union between gas control manifold and manual shutoff.

Install sediment trap in riser leading to furnace. The trap can be installed by connecting a tee to riser leading from furnace. Connect capped nipple into lower end of tee. The capped nipple should extend below level of gas controls. (See Fig. 13.)

Piping should be pressure tested in accordance with local and national plumbing and gas codes before furnace has been attached. If test pressure exceeds 0.5 psig (14-in. wc), the 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 the gas valve before test. (See Fig. 13.) It is recommended that ground joint union be loosened before pressure testing.

After all connections have been made, purge lines and check for gas leakage with regulated gas supply pressure.

INTERNAL

DIAMETER

(IN.)

LENGTH OF PIPE (FT)

10 20 30 40 50

GAS

SUPPLY

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, the furnace control status LED will flash rapidly and prevent heating operation.

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.

MANUAL SHUTOFF VALVE (REQUIRED)

SEDIMENT TRAP

UNION

Fig. 13—Typical Gas Pipe Arrangement

EAC - ELECTRONIC

AIR CLEANER

(115-VAC 1 AMP MAX)

78 9

456

123

PR2

PR1

PARK

COM

EAC-1

EAC-2

FU1

-HEAT

HI-GAS

LO-GAS

HI-COOL

SEC-1

10 11 12

789

456

123

MASTER SLAVE

TWIN

TEST

LED

SEC-2

HUM GRY/Y2W/W1

3-AMP FUSE

LED - DIAGNOSTIC LIGHT

TWIN / TEST TERMINAL

HUM - HUMIDIFIER (24-VAC 0.5 AMP MAX)

24-VOLT

1234

OFF

THERMOSTAT TERMINALS

24 V

COM

FURNACE AND BLOWER OFF DELAY SETUP SWITCHES

Fig. 14—Control Center

Step 8—Electrical Connections

115-V WIRING

Refer to unit rating plate or Table 6 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 current

→

edition of the National Electrical Code (NEC) ANSI/NFPA 70-1996 and any local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with CSA C22.1 Canadian Electrical Code or authorities having jurisdiction.

A89414

A93348

24-V WIRING

Refer to ESD Precautions Procedure before proceeding with 24-v connections.

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

14.) Connect terminal Y/Y2 as shown in Fig. 15 or 16 for proper operation in cooling mode. Use AWG No. 18 color-coded, copper thermostat wire only.

When furnace is installed in horizontal position with RH discharge air, 24-v wire connections can be made easier by removing the 2 control box mounting screws and letting control box turn so that 24-v screw terminals are visible. Be sure to reinstall control box after connections are made.

The 24-v circuit contains an automotive-type, 3-amp fuse located on main control. Any 24-v electrical shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp fuse. The control will flash code 24 when fuse needs replacement.

ACCESSORIES

1. Electronic air cleaner (EAC)

A terminal block (EAC-1 [hot] and EAC-2 [neutral]) is provided for EAC connection. (See Fig. 14.) The terminals are energized with 115v, 1-amp maximum during blower motor operation.

2. Humidifier (HUM)

Screw terminals (HUM-1 and C

OM) are provided for 24-v

humidifier connection. The terminals are energized with 24v,

0.5-amp maximum when the gas valve is energized.

Step 9—VENTING

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

→

Gas Code NFPA No. 54-1996/Z223.1-1996, or the Canadian Installation Code, CAN B149.1- and .2-M95, for proper vent sizing and installation requirements. Use enclosed Venting Tables for Category I Fan-Assisted Furnaces for 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 10—Start-Up, Adjustment, and Safety Check

GENERAL

The furnace must have a 115-v power supply properly connected and grounded. Correct polarity must be maintained to enable gas heating operation.

The gas service pressure must not exceed 0.5 psig (14-in. wc), and be no less than 0.16 psig (4.5-in. wc).

Thermostat wire connections at R and W/W1 are the minimum required for gas heating operation. W2 must be connected for 2-stage heating thermostats. C

OM, Y/Y2, and G are required for

cooling, heat pumps, and some clock thermostats. These must be made at 24-v terminal block on control. (See Fig. 14.)

Table 6—Electrical Data

UNIT SIZE

VOLTS— HERTZ—

PHASE

065-08 115—60—1 127 104 8.0 14 46 15 065-12 115—60—1 127 104 10.5 14 35 15 085-12 115—60—1 127 104 12.0 14 30 15 085-16 115—60—1 127 104 14.2 14 26 15 105-16 115-60-1 127 104 13.2 14 29 15 105-20 115—60—1 127 104 17.2 12 33 20 125-20 115—60—1 127 104 17.9 12 32 20

* Permissible limits of the voltage range at which the unit will operate satisfactorily. † Time-delay fuse is recommended. ‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

TWO-WIRE

HEATING-

BLK

WHT

115-V FUSED

DISCONNECT

BLK

WHT

GND

JUNCTION BOX

SWITCH

(WHEN REQUIRED)

OPERATING

VOLTAGE RANGE

Max* Min*

1-STAGE THERMOSTAT TERMINALS

FIVE

WIRE

ONLY

COM

W/W1

Y/Y2

CONTROL

BOX

24-V

TERMINAL

BLOCK

FURNACE

MAX UNIT

AMPS

MIN

WIRE

GAGE

MAX WIRE

LENGTH

FT‡

FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING

WYRG

FIELD-SUPPLIED

FUSED DISCONNECT



NOTES: 1. Connect Y-terminal as shown for proper operation.



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

CONDENSING

UNIT

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

CKT BKR AMPS†

208/230- OR 460-V THREE PHASE

208/230-V SINGLE PHASE

GND

MAX FUSE OR

HACR-TYPE

A97443

→ Fig. 15—Heating and Cooling Application Wiring Diagram With 1-Stage Thermostat and Condensing Unit

This furnace can be installed with either single-stage heating or 2-stage heating thermostat. For single-stage thermostats, connect thermostat W to W/W1 at furnace control terminal block. (See Fig. 15.) For single-stage thermostats the control determines, based on length of previous heating on and off cycles, when to operate in low- and high-gas heat for optimum comfort. Setup Switch-2 (SW-2) must be in the factory-shipped OFF position. See Fig. 17 and Tables 6 and 7 for setup switch information.

If 2-stage heating thermostat is to be used, move SW-2 to ON position at end of furnace installation. This overrides built-in control process for selecting high and low stage and allows 2-stage thermostat to select gas heating modes. The W2 from thermostat must be connected to W2 on control terminal block. (See Fig. 16.)

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

Only High-Gas Heat

Table 7—Setup Switch Description

SETUP

SWITCH NO.

SW-1

SW-2

Low-Gas Heat

(Adaptive Mode)

SW-3 and

SW4

NORMAL

POSITION

OFF

(Staged Gas

Heat)

OFF

(Single-Stage

Thermostat)

ON, OFF

Turn switch on to obtain only high-gas-heat operation on any call for heat regardless of whether R-W/W1, or R-W/W1,

-W2 is closed. SW-1 overrides SW-2.

Turn switch off for installations with single-stage thermostats; control selects low-gas-heat or high-gas-heat operation based on previous cycles. Turn switch on for installations with 2-stage thermostats to permit only low-gas-heat operation in response to closing R-W/W1. High-gas heat is supplied only when R to W/W1 and W2 is closed.

Switches control gas heating blower off delay. (See Table

8.)

DESCRIPTION OF USE

FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING

2-STAGE THERMOSTAT TERMINALS

W2 Y2 G Y1

BLK

WHT

115-V FUSED

DISCONNECT

SWITCH

(WHEN REQUIRED)

BLK

WHT

GND

JUNCTION BOX

SEVEN

WIRE

THREE-WIRE

HEATING-

ONLY

CONTROL

BOX

FURNACE

COM

W/W1

Y/Y2

GR

24-V

TERMINAL

BLOCK

W1 R

 

NOTES: 1. Connect Y-terminal as shown for proper operation.

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



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

FIELD-SUPPLIED

FUSED DISCONNECT

Y1 Y2

2-SPEED CONDENSING UNIT

208/230- OR 460-V THREE PHASE

208/230-V SINGLE PHASE

GND

→ Fig. 16—Heating and Cooling Application Diagram With 2-Stage Thermostat and Condensing Unit

A97444

Table 8—Blower Off Delay Setup Switch

Position

DESIRED HEATING

MODE BLOWER OFF

DELAY (SEC)

90 OFF OFF 135 OFF ON 180 ON OFF 225 ON ON

his furnace is equipped with 2 manual reset limit switches in gas control area. The switches will open and shut off power to gas valve if a flame rollout or an overheating condition occurs in gas control area. DO NOT bypass switches. Correct inadequate combustion air supply, component failure, restricted flue gas passageway before resetting switches.

SEQUENCE OF OPERATION

Using the schematic diagram follow sequence of operation through different modes. (See Fig. 18.) Read and follow wiring diagram very carefully.

NOTE: If power interruption occurs during "call for heat" (W/W1 or W/W1-and-W2), control starts 90-sec blower only on period 2 sec after power is restored if thermostat is still calling for gas heating. The red LED flashes code 12 during 90-sec period, after which LED will be on continuously as long as no faults are detected. After 90-sec period, furnace responds to thermostat normally.

Blower door must be installed for power to be conducted through blower door interlock switch ILK to furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot surface ignitor HSI, and gas valve GV.

1. Adaptive Heating Mode—Single-Stage Thermostat and 2-Stage Heating

(See Fig. 16 for thermostat connections.)

SETUP SWITCH

SW-3 SW-4

43 2

BLOWER-

OFF

DELAY

LOW

HEAT

(ADAPTIVE

ALGORITHM)

→ Fig. 17—Setup Switches on Control Center

(Factory Settings)

NOTE: With high-heat-only switch SW-1 off, low-heat-only

switch SW-2 selects either low-heat-only operation mode when on (see item 2. below), or adaptive heating mode when off in response to "call for heat." (See Fig. 17.) When high-heat-only switch SW-1 is on, it always causes high-gas-heat operation when R-W/W1 circuit is closed, regardless of the setting of low-heat-only switch SW-2.

This furnace can operate as a 2-stage furnace with a singlestage thermostat because furnace control CPU includes a programmed adaptive sequence of controlled operation which selects low-gas-heat or high-gas-heat operation. This selection is based upon stored history of the length of previous gas heating on/off periods of single-stage thermostat.

OFF

HIGH

HEAT

ONLY

A96402

324459-101 REV. A

A97508

applications. Insulate connector if not available.

OM" terminal for about two seconds. The control will

8. Factory connected when LGPS not used.

COMPONENT TEST

PLUG RECEPTACLE

LS LIMIT SWITCH , OVERTEMPERATURE-AUTO RESET, SPST (N.C.)

turn ON the inducer motor Low-Speed, inducer motor High-Speed, HSI, blower motor Low-Gas-Heat Speed, blower motor High-Gas-Heat Speed, and blower motor High-Cool Speed for 7-15 seconds each. Neither the gas valve nor the humidifier will be

turned ON.

To initiate the component test sequence with no thermostat inputs and with all inducer Post-Purge and Blower-Off Delay periods completed, short the "TWIN/TEST" terminal to the "

→ Fig. 18—Unit Wiring Diagram

PL3

IHI / LOR

IDR

WHT

BLK

PL3

123

BLK

WHT

BLK

YEL

ALS2

ORN

NORM

HI HT

LO HT

IDM

ALS1

DSS

ALS2

FRS1

(WHEN USED) 3

MGVR-2

HUM

BLK

WHT

BRN

CAP

BRN

WHT

NOTE #4

COM WHT

COMMON

L1 L2

HI-COOL

GRY

BRN

ORN

RED

SETTINGS

BLOWER-OFF DELAY

FACTORY

TRAN

RED

BLOWER-OFF DELAY

TWINNING

TWIN

BLK

EAC-2

HI-GAS

HEAT

GRN

BLU

LOW-HEAT ONLY

HIGH-HEAT ONLY

TEST

YELMED HI

NOTE #8 LPS

(WHEN USED)

PL1

JUMPER

MASTER

SLAVE

W/W1

BLU

RED

BLWM

RED

ORN

BLU

MED

RED

MED LO

NOTE #15

BLU

SPARE

EAC-1

FU1

SPARE

HEAT

LO-GAS

SEC1

SEC2

11 10

LED

TEST

TWIN

W/W1 Y/Y2 R G HUM

OFF

24V

W2 Com

LEGEND

N/A

HPSR

24VAC

BLK

PL2

YEL

135 SEC

180 SEC

N/A

NOTE #5

WHT

321

2-STAGE

FURNACE

225 SEC

BLK

CONTROL

OFF ON

FRS2

N/A 12

PR1 PR2

COM

PR2

SEC2

TRAN

115VAC

PR1

SEC1

FU1

RED

BLK

WHT

OFF

SWITCH

90 SEC

BLOWER-

OFF DELAY

(SEC.)

HPS

LGPS

NOTE #8

SW1

MGVR-1

CPU

Y/Y2

FSE

NOTE#7

N/A

SW2 SW3

SW4

NOTES:

Cooling/Heat Pump 2 sec onds.

seconds.

unsuccessful trials-for-ignition. Control will automatically

9. Symbols are an electrical representation only.

10. BLOWER-ON DELAY: Gas heating 45 seconds,

1. Use only copper wire between the disconnect switch and the unit.

2. If any of the original wire, as supplied, must be replaced, use the

reset after three hours.

11. Cooling/Heat Pump BLOWER-OFF DELAY is 90

12. IGNITION-LOCKOUT will occur after four consecutive

13. Control must be grounded at pin 10 of 12-pin connector.

14. NA - Not Applicable

15. Spare terminal and wire not available on some

same or equivalent type wire.

thermal overload switches.

Installation Instructions for details on optimum speed selection.

some downflow models.

3. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset

4. Blower motor speed selections are for average conditions. See

control to prove flame.

5. Replace only with a 3-AMP fuse.

6. Auxiliary limit switches (ALS1 & 2) used on some horizontal and

7. This wire must be connected to furnace sheet metal for

2 = HUMIDIFIER

1 = VALVE

PL1 12-CIRCUIT CONNECTOR

PL2 9-CIR CUIT CONNECTOR

MGVR MAIN GAS VA LVE RELAY, DPST (N.O.)

ALS1 AUXILIARY LIMIT SWITCH, OVER TEMP. MANUAL RESET, SPST (N.C.)

ALS2 AUXILIARY LIMIT SWITCH, OVER TEMP. AUTO RESET, SPST (N.C.)

BHI / LOR BLOWER MOTOR SPEED CHANGE RELAY, SPDT

BHT / CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT

SPST (MANUAL)

SLAVE STATUS (MANUAL CHANGE OVER)

ALSO STATUS CODE RECALL

JUNCTION

TERMINAL

CONTROL TERMINAL

FACTORY POWER WIRING (115VAC)

FACTORY CONTROL WIRING (24VAC)

FIELD POWER WIRING (115VAC)

FIELD CONTROL WIRING ( 24VAC)

CONDUCTOR ON CONTROL

FIELD WIRING SCREW TERMINAL

FIELD GROUND

EQUIPMENT GROUND

FIELD SPLICE

PL3 3-CIRCUIT IDM CONNECTOR

PL6 2-CIRCU IT HSI CONNECTOR

SW1 HIGH-HEAT-ONLY SWITCH, SPST (MANUAL)

SW2 LOW-HAT-ONLY SWITCH, SPST (MANUAL)*SW3 & 4 BLOWER-OFF DELAY SETTING SWITCHES,

TJ TWINNING JUMPER, SPDT FOR MASTER OR

TRAN TRANSFORMER-115VAC/24VAC

TWIN/TEST 1-CIRCUIT TWINNING BUSS CONNECTOR,

BLWM BLOWER MOTOR, 4 or 5 -SPEED, PERMANENT-SPLIT-CAPACIT OR

BLWR BLOWER MOTOR RELA Y, SPST (N.O.)

CAP CAPACI TOR

CPU MICROPROCESSOR AND CIRCUITRY

DSS DRAFT SAFEGUARD SWITCH (N.C.)

EAC-1 ELECTRONIC AIR CLEA NER CONNECTION (115 VAC, 1 AMP MAX.)

EAC-2 ELECTRONIC AIR CLEANE R CONNECTION (COMMON)

FRS1 FLAME ROLLOUT SWITCH OVERTEM P. MANUAL RESET, SPST (N.C.)

FRS2 FLAME ROLLOUT SWITCH OVERTEM P. MANUAL RESET, SPST (N.C.)

FSE FLAME-PROVING SENSOR E LECTRODE

FU1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYP E, FACTORY INSTALLED

FU2 FUSE, FIELD INSTALLED

GV GAS VALVE, REDUNDANT LOW-HEAT OPERATORS, 2-STAGE

HPS HIGH-HEAT PRESSURE SWITCH, SPST (N.O.)

HPSR HIGH-HEAT PRESSURE SWITCH RELAY, SPST (N.C.)

HSI HOT-SURFACE IGNITER (115 VAC)

HSIR HOT-SURFACE IGNITOR RE LAY, SPST (N.O.)

HUM 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)

IDM INDU CED DRAFT MOTOR, 2-SPEED, SHADED-POLE

IDR INDUCER MOTOR RELAY, SPST (N.O.)

IHI / LOR INDUCER MOTOR SPEED CHANGE RELAY, SPDT

ILK BLOWER DOOR INTERLOCK SWITCH, SPST (N.O.)

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STAT US CODES

LGPS LOW GAS-PRES SURE SWITCH, SPST (N.O.)

LPS LOW-HEAT PRESSURE SWITCH , SPST (N.O.)

BLWM

BRN

CAP

HSI

BRN

COM

NOTE #4

NOTE #15

MED LO

HI-GAS-HEAT

BHT / CLR

MED HI

MED

SPARE

HI-COOL

BLWR

SCHEMATIC DIAGRAM (NATURAL GAS & PROPANE)

LO-GAS-HEAT

NOTE #1

BHI / LOR

EQUIPMENT GROUND

ILK

PL6

PL2

COMMON

EAC-2

EAC-1

HSIR

TO 115VAC FIELD DISCONNECT SWITCH

GRN

BLU

BRN

GRN

HPS

IDM

BRN

GRY

CONNECTION DIAGRAM

LGPS

YEL

LPS

NOTE #8

FRS2

DSS

ORN

RED

FU2

NOTE #1

FUSED DISCONNECT

GRN

HSI

ALS1

FRS1

(WHEN USED)

GRN

WHT

BLK

SWITCH (WHEN REQ’D)

GRN

ILK

WHTPL6

RED

GRY

WHT

FSE

(WHEN USED)

NOTE #8

NOTE #6

(WHEN USED)

ORN

RED

SWITCH

HEAT

SET-UP

SWITCH

The furnace starts up in either low- or high-gas heat. If furnace starts up in low-gas heat, control CPU determines low-gas heat on time (from 0 to 16 minutes) which is permitted before switching to high-gas heat.

If power is interrupted, stored history is erased, and control CPU selects low-gas heat for up to 16 minutes and then switches to high-gas heat as long as thermostat continues to "call for heat." Subsequent selection is based on stored history of thermostat cycle times.

When the wall thermostat "calls for heat," R-W1 circuit closes. The furnace control performs a self-check, verifies low-heat and high-heat pressure switch contacts LPS and HPS are open, and starts inducer motor IDM in low speed or high speed as appropriate.

a. Inducer prepurge period—As inducer motor IDM comes up

to low speed or high speed, the low-heat pressure switch contacts LPS (or LPS and HPS) close to begin a 15-sec prepurge period.

b. Ignitor warm-up—At the end of prepurge period, hot

surface ignitor HSI is energized for a 17-sec ignitor warm-up period.

c. Trial-for-ignition sequence—When ignitor warm-up period

is completed, main gas valve relay contacts MGVR-1 and

-2 close to energize low-heat gas valve solenoid GV, gas valve opens, and 24-v power is supplied for a field-installed humidifier at terminals HUM and C

OM. Low-heat gas valve

solenoid GV permits gas flow to the burners where it is ignited. After 5 sec, ignitor HSI is de-energized, and a 2-sec flame-proving period begins.

If furnace control CPU selects high-gas-heat operation, high-heat gas valve solenoid GV is also energized after normally closed high-heat pressure switch relay HPSR closes and after inducer motor IDM goes to high speed and provides sufficient pressure to close high-heat pressure switch HPS. HPSR is open while furnace is powered in standby mode. If high-heat pressure switch HPS fails to close and low-heat pressure switch LPS closes, furnace operates at low-heat gas flow rate until high-heat pressure switch closes.

d. Flame-proving—When burner flame is proved at flame-

proving sensor electrode FSE, control CPU begins blower on delay period and continues to hold gas valve GV open. If burner flame is not proved within 2 sec, control CPU closes gas valve GV, and control CPU repeats ignition sequence for up to 3 more trials-for-ignition before going to ignition lockout. LOCKOUT IS RESET AUTOMATICALLY after 3 hr, or by momentarily interrupting 115-v power to furnace, or by interrupting 24-v power at SEC1 or SEC2 to control CPU (not at W/W1, G, R, etc.). Opening thermostat R-W circuit will not reset ignition lockout.

If flame is proved when flame should not be present, control CPU locks out of gas heating mode and operates inducer motor IDM on high speed until flame is no longer proved.

e. Blower on delay—If burner flame is proven, 45 sec after

gas valve GV is opened blower motor BLWM is energized on appropriate heating speed, low-gas-heat or high-gasheat speed. Simultaneously, EAC terminals EAC-1 and EAC-2 are energized with 115v and remain energized as long as blower motor BLWM is energized.

f. Switching from low- to high-gas heat—If furnace control

CPU switches from low-gas heat to high-gas heat, control CPU switches inducer motor IDM speed from low to high. The high-heat pressure switch relay HPSR closes. When

inducer motor IDM provides sufficient pressure to close high-heat pressure switch HPS, high-heat gas valve solenoid GV is energized. Blower motor BLWM switches speed for high-gas heat 5 sec after control CPU switches from low-gas heat to high-gas heat.

g. Switching from high- to low-gas heat—Control CPU will

not switch from high-gas heat to low-gas heat while thermostat R-W circuit is closed when a single-stage thermostat is used.

h. Blower off delay—When thermostat is satisfied, R-W

circuit is opened, de-energizing gas valve GV, stopping gas flow to burners, and de-energizing humidifier terminals HUM and C

OM. Inducer motor IDM remains energized for

a 5-sec post-purge period. Blower motor BLWM and EAC terminals EAC-1 and EAC-2 remain energized for 90, 135, 180, or 225 sec (depending on selection at blower off delay switches SW-3 and SW-4). Furnace control CPU is factory set for a 135-sec blower off delay.

2. Non-Adaptive Heating Mode—Two-Stage Thermostat and 2-Stage Heating

(See Fig. 16 for thermostat connections.)

NOTE: The low-heat-only switch SW-2 ON selects low-heatonly operation mode in response to closing thermostat R-W/W1 circuit. When high-heat-only switch SW-1 is off, closing thermostat R to W1-and-W2 circuits is required for high-gas-heat operation. When high-heat-only switch SW-1 is on, it always causes high-gas-heat operation when R-W/W1 circuit is closed, regardless of setting of low-heat-only switch SW-2 and regardless of whether R-W2 circuit is closed or open.

The start-up and shutdown functions and delays described in item 1 above apply to 2-stage heating mode as well, except for switching from low- to high-gas heat and vice versa.

a. When wall thermostat "calls for heat," R-W/W1 circuit

closes for low-gas heat or R to W1-and-W2 circuits close for high-gas heat. The furnace control performs a selfcheck, verifies low-heat and high-heat pressure switch contacts LPS and HPS are open, and starts inducer motor IDM in low speed or high speed as appropriate.

b. Switching from low- to high-gas heat—If thermostat

R-W/W1 circuit for low-gas heat is closed and R-W2 circuit for high-gas heat closes, control CPU switches inducer motor IDM speed from low to high. The high-heat pressure switch relay HPSR closes. When inducer motor IDM provides sufficient pressure to close high-heat pressure switch HPS, high-heat gas valve solenoid GV is energized. Blower motor BLWM switches speed for highgas heat 5 sec after R-W2 circuit closes.

c. Switching from high- to low-gas heat—If thermostat R-W2

circuit for high-gas heat opens and R-W/W1 circuit for low-gas heat remains closed, control CPU switches inducer motor IDM speed from high to low. The high-heat pressure switch relay HPSR opens to de-energize high-heat gas valve solenoid GV. When inducer motor IDM reduces pressure sufficiently, high-heat pressure switch HPS opens. The low-heat gas valve solenoid GV remains energized as long as low-heat pressure switch LPS remains closed. Blower motor BLWM switches speed for low-gas heat 5 sec after R-W2 circuit opens.

3. Cooling Mode

a. Single-Speed Cooling Outdoor Unit

(See Fig. 15 for thermostat connections.)

(1.) The thermostat closes R to G-and-Y circuits. The

R-Y circuit starts outdoor unit, and R to G-and-Y circuits start furnace blower motor BLWM on highcool speed.

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when blower motor BLWM is operating.

(3.) When thermostat is satisfied, R to G-and-Y circuits

are opened. The outdoor unit stops, and furnace blower motor BLWM continues operating on highcool speed for an additional 90 sec.

b. Two-Speed Cooling Outdoor Unit

(See Fig. 16 for thermostat connections.)

(1.) The thermostat closes R to G-and-Y1 circuits for low

cooling or closes R to G-and-Y1-and-Y/Y2 circuits for high cooling. The R-Y1 circuits start outdoor unit on low-cooling speed, and R-G circuit starts furnace blower motor BLWM on low-cooling speed (same speed as for low-gas heat). The R to Y1-and-Y2 circuits start outdoor unit on high-cooling speed, and R to G-and-Y2 circuits start furnace blower motor BLWM on high-cooling speed.

NOTE: Y1 is not located on furnace control, but is found in outdoor unit. The furnace control CPU controls blower motor BLWM speed by sensing only G for low-cooling speed and Y/Y2 for high-cooling speed.

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when blower motor BLWM is operating on either cooling speed.

(3.) When thermostat is satisfied, R to G-and-Y1 or

R to G-and-Y1-and-Y/Y2 circuits open. The outdoor unit stops, and furnace blower continues operating on cooling speed for an additional 90 sec.

4. Continuous Blower Mode

a. When R to G circuit is closed by thermostat, blower motor

BLWM operates on low-gas-heat speed (identical to lowcool speed). Terminals EAC-1 and EAC-2 are energized with 115v as long as blower motor BLWM is energized.

b. During "call for heat," blower motor BLWM stops during

ignitor warm-up (17 sec), ignition (7 sec), and blower on delay (45 sec), allowing furnace heat exchangers to heat up quickly.

(1.) The blower motor BLWM reverts to continuous

blower speed after heating cycle is completed. In high-gas-heat, furnace control CPU holds blower motor BLWM at high-gas-heat speed during selected blower off delay period before reverting to continuous blower speed.

(2.) When thermostat "calls for low cooling," blower

motor BLWM continues to operate on low-cool speed. When thermostat is satisfied, blower motor BLWM continues on continuous blower speed.

(3.) When thermostat "calls for high cooling," blower

motor BLWM operates on high-cool speed. When thermostat is satisfied, blower motor BLWM operates an additional 2 sec on high-cool speed before reverting back to continuous blower speed.

(4.) When R to G circuit is opened, blower motor BLWM

continues operating for an additional 90 sec if no other function requires blower motor BLWM operation.

5. Heat Pump

NOTE: An accessory interface kit is required with single-speed heat pumps. See interface kit Installation Instructions for singlespeed heat pump thermostat and interface connections. No interface kit is needed for 2-speed heat pumps. See 2-speed heat pump Installation Instructions for thermostat connections.

a. Single-Speed Heat Pump Cooling

(1.) The thermostat and interface kit close R to G-and-

Y/Y2 circuit to start furnace blower motor BLWM on high-cooling speed. (Y/Y2 input to furnace control is necessary to provide adequate cooling airflow.)

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when blower motor BLWM is operating.

(3.) When thermostat is satisfied, furnace blower motor

BLWM continues operating on high-cooling speed for an additional 90 sec.

b. Two-Speed Heat Pump Cooling

(1.) The thermostat R to G circuits start furnace blower

motor BLWM on low-cooling speed. Thermostat R to G-and-Y/Y2 circuits start furnace blower motor BLWM on high-cool speed.

NOTE: The furnace control CPU controls blower motor BLWM speed by sensing only G (for low-cooling speed) and Y2 (for high-cooling speed).

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when blower motor BLWM is operating on either cooling speed.

(3.) When thermostat is satisfied, furnace blower motor

BLWM continues operating on cooling speed for an additional 90 sec.

c. Single-Speed Heat Pump Heating

(1.) The thermostat and accessory interface kit R to G-

and-Y/Y2 circuits start furnace blower motor BLWM on heat pump high-heat speed (identical to high-cool speed).

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when blower motor BLWM is operating.

(3.) When thermostat is satisfied, furnace blower motor

BLWM continues operating on heat pump high-heat speed for an additional 90 sec.

d. Two-Speed Heat Pump Heating

(1.) The thermostat closes R to G circuit for low heat and

starts furnace blower motor BLWM on heat pump low-heat speed (identical to low-cooling speed). Closing R-Y/Y2 circuit to furnace provides blower motor BLWM heat pump high-heat speed.

NOTE: The furnace control CPU controls blower motor BLWM speed by sensing only G (for heat pump low-heat speed) and Y2 (for heat pump high-heat speed).

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when blower motor BLWM is operating on either heating speed.

(3.) When thermostat is satisfied, R to G or R to G-and-

Y2 circuits are opened. After opening R to G-and-Y2 circuit, the furnace blower motor BLWM continues operating on heating speed for an additional 90 sec.

(4.) Opening R-Y2 circuit reduces blower motor BLWM

speed to heat pump low-heat speed.

6. Defrost

a. When furnace control R to W/W1-and-Y/Y2 circuits are

closed, furnace control CPU continues blower motor

BLWM operation at heat pump heating speed until end of prepurge period, then shuts off until end of HSI ignitor on period (22 sec).

b. When installed with a heat pump, furnace control CPU

automatically holds blower off time to 22 sec during HSI ignitor on period. After 17 sec of HSI ignitor on period, a trial-for-ignition sequence occurs as described above for gas heating. After flame is proved and without blower on delay, blower motor BLWM then operates on high-gasheat speed during defrost. For both single-speed and 2-speed heat pumps, defrost mode is in high-gas heat only.

c. When furnace control R to W/W1 circuit is opened, furnace

control CPU begins normal inducer post-purge period, and blower motor BLWM remains on for blower off delay period. If R-G circuit remains closed, blower motor BLWM reverts to continuous operation.

START-UP PROCEDURES

1. Component test—The furnace features a component test system to help diagnose a system problem in case of component failure. To initiate component test procedure, ensure that there are no thermostat inputs to control and that all time delays have expired. Short TWIN/TEST terminal to ground or C

OM for 1 to 4 sec. See Fig. 14 for terminal locations.

NOTE: The component test feature will not operate if control is receiving any thermostat signals and until all time delays have expired. The component test sequence is as follows:

a. The furnace control checks itself, operates inducer motor

on low speed for 7 sec and on high speed for 7 sec, then stops.

b. The hot surface ignitor is then energized for 15 sec, then

de-energized.

c. The blower motor operates on low-gas-heat/heat pump

low-heat/low-cool/continuous fan speed for 7 sec, then stops.

d. The blower motor operates on high-gas-heat speed for 7

sec, then stops. The gas valve and humidifier terminal HUM are not energized for safety reasons.

NOTE: The EAC terminals are energized when blower is energized.

e. The blower operates on heat pump high-heat/high-cool

speed for 7 sec, then stops.

2. After all connections have been made, purge gas lines and check for leaks.

3. To operate furnace, follow procedures on operating instruction 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.

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft.

In the U.S.A., input rating for altitudes above 2000 ft must be reduced by 4 percent for each 1000 ft above sea level.

In Canada, input rating must be derated by 10 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.

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

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

local gas supplier.

b. Obtain yearly specific gravity average from local gas

supplier.

c. Verify furnace model. Table 10 can only be used for model

58TMA Furnaces.

d. Find installation altitude in Table 10.

NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 10.

e. Find closest natural gas heat value and specific gravity in

Table 10.

f. Follow heat value and specific gravity lines to point of

intersection to find orifice size and low- and high-heat manifold pressure settings for proper operation.

EXAMPLE: (0—2000 ft altitude) Heating value = 1075 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 45

Manifold pressure: 3.7-in. wc for high heat

1.5-in. wc for low heat * 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 proper input rate.

g. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY.

3. Adjust manifold pressure to obtain input rate.

a. Remove caps that conceal adjustment screws for low- and

high-heat gas valve regulators. (See Fig. 19.)

b. Move setup switch SW-2 on control center to ON position.

(See Fig. 17.) This keeps furnace locked in low-heat operation.

c. Jumper R and W/W1 thermostat connections on control

center to start furnace.

d. Turn low-heat adjusting screw (5/64 hex Allen wrench)

counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low-heat manifold pressure less than 1.3-in. wc or more than 1.7-in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices.

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.

BURNER

ORIFICE

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.

e. Move setup switch SW-2 to OFF position after completing

low-heat adjustment.

f. Jumper R and W2 thermostat connections on control center.

(See Fig. 14.) This keeps furnace locked in high-heat operation.

g. Turn high-heat adjusting screw (5/64 hex Allen wrench)

counterclockwise (out) to decrease input rate or clockwise (in) to increase rate.

NOTE: DO NOT set high-heat manifold pressure less than 3.2-in. wc or more than 3.8-in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices.

h. When correct input is obtained, replace caps that conceal

gas valve regulator adjustment screws. Main burner flame should be clear blue, almost transparent. (See Fig. 20.)

i. Remove jumper R to W2.

4. Verify natural gas input rate 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 4 percent derate for each 1000 ft above sea level. See Table 9 for derate multiplier factor and example.

EXAMPLE: 85,000 Btuh input furnace installed at 4300 ft.

Furnace Input

Rate at

Sea Level

85,000 X 0.82 = 69,700

Multiplier

Derate

Factor

Furnace Input Rate

at Installation

Altitude

CANADA

At installation altitudes from 2000 to 4500 ft, this furnace must be derated 10 percent by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example above and use 0.82 as derate multiplier factor.

b. Check that gas valve adjustment caps are in place for

proper input to be clocked.

c. Obtain yearly heat value average for local gas supply.

NOTE: Be sure heating value of gas used for calculations is correct for your altitude. Consult local gas utility for altitude adjustment of gas heating value.

d. Check and verify orifice size in furnace. NEVER AS-

SUME THE ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

e. Turn off all other gas appliances and pilots.

f. Move setup switch SW-2 to ON position. (See Fig. 17.)

This keeps furnace locked in low-heat operation.

g. Jumper R to W/W1.

h. Let furnace run for 3 minutes in low-heat operation.

i. Measure time (in sec) for gas meter to complete 1 revolu-

tion. Note reading.

j. Refer to Table 10 for cubic ft of gas per hr.

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

l. Move setup switch SW-2 to OFF position and jumper R and

W2 thermostat connections. (See Fig. 17.) This keeps furnace locked in high-heat operation. Repeat items h through k for high-heat operation.

EXAMPLE: (High-heat operation at 0—2000 ft altitude) Furnace input from rating plate is 85,000 Btuh Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 1050 Btu/cu ft Time for 1 revolution of 2-cu ft dial = 92 sec Gas rate = 80 cu ft/hr (from Table 10) Btu heating input = 80 X 1050 = 84,000 Btuh In this example, the orifice size and manifold pressure adjustment is within ±2 percent of the furnace input rate.

Table 9—Altitude Derate Multiplier for U.S.A.

ALTITUDE

(FT)

0—2000 0 1.00 2001—3000 8—12 0.90 3001—4000 12—16 0.86 4001—5000 16—20 0.82 5001—6000 20—24 0.78 6001—7000 24—28 0.74 7001—8000 18—32 0.70 8001—9000 32—36 0.66

9001—10,000 36—40 0.62

* Derate multiplier factor is based on midpoint altitude for altitude range.

%OF

DERATE

DERATE MULTIPLIER

FACTOR FOR U.S.A.*

NOTE: Measured gas inputs (high heat and low heat) must be

within ±2 percent of that stated on furnace rating plate when installed at sea level or derated per that stated above when installed at higher altitudes.

m. Remove jumper across R, W/W1, and W2 thermostat

connections to terminate call for heat.

5. Set temperature rise.

Place SW-2 in ON position. Jumper R to W/W1 and W2 to check high-gas-heat temperature rise. To check low-gas-heat temperature rise, remove jumper to W2. Determine air temperature rise for both high and low heat using the following steps. DO NOT exceed temperature rise ranges specified on unit rating plate for high and low heat.

Table 10—Model 58TMA Orifice Size and Manifold Pressure for Correct Input

(Tabulated Data Based on 21,000 Btuh High Heat/13,500 Btuh Low Heat per Burner,

Derated 4% for Each 1000 Ft Above Sea Level)*

ALTITUDE

RANGE

(FT)

0 925 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.8/1.6 42 3.2/1.3

to 975 44 3.5/1.5 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.4

2000 1025 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

U.S.A. 775 43 3.7/1.5 42 3.2/1.3 42 3.3/1.4 42 3.4/1.4 42 3.5/1.4

Altitudes 800 43 3.5/1.4 43 3.6/1.5 43 3.7/1.5 42 3.2/1.3 42 3.3/1.3

2001 825 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.5

to 850 44 3.6/1.5 44 3.7/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5

3000 875 44 3.4/1.4 44 3.5/1.4 44 3.6/1.5 44 3.7/1.5 44 3.8/1.6

or 900 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.4 44 3.6/1.5

Canada 925 46 3.8/1.6 45 3.8/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4

Altitudes 950 46 3.6/1.5 46 3.7/1.5 45 3.7/1.5 45 3.8/1.6 44 3.2/1.3

U.S.A. and Canada

2000 975 46 3.4/1.4 46 3.5/1.5 46 3.7/1.5 46 3.8/1.6 45 3.7/1.5

to 1000 47 3.7/1.5 47 3.8/1.6 46 3.5/1.4 46 3.6/1.5 46 3.7/1.5

4500 1025 47 3.5/1.5 47 3.6/1.5 47 3.8/1.6 46 3.4/1.4 46 3.5/1.5

ALTITUDE

RANGE

(FT)

3001 825 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.7/1.5 44 3.8/1.6

to 875 46 3.7/1.5 45 3.7/1.5 44 3.2/1.3 44 3.3/1.3 44 3.4/1.4

U.S.A. Only

4000 925 47 3.8/1.6 46 3.5/1.4 46 3.6/1.5 46 3.7/1.5 46 3.8/1.6

* For 125-20 size only, input is 20,500 Btuh for high fire. Deduct 0.1-in. from manifold pressure shown in table. Change orifice size if manifold pressure falls below 3.2-in. wc.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

850 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5 42 3.7/1.5 42 3.8/1.6 875 43 3.8/1.6 42 3.2/1.3 42 3.3/1.4 42 3.5/1.4 42 3.6/1.5 900 43 3.6/1.5 43 3.7/1.5 42 3.2/1.3 42 3.3/1.3 42 3.4/1.4

950 44 3.7/1.5 44 3.8/1.6 43 3.5/1.4 43 3.6/1.5 43 3.7/1.5

1000 44 3.3/1.4 44 3.5/1.4 44 3.6/1.5 44 3.7/1.5 44 3.8/1.6

1050 45 3.7/1.5 45 3.8/1.6 44 3.2/1.3 44 3.4/1.4 44 3.5/1.4 1075 46 3.7/1.5 46 3.8/1.6 45 3.7/1.5 44 3.2/1.3 44 3.3/1.4 1100 46 3.5/1.5 46 3.6/1.5 46 3.8/1.6 45 3.7/1.5 45 3.8/1.6

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

750 43 3.5/1.4 43 3.6/1.5 43 3.7/1.5 42 3.2/1.3 42 3.3/1.4 775 44 3.8/1.6 43 3.4/1.4 43 3.5/1.4 43 3.6/1.5 43 3.7/1.5 800 44 3.5/1.5 44 3.7/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.4

850 45 3.8/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.6/1.5

900 46 3.5/1.5 46 3.7/1.5 46 3.8/1.6 45 3.7/1.5 44 3.2/1.3

950 47 3.6/1.5 47 3.7/1.5 46 3.4/1.4 46 3.5/1.5 46 3.6/1.5 975 47 3.4/1.4 47 3.5/1.5 47 3.7/1.5 47 3.8/1.6 46 3.4/1.4

1000 48 3.7/1.5 48 3.8/1.6 47 3.5/1.4 47 3.6/1.5 47 3.7/1.5

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Table 10—Model 58TMA Orifice Size and Manifold Pressure for Correct Input—Continued

(TABULATED DATA BASED ON 21,000 BTUH HIGH HEAT/13,500 BTUH LOW HEAT PER BURNER,

DERATED 4% FOR EACH 1000 FT ABOVE SEA LEVEL)*

ALTITUDE

RANGE

(FT)

4001 800 45 3.7/1.5 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5

to 850 46 3.5/1.4 46 3.6/1.5 46 3.7/1.5 46 3.8/1.6 45 3.8/1.6

U.S.A. Only

5000 900 47 3.5/1.5 47 3.6/1.5 47 3.8/1.6 46 3.4/1.4 46 3.5/1.5

ALTITUDE

RANGE

(FT)

5001 800 46 3.4/1.4 46 3.5/1.5 46 3.7/1.5 46 3.8/1.6 45 3.7/1.5

to 850 47 3.4/1.4 47 3.6/1.5 47 3.7/1.5 47 3.8/1.6 46 3.5/1.4

U.S.A. Only

6000 900 48 3.5/1.4 48 3.6/1.5 48 3.7/1.5 47 3.4/1.4 47 3.5/1.4

ALTITUDE

RANGE

(FT)

6001 725 46 3.6/1.5 46 3.7/1.5 45 3.7/1.5 45 3.8/1.6 44 3.2/1.3

to 775 47 3.6/1.5 47 3.7/1.5 47 3.8/1.6 46 3.5/1.4 46 3.6/1.5

U.S.A. Only

7000 825 48 3.6/1.5 48 3.7/1.5 48 3.8/1.6 47 3.5/1.4 47 3.6/1.5

* For 125-20 size only, input is 20,500 Btuh for high fire. Deduct 0.1-in. from manifold pressure shown in table. Change orifice size if manifold pressure falls below 3.2-in. wc.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725 44 3.8/1.6 43 3.4/1.4 43 3.5/1.4 43 3.6/1.5 43 3.7/1.5 750 44 3.5/1.5 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.4 775 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.5

825 46 3.7/1.5 46 3.8/1.6 45 3.8/1.6 44 3.2/1.3 44 3.3/1.4

875 47 3.7/1.5 46 3.4/1.4 46 3.5/1.5 46 3.6/1.5 46 3.7/1.5

925 48 3.8/1.6 47 3.4/1.4 47 3.6/1.5 47 3.7/1.5 47 3.8/1.6 950 48 3.6/1.5 48 3.7/1.5 48 3.8/1.6 47 3.5/1.4 47 3.6/1.5

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

700 44 3.5/1.5 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.4 725 44 3.3/1.4 44 3.4/1.4 44 3.5/1.4 44 3.6/1.5 44 3.7/1.5 750 45 3.7/1.5 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.4 775 46 3.6/1.5 46 3.8/1.6 45 3.7/1.5 44 3.2/1.3 44 3.3/1.4

825 47 3.7/1.5 47 3.8/1.6 46 3.4/1.4 46 3.6/1.5 46 3.7/1.5

875 48 3.7/1.5 48 3.8/1.6 47 3.5/1.4 47 3.6/1.5 47 3.7/1.5

925 48 3.3/1.4 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5 48 3.8/1.6 950 49 3.7/1.5 49 3.8/1.6 48 3.3/1.4 48 3.5/1.4 48 3.6/1.5 975 49 3.5/1.4 49 3.6/1.5 49 3.7/1.5 48 3.3/1.4 48 3.4/1.4

1000 49 3.3/1.4 49 3.4/1.4 49 3.6/1.5 49 3.7/1.5 49 3.8/1.6

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

650 44 3.5/1.5 44 3.7/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.4 675 44 3.3/1.4 44 3.4/1.4 44 3.5/1.4 44 3.6/1.5 44 3.7/1.5 700 45 3.7/1.5 44 3.2/1.3 44 3.3/1.3 44 3.4/1.4 44 3.5/1.4

750 47 3.8/1.6 46 3.5/1.4 46 3.6/1.5 46 3.7/1.5 46 3.8/1.6

800 48 3.8/1.6 47 3.5/1.4 47 3.6/1.5 47 3.7/1.5 47 3.8/1.6

850 48 3.4/1.4 48 3.5/1.4 48 3.6/1.5 48 3.7/1.5 47 3.4/1.4 875 49 3.8/1.6 48 3.3/1.4 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5

0.58 0.60 0.62 0.64 0.66

Orifice

Manifold

Pressure

No.

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

No.

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

No.

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Table 10—Model 58TMA Orifice Size and Manifold Pressure for Correct Input—Continued

(TABULATED DATA BASED ON 21,000 BTUH HIGH HEAT/13,500 BTUH LOW HEAT PER BURNER,

DERATED 4% FOR EACH 1000 FT ABOVE SEA LEVEL)*

ALTITUDE

RANGE

(FT)

7001 700 47 3.8/1.6 46 3.4/1.4 46 3.6/1.5 46 3.7/1.5 46 3.8/1.6

to 750 48 3.7/1.5 47 3.4/1.4 47 3.5/1.5 47 3.6/1.5 47 3.7/1.5

U.S.A. Only

8000 800 48 3.3/1.4 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5 48 3.7/1.5

ALTITUDE

RANGE

(FT)

8001 650 47 3.8/1.6 46 3.4/1.4 46 3.5/1.5 46 3.7/1.5 46 3.8/1.6

to 700 48 3.7/1.5 48 3.8/1.6 47 3.5/1.4 47 3.6/1.5 47 3.7/1.5

U.S.A. Only

9000 750 49 3.8/1.6 48 3.3/1.4 48 3.4/1.4 48 3.5/1.5 48 3.7/1.5

ALTITUDE

RANGE

(FT)

9001 625 47 3.4/1.4 47 3.6/1.5 47 3.7/1.5 47 3.8/1.6 46 3.5/1.4

to 675 48 3.4/1.4 48 3.5/1.4 48 3.6/1.5 48 3.7/1.5 48 3.8/1.6

U.S.A. Only

10,000 725 49 3.4/1.4 49 3.5/1.5 49 3.7/1.5 49 3.8/1.6 48 3.3/1.4

* For 125-20 size only, input is 20,500 Btuh for high fire. Deduct 0.1-in. from manifold pressure shown in table. Change orifice size if manifold pressure falls below 3.2-in. wc.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

625 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.5 650 45 3.7/1.5 45 3.8/1.6 44 3.3/1.3 44 3.4/1.4 44 3.5/1.4 675 46 3.6/1.5 46 3.7/1.5 46 3.8/1.6 45 3.8/1.6 44 3.2/1.3

725 47 3.5/1.5 47 3.6/1.5 47 3.8/1.6 46 3.4/1.4 46 3.5/1.5

775 48 3.5/1.5 48 3.6/1.5 48 3.8/1.6 47 3.4/1.4 47 3.5/1.4

825 49 3.6/1.5 49 3.8/1.6 48 3.3/1.4 48 3.4/1.4 48 3.5/1.5 850 49 3.4/1.4 49 3.5/1.5 49 3.7/1.5 49 3.8/1.6 48 3.3/1.4

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

600 45 3.7/1.5 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.4 625 46 3.6/1.5 46 3.7/1.5 46 3.8/1.6 45 3.8/1.6 44 3.2/1.3

675 47 3.5/1.4 47 3.6/1.5 47 3.7/1.5 47 3.8/1.6 46 3.5/1.4

725 48 3.4/1.4 48 3.6/1.5 48 3.7/1.5 48 3.8/1.6 47 3.4/1.4

775 49 3.5/1.5 49 3.7/1.5 49 3.8/1.6 48 3.3/1.4 48 3.4/1.4 800 49 3.3/1.4 49 3.4/1.4 49 3.5/1.5 49 3.7/1.5 49 3.8/1.6

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

575 46 3.6/1.5 46 3.7/1.5 46 3.8/1.6 45 3.8/1.6 44 3.2/1.3 600 47 3.7/1.5 46 3.4/1.4 46 3.5/1.5 46 3.6/1.5 46 3.8/1.6

650 48 3.6/1.5 48 3.8/1.6 47 3.4/1.4 47 3.5/1.5 47 3.6/1.5

700 49 3.7/1.5 49 3.8/1.6 48 3.3/1.4 48 3.5/1.4 48 3.6/1.5

750 50 3.8/1.6 49 3.3/1.4 49 3.4/1.4 49 3.5/1.5 49 3.6/1.5 775 50 3.5/1.5 50 3.7/1.5 50 3.8/1.6 49 3.3/1.4 49 3.4/1.4

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

SECONDS

FOR 1

REVOLUTION

10 11 12 13 14

15 16 17 18 19

20 21 22 23 24

25 26 27 28 29

30 31 32 33 34

35 36 37 38 39

40 41 42 43 44

45 46 47 48 49

Table 11—Gas Rate (Cu Ft/Hr)

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

360

720 655 600 555 514

480 450 424 400 379

360 343 327 313 300

288 277 267 257 248

240 232 225 218 212

206 200 195 189 185

180 176 172 167 164

160 157 153 150 147

1800 1636 1500 1385 1286

1200 1125 1059 1000

947

900 857 818 783 750

720 692 667 643 621

600 581 563 545 529

514 500 486 474 462

450 439 429 419 409

400 391 383 375 367

327 300 277 257

240 225 212 200 189

180 171 164 157 150

144 138 133 129 124

120 116 113 109 106

103 100

97 95 92

90 88 86 84 82

80 78 76 75 73

SECONDS

FOR 1

REVOLUTION

50 51 52 53 54

55 56 57 58 59

60 62 64 66 68

70 72 74 76 78

80 82 84 86 88

90 92 94 96 98

100 102 104 106 108

110 112 116 120

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

72 71 69 68 67

65 64 63 62 61

60 58 56 54 53

51 50 48 47 46

45 44 43 42 41

40 39 38 38 37

36 35 35 34 33

33 32 31 30

ON/OFF SWITCH

144

360

141

355 138 136 133

131 129 126 124 122

120 116 112 109 106

103 100

97 95 92

90 88 86 84 82

80 78 76 75 74

72 71 69 68 67

65 64 62 60

346

340

333

327

321

316

310

305

300

290

281

273

265

257

250

243

237

231

225

220

214

209

205

200

196

192

188

184

180

178

173

170

167

164

161

155

150

INLET PRESSURE TAP

O

F

MANIFOLD

PRESSURE

TAP

→ Fig. 19—Redundant Automatic Gas Control

Valve

BURNER FLAME

LOW-FIRE ADJUSTMENT ALLEN SCREW (UNDER CAP)

HIGH-FIRE ADJUSTMENT ALLEN SCREW (UNDER CAP)

A97358

BURNER

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.

NOTE: If temperature rise is outside this range, first check:

(1.) Gas input for low- and high-heat operation.

(2.) Derate for altitude if applicable.

(3.) Return and supply ducts for excessive restrictions

causing static pressures greater than 0.50-in. wc.

c. Adjust air temperature rise by adjusting blower speed.

Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. For high heat, speed selection can be med-high, med (5-speed blowers only), or med-low (factory setting). For low heat, speed tap selection can be low (factory setting), med-low, or med (5-speed blowers only).

MANIFOLD

Fig. 20—Burner Flame

A89020

Disconnect electrical power before changing speed tap (or removing motor lead cap if used on 5-speed motors). A failure to follow this warning can cause personal injury or death.

NOTE: For furnaces with 5-speed motors, ensure that unused speed tap is either capped or, placed on SPARE terminal on control board before power is restored.

d. To change motor speed selection for high heat, remove

blower motor lead from control HIGH-GAS-HEAT terminal. (See Fig. 14 and Fig. 18.) Select desired blower motor speed lead from 1 of the other terminals and relocate it to HIGH-GAS-HEAT terminal. See Table 11 for lead color identification. Reconnect original lead to SPARE terminal (or use insulating cap, if used, applies only to furnaces with 5-speed blower motors). Follow this same procedure for proper selection of cool and low-gas-heat speed selection.

6. Set thermostat heat anticipator.

a. When using a nonelectronic thermostat, the thermostat heat

anticipation must be set to match amp draw of electrical

Table 12—Speed Selection

COLOR SPEED AS SHIPPED

White Common C

Black High Cool

Yellow Med-High SPARE

Orange† Med SPARE or Capped

Blue Med-Low High-Gas-Heat

Red Low* Low-Gas-Heat

* Continuous fan speed. † Available on 5-speed blowers only.

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

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

HOOK-AROUND AMMETER

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

A96316

Fig. 21—Amp Draw Check With Ammeter

components in R-W/W1 circuit. Accurate amp draw readings can be obtained at wires normally connected to thermostat subbase terminals R and W/W1. Fig. 21 illustrates an easy method of obtaining actual amp draw. The amp reading should be taken after blower motor has started and furnace is operating in low heat. To operate furnace in low heat, first move SW-2 to ON position, THEN connect ammeter wires as shown in Fig. 21. The thermostat anticipator should NOT be in this circuit while measuring current. If thermostat has no subbase, thermostat MUST be disconnected from R and W/W1 wires during current measurement. Return SW-2 to final desired location after completing reading. See thermostat manufacturer’s instructions for adjusting heat anticipator and for varying heating cycle length.

b. When using an electronic thermostat, set cycle rate for 3

cycles per hr.

CHECK SAFETY CONTROLS

The flame sensor, gas valve, and pressure switches were all checked in the Start-Up section as part of normal operation.

1. Check primary limit control.

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

The preferred method of checking 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 has shut off burners, return-air opening should be unblocked. By using this method to check limit control, it can be established that the limit is functioning properly and will operate if there is a motor failure.

2. Check draft safeguard switch.

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

a. Disconnect power to furnace and remove vent connector

from furnace flue collar. Be sure to allow time for vent connector 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 connector to furnace

flue collar.

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

3. Check flow-sensing pressure switches.

This control proves operation of draft inducer blower.

a. Turn off 115-v power to furnace.

b. Remove gas control door and disconnect inducer motor

lead wires from wire harness.

c. Turn on 115-v power to furnace

d. Close thermostat switch as if making normal furnace start.

If hot surface ignitor does not glow within several minutes and control flashes code 32, pressure switches are functioning properly.

e. Turn off 115-v power to furnace.

f. Reconnect inducer motor wires, replace gas control door,

and turn on 115-v power to furnace.

4. Check auxiliary limits.

a. Turn off 115-v power to furnace.

b. Remove blower access door.

c. Disconnect red motor lead at blower speed selector. Mark

terminal for proper reconnection.

d. Replace blower access door.

e. Turn on 115-v power to furnace. Be sure room thermostat

is calling for low heat.

f. Allow furnace to operate until auxiliary limit activates, but

DO NOT operate furnace longer than 4 minutes.

g. If furnace operates for 4 minutes, check/replace limit

switch(es).

h. Turn off 115-v power to furnace.

i. Remove blower access door.

j. Reconnect red motor lead, reset switch, and replace door.

k. Turn on 115-v power to furnace.

CHECKLIST

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

2. Check SW-1 through SW-4 after completing installation to ensure desired settings for thermostat type (SW-1 and SW-2) and blower off delay (SW-3 and SW-4). Refer to Tables 6 and

3. Verify manual reset switches have continuity.

4. Ensure blower and gas control access doors are properly installed.

5. Cycle test furnace with room thermostat.

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

7. Review User’s Manual with owner.

8. Leave literature packet near furnace.

SERVICE TRAINING

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

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book.

Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Training [ ] Classroom Service Training

A94328

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. 535-887 Printed in U.S.A. Form 58TMA-6SI Pg 24 8-97 Replaces: 58TMA-4SI

Carrier DOWNFLOW HORIZONTAL 2-SPEED, 2-STAGE 58TMA, 58TMA Install And Operation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual