Carrier 58CTA-CTX User Manual

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58CTA/CTX 2 --- S t a g e D e l u xe I n d u ce d --- C o m b ust i o n 4--- Way Multipoise Furnace

Installation, Start---up, Operating and

Service and Maintenance Instructions Series 130/D

SAFETY CONSIDERATIONS 2........................

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

CODES AND STANDARDS 5..........................

Safety 5...........................................

General Installation 5................................

Combustion and Ventilation Air 5......................

Duct Systems 5.....................................

Acoustical Lining and Fibrous Glass Duct 5...............

Gas Piping and Gas Pipe Pressure Testing 5...............

Electrical Connections 5..............................

Venting 5.........................................

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE 5.....................................

LOCATION 6.......................................

AIR FOR COMBUSTION AND VENTILATION 8.........

INSTALLATION 10..................................

UPFLOW INSTALLATION 10......................

DOWNFLOW INSTALLATION 11...................

HORIZONTAL INSTALLATION 11..................

FILTER ARRANGEMENT 15.......................

AIR DUCTS 15...................................

GAS PIPING 17..................................

ELECTRICAL CONNECTIONS 21..................

VENTING 26....................................

START--UP, ADJUSTMENT, AND SAFETY CHECK 34.....

General 34........................................

Start--Up Procedures 35..............................

Adjustments 35.....................................

Check Safety Controls 40.............................

Checklist 40.......................................

SERVICE AND MAINTENANCE PROCEDURES 45.....

Introduction 45...................................

Care and Maintenance 46...........................

Sequence of Operation 50...........................

Wiring Diagrams 53...............................

Troubleshooting 53................................

ama

ISO 9001:2000

CERTIFIED

REGISTERED

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

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1--2006E, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject, which is represented only by the standard in its entirety.

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(664mm)

(

26-1/8"

(FLUE COLLAR)

(22mm)

7/8" DI A

ACCESSORY

5-15/16"

33-5/16"

(846mm)

11/16"

(17mm)

1/2" DIA THERMOSTAT

58CT

NOTES:

1. Two additional 7/8---in. (22 mm) diameter holes are located in the top plate.

2. Minimum return ---air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a. For 800 CFM ---16 --- in. (406 mm) round or 14 1/2 x 12 ---in. (368 x 305 mm) rectangle. b. For 1200 CFM ---20 ---in. (508 mm) round or 14 1/2 x 19 1/2--- in. (368 x 495 mm) rectangle. c. For 1600 CFM ---22 ---in. (559 mm) round or 14 1/2 x 22 1/16--- in. (368 x 560mm) rectangle. d. For airflow requirements above 1800 CFM, see Air Del ivery table in Product Data literature f or specific use of single side inlets. The use of both sideinlets,a

(733mm)

28-7/8"

(641mm)

25-1/4"

22-9/16"

(573mm)

JUNCTION BOX LOCATION

WIRE ENTRY

3-15/16"

LEFT HAND GAS

ENTRY

7/8" DIA. ACCESSORY

(549mm)

21-5/8"

BOTTOM INLE T

24"

CASING

610mm)

1-11/16" (43mm)

24-7/8"

(632mm)

5-1/2"

(140mm)

2-7/16"

4-13/16"

(122mm)

8-9/16"

(217mm)

ALTERNAT E

VENT OUTLE T

(140mm)

3-3/4"

(95mm)

(62mm) 1-5/16" (33mm)

1-1/8"

(29mm)

13/16"

(21mm)

JUNCTION BOX

LOCATIONS (TYP)

5 PLACES (TYP)

5-1/2"

11/16"

(17mm)

AIRFLOW

19" (483mm) OUTLE T

1/2" DIA. K.O.THERMOSTAT WIRE ENTRY

(13mm)

1-3/4" DIA.RIGHT HAND

(44mm)

GAS ENTRY

7/8" DIA. K.O. WIRE ENTRY

(22mm)

7/8" DIA. ACCESSORY

(22mm)

(38mm)

1-1/2"

(560mm) 22-1/16"

SIDE INLE T

13/16"

(21mm)

11/16"

(17mm)

14-7/8"

(378mm)

1-1/4"

(32mm)

(25mm)

7-3/4"

(197mm)

combination of 1 side and th e bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

Fig. 1 -- Dimensional Drawing

9-5/8"

(244mm)

11-1/2"

(292mm)

A04037

SAFETY CONSIDERATIONS

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation, serious injury, death, or property damage.

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

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure.

Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

CAUTION

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory--authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions include in literature and attached to the unit. Consult local building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC) NFPA 70.

In Canada, refer to the current editions of the National Standards of Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane Installation Codes, and Canadian Electrical Code CSA C22.1

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 may 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.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing furnaces.

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Table1–Dimensions

FURNACE SIZE

045 --- 08/024045 14--- 3/16 (360) 12--- 9/16 (319) 12--- 11/16 (322) 9--- 5/16 (237) 4 (102) 104 (47) 16 (406) 045 --- 12/036045 14--- 3/16 (360) 12--- 9/16 (319) 12--- 11/16 (322) 9--- 5/16 (237) 4 (102) 107 (48) 16 (406) 070 --- 08/024070 14--- 3/16 (360) 12--- 9/16 (319) 12--- 11/16 (322) 9--- 5/16 (237) 4 (102) 111 (50) 16 (406) 070 --- 12/036070 14--- 3/16 (360) 12--- 9/16 (319) 12--- 11/16 (322) 9--- 5/16 (237) 4 (102) 115 (52) 16 (406) 070 --- 16/048070 17--- 1/2 (445) 15--- 7/8 (403) 16 (406) 11 --- 9/16 (294) 4 (102) 126 (57) 16 (406) 090 --- 14/042090 17--- 1/2 (445) 15--- 7/8 (403) 16 (406) 11 --- 9/16 (294) 4 (102) 127 (58) 16 (406) 090 --- 16/048090 21 (533) 19---3/8 (492) 19-- -1/2 (495) 13--- 5/16 (338) 4 (102) 140 (64) 20 (508) 090 --- 20/060090 21 (533) 19---3/8 (492) 19-- -1/2 (495) 13--- 5/16 (338) 4 (102) 146 (66) 20 (508) 110 --- 12/036110 17--- 1/2 (445) 15--- 7/8 (403) 16 (406) 11 --- 9/16 (294) 4 (102) 135 (61) 16 (406) 110 --- 16/048110 21 (533) 19---3/8 (492) 19-- -1/2 (495) 13--- 5/16 (338) 4 (102) 146 (66) 20 (508) 110 --- 22/066110 21 (533) 19---3/8 (492) 19-- -1/2 (495) 13--- 5/16 (338) 4 (102) 152 (69) 20 (508) 135 --- 16/048135 21 (533) 19---3/8 (492) 19-- -1/2 (495) 13--- 5/16 (338) 4 (102) 149 (68) 20 (508) 135 --- 22/066135 24--- 1/2 (622) 22--- 7/8 (581) 23 (584) 15 --- 1/16 (383) 4 (102) 163 (74) 24 (610) 155 --- 20/060155 24--- 1/2 (622) 22--- 7/8 (581) 23 (584) 15 --- 1/16 (383) 4 (102) 170 (77) 24 (610)

* 5 ---in. or 6 ---in. (127 or 152 mm) vent connector may be required in some cases.

{ 135 and 155 size f urnaces require 5 --- in. (127 mm) or larger vents. Use a 4 to 5 or 4 to 6---in. (102 to 127 or 102 to 152 mm) vent adapter between furnace and vent connector.

CABINET

WIDTH

IN (mm)

SUPPLY --- AIR

WIDTH

IN (mm)

RETURN--- AIR

WIDTH

IN (mm)

product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate 2. Install this furnace only in a

2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified in “Air for Combustion and Ventilation” section.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Gas Piping” section.

6. Always install furnace to operate within the furnace’s intended temperature--rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Start--Up, Adjustments, and Safety Check” section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See “Air Ducts” section.

8. A gas--fired furnace for installation in a residential garage must be installed as specified in the warning box in the “Location” section.

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

10. These Multipoise Gas--Fired Furnaces are CSA (formerly A.G.A. and C.G.A.) design--certified for use with natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory--shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to convert furnace for use with propane gas.

The Series 130/D 4--way multipoise Category I fan-- assisted furnace is CSA (formerly A.G.A.. and C.G.A.) design--certified. A Category I fan--assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory--shipped for use with natural gas. This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors.

These furnaces shall not be installed directly on carpeting, tile, or any other combustible material other than wood flooring. For downflow installations, a factory accessory floor base must be used when installed on combustible materials and wood flooring. This special base is not required when this furnace is installed on the manufacturer’s coil assembly, or when the manufacturer’s coil box is used. See Fig. 2 for clearance to combustible material information.

This furnace is designed for minimum continuous return--air temperature of 60_F(16_C) db or intermittent operation down to 55_F(13_C) db such as when used with a night setback thermostat. Return-- air temperature must not exceed 80_F(27_C) db. Failure to follow these return-- air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 3.)

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

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

C.L. TOP AND

BOTTOM FLUE

COLLAR

IN (mm)

FLUE

COLLAR*

IN (mm)

SHIP WT

LB (KG)

11. See Fig. 2 for required clearances to combustible construction.

12. Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 inches (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CAR, CAP, CNRV, CNPV or when Coil Box Part No. KCAKC is used. See Fig. 2 for clearance to combustible construction information.

INTRODUCTION

FILTER MEDIA

CABINET

IN (mm)

58CT

Page 4

58CT

Fig. 2 -- Clearances to Combustibles

A08471

Page 5

80 / 27 C

/ 16 C

A06745

Fig. 3 -- Return Air Temperature

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with

regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

In the United States and Canada, follow all codes and standards for the following:

Step 1 — Safety

S US: National Fuel Gas Code (NFGC) NFPA 54--2006/ANSI

Z223.1--2006 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

S CANADA: CSA B149.1--05 National Standard of Canada

Natural Gas and Propane Installation Code (CAN/CSA--B149.1--05)

Step 2 — General Installation

S US: Current edition of the NFGC and the NFPA 90B. For

copies, contact the National Fire Protection Association Inc., Batterymarch Park,Quincy, MA 02269; (www.NFPA.org) or for only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington DC 20001 (www.AGA.org.)

S CANADA: CAN/CSA--B149.1--05. For a copy, contact

Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada Step

Step 3 — Combustion and Ventilation Air

S US: Section 9.3 of the NFGC, NFPA 54/ ANSI Z223.1--2006

Air for Combustion and Ventilation

S CANADA: Part 8 of CAN/CSA--B149.1--05, Venting Systems

and Air Supply for Appliances

Step 4 — Duct Systems

S US and CANADA: Air Conditioning Contractors Association

(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Step 5 — Acoustical Lining and Fibrous Glass Duct

S US and CANADA: current edition of SMACNA and NFPA

90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Step 6 — Gas Piping and Gas Pipe Pressure Testing

S US: NFPA 54 / ANSI Z223.1--2006; chapters 5, 6, 7, and 8 and

National Plumbing Codes

S CANADA: CAN/CSA--B149.1--05 Parts 4, 5, and 6 and

Appendices A, B, E and H.

Step 7 — Electrical Connections

S US: National Electrical Code (NEC) ANSI/NFPA 70--2008 S CANADA: Canadian Electrical Code CSA C22.1

Step 8 — Venting

S US: NFGC; NFPA 54 / ANSI Z223.1--2006 chapters 12 and 13 S CANADA: CAN/CSA--B149.1--05 Part 8 and Appendix C

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or service of furnace may cause premature furnace component failure.

Electrostatic discharge can affect electronic components. Follow the Electrostatic Discharge Precautions Procedure listed below 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. Multiple disconnects may be required. 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 the 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 to recharge 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 (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the 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 4 before bringing the control or yourself in 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) mayalsobeusedtopreventESDdamage.

58CT

Page 6

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

58CT

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration. Some assembly and modifications are required when used in any of the four applications shown in Fig. 4.

NOTE: For high-- altitude installations, the high--altitude conversion kit MUST be installed at or above 5500 ft. (1676 M) above sea level. Obtain high--altitude conversion kit from your area authorized distributor.

This furnace must: S be installed so the electrical components are protected from

water.

S not be installed directly on any combustible material other than

wood flooring (refer to SAFETY CONSIDERATIONS).

S be located close to the chimney or vent and attached to an air

distribution system. Refer to Air Ducts section.

S be provided ample space for servicing and cleaning. Always

comply with minimum fire protection clearances shown on the furnace clearance to combustible construction label.

WARNING

CARBON MONOXIDE POISONING AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury or death, and furnace damage.

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. 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.

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

A02097

Fig. 4 -- Multipoise Orientations

The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:

S Commercial buildings S Buildings with indoor pools S Laundry rooms S Hobby or craft rooms, and S Chemical storage areas

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for

combustion:

S Permanent wave solutions S Chlorinated waxes and cleaners S Chlorine based swimming pool chemicals S Water softening chemicals S De--icing salts or chemicals S Carbon tetrachloride S Halogen type refrigerants S Cleaning solvents (such as perchloroethylene) S Printing inks, paint removers, varnishes, etc. S Hydrochloric acid S Cements and glues S Antistatic fabric softeners for clothes dryers

S Masonry acid washing materials

All fuel--burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return--air duct to prevent pulling air from the burner area and from draft safeguard opening.

Page 7

WARNING

FIRE, INJURY OR DEATH HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches (457 mm) above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFGC or CAN/CSA--B149.1--05. (See Fig. 5.)

Fig. 6 -- Prohibit Installation on Back

CAUTION

A02054

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 5 -- Installation in a Garage

WARNING

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect return--air ducts to the back of the furnace. (See Fig. 6.)

PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may cause premature component failure. This gas furnace may be used for construction heat provided that:

-- The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame roll--out and/or drawing combustion products into the structure.

--The furnace is controlled by a thermostat. It may not be ”hot wired” to provide heat continuously to the structure without thermostatic control.

--Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

--The temperature of the return air to the furnace is maintained between 55_F(13_C) and 80_F(27_C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

-- The air temperature rise is within the rated rise range on the furnace rating plate, and the gas input rate has been set to the nameplate value.

--The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

-- The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

--Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting according to these installation instructions.

58CT

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 the furnace, dampers or other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be

Page 8

equipped with means to prevent operation of either unit unless the damper is in the full--heat or full--cool position.

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

U.S. installations: Section 9.3 of the NFPA 54 /A ANSI Z223.1--2006, Air for Combustion and Ventilation, and applicable provisions of the local building codes.

Canadian installations: Part 8 of the CAN/CSA--B149.1--05, Venting Systems and Air Supply for Appliances and all authorities having jurisdiction.

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

58CT

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

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans 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. Refer to Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make--up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

S Spaces having less than 50 cubic feet per 1,000 Btuh require the

Outdoor Combustion Air Method.

S Spaces having at least 50 cubic feet per 1,000 Btuh may use the

Indoor Combustion Air, Standard or Known Air Infiltration Method.

Outdoor Combustion Air

Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

a. One opening MUST commence within 12 in. (300 mm)

of the ceiling and the second opening MUST commence within 12 in. (300 mm) of the floor.

b. Size openings and ducts per Fig. 7 and Table 2.

c. TWO HORIZONTALDUCTS require1 --in

per 2,000 Btuh (1,100 mm

/kW) of combined input for

of free area

all gas appliances in the space per Fig. 7 and Table 2.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

of free area per 4,000 Btuh (550 mm2/kW) for com-

-- i n bined input of all gas appliances in the space per Fig. 7 and Table 2.

3. ONE OUTDOOR OPENING requires:

a. One square inch of free area per 3,000 Btuh (734

/kW) for combined input of all gas appliances in the

mm space per Table 2 and

b. Not less than the sum of the areas of all vent connectors

in the space.

Table 2 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors

FURNACE

INPUT

(BTUH)

44,000 22 (14194) 6 (152) 14.7 (9484) 5 (127) 11 (7096) 4 (102) 66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)

88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152) 110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152) 132,000 66 (42580) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178) 154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

Round Duct

Dia.

In. (mm)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

Round Duct

Dia.

In. (mm)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

Round Duct

Dia.

In. (mm)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening

88,000

+ 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

Page 9

1 SQ IN.

12 ″ MAX

(305mm)

PER 4000 BTUH*

1 SQ IN .

BTUH*

1 SQ IN .

BTUH*

1 SQ IN. PER 4000 BTUH*

12 ″ MAX

PER

4000

OUTDOORS

PER 4000

12 ″ MAX

(305mm)

A03174

DUCTS

O UTDOORS

(305mm)

12 ″ MAX

1 SQ IN. PER 2000 BTUH*

DUCT S

OUTDOORS

1 SQ IN. PER 2000 BTUH*

(305mm)

12 ″ MAX

CIRCULA TING AIR DUCT S

*Minimum dimensions of 3 --- in. (76 mm). Note: Use any of the following combinations of openings:

A&BC&DD&EF&G

AIR DUCTS

C IRCULA TING

OF COMB USTION AIR

CLEARANCE IN FRONT

VENT THR OUGH R OOF

(76mm)

AT LEAST 3 IN .

OPENINGS SHALL BE

DUCT

OUTDOORS

Fig. 7 -- Air for Combustion, Ventilation, and Dilution for

Outdoors

The opening shall commence within 12 in. (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion Air Known --Air--Infiltration Rate

E NFPA & AGA Standard and

Methods

Indoor air is permitted for combustion, ventilation, and dilution, if the Standard or Known--Air--Infiltration Method is used.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in death and/or personal injury.

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in accordance with this instruction manual.

CIRCULATING AIR

DUCTS

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. (64516 sq. mm) with minimum dimensions of 3 in. (76 mm) †Minimumof3in.(76mm)whentype-B1ventisused.

VENT THROUGH ROOF

12" MAX

1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL

UNCONFINED SPACE

(152mm)

6" MIN (FRONT)

1 SQ IN. PER 1000 BTUH* IN DOOR

OPENINGS SHALL BE AT LEAST 3 IN.

OR WALL

CLEARANCE IN FRONT OF COMBUSTION AIR

12" MA X

(305mm)

A03175

Fig. 8 -- Air for Combustion, Ventilation, and Dilution from

Indoors

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 3 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space.

58CT

Page 10

Table 3 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN---ASSISTED TOTAL

ACH

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

0.00 NP NP NP NP NP NP NP NP NP

NP = Not P ermitted

Table 3--Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI

Z223.1-- 2006/NFPA 54--2006, 9.3.2.2:

1. For other than fan --assisted appliances, such as a draft hood--equipped water heater:

58CT

Volume

2. For fan--assisted appliances such as this furnace:

Volume

If:

= combined input of all other than fan--assisted

other

= combined input of all fan--assisted appliances in

fan

ACH = air changes per hour (ACH shall not exceed 0.60.)

The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if:

a. There are no closeable doors between rooms.

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in. mm in the space, but not less than 100 in. opening shall commence within 12 in. (300 mm) of the ceiling and the second opening shall commence within 12 in. (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). (See Fig.

8.)

c. Combining space on different floor levels. The volumes

of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in. rating of all gas appliances.

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1--in.2/4,000 Btuh of total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases.

(1,000s BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

SpaceVolume(ft.3)

21ft

Other

Fan

appliances in Btuh/hr

Btuh/hr

/kW) of the total input rating of all gas appliances

ACH

15ft

ACH

/1,000 Btuh (4,400 mm2/kW) of total input

other

1000 Btu/hr

fan

1000 Btu/hr

/1,000 Btuh (2,000

(0.06 m2). One

A04002

Combination of Indoor and Outdoor

1. Indoor openings shall comply with the Indoor Combus-

A04003

2. Outdoor openings shall be located as required in the Out-

3. Outdoor openings shall be sized as follows:

UPFLOW INSTALLATION

Bottom Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove and discard this panel when bottom return air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom

2. Rotate bottom filler panel downward to release holding

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when only side return air is used.

FAN--- ASSISTED TOTAL

(1,000s BTUH GAS INPUT RATE)

However, in buildings with unusually tight construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section. Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a con-

tinuous, sealed vapor barrier. Openings are gasketed or sealed and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole plates and floors, between wall-- ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.

Air

tion Air Method below and,

door Combustion Air Method mentioned previously and,

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air Meth- od below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size re-

quiredin Outdoor Combustion Air Method abovemultiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80 mm).

INSTALLATION

Inlet

filler panel. (See Fig. 9.)

tabs.

Inlet

Page 11

NOTE: Side return--air openings can be used in UPFLOW and most HORIZONTAL configurations. Do not use side return--air openings in DOWNFLOW configuration.

A02098

Fig. 9 -- Removing Bottom Closure Panel

Leveling Legs (If Desir

ed)

In upflow position with side return inlet(s), leveling legs may be used. (See Fig. 10.) Install field--supplied, 5/16 x 1--1/2 in. (8 x 38 mm) (max) corrosion--resistant machine bolts, washers and nuts.

NOTE: Bottom closure must be used when leveling legs are used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see item 1 in Bottom Return Air Inlet section in Step 1 above.

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace. (See Fig. 10.)

2. For each leg, install nut on bolt and then install bolt and nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

16 ″

(8mm)

16 ″

1 3 / 4 ″

(44mm)

/ 4 ″

(44mm)

(8mm)

/ 16 ″

(8mm)

16 ″

(44mm)

4 ″

A89014

(44mm)

Fig. 10 -- Leveling Legs

DOWNFLOW INSTALLA

TION

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the following 3 accessories are used:

S Special Base, KGASB S Cased Coil Assembly Part No. CNPV, CNRV, CAP, and CAR S Coil Box Part No. KCAKC

1. Determine application being installed from Table 4.

2. Construct hole in floor per Table 4 and Fig. 11.

3. Construct plenum to dimensions specified in Table 4 and Fig. 11.

4. If downflow subbase, KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CNPV, CNRV, CAP, CAR or Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

NOTE: It is recommended that the perforated supply--air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory--supplied cased coil or coil box. To remove the supply--air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 14.)

Bottom Return Air

Inlet

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLA

TION

The furnace can be installed horizontally in an attic or crawl space on either the left--hand (LH) or right--hand (RH) side. The furnace can be hung from floor joists, rafters or trusses or installed on a non--combustible platform, blocks, bricks or pad.

WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Suspended Furnace Support

The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown. (See Fig. 15 and

16.) Secure angle iron to bottom of furnace as shown. Heavy-- gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x 3/4--in. (19 mm) screw into the side and 2 #8 x 3/4--in. (19 mm) screw in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.)

If the screws are attached to ONLY the furnace sides and not the bottom, the straps must be vertical against the furnace sides and not pull away from the furnace sides, so that the strap attachment screws are not in tension (are loaded in shear) for reliable support.

58CT

Page 12

Platform Furnace

Support

Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in. (25 mm) clearance requirement on side, set furnace on non--combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

Roll--Out Pr

otection

Provide a minimum 17--3/4--in. x 22--in. (451 x 559 mm) piece of sheet metal for flame roll--out protection in front of burner area for furnaces closer than 12 inches (305 mm) above the combustible deck or suspended furnaces closer than 12 inches (305 mm) to joists. The sheet metal MUST extend underneath the furnace casing by 1 in. (25 mm) with the door removed.

The bottom closure panel on furnaces of widths 17-- 1/2 in. (445 mm) and larger may be used for flame roll--out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper orientation of roll--out shield.

58CT

Bottom Return Air

Inlet

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air

Inlet

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) are used without a bottom return air inlet.

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Fig. 12 -- Furnace, Plenum, and Subbase installed on a

Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

A96285

PLENUM

OPENING

FLOOR

Fig. 11 -- Floor and Plenum Opening Dimensions

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A08556

Fig. 13 -- Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

A96283

Page 13

Table 4 – Opening dimensions -- In. (mm)

FURNACE

CASING

WIDTH

14–3/16

(376)

17–1/2

(445)

(533)

24--- 1/2

(622)

APPLICATION

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

(KGASB subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on Combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR, or CAP Coil Assembly or KCAKC coil box

(KGASB subbase not required)

PLENUM OPENING FLOOR OPENING

A B C D

12--- 11/16

(322)

12--- 9/16

(319)

11--- 13/16

(284)

12--- 5/16

(319)

(406)

15--- 7/8

(403)

15--- 1/8

(384)

15--- 1/2

(394)

19--- 1/2

(495)

19--- 3/8

(492)

18--- 5/8

(473)

(483)

(584)

22--- 7/8

(581)

22--- 1/8

(562)

22--- 1/2

(572)

21--- 5/8

(549)

(483)

21--- 5/8

(549)

(483)

21--- 5/8

(549)

(483)

21--- 1/8

(537)

(483)

13--- 5/16

(338)

13--- 3/16

(335)

13--- 7/16

(341)

13--- 5/16

(338)

16--- 5/8

(422)

16--- 1/2

(419)

16--- 3/4

(425)

16--- 1/2

(419)

20--- 1/8

(511)

(508)

20--- 1/4

(514)

(508)

23--- 5/8

(600)

23--- 1/2

(597)

23--- 3/4

(603)

23--- 1/2

(597)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

58CT

UPFLO

90û

120û

MIN

W OWNFLOW

YES

NOT RECOMMENDED

120û MIN

Fig. 14 -- Duct Flanges

YES

NOT RECOMMENDED

HORIZONTAL

90û

120û

MIN

YES

NOT RECOMMENDE

A02329

Page 14

OUTER DOOR ASSEMBLY

4" (6 mm) THREADED ROD

4 REQ.

58CT

8” (203 mm) MIN FOR DOOR REMOVAL

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS REQ. PER ROD

1" (25 mm) SQUARE, 1 (32 x 32 x 6 mm) ANGLE IRON OR UNI-STRUT MAY BE USED

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH

3 #8 x

4" (19 mm) SCREWS

TYPICAL FOR 2 SUPPORTS

4" x

4" x 1

A02345

Fig. 15 -- Horizontal Unit Suspension

METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

Fig. 16 -- Horizontal Suspension with Straps

A03176

Page 15

LINE CONT A CT ONL Y PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE T OP AND TW O SIDES OF THE FURNA CE JA CKET AND BUILDING JOISTS , STUDS , OR FRAMING.

EQUIPMENT MANU AL

SHUT -OFF GAS VA LV E

SEDIMENT

TRAP

UNION

SHEET MET AL

GAS ENTR Y

17 3 / 4 ″

(559mm)

″

(451mm)

6 ″ M IN

TYPE-B VENT

(152mm)

Fig. 17 -- Typical Attic Installation

17 3 / 4 ″ 4 3 / 4 ″ 1 ″

(25mm)

EXTEND OUT 12 ″ FR OM FA CE OF DOOR

30-IN . (762mm) MIN WORK AREA

(451mm)

(121mm)

* WHEN USED W ITH SINGLE W ALL VEN T CONNECTIONS

OVERALL

UNDER DOOR

UNDER FURNACE

(305mm)

58CT

A03177

Not all horizontal furnaces are approved for side return air connections. (See Fig. 20.)

FILTER

ARRANGEMENT

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, or death.

Never operate a furnace without a filter or with filter access door removed.

There are no provisions for an internal filter rack in these furnaces. An external filter rack is required.

This furnace is shipped with a factory--supplied Media Filter Cabinet. The Media Filter Cabinet uses either a factory--supplied standard 3/4--in. (19 mm) filter or 4--in. (102 mm) wide Media Filter which can be purchased separately.

Refer to the instructions supplied with Media Cabinet for assembly and installation options.

DUCTS

AIR

General Requir

ements

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table 5--Air Delivery CFM (With Filter).

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

Secure ductwork with proper fasteners for type of ductwork used. Seal supply-- and return--duct connections to furnace with code approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration.

Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Tr

eatment

NOTE: Metal duct systems that do not have a 90_ elbow and 10

ft. (3 M) of main duct to the first branch take--off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Supply Air

Connections

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

Upflow and Horizontal

Furnaces

Connect supply--air duct to flanges on furnace supply--air outlet. Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supply--outlet--air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing side to attach supply air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace main casing.

Page 16

Table 5 – Air Delivery -- CFM (With Filter)*

FURNACE

SIZE

045--- 08 /

024045

045--- 12/

036045

070--- 081 /

024070

070--- 12/

036070

58CT

070--- 16/

048070

090--- 14/

042090

090--- 16/

048090

090--- 20/

060090

110--- 12/

036110

110--- 16/

048110

110--- 22/

066110

*A fil ter is required for each return ---air inlet. Airflow performance included 3/4---in. (19 mm) washable filter media such as contained in factory---authorized accessory filter rack. To determine airflow performance without this filter, assume an additional 0.1 in. wc available external static pressure.

--- --- Indicates unstable operating conditions.

RETURN--- AIR

INLET

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

Both Side or 1 Side & Bottom

1Side Only

Bottom or

Side(s)

Bottom or

Side(s)

Bottom Only

Bottom Sides or 1 Side & Bottom

1Side Only

SPEED

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

High

M e d --- Hi g h

High

M e d --- Hi g h

Medium

M e d --- Lo w

Low

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1120

930 820

725 1465 1295 1150 1030

860 1140

915

795

690 1440 1180 1015

885

695 1840

1610 1460 1260 1065

1650 1515 1385 1205 2060 1710 1470 1260 1030

2380 2185 1905 1595 1340

2485 2175 1845 1540 1280

2420 2160 1850 1530 1290

1625 1510 1360 1195 2055 1750 1545 1300 1050

2530 2225 1895 1565 1320

--- ---

2205 2485

2155 1830 1520 1275

1075

890 785

690 1400 1260 1120 1010

835 1105

885

770

665 1400 1165 1020

885

700 1790

1575 1430 1240 1040

1600 1485 1360 1180 2000 1695 1475 1365 1025

2295 2115 1865 1565 1310

2415 2130 1815 1515 1250

2345 2110 1815 1490 1250

1575 1470 1335 1180 1990 1725 1525 1290 1045

2460 2190 1885 1555 1295

--- ---

2175 2430

2135 1830 1505 1260

EXTERNAL STATIC PRESSURE (IN. WC)

1020

850 750

655 1325 1210 1085

980

810 1055

855

740

630 1355 1150 1010

880

700 1730

1535 1400 1215 1015

1535 1440 1320 1160 1930 1665 1450 1245 1020

2205 2045 1815 1530 1280

2330 2070 1770 1475 1220

2265 2045 1765 1455 1220

1515 1415 1295 1155 1910 1670 1490 1275 1015

2380 2135 1865 1535 1265

2415 2120

2360 2100 1810 1490 1240

960 805 700

605 1250 1155 1040

945

780 1010

825

700

590 1300 1125

990

865

690 1670

1485 1360 1180

985 1465

1380 1260 1120 1835 1585 1390 1225

990 2105

1960 1740 1485 1225

2230 2000 1720 1435 1190

2165 1960 1710 1420 1190

1445 1355 1250 1115 1815 1605 1445 1235

975 2285

2075 1820 1505 1235

2330 2065

2270 2040 1780 1470 1210

895 750 650

555 1175 1090

985

895

745

955

785

655

550 1240 1085

965

845

670 1605

1435 1315 1145

955 1385

1300 1195 1065 1755 1480 1335 1165

940 2005

1875 1670 1430 1170

2135 1930 1655 1385

115 2070

1885 1635 1375

115 1355

1285 1180 1065 1695 1515 1355 1165

935 2200

1995 1770 1465 1205

2235 1975

2175 1970 1730 1430 1180

815 680 585

495 1085 1015

920

835

700

885

725

600

475 1170 1030

925

815

640 1530

1370 1260

110

915 1285

1220 1120 1005 1620 1390 1230 1090

890 1900

1770 1590 1355 1120

2030 1840 1580 1335 1105

1960 1790 1560 1320 1110

1260 1185 1100

980 1575 1400 1260 1085

880 2085

1910 1700 1410 1160

2125 1900

2070 1885 1665 1385 1135

720 600 505 405 980 930 835 765 635

815 655 510 415

1090

970 875 770 600

1450 1305 1205 1040

875

1175 1115 1025

925 1490 1245 1120

995

810 1775

1655 1490 1275 1040

1920 1740 1500 1270 1035

1850 1695 1480 1250 1040

1165 1070

985

860 1425 1255 1135 1005

815 1970

1805 1610 1350 1105

1995 1790

1950 1790 1595 1330 1090

605 500 400 305 860 830 740 685 555

715 530 420 340

1000

890 800 700 540

1370 1230 1130

985 825

1055

990 915

810 1315 1110 1005

880

720 1650

1535 1390 1160

955 1790

1620 1395 1175

945 1720

1570 1380 1160

950

990

890

810

740 1230 1120 1020

895

715 1835

1695 1520 1265 1035

1860 1685

1825 1680 1505 1250 1025

455 345 235

--- --725 700 620 570 445 545 420 325 245 890 785 700 605 460

1275 1145 1055

915 765

895 830 710 630

1115

955 855 750 615

1510 1400 1245 1055

850

1645 1495 1270 1045

845

1570 1445 1250 1055

835 785

725 670 605

1090

975 880 750 610

1695 1565 1410 1175

950

1735 1580

1685 1560 1395 1165

930

340 195

--- ---

--- --560 545 510 345 260 390 280

--- ---

--- --745 645 560 475 345

1170 1055

965 835 695

645 600 565 510 910 775 690 600 500

1335 1240 1110

920 750

1485 1345 1090

915 745

1420 1305 1110

905 740

595 530 475 410 910 785 750 620 515

1545 1430 1290 1050

870

1605 1460

1535 1420 1275 1055

840

Page 17

Table 5 -- Air Delivery -- CFM (With Filter)* (Cont.)

FURNACE

SIZE

135--- 16/

048135

135--- 22/

066135

155--- 20/

060155

--- --- Indicates unstable operating conditions.

RETURN--- AIR

INLET

Bottom

Side(s)

Bottom

Only

Bottom Sides

1 Side & Bottom

1SideOnly

Bottom Only

Both Sides Or 1

Side & Bottom

1SideOnly

SPEED

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

M e d --- Lo w

Low

High

M e d --- Hi g h

High

M e d --- Hi g h

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

2090 1790 1545 1325 2485 2195 1880 1640

--- --2180 1880 1640

2320 2125 1845 1640

2465 2115 1800 1570

--- --2155

--- --2140

2010 1755 1525 1320 2400 2150 1850 1635

--- --2145 1850 1635

2250 2065 1825 1620

2430 2105 1790 1565

--- --2135

--- --2095

NOTE: For horizontal applications, the top--most flange may be bent past 90_ to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the

EXTERNAL STATIC PRESSURE (IN. WC)

1930 1705 1500 1295 2310 2090 1820 1615

2385 2060 1820 1615

2155 1995 1765 1580

2375 2075 1770 1550

2375 2095

2260 2040

1835 1640 1450 1265 2215 2000 1780 1585

2305 2010 1780 1585

2055 1910 1710 1540

2305 2030 1735 1525

2285 2040

2180 1975

1710 1550 1380 1210 2110 1920 1715 1530

2195 1945 1715 1530

1970 1815 1650 1485

2230 1980 1695 1495

2200 1975

2085 1890

1590 1465 1315 1150 2000 1825 1635 1465

2085 1865 1635 1465

1855 1710 1570 1410

2110 1910 1640 1445

2105 1895

1975 1810

1470 1360 1215

995 1880 1720

1540 1370

1960 1765 1540 1370

1725 1610 1475 1330

2000 1830 1570 1370

1995 1790

1865 1705

1335 1210 1005

865 1725 1565

1415 1255

1825 1660 1415 1255

1600 1490 1370 1220

1865 1725 1465 1270

1870 1685

1740 1595

1025

945 855

745 1535 1405

1290 1150

1670 1515 1290 1150

1450 1340 1240 1080

1725 1590 1345 1175

1730 1550

1605 1480

20.) Not all horizontal furnaces are approved for side return air connections. (See Fig. 20.)

PIPING

GAS

835 785 670

540 1355 1255

1160 1040

1465 1325 1160 1040

1280 1175 1100

960 1545

1425 1225 1070

1570 1400

1455 1325

coil are performed.

Downflow

Connect supply--air duct to supply--air outlet on furnace. Bend flange inward past 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing (when used). When installed on combustible material, supply--air duct must be connected to ONLY the accessory subbase, KGASB0201ALL, or a factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected to duct

Furnaces

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

external to furnace casing.

Return Air

FIRE HAZARD

Failure to follow this warning could cause personal injury, death and/or property damage.

Never connect return--air ducts to the back of the furnace.

Connections

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Use proper length of pipe to avoid stress on gas control manifold and a gas leak.

Follow instructions below.

58CT

Downflow Furnaces

The return--air duct must be connected to return--air opening (bottom inlet) as shown in Fig. 1. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and most horizontal furnaces. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. (See Fig. 19.)

Upflow and Horizontal

Furnaces

The return--air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 1. Bypass humidifier may be attached into unused return air side of the furnace casing. (See Fig. 18 and

WARNING

FIRE OR EXPLOSION HAZARD

Failure to protect gas valve inlet from water and debris could result in death, personal injury and/or property damage.

Gas valve inlet and/or inlet pipe must remain capped until gas supply line is permanently installed to protect the valve from moisture and debris. Also, install a sediment trap in the gas supply piping at the inlet to the gas valve.

Page 18

58CT

Fig. 18 -- Upflow Return Air Configurations and Restrictions

A02075

A02163

Fig. 19 -- Downflow Return Air Configurations and Restrictions

Fig. 20 -- Horizontal Return Air Configurations and Restrictions

A02162

Page 19

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S. and the CAN/CSA--B149.1--05 in Canada.

Table 6 – Maximum Capacity of Pipe

NOMINAL

IRON PIPE

SIZE

IN. (MM)

1/2 (12.7)

3/4 (19.0)

1( 25.4)

1-1/4 (31.8)

1-1/2 (38.1)

* Cubic ft. of natural 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 6.2 ANSI Z223 --- 2006/NFPA 54 ---2006.

INTERNAL

DIA.

IN. (MM)

0.622 (158)

0.824 (20.9)

1.049 (26.6)

1.380 (35.0)

1.610 (40.9)

LENGTH OF PIPE --- FT. (M)

(3.0)20(6.0)30(9.1)40(12.1)50(15.2)

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

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 inches (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T--handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

Refer to Table 6 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. (1.8 M). Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas.

supply connection to furnace and downstream of manual equipment shutoff valve.

NOTE: The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14--in. wc) stated on gas control valve. (See Fig. 53.) Some installations require gas entry on right side of furnace (as viewed in upflow). (See Fig. 21.)

2” (51mm)

Street Elbow

A08551

Fig. 21 -- Burner and Manifold

Install a sediment trap in riser leading to furnace as shown in Fig.

22. Connect a capped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control valve manifold and exterior manual equipment gas shutoff valve.

GAS SUPPLY

MANUAL SHUTOFF VALV E (REQUIRED)

SEDIMENT TRAP

UNION

58CT

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance. Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in. (51 mm) outside the furnace.

CAUTION

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace damage.

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

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. of furnace. A 1/8--in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas

A02035

Fig. 22 -- Typical Gas Pipe Arrangement

Page 20

FIVE

WIRE

THREE-WIRE

BLK

WHT

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

GND

BLK

WHT

JUNCTION BOX

58CT

HEATING-

ONLY

CONTROL

BOX

FURNACE

COM

W/W1

Y/Y2

24-VOLT

TERMINAL

BLOCK

A 1/8--in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

Piping should be pressure and leak tested in accordance with NFGC in the United States or CAN/CSA--B149.1--05 in Canada, local, and national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14--in. wc), gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than 0.5 psig (14--in. wc), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF.

ELECTRICAL

CONNECTIONS

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower access panel door switch opens 115--v power to control. No component operation can occur. Do not bypass or close switch with panel removed.

See Fig. 23 for field wiring diagram showing typical field 115--v wiring. Check all factory and field electrical connections for tightness.

Field--supplied wiring shall conform with the limitations of 63_F (33_C) rise.

NOTE 2

WCY RG

NOTE 1

NOTES: 1.

Connect Y/Y2-terminal as shown for proper operation. Some thermostats require a "C" terminal connection as shown.

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

3. same type or equivalent wire.

1-STAGE THERMOSTAT TERMINALS

Fig. 23 -- Field Wiring Diagram

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70--2008 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, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer’s ratings for proper wire gauge. Do not use gas piping as an electrical ground.

FURNACE MAY NOT OPERATE HAZARD

Failure to follow this caution may result in intermittent furnace operation.

Furnace control must be grounded for proper operation or else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw.

115 --V WIRING

Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 7 for equipment electrical specifications.

FIELD 24-VOLT WIRING FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING

FIELD-SUPPLIED

FUSED DISCONNECT

208/230- OR 460-VOLT THREE PHASE

208/230VOLT SINGLE PHASE

CONDENSING

UNIT

WARNING

CAUTION

GND

A95236

Page 21

Table 7 – Electrical Data

V O L T S --H E R T Z ---

PHASE

1 1 5 --- 60 --- 1 127 104 5.3 045 ---08/024045 7.42 49 (14.9) 15 14 1 1 5 --- 60 --- 1 127 104 7.1 045 ---12/036045 9.67 38 (11.5) 15 14 1 1 5 --- 60 --- 1 127 104 5.2 070 ---08/024070 7.22 51 (15.5) 15 14 1 1 5 --- 60 --- 1 127 104 7.3 070 ---12/036070 9.90 37 (11.2) 15 14 1 1 5 --- 60 --- 1 127 104 10.1 070 -- -16/048070 13.42 27 (8.2) 15 14 1 1 5 --- 60 --- 1 127 104 8.2 090 ---14/042090 10.84 34 (10.3) 15 14 1 1 5 --- 60 --- 1 127 104 9.9 090 ---16/048090 13.0 28 (8.5) 15 14 1 1 5 --- 60 --- 1 127 104 12.9 090 -- -20/060090 16.70 34 (10.3) 20 12 1 1 5 --- 60 --- 1 127 104 8.2 110 ---12/036110 10.76 34 (10.3) 15 14 1 1 5 --- 60 --- 1 127 104 10.1 110 -- -16/048110 13.19 28 (8.5) 15 14 1 1 5 --- 60 --- 1 127 104 13.7 110 -- -22/066110 17.60 32 (9.7) 20 12 1 1 5 --- 60 --- 1 127 104 10.2 135 -- -16/048135 13.28 27 (8.2) 15 14 1 1 5 --- 60 --- 1 127 104 14.5 135 -- -22/066135 18.61 30 (9.1) 20 12 1 1 5 --- 60 --- 1 127 104 15.0 155 -- -20/060155 19.34 29 (8.8) 20 12

* Permissible limits of the voltage range at which the unit operates satisfactorily. # Unit ampacity = 125% of largest operating component’s full load amps plus 100% of all other potential operating components (EAC, humidifier,

etc.) full load amps.

{ Time ---delay type is recommended. } Length shown is as measured 1 way along wire path between unit and service panel for maximum 2% voltage drop.

U.S. Installations: Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70--2008 and any local codes or ordinances that might apply.

Canadian Installations: Make all electrical connections in

OPERATING VOLTAGE

RANGE

MAX* MIN.*

MAX UNIT

AMPS

FURNACE

SIZE

UNIT

AMPACITY#

4. Fasten J-- Box to casing with the two screws removed in Step 1.

5. Route J--Box wires within furnace away from sharp edges, rotating parts, and hot surfaces.

MAXIMUM

WIRE

L E N G T H ---

FT. (M)‡

MAXIMUM

FUSE OR CKT BKR

AMPS†

MINIMUM

accordance with Canadian Electrical Code CSA C22.1 or authorities having jurisdiction.

WIRE

GAUGE

58CT

WARNING

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

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

Use a separate branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 7 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

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

J--BOX RELOCA

TION

NOTE: If factory location of J--Box is acceptable, go to next

section (ELECTRICAL CONNECTION TO J--BOX).

NOTE: On 14” wide casing models, the J--Box shall not be relocated to other side of furnace casing when the vent pipe is routed within the casing.

1. Remove and save two screws holding J--Box. (See Fig.

24.)

NOTE: The J--Box cover need not be removed from the J--Box in order to move the J--Box. Do NOT remove green ground screw inside J--Box. The ground screw is not threaded into the casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J--box outboard of the casing.

2. Cut wire tie on loop in furnace wires attached to J--Box.

3. Move J--Box to desired location.

TWO

A02099

Fig. 24 -- Relocating J--Box

ELECTRICAL CONNECTION TO

J--BOX

Field--Supplied Electrical Box on Furnace J--Box Bracket. See Fig. 26.

1. Remove cover from furnace J--Box.

2. Attach electrical box to furnace J--Box bracket with at least two field--supplied screws through holes in electrical box into holes in bracket. Use blunt--nose screws that will not pierce wire insulation.

3. Route furnace power wires through holes in electrical box and J--Box bracket, and make field--wire connections in electrical box. Use best practices (NEC in U.S. and CSA C22.1 in Canada) for wire bushings, strain relief, etc.

4. Route and secure field ground wire to green ground screw on J--Box bracket.

5. Connect line voltage leads as shown in Fig. 23.

Page 22

6. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

Electrical Box on Furnace Casing Side. See Fig.

WARNING

FIRE OR ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

If field--supplied manual disconnect switch is to be mounted on furnace casing side, select a location where a drill or fastener cannot damage electrical or gas components.

25.

58CT

Fig. 25 -- Field--Supplied Electrical Box on Furnace Casing

1. Select and remove a hole knockout in the casing where the electrical box is to be installed.

NOTE: Check that duct on side of furnace will not interfere with installed electrical box.

2. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing.

3. Fasten the electrical box to casing by driving two field-supplied screws from inside electrical box into casing steel.

4. Remove and save two screws holding J--Box. (See Fig.

24.)

5. Pull furnace power wires out of 1/2--inch (12 mm) diameter hole in J--Box. Do not loosen wires from strain--relief wire--tie on outside of J--Box.

6. Route furnace power wires through holes in casing and electrical box and into electrical box.

7. Pull field power wires into electrical box.

8. Remove cover from furnace J--Box.

9. Route field ground wire through holes in electrical box and casing, and into furnace J--Box.

10. Reattach furnace J--Box to furnace casing with screws removedinStep4.

A03221

11. Secure field ground wire to J--Box green ground screw.

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Fig. 23. Use best practices (NEC in U.S. and CSA C22.1 in Canada) for wire bushings, strain relief, etc.

13. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

POWER CORD INSTALLATION IN FURNACE

NOTE: Power cords must be able to handle the electrical

requirements listed in Table 7. Refer to power cord manufacturer’s listings.

1. Remove cover from J--Box.

2. Route listed power cord through 7/8--inch (22 mm) diameter hole in J--Box.

3. Secure power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used.

4. Secure field ground wire to green ground screw on J--Box bracket.

5. Connect line voltage leads as shown in Fig. 23.

6. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

BX. CABLE INSTALLATION IN FURNACE

1. Remove cover from J--Box.

2. Route BX cable into 7/8--inch (22 mm) diameter hole in J--Box.

3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.

4. Secure field ground wire to green ground screw on J--Box bracket.

5. Connect line voltage leads as shown in Fig. 23.

6. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

24--V

WIRING

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

33.) Connect terminal Y/Y2 as shown in Fig. 26--32 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 control. 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.

J--BOX

Page 23

58CT

See notes 2, 5, 8, 10, 11 and 12 on the page following these figures

Fig. 26 -- Two-- Stage Furnace with Two--Speed Air

Conditioner

A03179

See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13 and 15 on the page following these figures

A03178

Fig. 28 -- Two-- Stage Furnace with Two--Speed Heat Pump

(Dual Fuel)

See notes 1, 2, 4, 6, 7, 9, 10, 11, and 15 on the page following these figures

A03180

Fig. 27 -- Two-- Stage Furnace with Single--Speed Heat Pump

(Dual Fuel)

See notes 1, 2, 4, 11, 14, 15, and 16 on the page following these figures

Fig. 29 -- Dual Fuel Thermostat with Two--Stage Furnace

and Single--Speed Heat Pump

A03181

Page 24

58CT

See notes 1, 2, 3, 4, 12, 13, 14, 15, and 17 on the page following these figures

Fig. 30 -- Dual Fuel Thermostat with Two--Stage Furnace

and Two--Speed Heat Pump

Fig. 32 -- Single--Stage Thermostat with Two--Stage Furnace and Two--Speed Air Conditioner

A03182

Fig. 31 -- Two-- Stage Thermostat with Two--Stage Furnace

See notes 1 and 2 on the page following these figures

See notes 2, 11, and 12 on the page following these figures

and Two--Speed Air Conditioner

A03183

A03184

NOTES: F o r F i gu r e s 2 6 --- 3 2

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

2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

3. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.

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

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

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

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

8. Configuration Option No. 10 “Dual Fuel Selection” must be turned ON in all dual fuel applications.

9. NO connection should be made to the furnace HUM terminal when using a Thermidistat.

10. Optional connection: If wire is connected, dip switch SW1---2 on furnace control should be set in ON position to allow Thermidistat/Thermostat to control furnace staging.

11. Optional connection: If wire is connected, ACRDJ jumper on furnace control should be removed to allow Thermidistat/Thermostat to control outdoorunit staging.

12. When using both a two---stage furnace and a two---stage heat pump, the furnace must control its own high --- stage heating operation via furnace control algorithm.

13. The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.

14. DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two---speed heat pump control board. This is controlled internally by the Thermidistat/Dual Fuel Thermostat.

15. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single --- speed compressor operation. T his is factory defaul t.

16. Dip switch D on Dual Fuel T hermostat should be set in ON position for two---speed compressor operation.

Page 25

ACCESSORIES

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using 1/4--in female quick connect terminals to the two male 1/4--in quick--connect terminals on the control board marked EAC--1 and EAC--2. The terminals are rated for 115VAC, 1.0 amps maximum and are energized during blower motor operation. (See Fig. 33.)

2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the 1/4--in male quick --connect HUM terminal and COM--24V screw terminal on the control board thermostat strip. The HUM terminal is energized when gas valve relay (GVR) is energized. (See Fig. 33.)

NOTE: A field-- supplied, 115--v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation.

SETUP SWITCHES

LOW-HEAT ONLY AND

BLOWER OFF-DELAY

Y1 DHUM G COM

LHT OFF DLY

TWINNING AND/OR COMPONENT TEST

TERMINAL

OFF

1 2 3

NOTE: DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidistat, Zone Controller or similar device. See Thermidistatt, Zone Controller, thermostat, or controller manufacturer’s instructions for proper connection.

VENTING

The furnace shall be connected to a listed factory built chimney or vent or a clay--tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or concrete chimney is prohibited. When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of combustion products into the living space.

58CT

ACRDJ - AIR CONDITIONING

RELAY DISABLE JUMPER

24-V-THERMOSTAT TERMINALS

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC (L2) NEUTRAL

CONNECTIONS

HI HEAT LO HEAT

BLOWER SPEED

SELECTION TERMINALS

24V

WW1 Y/Y2 R

EAC-2

BLW

HI HEAT LO HEAT

SPARE-1

SPARE-2

TEST/TWIN

HUM

0.5-AMP024 VAC

FUSE 3-AMP

SEC-1 SEC-2

NEUTRAL-L2

COOL

SPARE-1 SPARE-2

Fig. 33 -- Furnace Control--PSC Blower Motor

ACRDJ

PLT

PL1

BHT/CLRBHI/LOR

1-AMP@115 VAC

EAC-1 PR-1

COOL

BLWR

IDR

115-VAC (L1) LINE

VOLTAGE CONNECTION

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

PL2

HSI HI LO

HSIR

TRANSFORMER 24-VAC

CONNECTIONS

PL1 - LOW VOLTAGE MAIN

HARNESS CONNECTOR

PL3 1

PL3

IHI/LOR

IDM

PL2 - HOT SURFACE IGNITER & INDUCER

MOTOR CONNECTOR

A02017

Page 26

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage,

58CT

corrosion and other deficiencies, which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas--fired burning appliance to their previous conditions of use.

Vent system or vent connectors may need to be resized. Vent systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the NFGC or CAN/CSA--B149.1--05.

GENERAL VENTING

Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National Fuel Gas Code ANSI Z223.1--2006/NFPA 54--2006 (NFGC), Parts 12 and 13 in the United States or the National Standard of Canada, Natural Gas and Propane Installation Code CSA--B149.1--05 (CAN/CSA--B149.1--05), Section 8 and Appendix C in Canada, the local building codes, and furnace and vent manufacturers’ instructions.

These furnaces are design--certified as Category I furnaces in accordance with ANSI Z21.47--2006/CSA 2.3--2006 and operate with a non--positive vent static pressure to minimize the potential for vent gas leakage. Category I furnaces operate with a flue loss not less than 17% to minimize the potential for condensation in the venting system. These furnaces are approved for common venting and multi--story venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the

REQUIREMENTS

CAN/CSA--B149.1--05, local building codes, and furnace and vent manufacturers’ instructions.

The following information and warning must be considered in addition to the requirements defined in the NFGC or the CAN/CSA--B149.1--05.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Do not bypass the draft safeguard switch, as an unsafe condition could exist which must be corrected.

1. If a vent (common or dedicated) becomes blocked, the furnace will be shut off by the draft safeguard switch located on the vent elbow.

2. Two-- stage furnaces require Type B vent connectors outside the casing in all configurations. Single wall vent connector may be used inside the furnace casing with the transition to Type B vent outside the furnace casing. Size the connector so that the FAN--Min vent connector capacity is equal to or lower than the low fire rate of the furnace and the FAN--Max vent connector capacity is equal to or higher than the furnace high fire rate.

3. Do not vent this Category I furnace into a single wall dedicated or common vent. The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors.

4. Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure.

5. In the US: Do not vent this appliance with any solid fuel burning appliance. In Canada: Check with the authority having jurisdiction for approval on use with solid fuel burning appliance.

6. Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed mechanical venter. See the SIDEWALL VENTING section.

7. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 34.

MASONRY CHIMNEY

NOTE: These furnaces are CSA design-- certified for use in

exterior tile--lined masonry chimneys with a factory accessory Chimney Adapter Kit. Refer to the furnace rating plate for correct kit usage. The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit number marked on the furnace rating plate.

If a clay tile--lined masonry chimney is being used and it is exposed to the outdoors below the roof line, relining might be required. Chimneys shall conform to the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances ANSI/NFPA 211--2006 in the United States and to a Provincial or Territorial Building Code in Canada (in its absence, the National Building Code of Canada) and must be in good condition.

U.S.A.--Refer to Sections 13.1.8 and 13.2.20 of the NFPA 54 / ANSI Z223.1--2006 or the authority having jurisdiction to determine whether relining is required. If relining is required, use a properly sized listed metal liner, Type--B vent, or a listed alternative venting design.

NOTE: See the NFPA 54 / ANSI Z223.1--2006, 13.1.8 and

13.2.20 regarding alternative venting design and the exception, which cover installations such as the Chimney Adapter Kits KGACA02014FC and KGACA02015FC, which are listed for use with these furnaces.

REQUIREMENTS

Page 27

CHIMNEY INSPECTION CHART

For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances in the U.S.A. or to the Canadian

installation Code CSA-B149.1 in Canada.

Crown

condition:

Missing mortar

or brick?

Is chimney

property lined with

clay tile liner?

Ye s

Is liner and top seal in good

condition?

Ye s

Debris

in cleanout?

Mortar, tile, metal vent,

fuel oil residue?

Ye s

Rebuild

crown.

Repair

liner or top seal

or reline chimney as

necessary.

Repair

Mortar

or tile

debris?

Reline

Ye s

Remove mortar

and tile debris

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Clay tile misalignment, missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

Remove metal vent

or liner.

Ye s

lined with properly

sized, listed liner or

Ye s

Is chimney

Type-B vent?

Ye s

Is chimney

to be dedicated to

a single

furnace?

Consult

Part B of

chimney adapter venting

instructions for

application

suitability.

Suitable

Ye s

Install chimney

adapter per

instructions.

chimney adapter venting

Not Suitable

Consult

Part C of

instructions for

application

suitability

Line chimney with property

sized, listed flexible metal

liner or Type-B vent per

NFGC or NSCNGPIC Vent

Sizing Tables and liner or

vent manufacturer’s

Installation instructions.

Suitable

Install chimney

adapter per

instructions.

Fig. 34 -- Chimney Inspection Chart

A03206

Page 28

The Chimney Adapter Kit is a listed alternative venting system for these furnaces. See the kit instructions for complete details.

Canada (and U.S.A.)--This furnace is permitted to be vented into a clay tile--lined masonry chimney that is exposed to the outdoors below the roof line, provided:

1. Vent connector is Type--B double--wall, and

2. This furnace is common vented with at least 1 draft hood-equipped appliance, and

3. The combined appliance input rating is less than the maximum capacity given in Table 8, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table 9 for the local 99% Winter Design Temperature. Chimneys having internal areas greater than 38 in

(24516 mm2)require furnace input ratings greater than the input ratings of these furnaces. See footnote at bottom of Table 9, and

5. The authority having jurisdiction approves.

If all of these conditions cannot be met, an alternative venting design shall be used, such as the listed chimney adapter kit with a

58CT

furnace listed for use with the kit, a listed chimney--lining system, or a Type--B common vent.

Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and/or (re)lining. Refer to Fig. 34 to perform a chimney inspection. If the inspection of a previously used tile--lined chimney:

a. Shows signs of vent gas condensation, the chimney

should be relined in accordance with local codes and the authority having jurisdiction.The chimney should be relined with a listed metal liner, Type--B vent, or a listed chimney adapterkit shallbe used to reducecondensation. If a condensate drain is required by local code, refer to theNFPA54 / ANSI Z223.1--2006, Section 12.10 foradditional information on condensate drains.

b. Indicates the chimney exceeds the maximum permissible

sizein the tables,the chimney should be rebuiltor relined to conform to the requirements of the equipment being installed and the authority having jurisdiction.

A chimney without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be lined with a UL listed (ULC listed in Canada) metal liner or UL listed Type--B vent. Relining with a listed metal liner or Type--B vent is considered to be a vent--in--a--chase.

If a metal liner or Type--B vent is used to line a chimney, no other appliance shall be vented into the annular space between the chimney and the metal liner.

Exterior Masonry Chimney FAN + NAT

Installations with Type--B Double--Wall Vent

Connectors ENFPA & AGA

Table 8 – Combined Appliance Maximum Input Rating in

Thousands of BTUH per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT. (M)

6 (1.8) 74 119 178 257 8 (2.4) 80 130 193 279

10 (3.) 84 138 207 299 15 (4.5) NR 152 233 334 20 (6.0) NR NR 250 368 30 (9.1) NR NR NR 404

(7741)19(12258)28(18064)38(24516)

SQ. IN. (SQ. MM)

Table 9 – Minimum Allowable Input Rating of Space--Heat-

ing Appliance in Thousands of BTUH per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

(FT)

Temperature: 17 to 26_F ( --- 8 t o --- 3 _C)

6 (1.8) 0 55 99 141

8 (2.4) 52 74 111 154

10 (3.0) NR 90 125 169

15 (4.6) NR NR 167 212

20 (6.1) NR NR 212 258

30 (9.1) NR NR NR 362

Temperature: 5 to 16 _F * ( --- 1 5 t o --- 9 _C)

6 (1.8) NR 78 121 166

8 (2.4) NR 94 135 182

10 (3.0) NR 111 149 198

15 (4.6) NR NR 193 247

20 (6.1) NR NR NR 293

30 (9.1) NR NR NR 377

Temperature: --- 10 to 4_F * ( --- 2 3 t o --- 1 6 _C)

6 (1.8) NR NR 145 196

8 (2.4) NR NR 159 213

10 (3.0) NR NR 175 231

15 (4.6) NR NR NR 283

20 (6.1) NR NR NR 333

30 (9.1) NR NR NR NR

Temperature: --- 11_F ( --- 2 4 _C) or lower

Not recommended for any vent configuration.

*The 99.6% heating db temperatures foun d in the 1997 or 2001 ASHRAE Fundamentals Handbook, Climatic Design Information chapter, Table 1A (United States) and 2A (Canada) or the 2005 ASHRAE Fundamentals handbook, Climatic Design Information chapter, and the CD ---ROM included with the 2005 ASHRAE Fundamentals Handbook.

(7741)19(12258)28(18064)38(24516)

Local 99% Winter Design

SQ. IN. (SQ. MM)

APPLIANCE APPLICATION REQUIREMENTS

Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100% of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air--Conditioning Engineers; or other approved engineering methods. Excessive over--sizing of the furnace could cause the furnace and/or vent to fail prematurely. When a metal vent or metal liner is used, the vent must be in good condition and be installed in accordance with the vent manufacturer’s instructions.

To prevent condensation in the furnace and vent system, the following precautions must be observed:

1. The return--air temperature must be at least 60_F(15_C)

db except for brief periods of time during warm--up from setback at no lower than 55_F(13_C) db or during initial start--up from a standby condition.

Page 29

2. Adjust the gas input rate per the installation instructions. Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes above 2000 ft

3. Adjust the air temperature rise to the midpoint of the rise range or slightly above. Low air temperature rise can cause low vent gas temperature and potential for condensation problems.

4. Set the thermostat heat anticipator or cycle rate to reduce short cycling.

Air for combustion must not be contaminated by halogen compounds which include chlorides, fluorides, bromides, and iodides. These compounds are found in many common home products such as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air freshener, and can cause corrosion of furnaces and vents. Avoid using such products in the combustion--air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds, causing premature failure of the furnace or venting system due to corrosion.

Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system. Do not use vent dampers on appliances common vented with this furnace.

ADDITIONAL VENTING REQUIREMENTS A 4 in. (102 mm) round vent elbow is supplied with the furnace.

A 5 in. or 6 in. (127 or 152 mm) vent connector may be required for some model furnaces. A field--supplied 4 in. to 5 in. (102 to 127 mm) or 4 in. to 6 in. (102 mm to 152 mm) sheet metal increaser fitting is required when 5 in. or 6 in. (127 or 152 mm) vent connector is used. See Fig. 35--47 Venting Orientation for approved vent configurations.

See Venting Notes after Fig. 47.

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

Fig. 35 -- Upflow Application--Vent Elbow Up

58CT

A03208

SEE NOTES: 1,2,3,4,7,8,9 on the pages following these figures

Fig. 36 -- Upflow Application--Vent Elbow Right

A03209

Page 30

58CT

SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures

SEE NOTES: 1,2,4,5,6,7,8,9,10 on the page following these figures

A03210

Fig. 37 -- Downflow Application--Vent Elbow Up then Left

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03207

Fig. 39 -- Downflow Application--Vent Elbow Left then Up

SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures.

Fig. 38 -- Downflow Application--Vent Elbow Up

A03211

A03212

Fig. 40 -- Downflow Application--Vent Elbow Up then Right

Page 31

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

A03213

Fig. 41 -- Horizontal Left Application -- Vent Elbow Left

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03215

Fig. 44 -- Horizontal Left Application -- Vent Elbow Up

58CT

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

Fig. 42 -- Horizontal Left Application -- Vent Elbow Right

then Up

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

Fig. 43 -- Horizontal Right Application -- Vent Elbow Right

A03214

A03218

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

Fig. 45 -- Horizontal Left Application -- Vent Elbow Right

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

Fig. 46 -- Horizontal Right Applicatio n -- Vent Elbow Left

then Up

A03216

A03219

Page 32

SEE NOTES: 1,2,4,5,7,8,9

Fig. 47 -- Horizontal Right Applicatio n--Vent Elbow Left

NOTES: Venting Notes for Fig. 35 ---47

1. For common vent, vent connector sizing and vent material: United S tates --- ---use the NFGC Canada ------use the CAN/CSA---B149.1 ---05

2. Immediately increase to 5 ---in. or 6 ---in. (127 or 152 mm) vent connector outside furnace casing when 5---in. (127 mm) vent connector is required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except wh en KGAVG0101DFG, Downflow VentGuardKit,isusedinthedownflowposition.

4. Type ---B vent where required, refer to Note 1 above.

58CT

5. Four ---in. (102 mm) single --- wall ( 26 ga. min.) vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external to the furnace.

6. Accessory Downflow Vent Guard Kit, KGAVG0101DFG required in downflow installations with lower vent configuration.

7. C himney Adapter K it may be r equired for exterior masonry chimney applications. Refer to Chimney Adapter Kit, KGACA02014FC or KGACA02015FC, for sizing and complete a pplication details.

8. Secure vent connector to furnace elbow with (2) corrosion ---resistan t sheet metal screws, spaced approximately 180_ apart.

9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120_ apart. Secure Type --- B vent connectors per vent connector manufacturer’s recommendations.

10. T he total height of the vent and connector shall be at least seven feet (2 M) for the 154,000 Btuh gas input rate model when installed in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward. (See Fig. 40.)

Caution!! For the following applications, use the minimum vertical heights as specified below.

For all other applications, follow exclusively the National Fuel Gas Code

A02068

FURNACE

ORIENTATION

Downflow

Horizontal Left

Downflow

*4 in. (102 mm) inside casing or vent guard

**Including 4 in. (102 mm) vent section(s) NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC.

VENT

ORIENTATION

Vent elbow left, then

up Fig. 39

Vent elbow right,

then up Fig. 42

Vent Elbow up Fig.

Vent elbow right Fig.

Vent elbow up then

left Fig. 37

Vent elbow up, then

right Fig. 40

FURNACE

INPUT(BTUH/HR)

154,000 132,000

110,000(036/--- 12 only)

154,000 132,000

154,000 5 (127) 7 (.65)

110,000 (036/ ---12 only) 5 (127) 10 (3.0)

MINIMUM VENT

DIAMETER

IN. (mm)*

MINIMUM VERTICAL

VENT HEIGHT

FT. (M)**

5 (127) 12 (3.6)

5 (127) 7 (.65)

Page 33

Fig. 48 -- Using Tin Snips to Cut Tie Points

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4--in. (102 mm) vent elbow is shipped for upflow configuration and may be rotated for other positions. Remove the 3 screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, re--install screws. The factory--supplied vent elbow does NOT count as part of the number of vent connector elbows.

The vent connector can exit the door through one of 5 locations on the door.

1. Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow with at least two field-- supplied, corrosion--resistant, sheet metal screws located 180_ apart.

NOTE: An accessory flue extension KGAFE0112UPH is available to extend from the furnace elbow to outside the furnace casing. If flue extension is used, fasten the flue extension to the vent elbow with at least two field--supplied, corrosion--resistant, sheet metal screws located 180_ apart. Fasten the vent connector to the flue extension with at least two field--supplied, corrosion resistant sheet metal screws located 180_ apart.

2. Vent the furnace with the appropriate connector as shown in Fig. 35--47.

3. Orient the door to determine the correct location of the door knockout to be removed.

4. Remove the correct U--shaped knockout in door.

NOTE: A number of techniques can be used to remove these knockouts as seen in Fig. 48 through 52. The knockout in the bottom of the door is unique due to its flanging and is more easily removed by first cutting the two tie points at the edge of the door, using aviation--type tin snips. (See Fig. 48.) A sharp blow to the rounded end of the knockout (See Fig. 49.) will separate more tie points and allow the knockout to be pulled loose. (See Fig. 50.) Remove all burrs any sharp edges.

A04127

58CT

For the rectangular J--box knockout, use tin snips along the door edge and use a sharp blow with a hammer to remove the knockout. Remove any burrs and sharp edges.

For the knockouts in the other locations on the door (top and sides), tin snips can also be used along the door edges; however, the preferred method is to use a hammer and screwdriver to strike a sharp blow (See Fig. 51.) directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout. (See Fig. 52.) Remove any burrs and sharp edges.

NOTE: If a knockout does not come out after two sharp blows, pull and snip as needed to remove the knockout. Additional blows may cause damage to the door.

A04128

Fig. 49 -- Rounded End of Knockout

Page 34

An accessory Vent Guard Kit, KGAVG0101DFG is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing door. Refer to the Vent Guard Kit Instructions for complete details.

The horizontal portion of the venting system shall slope upwards not less than 1/4--in. per linear ft. (6 mm/.3 M) from the furnace to the vent and shall be rigidly supported every 5 ft. (1.5 M) or less with metal hangers or straps to ensure there is no movement after installation.

SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal

venting. In the U.S.: Per section 10.3.4 of the NFPA 54 / ANSI

Z223.1--2006, any listed mechanical venter may be used, when approved by the authority having jurisdiction.

A04129

Fig. 50 -- Knockout Pulled Loose

58CT

In Canada: Per section 8.24.2 of the CAN/CSA--B149.1--05, any listed mechanical venter may be used, when approved by the authority having jurisdiction.

Select the listed mechanical venter to match the Btuh input of the furnace being vented. Follow all manufacturer’s installation requirements for venting and termination included with the listed mechanical venter.

START--UP, ADJUSTMENT, AND SAFETY

CHECK

Step 1 — General

A04130

Fig. 51 -- Hammer and Screwdriver Used for Knockout

A04131

Fig. 52 -- Remove Knockout with Hammer

WARNING

FIRE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

This furnace is equipped with manual reset limit switches in the gas control area. The switches open and shut off power to the gas valve if a flame roll--out or overheating condition occurs in the gas control area. DO NOT bypass the switches. Correct problem before resetting the switches.

1. Maintain 115--v wiring and ground. Improper polarity will result in rapid flashing LED and no furnace operation.

2. Make thermostat wire connections at the 24--v terminal block on the furnace control. Failure to make proper connections will result in improper operation. (See Fig. 23.)

3. Gas supply pressure to the furnace must be greater than

4.5--in. wc (0.16 psig ) but not exceed 14--in. wc (0.5 psig).

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

CAUTION

BURN HAZARD

Failure to follow this caution may cause personal injury.

Hot vent pipe is within reach of small children when installed in downflow position.

See the following instruction.

4. Check all manual--reset switches for continuity.

5. Install blower compartment door. Door must be in place to operate furnace.

6. Setup switch descriptions The 2 stage furnace has DIP switches used to select thermostat staging and blower off delay timings. For switch locations on Furnace control board, See Fig. 33 and 57.

7. Setup switch descriptions -- See Table 10.

Page 35

Table 10 – 2--Stage Furnace Setup Switch Description

SETUP

SWITCH NO.

S W --- 1 Adaptive Heat Mode OFF

S W --- 2 Blower OFF delay ON or OFF

S W --- 3 Blower OFF delay ON or OFF

SWITCH

NAME

NORMAL

POSITION

Step 2 — Start-- Up Procedures

WARNING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could cause personal injury, death and/or property damage.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

1. Purge gas lines after all connections have been made.

2. Check gas lines for leaks.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, or death.

Blower access door switch opens 115--v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.

3. To Begin Component Self--Test: Remove blower access door. Disconnect the thermostat R lead from furnace control board. Manually close blower door switch. Short (jumper) the COM--24v terminal on control to the TEST/TWIN 3/16--in. (8 mm) quick--connect terminal on control until the LED goes out (approximately 2 sec). Gas valve and humidifier will not be turned on. Remove jumper from terminals. (See Fig. 33 and Table 10.)

NOTE: The furnace control allows all components, except the gas valve, to be run for short period of time. This feature helps diagnose a system problem in case of a component failure. Component test feature will not operate if any thermostat signal is present at the control.

Refer to service label attached to furnace or See Fig. 56.

Component test sequence is as follows:

a. LED will display previous status code 4 times.

b. Inducer motor starts on high--speed and continues to run

until Step g of component test sequence.

c. Hot surface igniter is energized for 15 sec., then off.

d. Blower motor operates on LO--HEAT speed for 10 sec.

e. Blower motor operates on HI--HEAT speed for 10 sec.

f. Blower motor operates on COOL speed for 10 sec. g. Inducer motor goes to low--speed for 10 sec., then stops.

h. Reconnect R lead to furnace control board, remove tape

from blower door switch and re--install blower door.

4. Operate furnace per instruction on inner door.

DESCRIPTION

When OFF, allows 2 --- stage operation with a single stage thermostat.

Turn ON when using 2 stage thermostat to allow Low Heat opera---

tion when R to W/W1 closes and High Heat operation when R to

Control blower OFF delay time. Used in conjunction with SW--- 3.

Control blower OFF delay time. Used in conjunction with SW--- 2.

5. Verify furnace shut down by lowering thermostat setting below room temperature.

6. Verify furnace restarts by raising thermostat setting above room temperature.

OF USE

W/W1 and W2 close.

See Table 14.

Step 3 — Adjustments

WARNING

FIRE HAZARD

Failure to follow this warning could result in injury, death and/or property damage.

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess over--fire and heat exchanger failures.

CAUTION

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in reduced furnace life.

DO NOT re--drill orifices. Improper drilling (burrs, out--of round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of heat exchangers, causing failures. (See Fig.

49.)

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). Furnace input rate must be within +/--2% of furnace rating plate input. For altitudes above 5500 ft. (1676 M), a field--supplied high altitude pressure switch is required.

1. Determine the correct gas input rate.

In the U.S.:

The input rating for altitudes above 2,000 ft. (610 M) must be reduced by 4% for each 1,000 ft. (305 M) above sea level. For installations below 2000 ft. (610 M), refer to the unit rating plate. For installations above 2000 ft. (610 M), multiply the input on the rating plate by the derate multiplier in Table 11 for the correct input rate.

EXAMPLE: 88,000 BTUH INPUT FURNACE INSTALLED AT 4300 FT. (1310

Derate Furnace Input Rate

Furnace Input Rate X Multiplier = at Installation

at Sea Level Factor Altitude

88,000 X 0.90 = 79,200

In Canada: The input rating must be reduced by 10% for altitudes of 2,000 ft. (610 M) to 4,500 ft. (1372 M) above

58CT

Page 36

sea level by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example and use 0.90 as derate multiplier factor.

2. Determine the correct orifice and manifold pressure adjustment. All models in all positions except Low NOx models in downflow and horizontal positions use Table 15 (22,000 BTUH per burner).

Table 11 – Altitude Derate Multiplier for U.S.A.

3. Adjust manifold pressure to obtain low fire input rate. (See Fig. 53.)

a. Turn gas valve ON/OFF switch to OFF.

b. Remove manifold pressure tap plug from gas valve.

c. Connect a water column manometer or similar device to

manifold pressure tap.

d. Turn gas valve ON/OFF switch to ON.

58CT

ALTITUDE

FT. (M)

0–2000

(0--- 610)

2001–3000 (610--- 914)

3001–4000

(914--- 1219)

4001–5000

(1219--- 1524)

5001–6000

1524--- 1829)

6001–7000

(1829--- 2134)

7001–8000

(2134--- 2438)

8001–9000

(2438--- 2743)

9001–10,000

(2743--- 3048)

* Derate multiplier factors are based on midpoint al titude for altitude range.

PERCENT

OF DERATE

0 1.00

8–12 0.90

12–16 0.86

16–20 0.82

20–24 0.78

24–28 0.74

28–32 0.70

32–36 0.66

36–40 0.62

DERATE MULTIPLIER

FACTOR*

Low NOx models in downflow or horizontal positions MUST use Table 16 (21,000 BTUH per burner). See input listed on rating plate.

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

from local gas supplier.

b. Obtain average yearly gas specific gravity from local gas

supplier.

c. Find installation altitude in Table 15 or 16.

d. Find closest natural gas heat value and specific gravity

in Table 15 or 16

e. 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.

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

ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

g. Replace orifice with correct size, if required by Table 15

or 16. Use only factory--supplied orifices. See EXAMPLE 2.

EXAMPLE 2: (0--2000 ft. / 0--610 M altitude)

For 22,000 Btuh per burner application, use Table 15.

Heating value = 1000 Btuh/cu ft.

Specific gravity = 0.62

Therefore: Orifice No. 43*

Manifold pressure: 3.7--in. wc for high--heat

1.6--in. wc for low--heat

* Furnace is shipped with No. 43 orifices. In this example

all main burner orifices are the correct size and do not need

to be changed to obtain proper input rate.

A06667

Fig. 53 -- Redundant Automatic Gas Control Valve

e. Move setup switch LHT (SW--1) on furnace control to

ON position to lock furnace in low--heat operation. (See Fig. 33 and Table 10.)

f. Manually close blower door switch.

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

to start furnace. (See Fig. 33.)

h. Remove regulator adjustment cap from low--heat gas

valve pressure regulators. (See Fig. 53.) Turn low--heat adjusting screw (3/16 in. (5 mm) or smaller flat tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low--heat manifold pressure less than

1.4--in wc or more than 1.7--in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices.

i. Install low--heat regulator adjustment cap. j. Leave manometer or similar device connected and pro-

ceed to Step 4.

NOTE: If orifice hole appears damaged or it is suspected to have been re--drilled, check orifice hole with a numbered drill bit of correct size. Never re--drill an orifice. A burr--free and squarely aligned orifice hole is essential for proper flame characteristics.

4. Verify natural gas low--heat input rate by clocking meter.

NOTE: Gas valve regulator adjustment caps must be in place for proper input to be clocked.

a. Turn off all other gas appliances and pilots served by the

meter.

Page 37

b. Run for 3 minutes in low--heat operation.

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

tion and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow.

BURNER

ORIFICE

5. Set low--heat temperature rise. The furnace must operate within the temperature rise ranges specified on the furnace rating plate. Do not exceed temperature rise ranges specified on unit rating plate for high-- and low--heat. Determine the temperature rise as follows:

NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in incorrect temperature measurements.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Disconnect 115--v electrical power before changing speed tap.

A93059

Fig. 54 -- Orifice Hole

d. Refer to Table 12 for cubic ft. of gas per hr.

e. Multiply gas rate cu ft. /hr by heating value (Btuh/cu ft.

) to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct low heat input is achieved. Re--install low--heat regulator seal cap on gas valve.

a. Verify unit is running in low heat per Step 3. Place ther-

mometers in return and supply ducts as close to furnace as possible.Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with straight--run ducts.

b. When thermometer readings stabilize, subtract return--air

temperaturefromsupply--air temperatureto determineair temperature rise.

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

(1.) Gas input for low 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.

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Page 38

Table 12 – Gas Rate (cu ft. /hr)

SECONDS

FOR

REVOLUTION

58CT

10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367

SIZE OF TEST DIAL

1 CUFT. 2 CUFT. 5 CUFT. 1 CUFT. 2 CUFT. 5 CUFT.

SECONDS

FOR

REVOLUTION

SIZE OF TEST DIAL

c. Adjust air temperature rise by adjusting blower speed. In-

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

d. Remove thermostat jumpers and release Blower Access

Door Switch.

e. To change motor speed selection for low heat, remove

blower motor lead from control LO--HEAT terminal. (See Fig. 33.) Select desired blower motor speed lead from 1 of the other terminals and relocate it to the LO-HEAT terminal. (See Table 13 for lead color identification). Reconnect original lead to SPARE terminal.

f. Repeat steps a through e.

CAUTION

FURNACE OVERHEATING HAZARD

Failure to follow this caution may result in reduced furnace life.

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

g. When correct low heat input rate and temperature rise is

achieved, proceed to Step 6.

6. Adjust Manifold Pressure to Obtain High Heat Rate

a. Remove high fire regulator adjustment cap from gas

valve pressure regulator.

b. Manually close blower access door switch.

c. Jumper R, W/W1 and W2 thermostat connections on

control to run furnace in high heat. (See Fig. 33.)

d. d. Turn high--heat adjusting screw (3/16--in. (5 mm) or

smaller flat tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase rate.

e. Re--install high--fire adjustment caps.

f. Leave manifold or similar device connected and proceed

to Step 7.

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.

7. Verify natural gas high heat input rate by clocking meter.

NOTE: Gas valve regulator adjustment caps must be in place for proper input to be clocked.

a. Turn off all other gas appliances and pilots served by the

meter.

b. Run for 3 minutes in high--heat operation.

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

tion and note reading.

d. Refer to Table 12 for cubic ft. of gas per hr.

e. Multiply gas rate cu ft. /hr by heating value (Btuh/cu ft.)

to obtain input.

Page 39

NOTE: Using the 2 cu. ft. or 5 cu. ft. gas meter dial provides greater accuracy in verifying gas input rate.

If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct high heat input is achieved. Re--install high--heat regulator seal cap on gas valve.

8. Set high heat temperature rise. Jumper R to W/W1 and W2 to check high--gas-- heat temperature rise. Do not exceed temperature rise ranges specified on furnace rating plate for high heat. The furnace must operate within the temperature rise ranges specified on the furnace rating plate. Determine the air temperature rise as follows:

NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in incorrect temperature measurements.

a. Verify the furnace is operating in high heat per Step 6.

Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with straight--run ducts.

b. When thermometer readings stabilize, subtract return--air

temperaturefromsupply--air temperatureto determineair temperature rise.

NOTE: If the 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.

(4.) Dirty filter.

c. Adjust air temperature rise by adjusting blower speed. In-

crease 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).

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Disconnect 115--v electrical power before changing speed tap.

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

blowermotor lead from control HI--HEAT terminal. (See Fig. 33.) Select desired blower motor speed lead from 1 of the other terminals and relocate it to the HI--HEAT terminal. DO NOT use the low--heat tap that was already set. (See Table 13 for lead color identification). Reconnect original lead to SPARE terminal.

e. Repeat steps a thru e.

f. When correct high heat input rate and temperature rise is

achieved, turn gas valve ON/OFF switch to OFF.

g. Release Blower Access Door switch. h. Remove manometer or similar device from gas valve.

i. Re--install manifold pressure tap plug in gas valve. (See

Fig 54.)

WARNING

FIRE HAZARD

Failure to reinstall manifold pressure tap plug in gas valve could result in personal injury, property damage or death.

Reinstall manifold pressure tap plug in gas valve to prevent gas leak.

j. Remove thermostat jumper wire from furnace control

board.

k. Turn LHT switch OFF.

l. Turn gas valve ON/OFF switch to ON.

m. Proceed to Step 9, “Set Blower Off Delay” before in-

stalling blower access door.

CAUTION

FURNACE OVERHEATING HAZARD

Failure to follow this caution may result in reduced furnace life.

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

9. Set Blower Off Delay

a. Remove Blower Access Door if installed.

b. Turn Dip switch 2 and 3 ON or OFF for desired blower

off delay. (See Table 14 and Fig 34.)

10. Set thermostat heat anticipator.

a. Mechanical thermostat -- Set thermostat heat anticipator

to match the amp. draw of the electrical components in the R--W/W1 circuit. Accurate amp. draw readings can be obtainedatthewiresnormallyconnected to thermostat subbase terminals, R and W. The thermostat anticipator should NOT be in the circuit while measuring current.

(1.) Set LHT switch on furnace control board to ON.

(2.) Remove thermostat from sub--base or from wall.

(3.) Connect an amp. meter as shown in Fig. 55 across

the R and W subbase terminals or R and W wires at wall.

(4.) Record amp. draw across terminals when furnace is

in low heat and after blower starts.

(5.) Set heat anticipator on thermostatper thermostat in-

structions and install on subbase or wall.

(6.) Turn LHT switch OFF. (7.) Install blower access door.

b. Electronic thermostat: Set cycle rate for 3 cycles per hr.

11. Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow. See Table 5--Air Delivery--CFM (With Filter). See Table 13 for lead color identification.

Table 13 – Speed Selection

COLOR SPEED AS SHIPPED

White Common BLW Black High COOL

Yellow M e d --- Hi g h SPARE

Orange† Med SPARE

Blue M e d --- L o w HI ---HEAT

Red Low* LO HEAT

* Continuous ---blower speed---as shipped default { Not all models equipped with 5 speed motors

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Page 40

Table 14 – 2--Stage Furnace Blower OFF delay Setup Switch

DESIRED HEATING MODE

BLOWER OFF DELAY (SEC.)

90 OFF OFF 120 OFF ON 150 ON OFF 180 ON ON

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

HOOK-AROUND AMMETER

R Y W G

58CT

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

Fig. 55 -- Amp. Draw Check with Ammeter

Step 4 — Check Safety Controls

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

1. Check Main Limit Switch(es) This control shuts off combustion system and energizes air--circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established that limit is functioning properly and will operate if there is a restricted return--air supply or motor failure. If limit control does not function during this test, cause must be determined and corrected.

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of cardboard

or sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

d. Burners will re--light when furnace cools down.

2. Check draft safeguard switch. The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions.

a. Verify vent pipe is cool to the touch.

b. Disconnectpower to furnace and remove vent connector

from furnace vent elbow.

c. Restore power to furnace and set room thermostat above

room temperature.

d. After normal start--up, allow furnace to operate for 2

minutes, then block vent elbow in furnace 80% of vent area with a piece of flat sheet metal.

e. Furnaceshouldcycleoffwithin 2 minutes.Ifgasdoesnot

shut off within 2 minutes, determine reason draft safe-

A96316

SETUP SWITCH

S W --- 2

SETUP SWITCH

S W --- 3

guardswitch did not function properly and correctcondition.

f. Remove blockage from furnace vent elbow.

g. Switch will auto--reset when it cools.

h. Re--install vent connector.

NOTE: Should switch remain open longer than 3 minutes, furnace control board will lockout the furnace for 3 hours. To reset furnace control board, turn thermostat below room temperature or from HEAT to OFF and turn 115--v power OFF, then back ON.

3. Check Pressure Switch(es) This control proves operation of the draft inducer blower.

a. Turn off 115--v power to furnace.

b. 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 igniter should NOT glow and control diagnostic light flashes a status code 32. If hot surfaceigniter glows when inducermotor is disconnected, shut down furnace immediately.

e. Determine reason pressure switch did not function prop-

erly and correct condition.

f. Turn off 115--v power to furnace.

g. Reconnect inducer motor wires, replace outer door, and

turn on 115--v power.

h. Blower will run for 90 seconds before beginning the call

for heat again.

i. Furnace should ignite normally.

Step 5 — Checklist

1. Put away tools and instruments. Clean up debris.

2. Verify that switches for LHT and OFF--DELAY are blower OFF-- DELAY are selected as desired.

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

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturerfs instructions.

6. Review User’s Guide with owner.

7. Attach literature packet to

furnace.

Page 41

Table 15 – Orifice Size* and Manifold Pressures (In wc) for Gas Input Rate

58CT

A08485

Page 42

Table 15 -- Orifice Size and Manifold Pressures (In wc) for Gas Input Rate (cont.)

58CT

A08485A

Page 43

Table 16 – Orifice Size* and Manifold Pressures (In wc) for Gas Input Rate

58CT

A08219

Page 44

Table 16 -- Orifice Size* and Manifold Pressures (In wc) for Gas Input Rate (cont.)

58CT

A08219A

Page 45

SERVICE AND MAINTENANCE

PROCEDURES

WARNING

FIRE, PERSONAL INJURY AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

The ability to properly perform maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s Manual.

WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death, or property damage.

Before servicing, disconnect all electrical power to furnace. Verify proper operation after servicing.

CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in improper unit operation or failure of unit components.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

CAUTION

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental pollution.

Remove and recycle all components or materials (i.e. oil, refrigerant, control board, etc.) before unit final disposal.

Step 1 — Introduction

GENERAL

These instructions are written as if the furnace is installed in an upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4 positions shown in Fig. 4, you must revise your orientation to component location accordingly.

ELECTRICAL CONTROLS AND

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

There may be more than one electrical supply to the furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing.

The electrical ground and polarity for 115--v wiring must be properly maintained. Refer to Fig. 23 for field wiring information and to Fig. 57 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and flame--sensing electrode.

The 24--v circuit contains an automotive--type, 3--amp. fuse located on the control. (See Fig. 31.) Any shorts of the 24--v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a 3--amp. fuse. The control LED will display status code 24 when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED (Light--Emitting Diode) to aid in installation, servicing, and troubleshooting. It can be viewed through the sight glass in blower access door. The furnace control LED is either ON continuously, rapid flashing, or a code composed of 2 digits. The first digit is the number of short flashes, the second digit is the number of long flashes.

For an explanation of status codes, refer to service label located on blower access door or Fig. 56, and the troubleshooting guide which can be obtained from your distributor.

See Fig. 61 for a brief Troubleshooting guide.

For Controls with an Amber

The stored status codes will NOT be erased from the control memory, if 115-- or 24--v power is interrupted. The control will store up to five (5) status codes.

1. To retrieve status codes, proceed with the following:

NOTE: NO thermostat signal may be present at control, and all blower--OFF delays must be completed.

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

b. Remove outer access door.

c. Look into blower access door sight glass for current LED

status. Removing blower access door will open blower access door switch and terminate 115--v power to control so that status code is not displayed.

d. BRIEFLY remove insulated terminal wire from the draft

safeguard (DSS) switch until LED goes out, then reconnect it.

NOTE: If wire to DSS is disconnected longer than 4 sec, main blower starts, and retrieval request is ignored.

2. When above items have been completed, the LED flashes status code 4 times. Record this status code for further troubleshooting. After the LED flashes status code four times, BRIEFLY remove wire again from DSS switch until LED goes out, then reconnect it to retrieve previous status code (if available). Repeat as needed for more previous status codes or until Code 11 appears.

WIRING

LED

58CT

Page 46

If stat us code recall is needed, briefl y remove then reconnect one main limit wire to di splay last st ored status code. On RED LED boards do not remove power or blower door bef ore initiat ing status code recall.

EACH OF THE FOLLOWING STATUS CODES IS A TWO DI GIT NUMBER WITH THE FIRST DI GIT DETERMINED BY THE NUMBER OF SHORT FLASHE S AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.

11 NO PREVIOUS CODE - Stored status code is erased automatically after 72 hours.

On RED LED boards stored status codes can also be erased when power (115 VAC or 24 VAC) to control is interrupted.

12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for the

selected blower off-delay time, if unit is powered up during a call for heat (R-W/W1 closed) or (R-W/W1) opens during blower on-delay.

13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if a limit, draft safeguard, flame rollout,

or blocked vent switch (if used) is open longer than 3 minutes.

- Control will auto reset after three hours. - Refer to #33.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34. 21 GAS HEATING LOCKOUT - Control will NOT auto reset.

Check for: - Mis-wired gas v alve - Defective control (valve relay)

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is pro ved while gas valve is de-

energized. Inducer will run until fault is cleared. Check for:

- Leaky gas valve - Stuck-open gas valve

23 PRESSURE SWITCH DID NOT OPEN Check for: - Obstructed pressure tub ing

24 SECONDARY VOLTAGE FUSE IS OPEN Check for: - Short circuit in secondary

voltage (24VAC) wiring.

31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED

Control relay may be defective, ref er to status code #32

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R" thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" terminal.

58CT

Status LED will flash last status code and then turn ON the inducer motor. The inducer motor will start in HIGH speed and remain on HIGH speed until the end of the test then shift to LOW speed for 7 to 15 seconds. The hot s urface igniter, blower motor LO HEAT speed, blower motor HI HEAT speed, and blower motor COOL speed will be turned ON for 10-15 seconds each. Gas Valve and Humidifier will not be turned on. When the blower is turned OFF the inducer will be switched to low-speed for 10 seconds.

LED CODE

CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2. CONTINUOUS ON - Control has 24VAC power. RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions.

- Pressure switch stuck closed

STATUS

32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than

five minutes, inducer shuts off for 15 minutes before retry. If opens durin g blower on-delay period, blower will come on for the selected blower off-delay. Check for:

- Excessive wind - Restricted vent - Defective inducer motor

- Proper vent sizing - Defective pressure switch - Low inducer voltage (115 VAC)

- Inadequate combustion air supply - Low inlet gas pressure (i f LGPS used)

- Disconnected or obstructed pressure tubing

33 LIMIT CIRCUIT FAULT - Indica tes a limit, draft safeguard, flame rollout, or blocked vent

switch (if used) is open. Blower will r un for 4 minutes or until open switch remakes whichever is longer. If open longer th an 3 minutes, code changes t o lockout #13. If open less than 3 minutes status code #33 continues to flash until blower shuts off. Flame rollout switch and BVSS require manual reset. Check for: - Dirty fi lter or restricted duct system

- Defective blower motor or capacitor - Proper vent sizing - Restricted vent

- Defective switch or connections - Loose blower wheel - Excessive wind

- Inadequate combustion air supply (Flame Roll-out Switch open).

34 IGNITION PROVING FAILURE - Control will try three more times before lo ckout #14 occurs.

If flame signal lost during blower on-delay period, blower will come on for the selected blower off-delay. Check for: - Oxide buildup on flame sensor (clean with fine steel wool)

- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal)

- Manual valve shut-off - Control ground continuity

- Gas valve defective or gas valve turned off - Low inlet gas pressure

- Inadequate flame carryover or rough ignition - Defective Hot Surface Ignitor

- Flame sensor must not be grounded

- Green/Yellow wire MUST be connected to furnace sheet metal

43 LOW-HEAT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE SWITCH IS

CLOSED - Check for: - Disconnected or obstructed pressure tubing

- Mis-wired pressure switches - Low-heat pressure switch stuck open

- Low inlet gas pressure (if LGPS used)

45 CONTROL CIRCUITRY LOCKOUT Auto-reset afte r one hour lockout due to;

- Gas valve relay stuck open - Flame sense circuit failure - Software check error Reset power to clear lockout. Replace control if status code repeats.

Fig. 56 -- Service Label

Step 2 — Care and Maintenance

WARNING

SERVICE

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Never store anything on, near, or in contact with the furnace, such as:

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

3. Paint thinners and other painting compounds, paper bags, or other paper products. Explosure to these materials could lead to corrosion of the heat exchanger.

CARBON MONOXIDE POISONING AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, and/or property damage.

Never operate unit without a filter or with filter access door removed.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

327598-101 REV. C

A04210

For continuing high performance and to minimize possible furnace failure, periodic maintenance must be performed on this furnace. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death or property damage.

Turn off the gas and electrical supplies to the unit before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace.

The minimum maintenance on this furnace is as follows:

1. Check and clean air filter each month or more frequently if required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.

3. Check electrical connections for tightness and controls for proper operation each heating season. Service as necessary.

4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have furnace and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system before each heating season for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a qualified service agency.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or maintenance to the accessories as recommended in the accessory instructions.

Page 47

58CT

Fig. 57 -- Wiring Diagram

A07125

Page 48

TABLE 17 – FILTER SIZE INFORMATION (IN. / MM)

FURNACE CASING WIDTH

14---1/2 (368)

17---1/2 (445)

21 (533)

24 (610)

* Recommended ** Some f u r naces may have 2 filters.

(406 x635 x 19)

CLEANING AND/OR REPLACING AIR FILTER

The air filter arrangement will vary depending on the application. NOTE: If the filter has an airflow direction arrow, the arrow

must point towards the blower.

CAUTION

58CT

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

Media cabinet filter procedures: NOTE: Media Cabinet is included with two--stage furnace.

1. Turn off electrical supply to furnace before removing filter access door.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable 3/4--in. (19 mm) filter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry. Oiling or coating of the filter is not recommended. See Table 17 for size information.

5. If equipped with factory--specified disposable media filter, replace only with media filter having the same part number and size. For expandable replacement media, refer to the instructions included with the replacement media. If equipped with accessory KGAFR0301ALL external filter rack. See Table 17.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

BLOWER MOTOR AND

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower access door switch opens 115--v power to control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.

NOTE: The blower wheel should not be dropped or bent as balance will be affected.

The following steps should be performed by a qualified service agency.

WHEEL

WARNING

RETURN

16 x25 x 3/4

FILTER SIZE

BOTTOM

RETURN

14 x25 x 3/4

(356 x635 x 19)

16 x25 x 3/4

(406 x635 x 19)

20 x25 x 3/4

(508 x635 x 19)

24 x25 x 3/4

(610 x635 x 19)

FILTER TYPESIDE

Wash able*

To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

The inducer and blower motors are pre--lubricated and require no additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Loosen the thumbscrew from outer door and remove outer door.

3. For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door:

a. Disconnect vent connector from furnace vent elbow.

b. Disconnect and remove short piece of vent pipe from

within furnace.

4. Remove 2 screws from blower access door and remove blower access door.

5. Disconnect blower leads from furnace control. Record wire color and location for reassembly. All other factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing.

6. Remove 2 screws holding control box to blower shelf.

7. Hang control box from front of furnace casing and away from blower compartment.

8. Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace.

9. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be cleaned with a small paint or flux brush. Do not remove or disturb balance weights (clips) on blower wheel blades.

10. Vacuum any loose dust from blower housing, wheel and motor.

11. If a greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:

NOTE: Before disassembly, mark blower mounting arms, motor, and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnect capacitorwires(ifequipped)and ground wire

attached to blower housing.

b. Remove screws securing cutoff plate and remove cutoff

plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

(160+/--20 in.--lb. when reassembling).

d. Remove bolts holding motor to blowerhousing and slide

motorout of wheel(40+/--10 in.--lb. whenreassembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

12. Reassemble motor and blower by reversing steps 11e, through 11a. Be sure to reattach ground wire to the blower housing.

Page 49

13. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft. Loosen set screw on blower wheel and reposition if necessary.

14. Spin the blower wheel by hand to verify that the wheel does not rub on the housing.

15. Reinstall blower assembly in furnace.

16. Reinstall control box assembly in furnace.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in shortened heat exchanger life.

Heating fan speed(s) MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Recommended operation is at the midpoint of the rise range or slightly above. Refer to “SET TEMPERATURE RISE” under START--UP, ADJUSTMENT, and SAFETY CHECK.

NOTE: Refer to Table 13 for motor speed lead relocation if leads were not identified before disconnection.

17. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.

18. To check blower for proper rotation:

a. Turn on electrical supply.

b. Manually close blower access door switch.

NOTE: If thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before beginning a heating or cooling cycle.

c. Perform component self--test as shown at the bottom of

the SERVICE label, located on the front of blower access door.

d. Verify blower is rotating in the correct direction.

19. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace blower access door.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, or death.

Blower access door switch opens 115--v power to furnace control. No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes.

cycle. Turn outdoor circuit breaker on after completing cooling cycle.

CLEANING HEAT

The following steps should be performed by a qualified service agency:

NOTE: If the heat exchangers get a heavy accumulation of soot

and carbon, they should be replaced rather than trying to clean them thoroughly. A build--up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem.

If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to aid in reconnection of (be careful when disconnecting wires from switches because damage may occur):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter. g. Flame--sensing electrode

h. Flame rollout switches.

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box. Inducer assembly and elbow need not be removed from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the 5 screws that attach the burner assembly to the cell panel. The gas valve and individual burners need not be removed from support assembly. Remove NOx baffles if installed.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Fig. 58 and 59 for correct igniter location.

EXCHANGER

58CT

20. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Install and connect short piece of vent pipe insidefurnace

to existing vent.

b. Connect vent connector to vent elbow.

21. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section. If outdoor temperature is below 70_F(21_C) turn off circuit breaker to outdoor unit before running furnace in the cooling

A05025

Fig. 58 -- Igniter Position--Side View

Page 50

9. Using field--provided 25--caliber rifle cleaning brush, 36--in. (914 mm) long 1/4--in. (6 mm) diameter steel spring cable, a variable speed, reversible electric drill, and vacuum cleaner, clean cells as follows:

a. Remove metal screw fitting from wire brush to allow in-

sertion into cable.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by striking with ball--peen hammer. TIGHTNESS IS VERY IMPORTANT.

NOTE: The materials needed in item 9 can usually be purchased at local hardware stores.

(1.) Attach variable--speed, reversible drill to the end of

spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening of

cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upper pass of cell. (See Fig. 60.)

58CT

NOTE: A releasing agent such as cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G.E. 162, 6702, or Dow--Corning 738) are needed before starting installation. DO NOT substitute any other type of RTV sealant. G.E. 162 (P771--9003) is available through RCD in 3--oz. tubes.

(3.) Work cable in and out of cell 3 or 4 times to obtain

sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work cable out.

(4.) Insert brush end of cable in burner inlet opening of

cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5.) Repeat foregoing procedures until each cell in fur-

nace has been cleaned.

(6.) Using vacuum cleaner, remove residue from each

cell.

(7.) Using vacuum cleaner with soft brush attachment,

clean burner assembly.

(8.) Clean flame sensor with fine steel wool.

(9.) Install NOx baffles (if removed.)

(10.) Reinstall burner assembly. Center burners in cell

openings.

10. Remove old sealant from cell panel and collector box flange.

11. Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel.

12. Apply new sealant to flange of collector box and attach to cell panel using existing screws, making sure all screws are secure.

13. Reconnect wires to the following components (Use connection diagram on wiring label, if wires were not marked for reconnection locations.):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter. g. Flame--sensing electrode.

h. Flame rollout switches.

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field--supplied, corrosion --resistant, sheet metal screws located 180_ apart.

1-7/8

(47.6 mm)

A05026

Fig. 59 -- Igniter Position--Top View

A91252

Fig. 60 -- Cleaning Heat Exchanger Cell

16. Replace blower access door only, if it was removed.

17. Set thermostat above room temperature and check furnace for proper operation.

18. Verify blower airflow and speed changes between heating and cooling.

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage.

Never use a match or other open flame to check for gas leaks. Use a soap--and--water solution.

19. Check for gas leaks.

20. Replace outer access door.

Step 3 — Sequence of Operation

NOTE: Furnace control must be grounded for proper operation

or control will lockout. Control is grounded through green wire connected to gas valve and burner bracket screw. Using the schematic diagram in Fig. 57, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat (W/W1 or W/W1--and--W2), the control run the blower for the selected blower off--delay period two seconds after power is restored and if the thermostat is still calling for gas heating. The LED light will flash code 12 during this period, after which the LED will be ON continuous, as long as no faults are detected. After this period, the furnace will respond to the thermostat normally.

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

Page 51

1. Two--Stage Heating (Adaptive mode) with Single--

Stage Thermostat

(See Fig. 23 or 32 for thermostat connections)

NOTE: The low--heat only switch (LHT) selects either the low--heat only operation mode when ON, (see item 2. below) or the adaptive heating mode when OFF in response to a call for heat. (See Fig. 33.) When the W2 thermostat terminal is energized it will always cause high--heat operation when the R to W circuit is closed, regardless of the setting of the low--heat only switch. This furnace can operate as a two--stage furnace with a single--stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low--heat or high--heat operation. This selection is based upon the stored history of the length of previous gas--heating periods of the single--stage thermostat.

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

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

The wall thermostat “calls for heat”, closing the R to W circuit. The furnace control performs a self--check, verifies the low--heat and high--heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high--speed.

a. Inducer Prepurge Period

(1.) If the furnace control CPU selects low--heat opera-

tion the inducer motor IDM comes up to speed, the low--heat pressure switch LPS closes, and the furnace control CPU begins a 15--second prepurge period.After the low--heatpressureswitchre--closes thefurnace controlCPU will begin a 15--secondprepurgeperiod, and continueto run the inducermotor IDM at high--speed.

(2.) If the furnace control CPU selects high--heat opera-

tion, the inducer motor IDM remains running at high-- speed, and the high--heat pressure switch relay HPSR is de--energized to close the NC contact. When sufficient pressure is available the high--heat pressure switch HPS closes, and the high--heat gas valve solenoid GV--HI is energized. The furnace control CPU begins a 15--second prepurge period after the low-- heat pressure switch LPS closes. If the high--heatpressureswitch HPS fails to close and the low--heat pressure switch LPS closes, the furnace will operate at low--heat gas flow rate until the high-heat pressure switch closes for a maximum of 2 minutes after ignition.

b. Igniter Warm--Up--At the end of the prepurge period,

the (Hot Surface Igniter) HSI is energized for a 17--second igniter warm--up period.

c. Trial--for--Ignition Sequence--When the igniter warm--

up period is completed the main gas valve relay contacts GVR--1 and --2 close to energize the gas valve solenoid GV--M,thegasvalveopens,and24 vac power is supplied for a field--installed humidifier at the HUM terminal. The gasvalvesolenoid GV--M permitsgas flowto the burners where it is ignited by the HSI. Five sec after the GVR closes, a 2--sec flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2--sec flame proving period begins. If the furnace control CPU selects high--heat operation, the high--heat gas valve solenoid GV--HI is also energized.

d. Flame--Proving--When the burner flame is proved at the

flame--proving sensor electrode FSE, the inducer motor IDM switches to low--speed unless running at high-speed, and the furnace control CPU begins the blower-ON delay period and continues to hold thegasvalveGV-M open. If the burner flame is not proved within two seconds, the controlCPU willclose the gas valveGV--M, and the control CPU will repeat the ignition sequence for up to three more Trials--For--Ignition before going to Ignition-- Lockout. Lockout will be reset automatically after three hours, by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W/W1, G, R, etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM on high speed until flame is no longer proved.

e. Blower--ON Delay--If the burner flame is proven the

blower-- ON delay for low--heat and high--heat are as follows: Low--Heat--45 seconds after the gas valve GV--M is energized the blower motor (BLWM) is energized at LO HEAT speed. High--Heat--25 secondsafter the gas valve GV--M is energized the BLWM is energized at HI HEAT speed. Simultaneously, the electronic air cleaner (EAC--1) terminal is energized and remains energized as long as the BLWM is energized.

f. SwitchingfromLow--to High--Heat--If the furnacecon-

trol CPU switches from low--heat to high--heat, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high--heat pressure switch relay HPSR is de--energized to close the NC contact. When sufficient pressure is available the high--heat pressure switch HPS closes, and the high--heat gas valve solenoid GV--HI is energized. The blower motor BLWM will switch to HI HEAT speed five seconds after the furnace control CPU switches from low--heat to high--heat.

g. Switching from High-- to Low--Heat--The furnace con-

trol CPU will not switch from high--heat to low-- heat while the thermostat R--to--W circuit is closed when using a single stage thermostat.

h. Blower--OFF Delay--When the thermostat is satisfied, the

R to W circuit is opened, de--energizing the gas valve GV--M,stoppinggas flowto the burners,and de--energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 5--second post--purge period.The blowermotor BLWMand air cleanerterminal EAC--1 will remain energized for 90, 120, 150, or 180 seconds (depending on selection at blower--OFF delay switches). The furnace control CPU is factory--set for a 120--second blower--OFF delay.

2. Two-- Stage Thermostat and Two--Stage Heating (See Fig. 31 for thermostat connections)

NOTE: In this mode the LHT must be ON to select the low--heat only operation mode in response to closing the thermostat R--to--W1 circuit. Closing the thermostat R--to--W1--and--W2 circuits always causes high--heat operation, regardless of the setting of the low--heat--only switch.

The wall thermostat “calls for heat”, closing the R--to--W1 circuit for low--heat or closing the R--to--W1 and--W2 circuits for high-- heat. The furnace control performs a self--check, verifies the low--heat and high--heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high--speed.

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

58CT

Page 52

a. Switching from Low-- to High--Heat--If the thermostat

R--to-- W1 circuit is closed and the R --to--W2 circuit closes, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high--heatpressure switch relay HPSR is de--energized to close the NC contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high--heat gas valve solenoid GV--HI is energized. The blower motor BLWM will switch to HI HEAT speed five seconds after the R-- to--W2 circuit closes.

b. Switching from High-- to Low--Heat--If the thermostat

R--to--W2circuitopens,and theR--to--W1 circuitremains closed, the furnace control CPU will switch the inducer motor IDM speed from high to low. The high--heatpressure switch relay HPSR is energized to open the NC contact and de--energize the high--heat gas valve solenoid GV--HI. When the inducer motor IDM reduces pressure sufficiently, the high--heat pressure switch HPS will open. The gas valve solenoid GV--M will remain ener-

58CT

NOTE: The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to a call for cooling. (See Fig. 33.) When ACRDJ is in place, the furnace control CPU can turn on the air conditioning relay ACR to energize the Y/Y2 terminal and switch the outdoor unit to high--cooling.

The furnace control CPU can start up the cooling unit in either low-- or high--cooling. If starting up in low--cooling, the furnace control CPU determines the low--cooling on--time (from 0 to 20 minutes) which is permitted before switching to high--cooling. If the power is interrupted, the stored history is erased and the furnace control CPU will select low--cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the Y/Y2 terminal and switch the outdoor unit to high--cooling, as long as the thermostat continues to call for cooling. Subsequent selection is based on stored history of the thermostat cycle times. The wall thermostat “calls for cooling”, closing the R--to--G--and--Y circuits. The R--to--Y1 circuit starts the outdoor unit on low--cooling speed, and the R--to--G--and--Y1 circuits

gized as long as the low--heat pressure switch LPS remains closed. The blower motor BLWM will switch to LO HEAT speed five seconds after the R--to--W2 circuit opens.

3. Cooling Mode--The thermostat “calls for cooling.” a. Single--Speed Cooling--

(See Fig. 27 for thermostat connections) The thermostat closes the R--to--G--and--Y circuits. The R--to-- Y circuit starts the outdoor unit, and the R--to-G--and--Y/Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC--1 is energized with 115 vac when the blower motor BLWMis operating.

When the thermostat is satisfied, the R--to--G and--Y circuits are opened. The outdoor unit will stop, and the furnaceblowermotorBLWMwillcontinueoperatingon the COOL speed for an additional 90 seconds. JumperY/Y2 to DHUM to reduce the cooling off--delay to 5 seconds. (See Fig. 24.)

b. Single--Stage Thermostat and Two--Speed Cooling

(Adaptive Mode)

(See Fig. 32 for thermostat connections) This furnace can operate a two-- speed cooling unit with a single--stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low--cooling or high-coolingoperation. This selection is basedupon the stored history of the length of previous cooling period of the single--stage thermostat.

starts the furnace blower motor BLWM at low--cool speed (same speed as LO HEAT). If the furnace control CPU switches from low--cooling to high--cooling, the furnace control CPU will energize the air conditioning relay ACR. When the air conditioning relay ACR is energized the R--to--Y1--and--Y2 circuits switch the outdoor unit to high--cooling speed, and the R--to--G--and--Y1--and--Y/Y2 circuits switch the furnace blower motor BLWM to COOL speed.

NOTE: When transitioning from low--cooling to high--cooling the outdoor unit compressor will shut down for 1 minute while the BLWM continues to run at low--cool speed (same speed as LO--HEAT) until the outdoor unit compressor comes back on at high speed.

The electronic air cleaner terminal EAC-- 1 is energized with 115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R--to--G--and--Y circuit are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC--1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off--delay to 5 seconds. (See Fig. 34.)

c. Two--Stage Thermostat and Two--Speed Cooling (See

Fig. 31 for thermostat connections)

NOTE: The air conditioning relay disable jumper ACRDJ must be disconnected to allow thermostat control of the outdoor unit staging. (See Fig. 33.)

The thermostat closes the R--to-- G--and--Y1 circuits for low--cooling or closes the R--to--G--and--Y1--and--Y2 circuits for high--cooling. The R--to--Y1 circuit starts the outdoor unit on low--cooling speed, and the R-- to--G--and--Y1 circuit starts the furnace blower motor BLWM on low--cool speed (same speed as LO HEAT). The R--to--Y1--and--Y2 circuits start the outdoor unit on high--cooling speed, and the R--to--G--and-- Y/Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC--1 is energized with 115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R--to--G--and--Y1 or R--to--G--and--Y1--and--Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC--1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off--delay to 5 seconds. (See Fig. 33.)

4. Thermidistat Mode (See Fig. 26 -- 28 for Thermidistat connections) The dehumidification output, DHUM on the Thermidistat should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM input is activated, which means 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates in Thermidistat mode. If the DHUM input is low for more than 48 hours, the furnace control reverts back to non--Thermidistat mode. The cooling operation described in item 3. above also applies to operation with a Thermidistat. The exceptions are listed below:

a. Low cooling -- When the R--to--G--and--Y1 circuit is

closed and thereis a demandfor dehumidification,thefurnaceblowermotorBLWM will continue running atlow-cool speed (same speed as LO HEAT).

b. High cooling --When the R--to--G--and-- Y/Y2 circuit is

closed and thereis a demandfor dehumidification,thefurnace blower motor BLWM will drop the blower speed from COOL to HI HEAT for a maximum of 10 minutes before reverting back to COOL speed. If there is still a demand for dehumidification after 20 minutes, the fur-

Page 53

nace control CPU will drop the blower speed back to HI HEAT speed. This alternating 10--minute cycle will continue as long as there is a call for cooling.

c. Cooling off--delay -- When the “call for cooling” is satis-

fiedand thereis a demand for dehumidification, the cooling blower--off delay is decreased from 90 seconds to 5 seconds.

5. Continuous Blower Mode When the R--to--G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous--blower speed (can be set to LO HEAT, HI HEAT, or COOL speed). Factory default is LO HEAT speed. Terminal EAC--1 is energized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will stop during igniter warm--up (17 seconds), ignition (7 seconds), and blower--ON delay (45 seconds in low--heat, and 25 seconds in high--heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower--ON delay period at LO HEAT or HI HEAT speed respectively. The blower motor BLWM will revert to continuous--blower speed after the heating cycle is completed. In high--heat, the furnace control CPU will hold the blower motor BLWM at HI HEAT speed during the selected blower--OFF delay period before reverting to continuous--blower speed. When the thermostat “calls for low--cooling”, the blower motor BLWM will switch to operate at low--cool speed (same speed as LO HEAT). When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on low--cool speed before reverting back to continuous--blower speed. When the thermostat “calls for high--cooling”, the blower motor BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous--blower speed. When the R--to--G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

Continuous Blower Speed Selection from Thermostat

To select different continuous--blower speeds from the room thermostat, momentarily turn off the FAN switch or push button on the room thermostat for 1--3 seconds after the blower motor BLWM is operating. The furnace control CPU will shift the continuous--blower speed from the factory setting of LO HEAT to HI HEAT speed. Momentarily turning off the FAN switch again at the thermostat will shift the continuous--blower speed from HI HEAT to COOL. Repeating the procedure will shift the continuous-blower speed from COOL to LO HEAT speed. The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption.

NOTE: If the blower--off delay is set to the maximum, the adjustable continuous--fan feature is locked (i.e., fan speed cannot be changed from its current setting).

6. Heat Pump (See Fig. 27 through 30 for thermostat connections) When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the R--to-- W/W1--and--Y1 or R--to--W/W1--and--Y1--and--G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at low--cool speed (same speed as LO HEAT), and begin a low--heat cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at LO HEAT speed. When the W/W1 input signal disappears, the furnace control begins a normal inducer post--purge period and the blower remains running at LO HEAT speed. If the R--to-- W/W1--and-- Y1-- and--G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower-- OFF delay period. If the R--to--W/W1--and--Y1 signals disappear, leaving the G signal, the blower motor BLWM will remain on for the selected blower--OFF delay period then switch to continuous--blower speed. When the R--to--W/W1--and --Y/Y2, R --to--W/W1--and-Y / Y 2 -- a n d -- G , R -- t o -- W / W 1 -- a n d -- Y 1 -- a n d -- Y / Y 2 , o r R--to--W/W1--and-- Y1--and--Y/Y2--and--G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at COOL speed, and begin a high--heat cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HI HEAT speed. When the W/W1 input signal disappears, the furnace control begins a normal inducer post--purge period and the blower switches to COOL speed after a 3 second delay. If t h e R -- t o -- W / W 1 -- a n d -- Y / Y 2 -- a n d -- G o r R -- t o -- W / W 1 -- a n d

--Y1--and-- Y/Y2--and--G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower--OFF delay period. If the R--to--W/W1-a n d -- Y / Y 2 o r R -- t o -- W / W 1 -- a n d -- Y 1 -- a n d -- Y / Y 2 s i g n a l s disappear, leaving the G signal, the blower motor BLWM will remain on for the selected blower-- OFF delay period then switch to continuous--blower speed.

Step 4 — Wiring Diagrams

Refer to wiring diagram, Fig. 57.

Step 5 — Troubleshooting

Refer to the service label. (See Fig. 56—Service Label.) The Troubleshooting Guide can be a useful tool in isolating furnace operation problems. Beginning with the word “Start,” answer each question and follow the appropriate arrow to the next item.

The Guide will help to identify the problem or failed component. After replacing any component, verify correct operation sequence.

58CT

Page 54

k to START.

lem repeat when using a

connect the Com24V thermostat terminal to

furnace control. Either install a ballast resistor,

jumper wire?

Does the prob

YES

The thermostat is not compatible with the

the thermostat, or replace the thermostat.

Is door switch closed?

Is circuit breaker closed?

YES

breaker to furnace.

Check for continuity in wire from circuit

er and go bac

Close circuit break

interconnecting cable.

Check room thermostat or

thermostat terminals on the furnace control?

Is 24V present at W/W1, W2, Y1, Y/Y2 or G

YES

furnace control.

Disconnect all the thermostat wires from the

58CT

Is there 115V going to switch?

YES

Replace door switch.

YES

Replace furnace control.

erased whenever (115V or 24V) is interrupted.

LED boards stored status codes can also be

codes are erased after 72 hours. On RED

or cooling cycle to check operation. Status

Y/Y2, and G (24V) thermostat signals?

Replace transformer.

Does the control respond to W/W1, W2, Y1,

Run system through a low-heat, high-heat,

YES

Is door switch closed?

YES

TROUBLESHOOTING GUIDE

Is there 115V at L1 and L2?

YES

START

Is LED status light on?

YES

Is there 24V at SEC-1 and SEC-2?

Replace furnace control.

switched to low-speed for 10 seconds.

not be turned on. When the blower motor is turned OFF the inducer will be

COOL speed will run for 10 – 15 seconds each. Gas valve and humidifier will

component test. The HSI, blower motor LO HEAT speed, HI HEAT speed, and

the control will turn ON at HI HEAT speed. The inducer will run for the entire

4 times, the control will start the component test sequence. Once indicated

long flash) if there was no previous fault. After the control repeats the code

flash the status code of the previous fault or status code #11 (1 short and 1

TEST/TWIN terminal to Com24V terminal until the LED goes out. LED will

You can also recall the previous status code by momentarily shorting the

not remove power or blower access panel before initiating status code recall.

draft safeguard switch to display stored status code. On RED LED control do

To recall status code briefly remove and reconnect one RED wire from the

voltage (24V) transformer phasing.

units are twinned, check for proper low-

Check for correct line voltage polarity. If

mined

YES

f short flashes and the second

digit by the number of long flashes?

by the number o

2 digit number with the first digit deter

with a combination of short and long flashes?

Is LED status light blinking ON/OFF slowly

Determine status code. The status code is a

YES

without a pause?

Is LED status light blinking rapidly

Fig. 61 -- Troubleshooting Guide -- 2--Speed

than #11?

Was there a previous status code other

YES

or the status code that

was flashed.

Go to section below f

A02107A

Page 55

Reset power to clear lockout. Replace

- Software check error.

- Gas valve relay stuck open.

- Flame circuit failure.

reset after 1 hour lockout due to:

45 CONTROL CIRCUITRY LOCKOUT Auto-

WHILE HIGH-HEAT PRESSURE

43 LOW-HEAT PRESSURE SWITCH OPEN

- Disconnected or obstructed pressure

- Low-heat pressure switch stuck open.

SWITCH IS CLOSED - Check for:

control if code repeats.

tube.

- Low inlet gas pressure (if LGPS used).

- Miswired pressure switches.

Replace defective component.

Check for continuity in the harness and igniter.

Replace furnace control.

YES

present for the 15 second period?

NEUTRAL-L2 on the control. Was 115V

Check for 115V between pin 1 and

initiate another component test sequence.

Unplug igniter harness from control and

Check for:

Replace valve.

Check that all gas valves are turned on.

Check connections. If OK, replace control.

YES

valve receive 24V?

across gas valve connections. Does gas

thermostat to call for heat. Connect voltmeter

Reconnect the R thermostat lead and set

ignition.

- Low inlet gas pressure.

- Inadequate flame carryover or rough

YES

Does gas valve open and allow gas to flow?

(.045” nominal)

- Blocked or incorrect carry- over gap.

- Proper firing rate.

ners ignite?

Do the main bur

ow blower to come on and repeat test to

check for intermittent operation.

All

YES

Do the main burners stay on?

burners will not stay on, repeat check in high-

near typical value (4.0-6.0 nominal) and

Check connections and retry. If current is

DC microamps below 0.5?

current during trial for ignition period. Is the

Repeat call for heat and check flame sensor

If burners operate in high-heat then

sensor location.

If OK, check burner carryover and flame

switch to low-heat, check manifold pressure.

control.

heat. If burners will still not stay on replace

YES

6.0 microamps.

recheck current. Nominal current is 4.0 to

Clean flame sensor with fine steel wool and

Replace electrode.

Is current near typical value?

YES

Replace furnace control.

Will main burners ignite and stay on?

58CT

YES

Fixed.

NOT CLOSE OR REOPENED – If open

32 LOW-HEAT PRESSURE SWITCH DID

low-heat, high-heat, or cooling cycle to

is interrupted. Run system through a

erased whenever power (115V or 24V)

boards stored status codes can also be

are erased after 72 hours. On RED LED

11 NO PREVIOUS CODE – Stored codes

- Low inducer voltage (115V).

check system.

- Inadequate combustion air supply.

Blower runs for the selected blower off-

(115V OR 24V) – Normal operation.

12 BLOWER ON AFTER POWER UP –

- Disconnected or obstructed pressure

- Low inlet gas pressure (if LGPS used).

- Proper vent sizing.

delay. Check for:

will come on for the selected blower off-

during blower on-delay period, blower

for 15 minutes before retry. If opens

longer than 5 minutes, inducer shuts off

tubing.

- Restricted vent.

- Excessive wind.

- Defective pressure switch.

- Defective inducer motor.

33 LIMIT CIRCUIT FAULT – Indicates the

period.

W/W1 opens) during the blower on-delay

for heat (R-W/W1 closed) or when (R-

delay, if unit is powered up during a call

13 LIMIT CIRCUIT LOCKOUT – Lockout

Flame

ower shuts off

ower will run for 4 minutes or until

witch remakes whichever is longer.

rollout switch and BVSS requires manual

to flash until b

than 3 min. status code #33 continues

changes to lockout #13. If open less

If open longer than 3 minutes, code

open s

open.

blocked vent shutoff switch* (if used) is

limit, draft safeguard, flame rollout, or

Control wi ll

3 minutes.

ignite gas and prove flame in 4 attempts.

auto-reset after 3 hours. See code 33.

is open longer than

rollout, or blocked vent switch* (if used)

occurs if the limit, draft safeguard, flame

14 IGNITION LOCKOUT – System failed to

: or

k f

ower wheel.

Chec

- Dirty filter or restricted duct system.

reset.

- Defective switch or connections.

- Loose bl

status code 34.

Control will auto-reset after 3 hours. See

ower motor or capacitor.

(flame rollout switch open).

- Defective bl

- Inadequate combustion air supply

wer and wait 5 minutes to retry.

- Stuck closed gas valve relay on

Check for:

21 GAS HEATING LOCKOUT – Turn off

estricted vent.

-R

- Proper vent sizing.

control.

- Miswire or short to gas valve wire.

- Excessive wind.

xt step.

ollowing items first before

If flame signal is lost during

as valve turned off.

-G

proceeding to the ne

Check the f

come on for the selected blower off-delay.

the blower on-delay period, blower will

#14 occurs.

sequence 3 more times before lockout

period, the control will repeat the ignition

is not sensed during the trial for ignition

34 IGNITION PROVING FAILURE – If flame

ved while gas valve is de-

Check for:

cleared.

energized. Inducer will run until fault is

Flame is pro

22 ABNORMAL FLAME-PROVING SIGNAL

alve.

- Stuck open or leaky gas v

- Obstructed pressure tube.

Check for:

23 PRESSURE SWITCH DID NOT OPEN

- Manual shut-off valve.

- Pressure switch stuck closed.

YES

to furnace sheet metal.

the system can be operated in the

the gas valve, igniter, or flame sensor

To determine whether the problem is in

- Flame sensor must not be grounded.

- Green/Yellow wire MUST be connected

k for:

- Short circuit in secondary voltage

OPEN Chec

24 SECONDARY VOLTAGE FUSE IS

igniter glow orange/white by the end of

component test sequence. Does the

from the control and initiate the

First remove the R thermostat connection

component test mode to check the igniter.

to isolate short circuit.

leads. Disconnect thermostat leads

(24V) wiring including thermostat

the 15 second warm-up period?

* Blocked vent shutoff switch used in Chimney Adapter Kit

wired.

ontrol relay may be defective.

- See status code 32.

- Gas valve is mis

-C

REOPENED - Check for:

RELAY DID NOT CLOSE OR

31 HIGH-HEAT PRESSURE SWITCH OR

A05001

Page 56

58CT

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

Printed in U.S.A. Edition Date: 11/08

Catalog No:58CT---10SI

Replaces:58CT--9SI