Carrier 58DP User Manual

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Page 1

58DP,DR

HEATING A COOLING

Downflow Gas-Fired Natural-Draft Furnaces

Installation, Start-Up and Service

Instructions

NOTE: Read the entire instructions before starting the

installation.

NOTE: The Energy Guide tag can be removed from the fur

nace when the installation is complete.

INTRODUCTION

Before installing the furnace, refer to “Procedures for Natural-Draft Gas-Fired Furnaces” (packaged with the

equipment) for information concerning combustion, venting, piping, and other standard installation practices. Further reference is made to the current edition of the National Fuel

Gas Code NFPA No. 54, T1A-54-1984-1/ANSI Z223.1-1984, Z223.1a-1987.

Each furnace is shipped from the factory completely assem bled with multispeed direct-drive blower and wired ready for downflow indoor heating installation only. AU sizes feature a printed-circuit board control center with easy-to-read, lowvoltage terminal strip to ensure proper connections.

A CAUTION

Do not install furnace in a damp, corrosive, or contami nated atmosphere. Make sure all combustion and circu lating air requirements listed in “Procedures for Natural-Draft Gas-Fired Furnaces” are adhered to, in addition to all local codes and ordinances.

Do not use this furnace during construction when adhe sives, sealers and/or new carpets are being installèd. If the furnace is required during construction, use clean outside air for combustion and ventilation. Compoxmds of chlorine and fluorine when burned with combustion air form acids which will cause corrosion of the heat

exchangers and metal vent system. Some of these com pounds are paneling and dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction process.

The design of the downflow gas-flred furnace is A.G.A. cer tified for installation on noncombustible flooring. The fur nace may be installed on combustible flooring when installed with the accessory floor base. This furnace is for installation in alcoves, basements, closets, or utility rooms. This furnace line is not A.G.A. design certified for installa tion in a mobile home, recreation vehicle, or outdoors.

Installation comprises the following:

*1. Inspection

*11. Location, Ventilation, and Air for Combustion

*III. Gas Piping

*IV. Venting

V. Supply-Air Plenum Installation

VI. Electrical

EFFICIENCY RATING CERTIFIED

Sizes 050 075 thru 150 Sides—Single-Wall Vent 1 1

Back 0 0 Top of Plenum Vent Connector—Single-Wall 6 6

Front-Combustion Air* * 6 6

*The 6-inch front clearance is needed for combustion-air entry and

drafthood reiief.

ama

Fig. 1—Model 58DP

Table 1—Clearances (In Inches)

Type-BI Double-Wall Vent 0 1

1 1

Type-B1 Double-Wall 1 1

Service 30 30

A78593

VII. Sequence of Operation

VIII. Filter

IX. Startup and Adjustment

X. Care and Maintenance

*To perform these sections (or installation steps), refer to the appropriate sections of “Procedures for Natural-Draft Gas-Fired Furnaces” booklet packaged with this unit.

For accessory installation details, refer to the applicable

installation literature.

V. SUPPLY-AIR PLENUM INSTALLATION A. Installation on a concrete slab

1. See Fig. 2 for dimensions and location of supply-air

opening in furnace bottom.

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

'' I ^ PC 101 Cataiog No. 535-871 Printed in U.S.A. Form 58DP,DR-2SI 11/87

Tab I6al8a

Pgl

Repiaces: 58DP,DR-1Si

Page 2

Table 2—Dimensions (in Inches)

Size Vent 050-BA 075-AA 075-BA 100-AA 17’¿ 100-BA 125-AA 21 125-BA 150-BA

14^16 12^,6

M'h M'k

177^

24’¿

15%

157s 15% 15%

19% 19%

22'%s

12-’-’/i6

16 4 16 4 16 5

16 19% 5 19%

Fig. 2—Dimensionai Drawing

Table 3—Ratings and Performance*

Size

050-BA 075-AA 075-BA 100-AA 100-BA 125-AA 125-AA 150-BA

*The above ratings are certified for aititudes to 2000 ft. For elevators above 2000 ft, reduce ratings 4% for each 1000 ft above sea level. Refer to'

National Fuel Gas Code Table F4. fDetermined by U.S. Government tests. ijrDeduct 1000 Btuh for Model 58DR.

Input Btuh

50,000 39,000f 75,000 58,000

100,000 78,000t

125,000 97,000f

150,000

Capacity

Btuht

116,000f

Temp

Rise

Range

45—75 0.50 70—100 0.12 45—75 0.50 895 70—100 0.20 850 60—90 0.50 70—100 0.20 60—90 55—85 0.50 1535

Ext Static

Pressure

0.50

Heating

CFM

Ext Static

600 0.5 800 %-SP 630

960 0.5 1630 %-PSC 1050 1195 0.5 1620 'k-PSC 187

Cooling Motor

Pressure

— —

0.5 1255 %-SP 157

— —

0.5 2075 %-PSC

CFM

—

HP&

Type

7io-SP

%-SP

'h-SP

2. Construct hole in floor per dimensions in Fig. 3 and

Table 4.

3. Place plenum and furnace as shown in Fig. 4.

B. Installation on a combustible floor

1. Read Installation Instructions packaged with acces sory combustible floor base.

2. Cut and frame hole in floor per dimensions hsted in Installation Instructions packaged with combustible floor base. If this requires cutting of a floor joist, tie ends of cut joist into adjacent joists so that proper floor support win be maintained.

3. Assemble and install combustible floor base per

instructions packaged with base.

4. When completed, combustible floor base, plenum, and furnace (or coü casing when used) should be installed as shown in Fig. 6.

A73382

5 6

Approx

Shipping

Weight

129 148

163 170 187

227

Fig. 3—Floor Opening for

Concrete Slab

Table 4—Opening Dimensions

Furnace Casing

Width 14%6

17%

24%

♦These dimensions apply when a Model 28RC or RD Evaporator Coil

casing is to be installed.

A B

13% 19%

16%6

19% 19%

23%6

Heat-Only Heat/Cool*

19%

19%6 19%s 19%6 19%6

—2—

Page 3

Fig. 5—Combustible Floor Base

A WARNING

The cabinet must have an uninterrupted or unbroken ground according to National Electrical Code, ANSI/ NFPA 70-1987, or local codes to minimize personal

injury if an electrical fault should occur. This may con sist of electrical wire or conduit approved for electrical ground when installed in accordance with existing elec trical codes. Do not use gas piping as an electrical ground. A failure to adhere to this warning can result in an electrical shock, fire, or death.

If line-voltage wiring to the unit is encased in a nonmetallic sheath, connect the incoming ground wire to the grounding wire inside the furnace J-box. If metallic conduit is used, it will serve as the ground.

B. Low-Voltage Wiring

Make field low-voltage connections at the low-voltage termi nal strip. See Fig. 9.

NOTE: Use AWG No. 18 “color-coded” copper thermostat

wire for lengths up to 100 ft. Above 100 ft, use AWG No. 16 wire.

Fig. 6—Furnace, Plenum, and

Base Installed on a Combustible Floor

VI. ELECTRICAL CONNECTIONS A. Line-Voltage Wiring

NOTE: Refer to “Procedures for Natural-Draft Gas Fur

naces” (packaged with the equipment) for additional information.

A CAUTION

Do not connect aluminum wire between disconnect switch and furnace.

See Fig. 9 for wiring diagram showing the proper field high-

and low-voltage wiring. Use a separate fused branch electrical circuit containing a

properly sized fuse or HACR-type circuit breaker for this furnace. A disconnecting means must be located within sight from, and readily accessible to, the furnace. In some areas, the unit door switch may qualify as the disconnecting means.

Fig. 7—Amp Draw Check With Ammeter

mSm

A79077

Fig, 8—Printed-Circuit Control Center

—3—

A78461.

Page 4

Fig. 5—Combustibie Floor Base

A WARNING

The cabinet must have an uninterrupted or unbroken ground according to National Electrical Code, ANSI/ NFPA 70-1987, or local codes to minirnize personal injury if an electrical fault should occur. This may con sist of electrical wire or conduit approved for electrical ground when installed in accordance with existing elec trical codes. Do not use gas piping as an electrical

ground. A failure to adhere to this warning can result in an electrical shock, fire, or death.

If line-voltage wiring to the unit is encased in a nonmetaUic sheath, connect the incoming ground wire to the grounding wire inside the furnace J-box. If metallic conduit is used, it will serve as the ground.

B. Low-Voltage Wiring

Make field low-voltage connections at the low-voltage termi nal strip. See Fig. 9.

NOTE; Use AWG No. 18 “color-coded” copper thermostat

wire for lengths up to 100 ft. Above 100 ft, use AWG No. 16

wire.

Fig. 6—Furnace, Plenum, and

Base Installed on a Combustible Floor

VI. ELECTRICAL CONNECTIONS A. Line-Voltage Wiring

NOTE; Refer to “Procedures for Natural-Draft Gas Fur

naces” (packaged with the equipment) for additional information.

A CAUTION

Do not connect aluminum wire between disconnect switch and furnace.

See Fig. 9 for wiring diagram showing the proper field highand low-voltage wiring.

Use a separate fused branch electrical circuit containing a properly sized fuse or HACR-t5q)e circuit breaker for this furnace. A disconnecting means must be located within

sight from, and readily accessible to, the furnace. In some

areas, the unit door switch may qualify as the disconnecting means.

Fig. 7—Amp Draw Check With Ammeter

A79077

Fig. 8—PrInted-CIrcult Control Center

—3-

A78461.

Page 5

TRAN

FUSED DISCONNECT SWITCH

SWITCH (WHEN REQ'D) /

FU2

PR1

GRN ^ CRNGRN

AUX. J-BOX

COM.

HIGH

MED HIGH

BRN

GAP

(WHEN USED)

BREAKAWAY TAB REMOVED WHEN CONNECTING VENT DAMPER (SEE INSTALLATION INSTRUCTIONS)

NOTES:

* DOWNFLOW FURNACES ONLY

1- I--rm HEATING FAN RELAY OONTACT IS

' HFR APPLIED TO FURNACE.

2. TO CHANGE MOTOR SPEED, MOVE RED WIRE TO DESIRED SPEED SETTING.

3. IF ANY OF ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH AWM (105°C) WIRE OR ITS EQUIVALENT.

4. MOTOR IS THERMALLY OVERLOAD’PROTECTED.

5. FACTORY SPEED SELECTION IS FOR AVERAGE CONDITIONS, SEE INSTALLATION INSTRUCTIONS FOR OPTIMUM SPEED SELECTION. MOTOR MAY BE 3 OR 4 SPEED.

6. SYMBOLS ARE ELECT. REPRESENTATION ONLY.

7. FACTORY CONNECTED WHEN ACCESSORY NOT USED.

LEGEND AL3 AUXILIARY LIMIT SWITCH, MANUAL-RESET

CAP RUN CAPACITOR CFR COOLING FAN RELAY CDPDT FL FUSIBLE LINK FU1 FUSE IN LINE 2 AMP FU2 FIELD FUSE GV GAS VALVE HFR HEATING FAN RELAY (SPST-NC)

ILK SWITCH^ BLOW. DOOR INTERLOCK (SPST-NO) LOD LOCKOUt TIMER DEVICE (SPST-NO) LS LIMIT SWITCH^ AUTO.-RESET (SPST-NC) MTR MOTOR, BLOWER PCB PRINTED CIRCUIT BOARD PI PILOT IGNITER SP SAFETY PILOT (FLAME SENSING) TRAN TRANSFORMER VSSS VENT SAFETY SHUTOFF SWITCH, MANUAL-

FIELD SPLICE PLUG RECEPTACLE JUNCTION UNMARKED TERMINAL

— TERMINAL PCB FACTORY CONN.

------- FACTORY WIRING (120V AC)

------- FACTORY WIRING (LOW VOLTAGE)

---- FIELD WIRING (120V AC)

------

FIELD WIRING (24V AC)

== CONDUCTOR ON PRINTED CIRCUIT BOARD

MED LOW

LOW

MTR

NORMALLY CLOSED UNTIL 115V AC IS

(SPST-NC)

RESET (SPST-NC)

BLK

WHT

WHT BLK

RED

C Y Gr 6h/ V R W

0 0 0 0 0 0

BLK

WHT

CFR

TO THERMOSTAT

ILK

LINE

HFR

HFR CFR

(WHEN USED)

RED

BLU RED

1 r

SEC-2 SEC-1

LIM-2 LIM-1

GAS-2

GAS-3 GAS-1

LIM-1 SEC-1 FU1

-1^ k-

0 SCREW TERMINAL FOR FIELD WIRING

FIELD GROUND

/-fy EQUIP. GROUND

SEE NOTE

YEL

LOD-

(WHEN USED)

ELECTRONIC

AIR CLEANER

(WHEN USED)

EAC-1

120V AC

t' 't

19 7|

-1

i !

t T

Ttt

310586-402 REV. C

EAC-2

___

PI i

LINE-2

CAP

SEC-2

BRN

COM.

Fig. 10—Wiring Diagram (liD Piiot)

-4-

A87405

Page 6

FUSED DISCONNECT

SWITCH CWHEN REQ'D)

ILK SWITCH

BLK

TRAN CWHEN USEDD

BRN

CAP

CWHEN USED)

NOTES:

DOWNFLOW FURNACES ONLY

1 .

HFR ■ APPLIED TO FURNACE.

TO CHANGE MOTOR SPEED, MOVE BLK OR RED WIRE TO DESIRED SPEED SETTING.

IF ANY OF ORIGINAL WIRE AS SUPPLIED WITH

3. THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH AWM C105”C) WIRE OR ITS EQUIVALENT. MOTOR IS THERMALLY OVERLOAD PROTECTED.

FACTORY SPEED SELECTION IS FOR AVERAGE CONDITIONS, SEE INSTALLATION INSTRUCTIONS FOR OPTIMUM SPEED SELECTION. MOTOR MAY BE 3 OR 4 SPEED.

SYMBOLS ARE AN ELECTRICAL REPRESENTATION ONLY.

LEGEND

ALS AUXILIARY LIMIT SWITCH, MANUAL-RESET CAP RUN CAPACITOR

CFR COOLING FAN RELAY (DPDT) FL FUSIBLE LINK FUl FUSE IN LINE 2 AMP FU2 FIELD FUSE 6V GAS VALVE HFR HEATING FAN RELAY CSPST-NC)

ILK SWITCH, BLOWER DOOR INTERLOCK CSPST-NO) LS LIMIT SWITCH, AUTOMATIC-RESET CSPST-NC) MTR MOTOR, BLOWER PCB PRINTED CIRCUIT BOARD TRAN TRANSFORMER VSSS VENT SAFETY SHUTOFF SWITCH, MANUAL-RESET

— TERMINAL PCB FACTORY CONN.

----

---== CONDUCTOR ON PRINTED CIRCUIT BOARD

HEATING FAN RELAY CONTACT IS NORMALLY CLOSED UNTIL 115V AC

CSPST-NC)

FIELD SPLICE PLUG RECEPTACLE JUNCTION MARKED TERMINAL UNMARKED TERMINAL

FACTORY WIRING Cl 20V AC)

FACTORY WIRING CLOW VOLTAGE)

FIELD WIRING C120V AC)

0 SCREW TERMINAL FOR FIELD WIRING

^ FIELD GROUND

ffj EQUIP. GROUND

TO THERMOSTAT

JUMPER REMOVED r WITH BREAKAWAY TAB

HFR CFR

LIM-1 SEC-1 FUI

.0YY

VENT DAMPER

CWHEN USED)

ELECTRONIC

AIR CLEANER

CWHEN USED)

PR-1

CWHEN USED) TRAN

TIME

DELAY

CIRCUIT

GAS-3

310471-402 REV. B

SIGNALht

BREAKAWAY TAB REMOVED WHEN CONNECTING VENT DAMPER CSEE

INSTALLATION INSTRUCTIONS)

NE-2 ^

CAP

;)

COM.

---

r?\

----------

^EAC-2

AC ■

■PR-2

■SEC-2

GAS-2

Fig. 11—Wiring Diagram (Match-iit Piiot)

—5—

A87406

Page 7

IMPORTANT: The thermostat heat anticipation must be set

to match the amp draw of the gas valve and electrical com ponents in the R-W circuit. Accurate amp draw readings can be obtained at thermostat subbase terminals R & W. Fig. 7 illustrates an easy method for obtaining the actual amp draw.

The room thermostat should be located where it wiU be in the natural circulation path of room air. Avoid locations where the thermostat would be exposed to cold-air infiltra tion, drafts from windows, doors, or other openings leading to the outside, or exposure to air currents from warm- or cold-air registers; or to exposure where the natural circula

tion of the air is cut off—such as behind doors, above or below mantels, shelves, etc.

The thermostat should not be exposed to heat from nearby fireplaces, radios, televisions, lamps, or rays from the sun. Nor should the thermostat be mounted on a wall containing pipes or warm-air ducts, or a flue or vent that could affect its operation and prevent it from properly controlling the room temperature. Any hole in the plaster or panel through which the wires pass from the thermostat should be ade quately sealed with suitable material to prevent drafts from affecting the therniostat.

C. Blower Control Center

Each furnace features a printed-circuit control center. This will aid the installer and serviceman when installing and servicing the unit. See Fig. 8. A low-voltage terminal board is marked for easy connection of field wiring.

VII. SEQUENCE OF OPERATION

NOTE: The wiring diagrams shown in Figs. 10 and 11 cover

heating/coohng units.

A. Heating

Gas and electrical supplies must be turned on at the furnace.

NOTE: When power is apphed to heat relay cofl. HFR in the

control circuit, the normally closed contacts in the blower circuit will open.

1. White Rodgers 36E Gas Valve piD Models). See Fig. 10.

When the thermostat “calls for heat,” the control circuit is closed between terminals R and W. Power from transformer TRAN through fusible link FL, hmit switches LS & ALS and vent safety shut-off switch VSSS, energizes the pilot valve part of automatic gas valve GV and pilot igniter PI. The pilot valve opens, permitting gas flow to the pilot burner where it is ignited.

The pilot valve portion of automatic gas valve GV has a “pick” solenoid coil and latching “hold” device. The “pick” coU must be energized to open the pilot valve, but only the “hold” device must be energized to keep it open.

The “hold” device varies with the gas valve design used on

the furnace. It could be an internal pressure switch in series with the “pick” solenoid coil, an raternsil electrical resistor in series with the solenoid “pick” coil, or a separate electriceil solenoid coU.

When the pilot flame is estabhshed, safety pilot SP switches its contacts in approximately 40 to 60 seconds, energizing the main valve portion of gas valve GV and deenergizing safety pilot igniter SP and the “pick” coil of the pilot sole noid portion in gas valve GV. The pilot valve is held open by the “hold” device within gas valve GV.

The main valve portion of gas valve GV has a delayed open ing operator that opens within 6 to 15 seconds after it is energized, permitting gas flow to the main burners where the gas is ignited by pilot SP.

2. Honeywell VR 800A Gas Valve (Match-Lit Models). See Fig. 11

The furnace pilot must be ht to energize the thermal magnet

circuit of gas valve GV, thus permitting gas flow to the remaining portion of the valve.

When the thermostat “calls for heat,” the control circuit is closed between terminals R and W. Power from transformer TRAN through fusible linkn FL, limit switch LS & ALS and vent safety shutoff switch VSSS energizes gas valve GV, causing the valve to open and permitting gas flow to the

main burners, where it is ignited by the pilot.

3. Blower Circuit

With power through the solid-state time-delay circuit on printed-circuit board PCB and heat relay HFR, blower motor MTR is energized on heating speed approximately 75

seconds after gas valve GV has been energized (or the pilot

flame has been proven in the case of IID systems).

4. Limit Control

If the furnace overheats for any reason, hmit control LS switches, breaking the circuit to automatic gas valve GV. The gas valve closes immediately, stopping gas flow to the main burners and the pilot. In addition, Iplower motor MTR continues to operate because heat relay HFR is deenergized to cool down the furnace.

Manual reset auxffiary limit switch ALS is located on the top right-hand corner of the furnace. In the event of blower motor failure, this switch breaks the electrical circuit to the gas valve, stopping gas flow to the main burners. The switch must be manuahy reset after the blower motor has been replace.

Fusible link FL is provided in the transformer TRAN sec

ondary circuit as protection from overheating conditions in the vestibule area of the furnace. Should this condition exist, the fuse opens and deenergizes gas valve GV and heat relay HFR, stopping the gas flow to the burners and start ing blower motor MTR.

When the thermostat is satisfied, the circuit between R and W is broken, deenergizing automatic gas valve GV, pilot SP (when used), and the solid-state time-delay circuit on printed-circuit board. The gas flow stops immediately to the

pilot and main burners with the IID controls, and to the

main burners only with standing pilot controls. After approximately 105 seconds, heat relay HFR is energized and blower motor MTR stops.

5. Vent Safety Shut-off System Switch

The purpose of this control is to safely shutdown the fur nace if a blocked vent condition occurs.

During a blocked vent condition, temperature in the drafthood opening will rise causing vent safety shut-off switch to open, breaking the circuit to gas valve GV. The

gas valve closes immediately, stopping gas flow to the main burners and pilot, and the blower will run continuously.

The furnace will remain in this mode until the vent safety

shut-off system switch is manually reset.

B. Vent Damper (When Used)

With gas and electrical power supphed to the furnace, the vent damper motor is deenergized, and the vent damper is closed until the thermostat “calls for heat.”

On a “call for heat” by the thermostat, the vent damper motor is energized and the damper opens. When the vent damper reaches the full-open position, the damper motor is deenergized and a circuit is completed to the main gas valve via the pilot. At this time, the main gas valve is energized and the main burners are ignited; the vent damper will

—6—

Page 8

remain open until the thermostat is satisfied. When the thermostat is satisfied, it will deenergize the main

gas valve and stop the gas flow. The vent damper motor will energize and close the damper. When the vent damper reaches the full-closed position, the damper motor is deenergized and will remain so until the next “call for heat” by the thermostat.

C. Cooling (Cooling Models Only)

When the thermostat “calls for cooHng,” power from trans former TRAN energizes the condensing unit contactor, cool ing relay coil CFR, closing its contacts and energizing blower motor MTR on its cooling speed. It continues to operate until the thermostat is satisfied.

When the thermostat is satisfied, the circuit to terminal Gc is broken, deenergizing cooling relay coil CFR which, in turn, opens its contacts, stopping blower motor MTR.

VIII. FILTER ARRANGEMENT

The two factory-supplied filters are shipped in the blower compartment. After the return-air duct has been connected to the furnace, install the filters in a V-formation inside the retum-air plenum. See Fig. 12.

WARNING

Never operate the unit without a filter or with the filter

access door removed. A failure to adhere to this warn

ing can cause a fire, physical injury, or death.

NOTE: The gas valve regulator has been nominally-set at

3.5 in. wc for natural gas. Refer to “Procedures for NaturalDraft Gas Furnace Installation” for readjusting when checking input.

A. Adjustment of Blower Speed

A WARNING

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

To change motor speed taps, remove the motor tap lead (See Table 5.) and relocate it on the desired terminal on the plug

in terminal block/speed selector located on the blower.

A CAUTION

When adjusting the blower speed, make certain that the temperature rise across the heat exchanger does not exceed that specified on the rating plate.

Table 5—Speed Selector

Speed

Common C

Med-Hi 2

Med-Low 3

Low 4

♦Furnaces without a cooling fan relay are equipped with a 3-speed

motor.

fWhite wire from control box to common; black wire from control box

to cooling speed selection (when used); red wire from control box to heating speed selection.

Tap No.*t

A78654

Fig. 12—Position of Filters

IX. STARTUP AND ADJUSTMENT

In addition to the following information, refer to “Proce dures for Natural-Draft Gas-Fired Furnaces” packaged with the unit.

NOTE: There is a switch located in the blower compartment

that breaks the electrical power supply when the blower access door is removed. Be sure the blower access door is properly installed.

CAUTION

This furnace is equipped with a fusible link in the vesti

bule area that wQl melt if an overheating condition caused by an inadequate combustion-air supply or improper venting practices develops. Do not jumper this fuse. Correct the condition and replace the fuse with an identical part.

The gas service pressure must not exceed 0.5 psig (14

in. wc).

B. Automatic Gas Control Valve

These units are equipped with an automatic gas control valve. If not already checked when lighting the main burner, check the proper operation of this valve by moving the room thermostat pointer above and below room temper ature and observing that the meiin burners light on “call for heat” and go off when the pointer is moved below room tem perature setting.

NOTE: For ease of adjusting the pilot flame, disconnect ter

minal No. 1 at the gas valve. This will prevent main burner ignition and allow time to adjust the pilot. Reconnect the power lead after adjustment.

X. CARE AND MAINTENANCE

A CAUTION

Because of possible damage to the equipment or per sonal- injury, maintenance should be performed by qual ified persons only.

A WARNING

Never store anything on, or in contact with, the fur nace, such as:

1. Spray or aerosol cans, rags, brooms, dust mops,

vacuum cleaners, or other cleaning tools.

2. Soap powders, bleaches, weixes 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.

A failure to adhere to this warning can cause corrosion of the heat exchanger and vent system, fire, personal injmy, or death.

-7—

Page 9

MANUAL ON/OFF

ULATOR USTMENT

MANUALON/OFF

REGULATOR ADJUSTMENT

'rm

í/

A78568

Fig. 13—Honeywell Model VR 800A

For continuing high performance, and to niinhnize possible equipment failure, it is essential that periodic maintenance be performed on this equipment. Consult your local Dealer

as to the proper frequency of maintenance and the availabil ity of a maintenance contract.

The abihty to properly perform maintenance on this equip ment requires certain mechanical skills and tools. If you do not possess these, contact your Dealer for maintenance.

WARNING

Turn off the gas and electrical supplies to the unit before performing any medntenance or service it. FoUow the rehghting instructions on the label attached to the furnace. A failure to adhere to this warning can cause personal injury.

The minimum maintenance that should be performed on the equipment is as follows:

1. Check and clean or replace air filter each month or as

required.

2. Check blower motor and wheel for cleanliness and lubri

cation each heating and cooUng season. Clean and lubricate as necessary.

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

A WARNING

PILOT TUBE CONNECTOR

MANIFOLD PRESSURE TAP A87230

Fig. 14—White Rodgers Model 36E

4. Some furnaces are equipped with permanent, washable

filters. Clean those filters as follows:

a. Clean with tap water.

b. Rinse and let dry. No oiling or coating of filters is

required.

c. Reinstall filters with cross-hatch binding facing

blower.

B. Blower Motor Wheel

Clean and lubricate as follows:

1. Remove upper access panel.

2. Loosen screw in vent pipe enclosure front and remove vent enclosure front by sliding forward (toward front of unit).

3. Disconnect vent pipe at first joint above unit and swing vent pipe assembly to side, supported by suit able means (block of wood, etc.).

4. Shde vent pipe upward through rectangular opening in top plate and remove vent pipe from furnace.

5. Remove four screws in vent pipe enclosure back, and

remove enclosure back by tilting top toward blower and sliding bottom toward front of furnace.

6. Disconnect electrical leads from right side of motor

speed selector. Note location of wires for reassembly.

7. Remove screws holding blower assembly against

blower deck and shde blower assembly out of furnace.

8. Squeeze side tabs of motor speed selector and puU it

from blower housing.

As with any mechanical equipment, personal injury can

result from sharp metal edges, etc.; therefore, be careful when removing parts.

A. Air Filter

Each furnace accommodates two filters which can be installed above the furnace in the return-air plenum. See Fig. 12.

To clean or replace the filters, proceed as follows:

1. Disconnect electrical power before removing access

panel.

2. Remove upper access panel.

3. Reach up behind top plate, tilt filters toward center of retum-air plenum, remove filters, and replace or clean as needed.

V 4,

A77007

Fig. 15—Dual Blower With Left-Hand

Housing and Wheel Removed

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Page 10

9. Units with motor capacitor, loosen screw in strap hold

ing capacitor to blower housing and slide capacitor from under strap.

10. Mark blower wheel, motor, and motor support in rela

tion to blower housing before disassembly, to insure proper reassembly.

11. Loosen setscrew holding blower wheel onto motor

shaft.

12. Remove bolts holding motor mount to blower housing and slide motor and mount out of housing. Some motors have a ground wire attached to blower housing; disconnect it also.

13. Lubricate motor.

a. Remove dust caps or plugs from oU ports located at

each end of motor.

b. Use good grade of SAE 20 nondetergent motor oU

and put one teaspoon, 5cc, 3/16 oz., or 16 to 25 drops in each oil port.

c. Allow tune for total quantity of oil to be absorbed

by each bearing.

d. After oiling motor, be sure to wipe excess oil from

motor housing.

e. Replace dust caps or plugs on oil ports.

14. Remove blower wheel from housing.

a. Mark blower wheel orientation and cutoff location

to insure proper reassembly.

b. Remove screws holding cutoff plate and remove cut

off plate from housing.

c. Lift blower wheel from housing through opening.

15. Clean blower wheel and motor by using vacuum with soft brush attachment. Care must be exercised not to disturb balance weights (clips) on blower wheel vanes. Also do not drop or bend wheel, as balance will be affected.

16. Reassemble blower by reversing procedures 14a thru

14c. Be sure wheel is positioned for proper rotation.

17. Reassemble motor and blower by reversing procedures 8 thru 12. If motor has ground wire, be sure it is con

nected as before. Be sure the blower wheel setscrew is

on the flat of the motor shaft when tightening the setscrew.

18. Reinstall blower assembly in furnace.

19. Reinstall vent enclosure back.

20. Reinstall vent pipe through opening in top plate, secure to drafthood and connect remainder of vent pipe

assembly.

21. Reinstall vent enclosure front, and secure with screw.

22. Reinstall access panel.

C. Cleaning Heat Exchanger

If it becomes necessary to clean the heat exchanger because

of carbon deposits, soot, etc., proceed as follows:

1. Turn off gas and electrical supply to furnace.

2. Remove front access doors.

3. Remove vent pipe enclosure front and flue pipe.

4. Remove draft diverter. Screws are located inside draft

diverter opening.

5. Remove flue baffles from flue outlets of heat

exchanger.

A79080

Fig. 16—Position of Electrode to Pilot

6. Remove secondary-air shield and burners. To remove

pilot burner, disconnect pilot supply tube (and thermo

couple on 100% shut-off models) at gas valve.

7. Clean flue ways writh brush and or vacuum. Check heat

exchanger for leaks and cracks. Replace if necessary.

8. Replace flue baffles. Be sure aU screws are in place emd

tight.

9. Replace draft diverter and vent connector. Be sure

screws are replaced and tight.

10. Using vacuum cleaner wdth soft brush attachment, clean burners. After cleaning, replace burners and secondary-air shield.

11. Turn on gas and electricity. Check for gas leaks.

A WARNING

Never use a match or other open flame to check for gas

leaks. Use a soap-and-water solution. A failure to

adhere to this warning can cause an explosion, fire, per sonal injury, or death.

D. Pilot

Check the pilot and clean if necessary at the beginning of each heating season. The pilot flame should be high enough for proper inipingement of the safety element and to light the burners. Remove the accvunulation of soot and carbon from the thermocouple safety element or sensing probe.

E. Electrical Controls and Wiring

NOTE: There may be more them one electrical supply to

unit. With power disconnected to unit, check aU electrical connec

tions for tightness. Tighten any screws or electrical connec tions. If any smoky or burned connections are noticed, dis assemble the connection, clean all parts, and stripped wore, and reassemble properly and securely. Electrical controls are difficult to check without proper instrumentation; there fore, reconnect electrical power to unit and observe unit through one complete operating cycle. If there are any dis crepancies in the operating cycle, contact your Dealer and request service.

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