58DP,DR
HEATING« COOLING
Downflow Gas-Fired Natural-Draft Furnaces
58DP Series 150 and 160
58DR Series 130
Installation, Start-Up and Service Instructions
NOTE: Read the entire instructions before starting the
installation.
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 standeird installation practices. Further
reference is made to the current edition of the National Fuel
Gas Code NFPA No. 54-1988/ANSI Z223.1-1988.
Reference should also be made to the regulations of the
serving gas supplier and the local building, heating, plumb
ing, or other codes in effect in the area in which the installa
tion is made.
SAFETY CONSIDERATIONS
Installation and servicing of heating equipment can be haz
ardous due to gas and electrical components. Only trained
and qualified personnel should install, repair, or service
heating equipment.
Untrained personnel can perform basic meuntenance func
tions such as cleaning and replacing air filters. AU other
operations must be performed by trained service personnel,
when working on heating equipment, observe precautions in
the literature, tags, and labels attached to or shipped with
the unit and other safety precautions that may apply.
Follow all safety codes, including NFPA No. 54/ANSI
Z223.1-1988, National Fuel Gas Code. Wear safety glasses
and work gloves. Have fire extinguisher available during
startup and adjustment procedures and service call.
Recomized safety information: This is the safety-alert sym
bol A. When you see this symbol on the furnace and in
instructions or manueils, be alert to the potential for per
sonal injury.
Understand the signal word—DANGER, WARNING, or
CAUTION. These words are used with the safety-alert sym
bol. DANGER identifies the most serious hazards which
will result in severe personal injury or death. WARNING
on the other hand could result in personal injury or death.
CAUTION is used to identify unsafe practices, which would
result in minor personal injury or product and property
damage.
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, 24volt terminal strip to ensure proper connections.
Fig. 1—Model 58DP
Table 1—Clearances (In Inches)
(From Combustible Materials)
Sizes
Sides—Single-Wall Vent
Type-B Double-Wall Vent 0
Back 0 0
Top of Plenum 1
Vent Connector—Single-Wall 6 6
Type-B Double-Wall
Front—Combustion Air* 6 6
Service
*The 6-inch front clearance is needed for combustion-air entry and
drafthood relief.
»■NOTE: The furnaces covered by these instructions are
050 075 thru 150
1 1
1
1
1 1
30 30
design-certified for use with the vent damper specified on
the furnace rating plate. See instructions packaged with the
vent deunper for its installation.
A CAUTION
Application of this furnace should be indoors with spe
cial attention given to vent sizing and material, gas
input rate, air temperature rise, and unit sizing.
Improper installation or misapplication of the furnace
can require excessive servicing or cause premature com
ponent failure.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
'' I ^ PC 101 Catalog No. 565-873 Printed in U.S.A. Form 58DP,DR-4Si 5/89 Pg 1 Replaces: 58DP,DR-2SI
Tab I6al8a
8 THERMOSTAT CONN
/
Table 2—Dimensions (In Inches)
A
14^6 12"/,e 12”/,6
17^2
M'k
M'b
17Ya
21 19%
2A'k
1
5. ^
r'
— -?>•
o:a
KNOCKOUT
AUX GAS
INLET
AIRFLOW
Size
050-BA
075-AA
075-BA
100-AA
100-BA
125-AA 21 19%
125-BA
150-BA
A78595
Fig. 2—Dimensional 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 gas input ratings are certified for eievations to 2000 ft. For elevations above 2000 ft, reduce input 4% for each 1000 ft above sea ievei.
tDetermined by U.S. Government tests.
tDeduct 1000 Btuh for Modei58DR. , ' ;
input
Btuh*
50,000 39,000t
75,000 58,000
100,000 78,000t
125,000 97,000t
150,000 116,000t
Capacity
Btuht*
Temp
Rise
Range
45—75 0.50
70—100 0.12
45—75 0.50
70—100 0.20
60—90 0.50
70—100 0.20
60—90 0.50
55—85 , 0.50
Ext Static
Pressure
Heating
CFM
600 0.5
630
895
850
960
1050
1195 0.5
1535
Ext Static
Pressure
0.5
0.5 1630 %-PSC
0.5 2075
Cooling
— —
— —
—
D E Vent
15^
15%
15%
15%
22%e
CFM
800 73-SP 129
1255 %-SP 157
—
1620 %-PSC 187
16
16
16 5
16 5
19Ya
19% 5
23 6
Motor
HP&
Type
%0-SP 148
Vs-SP 163
%-SP
Ya-PSC 227
Approx
Shipping
Weight
4
4
4
5
170
187
A73382
Fig. 3—Floor Opening for
Concrete Slab
Table 4—Opening Dimensions
Furnace Casing A B
Width Heat-Only Heat/Cool*
14%s
17%
21 19% 19%
24%
♦These dimensions appiy when a Model 28RC or RD Evaporator Coil cas
ing is to be installed.
13%
167,6
237,6
19=/s 197,6
19%
19%
. 197,6
197,6
197,6
This furnace is designed for a minimum continuous return
air temperature of 60 degrees F DB or an intermittent oper
ation down to 55 degrees F DB such as when used with a
thermostat night setback. Return air temperature must not
exceed a maximum of 85 degrees F DB.
A WARNING
Improper histaUation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poison
ing, explosion, fire, electrical shock, or other conditions
which may cause personal injury or property damage.
Consult a qualified installer, service agency, local gas
supplier or your Distributor or Branch for information
or assistance. The qualified installer or agency must use
only factory authorized and listed kits or accessories
when modifying this product. A failure to adhere to this
warning can cause electrical shock, fire, personal injury,
or death.
FURNACE
■PLENUM
A73383
Fig. 4—Furnace on a Concrete Siab
WA
Fig. 5—Furnace, Plenum, and
Base Installed on a Combustible Floor
A CAUTION
Do not insteill furnace in a damp, corrosive, or contami
nated atmosphere. Make sure all combustion and circu
lating air requirements listed in “Procedures for
Natured-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 installed. If
the furnace is required during construction, use clean
outside air for combustion and ventilation. Compounds
of chlorine and fluorine when burned with combustion
air form acids which wiU 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.
*IV. Venting
V. Supply-Air Plenum Installation
VI. Electrical
VII. Sequence of Operation
VIII. Füter
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 hterature. Terminals EAC-1 and EAC-2 in the
control box are for direct connection of an electronic air
cleaner.
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.
2. Construct hole in floor per dimensions in Fig. 3 and
Table 4.
3. Place plenum and furnace as shown in Fig. 4.
The design of the downflow gas-fired 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 downflow subbase. This furnace
is for installation in alcoves, basements, closets, or utility
rooms. This furnace fine is not A.G.A. design certified for
installation in a mobile home, recreation vehicle, or
outdoors.
Installation comprises the following:
*1. Inspection
*11. Location, Ventilation, and Air for Combustion
*III. Gas Piping
Fig. 6—Amp Draw Check With Ammeter
A79077
Fig. 7—PrInted-CIrcult Control Center
- FIELD24-VOLTWIRlNC
FUSED DISCONNECT
SW ITCH (WHEN REQ'D)
CAP
(WHEN USED)
ILK SWITCH
TRAN
BREAKAWAY TAB REMOVED WHEN CONNECTING VENT DAMPER (SEE INSTALLATION INSTRUCT IONS)-
NOTES:
m DOWNFLOW FURNACES ONLY
I.
I
----
rz—I HEATING FAN RELAY CONTACT IS
•-rkF* NORMALLY CLOSED UNTIL 115V AC IS
HFR APPLIED TO FURNACE.
TO CHANGE MOTOR SPEED, MOVE RED WIRE TO
2.
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.
4.
FACTORY SPEED SELECTION IS FOR AVERAGE
5.
CONDITIONS, SEE INSTALLATION INSTRUCTIONS
FOR OPTIMUM SPEED SELECTION. MOTOR MAY
BE 3 OR 4 SPEED.
SYMBOLS ARE ELECT. REPRESENTATION ONLY.
6.
FACTORY CONNECTED WHEN ACCESSORY NOT USED.
7.
LEGEND
ALS
CAP
CFR
FL
FU2
GV
HFR
ILK
LOD
LS
MTR
PCB
PI
SP
TRAN
VSS5
/fy
AUXILIARY LIMIT SWITCH, MANUAL-RESET
C5PST-NC)
RUN CAPACITOR
COOLING FAN RELAY CDPDT
FUSIBLE LINK
FIELD FUSE
GAS VALVE
HEATING FAN RELAY CSPST-NC)
SWITCH, BLOW. DOOR INTERLOCK CSPST-NO)
LOCKOUt TIMER DEVICE CSPST-NO)
LIMIT SWITCH, AUTO.-RESET CSPST-NC)
MOTOR, BLOWER
PRINTED CIRCUIT BOARD
PILOT IGNITER
SAFETY PILOT (FLAME SENSING)
TRANSFORMER
VENT SAFETY SHUTOFF SWITCH, MANUAL-
RESET CSPST-NC)
FIELD SPLICE
PLUG RECEPTACLE
JUNCTION
UNMARKED TERMINAL
O
TERMINAL PCB FACTORY CONN.
FACTORY WIRING. C120V AC)
FACTORY WIRING CLOW VOLTAGE)
FIELD WIRING C120V AC)
FIELD WIRING C24V AC)
CONDUCTOR ON PRINTED CIRCUIT BOARD
SCREW TERMINAL FOR FIELD WIRING
0
FIELD GROUND
EQUIP. GROUND
TO THERMOSTAT
314296-401 REV. A
Fig. 9—Wiring Diagram (IID Pilot)
YEL
LOD-
CWHEN USED)
ELECTRONIC
AIR CLEANER
(WHEN USED)
EAC-2
A89168
FUSED DISCONNECT
-■D3-
FU2
D)
BLK
WHT
ILK SWITC^l^
BLK
)JHT
BLK
TRAN
RED
CWHEN USED)
GRN
CAP
CWHEN USED)
NOTES:
DOWNFLOW FURNACES ONLY
HEATING FAN RELAY CONTACT IS
NORMALLY CLOSED UNTIL IlSV AC IS
HFR ■ APPLIED TO FURNACE.
2. TO CHANGE MOTOR SPEED, MOVE BLK OR 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 C10S°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 AN ELECTRICAL REPRESENTATION ONLY.
LEGEND
ALS AUXILIARY LIMIT SWITCH, MANUAL-RESET
CAP RUN CAPACITOR
CFR COOLING FAN RELAY CDPDT)
FL FUSIBLE LINK
FUl FUSE IN LINE 2 AMP
FU2 FIELD FUSE
GV GAS VALVE
HFR HEATING FAN RELAY CSPST-NC)
ILK SWITCH, BLOWER DOOR INTERLOCK (SPST-NO)
LS LIMIT SWITCH, AUTOMATIC-RESET CSPST-NC)
MTR MOTOR, BLOWER
PCB PRINTED CIRCUIT BOARD
TRAN TRANSFORMER
VSSS VENT SAFETY SHUTOFF SWITCH, MANUAL-RESET
-•
--------
Q MARKED TERMINAL
O UNMARKED TERMINAL
--------
---------- FACTORY WIRING CLOW VOLTAGE)
---------
— CONDUCTOR ON PRINTED CIRCUIT BOARD
CSPST-NC)
CSPST-NC)
FIELD SPLICE
PLUG RECEPTACLE
JUNCTION
TERMINAL PCB FACTORY CONN.
FACTORY WIRING Cl20V AC)
FIELD WIRING C120V AC)
GRN^
AUX. J-BOX
0 SCREW TERMINAL FOR FIELD WIRING
^ FIELD GROUND
fj-/ EQUIP. GROUND
TO THERMOSTAT
BREAKAWAY TAB
REMOVED WHEN
CONNECTING VENT
DAMPER CSEE
INSTALLATION
INSTRUCTIONS)
310471-402 REV. B
BRN
-> Fig. 10—Wiring Diagram (Match-iit Pilot)
A89167
B. Installation on a combustible floor
1. Read Installation Instructions packaged with acces
sory combustible floor base.
2. Cut eind frame hole in floor per dimensions listed 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 will be maintained.
3. Assemble and install downflow subbase per instruc
tions packaged with subbase.
4. When completed, subbase, plenum, and furnace (or coil
casing when used) should be installed as shown in
Fig. 5.
VI. ELECTRICAL CONNECTIONS
A. 115-Volt 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 emd furnace. Use only copper conductors.
See Fig. 8 for wiring diagram showing the proper field 115and 24-volt 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
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 115-volt 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
win serve as the ground.
B. 24-Volt Wiring
Make field 24-volt connections at the 24-volt terminal strip.
See Fig. 8.
NOTE: Use AWG No. 18 “color-coded” copper thermostat
wire for lengths up to 100 ft. Above 100 ft, use AWG No. 16
wire.
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 circmt. Accurate amp draw readings
can be obtained at thermostat subbase terminals R & W.
Fig. 6 illustrates an easy method for obtaining the actual
amp draw.
The room thermostat should be located where it will be m
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 eiir 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-edr 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 thermostat.
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. 7. A 24-volt terminal board is
marked for easy connection of field wiring.
VII. SEQUENCE OF OPERATION
NOTE: The wiring diagrams shown in Figs. 9 and 10 cover
heating/coofing units.
A. Heating
Gas and electrical supplies must be turned on at the
furnace.
NOTE: When power is apphed to heat relay coU HFR in the
control circuit, the normally-closed contacts in the blower
circuit wUl open.
1. White Rodgers 36E Gas Valve (IID Models). See Fig. 9.
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 internal electrical resistor
in series with the solenoid “pick” coU, or a separate electri
cal solenoid coil.
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 VR800A and VR8200H Gas Valves (MatchLit Models). See Fig. 10
The furnace pilot must be ht to energize the thermal magnet
circuit of gas valve GV, thus permitting gas flow to the
remedning 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, hmit 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 phot.
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, limit 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, blower motor MTR
continues to operate because heat relay HFR is deenergized
to cool down the furnace.
Manual reset auxiliary limit switch ALS is located on the
top right-hand comer of the furnace. In the event of blower
motor failure, this switch breeiks the electrical circuit to the
gas valve, stopping gas flow to the main burners. The
switch must be manually 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 Emd 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 completely blocked vent condition occurs.
During a blocked vent condition, temperature in the
drafthood relief opening wfll rise causing vent safety shut
off switch to open, breaking the circuit to gas valye GV. The
gas valve closes immediately, stopping gas flow to the main
burners and pilot, and the blower wfll run continuously.
The furnace wiU 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 supplied 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 deunper 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
remain open until the thermostat is satisfied.
When the thermostat is satisfied, it wfll deenergize the main
gas valve and stop the gas flow. The vent damper motor wfll
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 cooling,” 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 hi a V-formation inside the
return-air plenum. See Fig. 11.
A 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.
,-INSTALLATION
POSITION
OF FILTERS
A78654
Fig. 11—Position of Fiiters
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.
A CAUTION
This furnace is equipped with a fusible link in the vesti
bule area that wfll melt if an overheating condition
caused by an inadequate combustion-Eur 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).
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
Hi
Med-Hi
Med-Low 3
Low
*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 heat
ing speed selection.
B. Automatic Gas Control Valve
Tap No.*t
1
2
4
These units are equipped with an automatic gas control
valve. If not already checked when lighting the msdn
burner, check the proper operation of this valve by moving
the room thermostat pointer above and below room temper
ature and observing that the main burners Hght on “caU for
heat” and go off when the pointer is moved below room tem
perature setting.
NOTE: For ease of adjusting the IID pilot flame, disconnect
one power lead at main gas valve. For Model 36E Gas
Valve, discoimect terhnnal No. 1; and for Model VR800A or
VR8200H Gas Valve, turn manual valve knob to PILOT.
This wiU prevent main burner ignition and allow time to
adjust the pilot. Reconnect the power lead or turn manual
valve knob to ON after adjustment.
A CAUTION
Be sure to foUow startup and pilot safety check proce
dures as outlined in “Procedures for Natural-Draft
Gas-Fired Furnaces” instructions packaged with the
equipment.
X. CARE AND MAINTENANCE
A CAUTION
Because of possible deunage 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, waxes or other cleaning
compounds, plastic or plastic containers, gasoline,
kerosene, cigEirette lighter fluid, dry deeming 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
injury, or death.
^ Fig. 13—Honeywell Model VR8200H
For continuing high performance, and to niininiize 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 ability 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.
A WARNING
Turn off the gas and electrical supplies to the unit
before performing any mEiintenance or service. Follow
the relighting instructions on the label attached to the
furnace. A failure to adhere to this warning can cause
persond 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 cleemliness and lubri
cation (when oilers are provided) each heating and cool
ing 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
As with any mechanical equipment, personal injury can
result from sharp metal edges, etc.; therefore, be careful
when removing parts.
PILOT
ADJUSTMENT-
IN LE'
PRES
TAP
Fig. 14—White Rodgers Model 36E
A. Air Filter
OUTLET
PRESSURE TAP
A87230
Each furnace accommodates two filters which can be
installed above the furnace in the return-air plenum. See
Fig. 11.
To clean or replace the filters, proceed as follows:
1. Disconnect electrical power before removing access
panel.
2. Remove upper access door.
3. Reach up behind top plate, tilt filters toward center of
return-8ur plenum, remove filters, and replace or clean
as needed.
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 oihng or coating of filters is
required.
c. Reinstall filters with cross-hatch binding facing
blower.
B. Blower Motor Wheel
For long life, economy, and high efficiency; clean accumu
lated dirt and grease from blower wheel and motor annually.
Lubricate motor every 5 years if motor is used on intermit
tent operation (thermostat FAN switch in AUTO position),
or every 2 years if motor is in continuous operation (thermo
stat FAN switch m ON position).
Clean and lubricate as follows:
1. Remove upper access door.
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. Slide 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 toweurd 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.
9. Units with motor capacitor, loosen screw in strap hold
ing capacitor to blower housing and shde 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 shde motor and mount out of housing. Some
motors have a ground wire attached to blower housing;
disconnect it also.
13. Lubricate motor (when oilers are provided).
a. Remove dust caps or plugs from oil ports located at
each end of motor.
b. Use good grade of SAE 20 nondetergent motor oil
and put one teaspoon, 5cc, 3/16 oz., or 16 to 25
drops in each oU port.
c. AUow time for total quantity of oil to be absorbed
by each bearing.
d. After oihng 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 (chps) on blower wheel vanes.
Also do not drop or bend wheel, as balance wih 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.
1
A
Fig. 15—Dual Blower With Left-Hand
Housing and Wheei Removed
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. Connect electrical leads to Molex speed selector. Please
note that connections are polarized for assembly—do
not force.
23. Reinstall access door.
9
Table 6—Trouble Analysis Chart
A WARNING
To avoid possibility of fixe, explosion, electric shock, personal injury or death, turn off gas and power supply to unit
before servicing (unless specific test requires gas and electric suppHes).
SYMPTOM CAUSE
Furnace will not operate
Pilot will not light
Burners will not ignite.
Blower operates continuously
Inadequate heating
Aldehyde odors, (CO),
sooting flame-
floating flame
No 115-volt power to furnace
Blower door not in place
Defective blower door switch Replace switch.
Vent safety shut-off switch open
No spark at electrode Readjust, if necessary, so that gap between electrode tip
Spark shorting out to main burner Readjust electrode as specified.
No gas at pilot burner
No 115-volt power to furnace Connect to power supply. Check fuse, wiring, or circuit breaker.
No 24-volt power to control circuit Replace transformer.
Miswired or loose connections
No gas at main burners
Dirty pilot—yellow flame
Thermostat fan switch in ON position
Fusible link blown
Dirty filter causing limit operating
Defective heat relay
Vent safety shut-off switch open
Furnace undersized for application
Gas input to furnace too low
Limit switch cycles main burners
Manual reset limit switch contacts open
Manual reset switch contacts open (Burner
on time must be minutes minimum.)
Thermostat anticipator set too low
Incomplete combustion—
poor flame characteristics
Copnnect to power supply. Check fuse, wiring, or circuit breaker.
Install furnace blower door.
Check for vent blockage and proper installation of vent pipe.
and pilot burner is as shown in Fig. 16.
Clean dirt or moisture accumulation from electrode ceramic with cloth.
Cracked ceramic—replace pilot electrode assembly.
Check for loose or broken wiring at and between spark generator and
electrode. Replace wire or tighten connection as necessary.
Check fuse or circuit breaker for 115-volt supply to furnace.
Check blower access panel for proper installation.
Check 24-volt input to spark generator. If you read 24 volts and above
steps have been completed, replace spark generator assembly.
Clean pilot orifice.
Check voltage to terminals 3 and 5 or TR and TH of gas valve.
Check for proper opening of pilot valve, broken wires, or loose
connections. If no deficiency is found, replace valve assembly.
Check all wiring and all wirenut connections.
Check voltage to terminals 1 and 2 or TR and TH of gas valve.
Check for proper opening of main gas valve, broken wires, or loose
connections. If no deficiency is found, replace gas valve assembly.
Clean pilot orifice.
Move thermostat fan switch to AUTO position.
Correct combustion air, vent system, and/or heat exchanger
blockage—replace fuse link with identical part.
Clean or replace dirty air filter—reinstall.
Replace printed-circuit board.
Check for vent blockage and proper installation of vent pipe.
Replace with proper size furnace.
Check gas pressure at manifold. Clock gas meter for input. If too low,
increase manifold pressure or install correct orifices.
Clean or replace dirty air filter—reinstall.
Increase blower speed.
Open registers—ductwork restricted.
Blower motor failure—replace motor.
Check and adjust thermostat anticipator to proper setting.
Replace with proper size furnace.
Check thermostat circuit amps and set anticipator accordingly.
See Fig. 6.
Adjust air shutter on burners to provide soft blue flame. Check all
screws around flue outlets and burner compartment. Tighten.
See “Section II, Location & Air for Combustion & Ventilation”
(Procedures for Natural-Draft Gas-Fired Furnaces).
Replace cracked heat exchanger.
Reduce input and check orifices—furnace overfired.
Check vent for restriction.
REMEDY
11
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
BookI 1 I 4 PC 101 Catalog No. 565-873 Printed in U.S.A. Form 58DP.DR-4SI 5/89 Pg 12 Replaces; 58DP,DR-2SI
Tab I6al8a
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Tab I6al8a
I
PC 101 Catalog No. 565-873 Printed in U.S.A. Form 58DP,DR-4SI 5/89 Pg 12 Replaces: 58DP,DR-2SI
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