Carrier 101 Series, 58EJB Series Installation, Start-up, And Operating Instructions Manual

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Page 1

Deluxe Horizontal Gas-Fired

Condensing Furnaces

Installation, Start-up, and Operating Instructions

Sizes 050-125, Series 101

NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATIONS

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

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

Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No. 54-1992/ANSI Z223.1-1992. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1and .2-M91 Natural Gas and Propane Gas Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls.

Recognize safety information. This is the safety-alert symbol When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury. Understand the signal word DANGER, WARNING, or 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 that could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions that will result in enhanced installation, reliability, or operation.

INTRODUCTION

The design of the 58EJB Deluxe Horizontal Gas-Fired Condensing Furnace is A.G.A./C.G.A. certified as a Category IV furnace for natural and propane gases and for installation in alcoves, basements, crawlspaces, utility rooms, and attics. The design of the horizontal gas-fired furnace is A.G.A./C.G.A. certified for installation on noncombustible floors. This furnace may be installed on combustible wood flooring; however, it may not be installed directly on carpeting, tile, or any combustible material other than wood. The design of this furnace line is not A.G.A. certified for installation in recreational vehicles, manufactured housing (mobile homes), or outdoors.

Before installing this furnace, refer to the current edition of the NFGC NFPA 54-1992/ANSI Z223.1-1992 which is available from the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269, American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209, or from Literature Distribution.

In Canada, contact Standards Department of Canadian Gas Association, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B2R3.

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

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

instructions as a minimum for a safe installation.

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

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

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

ama

58EJB

CANADIAN GAS ASSOCIATION

APP R O VE D

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

Book 1 4 Tab 6a 8a

PC 101 Catalog No. 535-869 Printed in U.S.A. Form 58EJB-1SI Pg 1 2-94 Replaces: 58EJA-3SI

Page 2

⁄8″

C (VENT CONNECTION)

⁄8″ ELECTRICAL

CONNECTION

3″

⁄8″

AIR FLOW

⁄8″

ELECTRICAL &

THERMOSTAT

CONNECTION

⁄8″

⁄2″

D (NUMBER OF HX) COMBUSTION-AIR

CONNECTION

Dimension (In.)

INPUT BTUH

UNIT WIDTH

A B C D

50,000 13-1/2 11-5/8 2 2

75,000 13-1/2 11-5/8 2 3 100,000 17 15-1/8 3* 4 125,000 20-1/2 18-5/8 3* 5

* Vent size is 3 in. with factory-supplied 2-X-3 in. bell reducer.

DUCT SUPPLY

AND RETURN

OPENINGS

Fig. 1—Dimensional Drawing

⁄2″

⁄4″

COMBUSTION-AIR

VENT DIAMETER

55″

7″

⁄8″

⁄4″

17″

⁄2″ GAS CONNECTION

⁄2″ CONDENSATE DRAIN

⁄8″

HEAT EXCHANGERS

⁄8″

NUMBER OF

A91190

If this furnace is used during construction when adhesives, sealers, and/or new carpets are being installed, make sure all combustion and circulating air requirements are followed. If operation of 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 will cause corrosion of the heat exchangers. Some of these compounds are found in paneling and dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction process.

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

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

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

This furnace is equipped with a metal blower wheel shipping bracket which MUST be removed before starting the unit.

Table 1—Attic or Alcove Clearances From

Combustible Materials (In.)

UNIT SIZE

Sides 0

Back 0*

Top of Plenum 0

Vent Connector

(PVC Pipe)

Front Casing 1†

Front Service 30

* Zero in. with controls on front of furnace, 1 in. from back of elbow with combustion-air inlet on back of furnace, and 1 in. from end of inducer motor with controls located on back of furnace. † Measured from end of inducer motor.

050, 075, 100,

AND 125

Table 2—Dimensions (In.)

UNIT SIZE LENGTH WIDTH WEIGHT (LB)

050-12 55 13-1/2 136 075-12 55 13-1/2 148 100-16 55 17 167 125-20 55 20-1/2 185

INSTALLATION

Step 1—Location

This furnace may be located in an attic, basement, crawlspace, alcove, or suspended from the ceiling of a utility room or basement.

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Fig. 2—Typical Attic Installation

Do not install the furnace on its back or side. Safety control

operation will be adversely affected. Never connect return-air

ducts to the back of the furnace. Failure to follow this warning

could result in a fire, personal injury, or death.

This furnace may be installed in an unconditioned space with

possible ambient temperatures of 32°F or lower if special

installation requirements are met. See Step 7—Direct Venting

and Step 9—Condensate Drainage.

GENERAL — When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace to ensure there will not be a negative pressure condition within the equipment room or space.

This furnace must be located so the electrical components are protected from water.

This furnace may be located in a confined space without special provisions for dilution or ventilation air.

Locate the furnace as close to the center of the air distribution system as possible.

For proper furnace operation, locate and install the furnace so it is within 1/2 in. of level. Refer to Step 9—Condensate Drainage.

Locate the furnace so that maximum allowable vent and combustion-air pipe lengths are not exceeded. Refer to Step 7—Direct Venting.

Provide ample space for servicing and cleaning. Always comply with the minimum fire protection clearances shown on the unit rating plate and in Table 1.

Locate the furnace where available electrical and gas supplies meet the specifications on the furnace rating plate.

A91192

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

HAZARDOUS LOCATIONS — When the furnace is installed in a residential garage, it must be installed so that the burners and ignition source are located a minimum of 18 in. above the floor. The furnace alos must be located or protected to avoid physical damage by vehicles.

When the furnace is installed in a public garage, airplane hangar, or another building having a hazardous atmosphere, the unit must be installed in accordance with the requirements of the National Fire Protection Association, Inc.

This furnace is not watertight and is not designed for outdoor installation. This furnace shall be installed in such a manner as to protect the electrical components from water. Outdoor installation would lead to a hazardous electrical condition and premature component failure. Failure to follow this warning could result in fire, personal injury, or death.

Step 2—Horizontal Attic Installation

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

The furnace can be installed horizontally for either left- or right-side supply. See Fig. 2 for a typical attic installation and Step 10 for field reversing procedure.

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1. Construct a working platform on location where all required furnace clearances are met. (See Table 1 and Fig. 2.)

2. Position furnace in desired location.

3. Connect gas supply pipe. See Fig. 2 for typical gas piping.

4. Connect supply- and return-air ducts.

5. Install 24- X 24-in. sheet metal shield on platform in front of controls as shown in Fig. 2.

Step 3—Horizontal Crawlspace Installation

The furnace can be installed horizontally for either left- or right-side supply. In a crawlspace, the furnace can either be hung from the floor joists or installed on suitable blocks or a pad. The furnace can be suspended using steel pipe straps around each end of the furnace. These straps should be attached to the furnace with sheet metal screws and to the floor joists with lag bolts. A framed assembly of angle iron suspended with all-thread rod of suitable diameter may be used to support the length of the furnace.

The horizontal crawlspace installation is very similar to the attic. Refer to Step 2, items 2, 3, 4, and 5. A 24- X 24-in. sheet metal shield must be installed above the controls for crawlspace installations. Extend the sheet metal shield over the furnace top far enough to cover the gas pipe entry hole.

Step 4—Filter Arrangement

Connect a capped nipple to the lower end of the tee. The capped nipple should extend below the level of the gas controls. Place a ground joint union between the gas control manifold and the manual gas shut-off valve. (See Fig. 3.)

An accessible manual shut-off valve MUST be installed upstream of the furnace gas controls and within 6 ft of the furnace. A 1/8-in. NPT plugged tapping, accessible for test gage connection, MUST be installed immediately upstream of the gas supply connection to the furnace and downstream of the manual shut-off valve.

GAS SUPPLY

MANUAL SHUTOFF

UNION

SEDIMENT

TRAP

VALVE

A91212

Fig. 3—Typical Gas Piping

Never operate the unit without a filter or with the filter removed. Failure to follow this caution can result in a fire, personal injury, or death.

The factory-supplied filter and wire filter retainer are shipped with the furnace. After the return-air duct has been connected to the furnace, install the filter in the blower compartment, just ahead of the return-air plenum, and secure it with the wire filter retainer. The cross-mesh binding side of the filter should face the blower.

Step 5—Gas Piping

Gas piping must be installed in accordance with national and local codes. Refer to the current edition of the NFGC.

The gas supply line should be a separate line running directly from the meter to the furnace, if possible. Refer to Table 3 for the recommended gas pipe sizing. Risers must be used to connect to the furnace and to the meter.

Table 3—Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE SIZE

(IN.)

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

1 1.049 680 465 375 320 285 1-1/4 1.380 1400 950 770 660 580 1-1/2 1.610 2100 1460 1180 990 900

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a pressure drop of 0.5-in wc (based on a 0.60 specific gravity gas). Ref: Table 10-2 NFPA 54-1992.

INTERNAL

DIAMETER (IN.)

Support all piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft.

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

Install a sediment trap in the riser leading to the furnace. The trap can be installed by connecting a tee to the riser leading to the furnace, so that the straight-through section of the tee is vertical.

LENGTH OF PIPE (FT)

10 20 30 40 50

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

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

0.5 psig (14-in. wc), close the manual shut-off valve located on the gas valve before the test. It is recommended that the ground joint union be loosened before pressure testing.

Use a backup wrench when connecting the gas pipe to the furnace to avoid damaging gas controls.

After all connections have been made, purge the lines and check for leakage.

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

Step 6—Electrical Connections

See Fig. 17 for a wiring diagram showing the proper field 115- and 24-v wiring. Check all factory and field electrical connections for tightness.

115-V WIRING — Before proceeding with the electrical connections, make certain that voltage, frequency, and phase correspond to that specified on the unit rating plate. Also, check to be sure that the service provided by the utility is sufficient to handle the load imposed by this equipment. Refer to rating plate or to Table 4 for the equipment electrical specifications.

Page 5

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

FOUR

WIRE

G W Y R

TWO-WIRE

HEATING-

ONLY

115-VOLT

SINGLE

PHASE

GND

115-VOLT

FIELD-SUPPLIED

FUSED DISCONNECT

GND

C R

24-VOLT

TERMINAL

BLOCK

NOTE :

1. Connect Y-terminal as shown for proper cooling operation.

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

3. Proper polarity must be maintained for 115-volt wiring.

Fig. 4—Heating and Cooling Application Wiring Diagram

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

Make all electrical connections in accordance with the National Electric Code (NEC) ANSI/NFPA 70-1993 and any local codes or ordinances that might apply.

For Canadian installations, all electrical connections must be made in accordance with CSA C22.1 Canadian Electrical Code, or authorities having jurisdiction.

Use a separate, fused branch electrical circuit containing a properly sized fuse or HACR-type circuit breaker for this furnace. See Table 4 for wire size and fuse specifications. A disconnecting means must be located within sight of and readily accessible to the furnace.

THERMOSTAT TERMINALS

FIELD-SUPPLIED FUSED DISCONNECT

208/230- OR 460-VOLT THREE PHASE

GNDGND

208/230- VOLT SINGLE

GND

PHASE

CONDENSING

UNIT

TWO WIRE

A91338

24-V WIRING — Make field 24-v connections at the 24-v terminal block. Connect Y terminal as shown in Fig. 4 for proper cooling operation. The 24-v terminal board is marked for easy connection of field wiring. (See Fig. 5.)

ELECTRONIC

AIR CLEANER

TERMINALS

(115 VAC, 1 AMP MAX) 3-AMP FUSE

W Y R C G

HUMIDIFIER TERMINAL

(24 VAC, 0.5 AMP MAX)

EAC-2 EAC-1

HUM-1

BLOWER OF DELAY SELF TEST

90 100 180 225

JW9

The cabinet MUST have an uninterrupted or unbroken ground according to NEC, ANSI/ NFPA 70-1992, Canadian Electrical Code, CSA C22.1, or local codes to minimize personal injury if an electrical fault should occur. This ground may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in an electrical shock, fire, or death.

If manual disconnect switch is to be mounted on the furnace, select a location where a drill or fastener will not contact electrical or gas components.

NOTE: Proper polarity MUST be maintained for 115-v wiring. If polarity is incorrect, the pilot flame will not be sensed and the ignition control will shut down the unit until the control is reset.

24-VOLT THERMOSTAT

SELF-TEST PINS

TERMINALS

BLOWER OFF-DELAY

ADJUSTMENT CONTROL

Fig. 5—Control Board

NOTE: Use AWG No. 18 color-coded copper thermostat wire for

lengths up to 100 ft. For wire lengths over 100 ft, use AWG No. 16 wire.

ACCESSORIES — Install accessories per manufacturer’s instructions. Cycle test furnace and accessories twice to ensure proper operation.

Step 7—Direct Venting

The 58EJB Furnace requires a dedicated (one 58EJB Furnace only) direct vent system. In a direct vent system all air for combustion is taken directly from the outside atmosphere and all flue gases are discharged to the outside atmosphere.

A91333

Page 6

Table 4—Electrical Data

UNIT SIZE

050-12 115—60—1 127 104 10.5 14 44 15 075-12 115—60—1 127 104 10.5 14 44 15 100-16 115—60—1 127 104 15.0 12 49 20 125-20 115—60—1 127 104 15.0 12 49 20

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

VOLTS— HERTZ—

PHASE

OPERATING

VOLTAGE RANGE

Maximum* Minimum*

MAXIMUM

UNIT

AMPS

MINIMUM

WIRE

SIZE

MAXIMUM WIRE

LENGTH

(FT)‡

MAXIMUM FUSE OR

HACR-TYPE

CKT BKR AMPS†

REMOVAL OF EXISTING FURNACES FROM COMMON VENT SYSTEMS — If the furnace being replaced was connected to a common vent system with another appliance(s), these steps shall be followed with each appliance remaining connected to the common vent system placed in operation. Ensure that the other appliances remaining connected to the common vent system are not in operation.

1. Seal any unused openings in the common vent system.

2. Visually inspect the vent system for proper size and horizontal pitch, and determine there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors, windows, and doors between the space in which the appliances remaining connected to the common vent system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common vent system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4. Follow the lighting instructions and place the appliance in operation. Adjust the thermostat so appliance will operate continuously.

5. Test for flue gas spillage at the drafthood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, etc.

6. After it has been determined that each appliance remaining connected to the common vent system properly vents when tested as above, return doors, windows, exhaust fans, fireplace dampers, any other gas burning appliances to their previous condition of use.

7. If improper venting is observed during any of the above tests, the common vent system must be corrected. The vent system or vent connectors may need to be resized. When resizing vent systems or vent connectors, the minimum size of the system or connector must be as determined using the appropriate table found in Appendix G of the NFGC, or Section 5 of NSCNGPIC for Canadian Standards.

COMBUSTION-AIR AND VENT PIPING — The combustionair and vent pipe fittings must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards D1785 (schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and SDR-26 PVC), D2661 (ABS-DWV), or F628 (schedule-40 ABS). Pipe cement and primer must conform to ASTM standards D2564 (PVC) or D2235 (ABS). See Table 5 for maximum pipe lengths (including maximum lengths adjusted for high-altitude installations) and Fig. 6 or 7 for exterior piping arrangements.

HORIZONTAL VENT TERMINATION

NOTE: 7″ MIN CLEARANCE TO NEAREST

BUILDING OR WALL

⁄2″ MIN

″ MAX

WALL THICKNESS

12″ MIN 24

AIR INLET

COUPLING

NOTE: HORIZONTAL VENT

TOP VIEW SIDE VIEW

RUNS MUST HAVE A

⁄4″ SLOPE TOWARD

THE FURNACE FOR EVERY 12

COMBUSTION-AIR INLET

″ OF PIPE

″ MAX

FLUE OUTLET

TERMINATION BRACKET

12″ MIN

″ MAX

VENT DRAIN

COMBUSTION-AIR

(ELBOW WITH

AIR SPLITTER)

12″ MIN

″ MAX

VENT (PVC TEE)

A91213

Fig. 6—Sidewall Termination

Table 5—Maximum Allowable Pipe Length (Ft)

ALTITUDE ABOVE

SEA LEVEL

(FT)

0 to 2000 50 50 50 50 50 2001 to 3000 44 43 43 42 42 3001 to 4000 40 39 38 37 36 4001 to 5000 37 36 35 34 33 5001 to 6000 34 32 31 29 28 6001 to 7000 31 29 28 26 25 7001 to 8000 27 25 23 21 19 8001 to 9000 24 22 20 18 16

9001 to 10,000 21 18 16 13 11

NOTE:

1. Up to five 90° elbows may be used, not including the vent termination. Assume that two 45° elbows equal one 90° elbow.

2. Pipe length based on 2-in. diameter pipe for size 050-12 and 075-12, and 3-in. diameter pipe for size 100-16 and 125-20.

3. Minimum pipe length is 5 ft for all applications.

NUMBER OF 90° ELBOWS

1 2 3 4 5

Page 7

In Canada construct all combustion-air and vent pipes for this unit of CSA or ULC certified schedule-40 PVC, PVC-DWV or ABSDWV pipe and pipe cement. SDR pipe is not approved in Canada.

A secondary vent pipe drain (provided) MUST be installed in the furnace vent pipe as shown in Fig. 6 and 7. This ensures proper drainage of condensation that collects in the vent pipe. A vertical pipe may be installed in the inducer housing outlet, but it must turn horizontally at a 90° angle into the vent drain before continuing out of the structure. (See Fig. 6 or 7.) No straight vertical vent piping may be used.

Z-SHAPED

TERMINATION

BRACKET

12″ MIN ABOVE

ANTICIPATED MAX SNOW LEVEL

12″ MIN

″ MAX

NOTE: HORIZONTAL VENT

RUNS MUST HAVE A

⁄4″ SLOPE TOWARD

THE FURNACE FOR EVERY 12

NOTE: Z-SHAPED BRACKET

MUST BE INSTALLED AS SHOWN TO SECURE PIPES PROPERLY

PVC TEE

VENT

COMBUSTION-AIR (ELBOW WITH AIR SPLITTER)

″ OF PIPE

A91214

Fig. 7—Rooftop Termination (Preferred)

If installing 2 or more 58EJB Furnaces refer to the Multiventing and Vent Terminations section of this instruction.

Combustion air must NOT be taken from inside the structure because that air frequently is contaminated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, adhesives, paint, and other household products. Maintain a minimum of 36 in. between combustion-air inlet and clothes dryer vent. Locate the combustion-air inlet as far as possible from the swimming pool and swimming pool pump house.

When the vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, the pipe must be insulated with 1/2-in. thick Armaflex-type insulation.

When the combustion-air pipe is installed above a suspended ceiling, the pipe must be insulated with 1/2-in. Armaflex-type insulation. The combustion-air pipe should also be insulated when it passes through a warm, humid space.

Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well ventilated areas. Avoid breathing of the vapor and contact with the skin or eyes. Failure to follow this warning could result in a fire, property damage, personal injury, or death.

The vent terminal bracket described in the next section MUST be used in constructing the vent terminal for this unit. Pipes must terminate through either the roof or the sidewall although roof termination is preferable. Locate sidewall terminations to prevent damage to shrubs, condensing unit, and siding materials. Table 6 gives clearance requirements.

Table 6—Combustion-Air and Vent Terminal

Clearances

LOCATION

Above anticipated snow depth 1 1 Dryer vent 3 4 From plumbing vent stack 3 3 Gas appliance vent terminal and

chimney From any opening where vent gases

could enter building Above grade level 1 1 From combustion-air opening of any

appliance From a fresh air intake 3* 6 From electric or gas meters, regula-

tors, and relief equipment Above grade when adjacent to public

walkway

* Three ft above an intake located within 10 ft. † Horizontal distance.

CLEARANCE (FT)

U.S.A. Canada

4 4

1 3

1 6

4† 6

7 7

All combustion-air and vent pipes must be airtight and watertight except top joint of the elbow on the combustion-air inlet plate which must be left unglued to facilitate removal of burners. The pipes must also terminate exactly as shown in Fig. 6 or 7. Failure to follow this warning could result in property damage, personal injury, or death.

NOTE: The unit is shipped with a 3- to 2-in. bell reducer for units where 3-in. combustion-air pipe is required.

NOTE: Do not count the elbows to which the terminal bracket attaches or any elbow between the bracket and the open end of the pipe. (See Fig. 6 or 7.) Also, do not count pipe sections inside furnace casing.

NOTE: It is recommended that all pipes be cut, prepared, and preassembled before permanently cementing any joint.

1. Attach PVC pipe to inducer housing outlet, run vent pipe vertically for a short distance. Turn piping horizontally 90° to allow installation of secondary vent drain before continuing out of structure. (See Fig. 6 or 7.)

NOTE: If 3-in. vent pipe is required, the 3- to 2-in. reducing adapter provided must be used. Install the adapter as close to the inducer housing outlet as possible.

2. Connect 90° elbow to combustion-air inlet plate with elbow pointing upward. (See Fig. 8.) Do NOT cement the elbow to the conbustion-air inlet plate since this joint must be unglued to facilitate removal of burners during maintenance.

Page 8

AIR INLET

PIPE

In all installations the

NOTE:

combustion-air inlet piping must be connected with an elbow pointing up to allow access to the burner assembly.

DO NOT SEAL

THIS JOINT

COMBUSTION-AIR INLET PLATE

A91215

Fig. 8—Combustion-Air Piping

3. Working from furnace to outside, cut pipe to required length(s).

4. Deburr inside and outside of pipe.

5. Chamfer outside edge of pipe for better distribution of primer and cement.

6. Clean and dry all surfaces to be joined.

7. Check dry fit of pipe and mark insertion depth on pipe.

8. After pipes have been cut and preassembled, apply generous layer of cement primer to pipe fitting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat.

9. While the cement is still wet, twist pipe into socket with a 1/4-turn. Be sure pipe is fully inserted into fitting socket.

10. Wipe excess cement from joint. A continuous bead of cement will be visible around the perimeter of a properly made joint.

11. Handle pipe joints carefully until cement sets.

12. Support piping at minimum of every 5 ft (3 ft for SDR-21 or

-26 PVC) using perforated metal hanging strap. Slope combustion-air and vent pipes toward furnace a minimum of 1/4 in. per linear ft with no sags between hangers.

13. Use appropriate methods to seal openings where vent and combustion-air pipes pass through roof or side wall.

c. Top of chimney is sealed and weatherproofed.

3. Sidewall termination. (See Fig. 6.) a. Terminations must be made 12 in. above anticipated annual

snow accumulation level or grade, whichever is greater.

b. Minimum of 4 ft clearance must be provided from electric

or gas meters, regulators, and relief equipment.

4. Install 90° elbows as shown in Fig. 6 or 7, or use a 180° U-fitting.

5. Install tee as shown in Fig. 6 or 7.

6. Check required dimensions as shown in Fig. 6 or 7.

7. Disassemble loose pipe fittings. Clean and cement fittings using same procedures as outlined for system piping.

8. Secure combustion-air and vent pipe terminations with Z-shaped termination bracket (provided).

MULTIVENTING AND VENT TERMINATIONS OF 58EJB FURNACES — When 2 or more 58EJB Furnaces are vented near each other, each furnace must be individually vented. Never common vent or breach-vent these furnaces. There must be a 12-in. separation between the combustion-air and vent pipes of the first and second furnaces. The next vent termination must be at least 4 ft away from the first 2 terminations. It is important that the vent terminations be constructed in this manner to avoid recirculation of flue gases.

Step 9—Condensate Drainage

This furnace must use the condensate trap supplied with the unit. See Fig. 9 for proper drain installation. The drain must terminate at a floor drain, sewer system, or drain vent for proper condensate removal. Drain installation must conform with local building codes. For proper condensate drainage from the furnace, the furnace MUST be within 1/2 in. of level. That is, the highest corner of the furnace must not be more than 1/2 in. higher than the lowest corner.

TO VENT

TERMINATION

VENT DRAIN

TUBE

INDUCER HOUSING TUBE

1″

Step 8—Vent Terminal Kit Installation

The combustion-air and vent pipes must terminate outside the structure. A factory-supplied terminal kit must be installed as in 1 of the installations shown in Fig. 6 or 7. A roof termination is preferred. The combustion-air inlet fitting is the factory-provided elbow with air splitter. (See Fig. 7.)

1. Roof termination is preferred. (See Fig. 7.) a. Inlet of combustion-air pipe must terminate no less than 12

in. above roof or snow accumulation level.

b. Inlet of combustion-air pipe must terminate 12 in. away

from vertical wall or other protrusion.

2. Termination through existing chimney may be used provided: a. No other gas-fired or wood-burning appliance is vented

into chimney.

b. Both combustion-air and vent pipes run entire length of

chimney.

Connect to approved

NOTE:

sewer system per these instructions and local codes.

Fig. 9—Condensate Drain System

NOTE: The condensate trap MUST be connected to the PVC tee

on the drain line exiting the unit as shown in Fig. 9. Failure to place the trap at this location may cause erratic unit operation and nuisance furnace shutdown.

The 1/2-in. diameter schedule-40 PVC or CPVC condensate drain piping and pipe fittings must conform to ANSI standards and ASTM D1785 or D2846. The schedule-40 PVC or CPVC cement and primer must conform to ASTM D2564 or F493.

A91176

Page 9

BLOWER

DOOR

BLOWER

DOOR

CONTROL LAYOUT (AS SHIPPED)

Fig. 10—Control Layout for Reversal

In Canada, use CSA or ULC certified schedule-40 PVC or CPVC drain pipe and cement.

When a condensate pump is required, select a pump that is approved for condensing furnace applications. To avoid condensate spillage, select a pump with an overflow switch.

1. Determine which side of furnace drain will exit, then cut and preassemble drain piping (not provided) directly to an open drain. Refer to Step 7—Direct Venting for instructions on preparing and cementing plastic pipe.

2. Cement condensate drain tee on pipe assembly from furnace, then connect to condensate trap. (See Fig. 9.)

3. Attach tubing (provided with furnace) to drain connections on inducer housing, vent drain, and condensate drain tee as shown in Fig. 9.

4. Connect other ends of tubing to barbed tee (provided) as shown in Fig. 9.

5. Cement remaining pipe joints.

NOTE: If this furnace is installed in an unconditioned space (such as an attic or crawlspace) where the temperature is at or near the outdoor ambient temperature, a UL listed, thermostaticallycontrolled or self-regulating heat tape must be installed along the entire length of the condensate drain line in the unconditioned space.

Failure to install heat tape on condensate lines in an unconditioned space could lead to condensation freezing in drain line, resulting in nuisance furnace shutdown and hazardous conditions.

Step 10—Reversing Procedure NOTE: This procedure must be performed only by trained and

qualified personnel. Due to the complexity of the procedure as well as the time required, it is strongly recommended that the unit be field-reversed prior to transporting it to the installation site. Refer to Fig. 10 throughout the procedure.

Before proceeding with field reversal of controls, ensure all electrical and gas supplies to the furnace are off. All gas piping should be disconnected from the furnace. Failure to do so could result in a hazardous condition causing property damage, personal injury, or death.

CONTROL LAYOUT (FIELD REVERSED)

A91216

Before starting the field reversal, be sure to have a correct wiring diagram available and be prepared to mark all wires as they are disconnected.

The inducer assembly, burner controls, gas valve, and electrical controls are designed to be field reversed as necessary for certain field installations and applications per the following procedure.

1. Remove manifold cover plate and air inlet plate/burner removal cover.

2. Disconnect electrical wiring from gas valve and ignition wire.

3. Remove both manifold retention plates from front and rear of unit.

4. Remove burner/manifold assembly from unit and place assembly on a flat work surface.

5. Remove ignition wire and pilot tubing from grommet.

6. Remove gas valve from manifold using a backup wrench.

7. Remove manifold extension pipe and manifold cap from manifold.

8. Clean any old joint compound (pipe dope) from manifold, manifold extension pipe, and manifold cap.

NOTE: Pipe dope must be resistant to the action of propane gas.

9. Reapply pipe dope to male threads of piping and reassemble manifold assembly as follows.

a. Install manifold extension pipe at previous location of

manifold cap. Tighten extension into position so it points toward blower when installed.

b. Install manifold cap at previous location of manifold

extension pipe.

c. Install gas valve onto manifold extension pipe so manual

ON/OFF knob is in 12 o’clock position.

d. Tighten manifold cap on manifold pipe.

10. Remove screws securing pilot bracket to burner support between first 2 burners.

11. Install pilot bracket between crossovers of first 2 burners on gas valve side of manifold.

12. Rebend pilot tubing to new location of pilot and gas valve. Ensure pilot tubing is free of kinks.

13. Route pilot tubing through grommet and reattach to pilot and gas valve. Check pilot to ensure pilot orifice is in place before connecting tubing.

14. Route ignition wire through grommet and connect to plug on pilot.

15. Check pilot position per dimensions shown in Fig. 12.

16. Reinstall manifold retention plate on front (control side) of unit with screws loose.

Page 10

SWITCH BRACKET

/8″

Fig. 13—Pressure Tubing Diagram

A91218

PRESSURE SWITCH TUBE ROUTING

TOP OF THE CONDENSING COIL

BOTTOM OF THE CONDENSING COIL

INDUCED DRAFT MOTOR

REMOVE

BASE BRACKET

A92306

Fig. 11—Rollout Switch Assembly

A91064

Fig. 12—Position of Pilot Assembly to Burner

17. Reinstall rear center panel of unit.

18. Remove burner patch plate from rear center panel of unit, cut insulation, and reinstall burner/manifold assembly through rear of unit. Ensure manifold assembly slides under front manifold retention plate.

19. Reinstall rear manifold retention plate and tighten screws on both retention plates.

20. Disconnect wiring from limit switch and remove limit switch.

21. Disconnect wiring from pressure switches using needle nose pliers.

22. Remove control box cover and disconnect blower leads from control board.

23. Disconnect tubing to pressure switches (mark tubing P1 and P2) and remove switches. (See Fig. 13.)

24. Remove control box from unit with draft inducer motor attached.

25. Remove 4 screws securing inducer assembly plate to front center panel.

26. Remove 4 screws securing front center panel to vent return pipe.

27. To avoid cuts during this procedure, place a piece of cardboard between condensing heat exchanger fins and vent return pipe. From rear of unit, remove 4 screws securing vent return pipe to bottom plate of condensing heat exchanger.

NOTE: Any gaskets or seals broken in items 25, 26, or 27 MUST be resealed properly to ensure safe furnace operation.

If the integrity of any gasket or seal is questionable due to separation of the gasket material, malformed appearance, or any noticeable deformity, the gasket material must be replaced. Failure to replace gaskets may result in nuisance tripping of safety controls, unit operation failure, or other conditions which may lead to personal injury.

28. Inspect gasket material on vent return pipe and on condensing heat exchanger bottom plate. Replace gasket material if necessary.

29. Reinstall vent return pipe so pipe outlet is facing rear of unit. Reinstall 4 washers and nuts securing pipe to heat exchanger bottom plate. Remove and discard cardboard previously placed between fins and pipe. Remove patch plate and cut insulation on rear center panel and position vent return pipe through panel. Secure pipe to panel with 4 screws.

30. Remove blower motor wiring harness strain relief from front center panel. Cut insulation and reinstall strain relief in same opening on back center panel. Route harness behind vent return pipe and through strain relief.

31. Remove pressure tubing strain relief from front center panel. Pull tubing through grommets and remove grommets. Cut insulation and reinstall grommets in similar openings in rear center panel. Route pressure tubing through grommets. Label 1 tube "top of coil" and the other "bottom of coil."

32. Reinstall rear heat exchanger panel.

33. Position control box (with wiring still attached to draft inducer motor and burner cover plate) on rear heat exchanger panel, route blower wiring into control box, and reinstall box.

34. Inspect gasket material on draft inducer assembly plate, and replace gasket material if necessary.

35. Reinstall draft inducer assembly on rear center panel over vent return pipe.

36. Reinstall air inlet plate/burner removal cover and manifold cover plate.

37. Reinstall limit switch with sensing disc toward blower.

38. Remove condensate drain line and reinstall through rear center panel.

39. Reinstall pressure switches on rear center panel. Route pressure tubing to switches and reconnect tubing as shown in Fig.

13.

Page 11

40. Remove blower access panel from front of unit and reinstall on rear of unit. Reinstall rear blower panel on front of unit. Reinstall top of unit. Install patch plates on front center panel and seal all remaining holes as necessary.

41. Reconnect wiring to blower motor, gas valve, pressure switches, and limit switches using unit wiring diagram. (See Fig. 17.) Ensure all wiring is properly connected and tight.

NOTE: Upon completing the installation, pressure test the furnace (using the following procedure) as critical gaskets/seals have been broken.

PRESSURE TEST

Do not place the unit into operation without checking the system pressures of the unit as outlined in this procedure. Failure to follow the pressure test procedure may result in a non- operational unit, nuisance tripping and/or a condition which may lead to personal injury.

1. Check wiring to insure it is properly connected and tight.

2. Place a jumper wire across pressure switches to bypass both controls.

3. Turn gas valve off.

4. Set room thermostat above room temperature.

5. Turn on electrical supply to furnace.

6. Check pressures at: a. Induced-draft motor tap (located at top left of motor

casing). b. Tube previously labelled "top of coil." c. Tube previously labelled "bottom of coil."

Excessive variation of the pressures listed in Table 7 indicates a system leak and/or blockage. This is especially true of the induced-draft motor pressure. An induced-draft motor pressure in the 1.5-in. to 1.6-in. wc range of vacuum pressure indicates a leak in the system and/or excessive vent length. Corrective action must be taken before the unit is placed into operation. Failure to take corrective action may result in a non-operational unit, condensate leakage, nuisance tripping, premature unit failure, and/or a condition which may lead to personal injury.

7. Use Table 7 to verify a properly-sealed unit.

NOTE: The pressures listed are for an ambient temperature of approximately 76°F. These pressures may vary slightly due to temperature, vent configuration, and vent length. The table is a general guideline of system pressures and may vary slightly from unit to unit.

Table 7—Unit Pressures (In. wc)

UNIT SIZE/

VENTING

50/Min Vent

Max Vent

75/Min Vent

Max Vent

100/Min Vent

Max Vent

125/Min Vent

Max Vent

INDUCED-DRAFT

MOTOR

PRESSURE

2.5

2.0

2.4

2.2

2.5

2.3

TOP OF COIL

PRESSURE

0.32

0.37

0.58

0.23

0.29

0.28

0.38

BOTTOM OF

COIL

PRESSURE

0.94

1.45

1.50

1.60

1.70

8. Reconnect pressure switch tubing as shown in Fig. 13.

9. Turn off electrical supply to unit.

10. Remove jumper wire on pressure switches.

11. Turn on gas valve.

12. Turn on electrical supply to unit. Unit should begin ignition cycle.

Step 11—Start-up, Adjustment, and Safety Check

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

The unit must not be installed, operated, and then turned off and left turned off in an unoccupied structure during cold weather when the temperature drops to 32°F and below. Freezing condensate left in the furnace will damage the equipment. See Service and Maintenance Instructions for winterizing procedure.

SEQUENCE OF OPERATION — Using the schematic diagram in Fig. 17, follow the sequence of operation through the different modes. This furnace has a unique control system—read and follow the wiring diagram very carefully.

1. When thermostat "calls for heat", the R-W circuit closes. a. Ignition sequence—Power from the transformer energizes

the fan control board. The fan control energizes the induced-draft blower motor. Pressure switches P1 and P2 normally open contacts close to initiate the ignition sequence.

b. Ignition trial—The ignition control energizes the pilot gas

valve. The ignition electrode begins sparking to light the pilot. When the pilot flame is sensed, the main gas valve opens and the pilot flame lights the burners. If the pilot flame is not sensed, the ignition control locks out after 90 sec. Reset the ignition control by turning the thermostat below room temperature for 1 minute and then above room temperature.

c. Blower on delay— The fan control starts the blower after

30 sec. The blower on delay is not adjustable.

d. Blower off delay—When the thermostat is satisfied, the

circuit between R and W is broken, de-energizing the gas valve and stopping gas flow to the burners. The blower motor remains energized 60, 90, 120, or 150 sec depending on the blower off delay selection (factory shipped set for 60-sec delay).

2. Cooling mode. The thermostat "calls for cooling" closing R and R-Y circuits.

The R-Y circuit starts the outdoor condensing unit, and the combined R-Y and R-G circuit starts the furnace blower motor on cooling speed. The (EAC) terminals are energized with 115v whenever the blower is operating.

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

START-UP PROCEDURES

1. Fill condensate trap with water. a. Disconnect condensate drain tube from bottom of inducer

housing.

Page 12

GAS HEAT

VALUE

(BTU/CU FT)

860

875

890

905

920

935

950

965

980

995

1010

1025

1040

1055

1070

1085

1100

Table 8—Model 58EJB Orifice Size and Manifold Pressure for Correct Input Rate

(Tabulated data based on altitudes up to 2000 ft and 25,000 Btuh per burner)

SPECIFIC GRAVITY OF NATURAL GAS

0.56 0.58 0.60 0.62 0.64 0.66 0.68 0.70 0.72

Orf.

Mnfld

Orf.

Mnfld

Orf.

Mnfld

Orf.

Mnfld

Orf.

Mnfld

Orf.

Mnfld

Orf.

Mnfld

Orf.

No.

37 38 —

37 38 39

38 39 —

38 39 40

39 40 41

40 41 —

41 42 —

42 — —

43 — —

Press

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.4

3.7

3.3

3.5

3.8

3.2

3.4

3.7

3.3

3.6 —

3.2

3.5 —

3.4

3.8 —

3.3

3.7 —

3.2

3.6 —

3.4 — —

3.3 — —

3.2 — —

3.8 — —

No.

37 38 —

37 38 39

38 39 —

38 39 40

39 40 —

39 40 41

40 41 —

41 42 —

42 — —

Press

3.4

3.8 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.4

3.7

3.3

3.6 —

3.2

3.4

3.7

3.3

3.6 —

3.2

3.5 —

3.4

3.8 —

3.3

3.7 —

3.2

3.6 —

3.5 — —

3.4 — —

3.3 — —

3.2 — —

No.

36 37 —

37 38 —

37 38 39

38 39 —

38 39 40

39 40 —

39 40 41

40 41 —

40 41 42

41 42 —

42 — —

Press

3.2

3.5 —

3.4

3.8 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.5

3.7

3.3

3.6 —

3.2

3.5

3.7

3.4

3.6 —

3.3

3.5 —

3.2

3.4

3.8

3.3

3.7 —

3.2

3.6 —

3.5 — —

3.4 — —

3.3 — —

No.

36 37 —

37 38 —

37 38 39

38 39 —

38 39 40

39 40 —

39 40 41

40 41 —

40 41 42

41 42 —

42 — —

Press

3.3

3.7 —

3.2

3.5 —

3.4

3.8 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.5

3.7

3.4

3.6 —

3.3

3.5

3.8

3.2

3.4

3.6

3.3

3.5 —

3.2

3.4

3.8

3.3

3.7 —

3.2

3.6 —

3.2

3.5 —

3.4 — —

No.

36 37 —

37 38 —

37 38 39

38 39 —

38 39 40

39 40 —

39 40 41

40 41 —

40 41 42

41 42 —

Press

3.4

3.8 —

3.3

3.6 —

3.2

3.5 —

3.4

3.8 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.5

3.7

3.4

3.6 —

3.3

3.5

3.8

3.2

3.4

3.7

3.3

3.6 —

3.2

3.4

3.8

3.4

3.7 —

3.3

3.6 —

3.2

3.5 —

No.

36 — —

36 37 —

37 38 —

37 38 39

38 39 —

38 39 40

39 40 —

39 40 41

40 41 —

40 41 42

41 42 —

Press

3.5 — —

3.4

3.8 —

3.3

3.6 —

3.2

3.5 —

3.4

3.7 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.5

3.7

3.4

3.6 —

3.3

3.5

3.8

3.2

3.4

3.7

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6 —

No.

35 36

—

— —

36 37

—

36 37 —

37 38 —

37 38 39

38 39 —

38 39 40

39 40 —

39 40 41

40 41 —

40 41 42

41 42 —

Press

3.2

3.6 —

3.5 — —

3.4

3.7 —

3.3

3.6 —

3.2

3.5 —

3.4

3.7 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.5

3.7

3.4

3.6 —

3.3

3.5

3.8

3.2

3.4

3.7

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

No.

34 35 36

35 36 —

36 — —

36 37 —

36 37 38

37 38 —

37 38 39

38 39 —

38 39 40

39 40 —

39 40 41

40 41 —

Mnfld Press

3.2

3.3

3.7

3.2

3.6 —

3.5 — —

3.4

3.7 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.5

3.7

3.4

3.6 —

3.3

3.5

3.8

3.2

3.4

3.7

3.3

3.6 —

3.2

3.5 —

Orf. No.

34 35 —

34 35 36

35 36 —

36 37 —

36 37 38

37 38 —

37 38 39

38 39 —

38 39 40

39 40 —

39 40 41

40 41 —

Mnfld Press

3.3

3.4 —

3.2

3.3

3.7

3.2

3.6 —

3.5

3.8 —

3.4

3.7 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6 —

3.2

3.5

3.8

3.4

3.7 —

3.3

3.6

3.8

3.2

3.5

3.7

3.4

3.6 —

3.3

3.5

3.8

3.2

3.4

3.7

3.3

3.6 —

b. Insert funnel into tube and pour 1 quart of water into tube.

This should overfill the trap and flow into an open drain.

c. Reconnect drain tube to bottom of inducer housing.

2. Purge gas lines.

If not previously done, purge the lines after all connections have been made and check for leaks.

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

3. Furnace Operation

Follow procedures on operating instruction label attached to furnace. With furnace operating, set thermostat below room temperature and observe that furnace goes off. Set thermostat above room temperature and observe that furnace restarts.

ADJUSTMENTS NOTE: Do not use the Carrier orifice calculator for this unit—the

orifice K-factor for this unit is different.

1. Set gas input rate.

There are 2 methods of adjusting gas input rate. The preferred method is by using Table 8 and following instructions in item a. The second method is by clocking the gas meter and following instructions in item b. Item b must be used for altitudes above 2000 ft.

a. Determine natural gas orifice size and manifold pressure

for correct input by using Table 8. Adjust manifold pressure per item c.

Page 13

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

supply.

(3.) Verify the furnace model. Table 8 can only be used for

model 58EJB Furnaces.

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

Table 8.

(5.) Follow heat value line and specific gravity line to

point of intersection to find orifice size and manifold pressure settings for proper operation at given natural gas condition.

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

ASSUME THE ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

EXAMPLE: Heat value 1025 Btu/cu ft Specific gravity of 0.62 Therefore, Orifice No. 41, Manifold pressure 3.5-in. wc The furnace is shipped with No. 42 orifices. In this example all main burner orifices must be changed and manifold pressure must be adjusted.

(1.) Remove burner enclosure front and cap that conceals

adjustment screw for gas valve regulator. (See Fig.

14.)

(2.) Turn adjusting screw either counterclockwise (out) to

decrease input rate or clockwise (in) to increase rate. When adjusting input rate, DO NOT set manifold pressure less than 3.2 or more than 3.8-in. wc for natural gas. Make any major adjustments by changing main burner orifices.

MANUAL

ON/OFF

MANIFOLD

PRESSURE

TAP

INLET PRESSURE TAP

REGULATOR ADJUSTMENT

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

b. Determine natural gas input rate by clocking gas meter and

adjusting manifold pressure per item c.

NOTE: Be sure all pressure tubing, combustion-air and vent pipes, and burner enclosure plates are in place when checking input.

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

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

(2.) Turn off all other gas appliances and pilots. (3.) Start furnace and let it run for 3 minutes. (4.) Measure time (in sec) for gas meter test dial to

complete 1 revolution. (5.) Refer to Table 9 for cubic ft of gas per hr. (6.) Multiply gas rate (cu ft/hr) by heating value (Btu/cu

ft). Obtain heating value from local gas utility.

EXAMPLE: Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 1070 Btu/cu ft Time for 1 revolution of 2 cu ft dial = 72 sec Gas rate = 100 cu ft/hr (from Table 9) Btu heating input = 100 X 1070 = 107,000 Btuh

(7.) Measured gas input must not exceed gas input on unit

rating plate.

NOTE: High altitude—Gas input on rating plate is for altitudes up to 2000 ft. Ratings for altitudes over 2000 ft must be 4 percent less for each 1000 ft above sea level. To obtain the adjusted altitude rating, adjust the manifold pressure, item c, and replace the main burner orifices as needed. Refer to NFGC Appendix F, Table F-4 for proper orifice sizing at high altitudes.

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

c. Adjust gas input.

NOTE: The gas meter must always be clocked with the burner enclosure front installed. The gas valve has been nominally set at

3.5-in. wc for natural gas.

A91219

Fig. 14—Redundant Automatic Gas Valve

DO NOT redrill orifices. Improper drilling (burrs, out-ofround holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of the burners and heat exchangers, causing failures.

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

(3.) Replace burner enclosure plates and measure adjusted

gas input rate using method outlined in item b.

(4.) Replace cap that conceals gas valve regulator adjust-

ment screw.

Be sure burner enclosure front is in place after adjustments have been made.

d. Look through sight glass in burner enclosure and check

burner flame. The main burner flame should be clear blue, almost transparent. (See Fig. 15.)

2. Set temperature rise.

The furnace must not be operated outside the range of temperature rise specified on the unit rating plate. Determine the air temperature rise as follows.

a. Place thermometers in return and supply ducts as near

furnace as possible. Be sure thermometers do not "see" heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight-run ducts.

b. When thermometer readings stabilize, subtract return-air

temperature from supply-air temperature to determine air temperature rise.

Page 14

BURNER FLAMEPILOT FLAME

BURNER

MANIFOLD

Fig. 15—Burner Flame

Table 9—Gas Rate Cu Ft/Hr

SECONDS

FOR 1

REVOLUTION

10 11 12 13 14

15 16 17 18 19

20 21 22 23 24

25 26 27 28 29

30 31 32 33 34

35 36 37 38 39

40 41 42 43 44

45 46 47 48 49

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

360

720 655 600 555 514

480 450 424 400 379

360 343 327 313 300

288 277 267 257 248

240 232 225 218 212

206 200 195 189 185

180 176 172 167 164

160 157 153 150 147

1800 1636 1500 1385 1286

1200 1125 1059

100 947

900 857 818 783 750

720 692 667 643 621

600 581 563 545 529

514 500 486 474 462

450 439 429 419 409

400 391 383 375 367

327 300 277 257

240 225 212 200 189

180 171 164 157 150

144 138 133 129 124

120 116 113 109 106

103 100

97 95 92

90 88 86 84 82

80 78 76 75 73

SECONDS

FOR 1

REVOLUTION

50 51 52 53 54

55 56 57 58 59

60 62 64 66 68

70 72 74 76 78

80 82 84 86 88

90 92 94 96 98

100 102 104 106 108

110 112 116 120

c. Adjust temperature rise by adjusting blower speed. Increase

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

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

144

141

138

136

133

131

129

126

124

122

120

116

112

109

106

103

100 48 47 46

45 44 43 42 41

40 39 38 38 37

36 35 35 34 33

33 32 31 30

A84076

97 95 92

90 88 86 84 82

80 78 76 75 74

72 71 69 68 67

65 64 62 60

360 355 346 340 333

327 321 316 310 305

300 290 281 273 265

257 250 243 237 231

225 220 214 209 205

200 196 192 188 184

180 178 173 170 167

164 161 155 150

Disconnect the electrical power before changing the speed tap. Failure to follow this warning could result in personal injury.

d. To change motor speed taps, remove the motor tap lead and

relocate it on the desired terminal on the plug in terminal block/speed selector located at the blower motor. (See Table 10.)

Table 10—Blower Speed Selection

SPEED TAP NO.

Common 1

High 2

Medium 3

Low 4

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

3. Set thermostat heat anticipator.

The thermostat heat anticipator must be set to match the amp draw of the components in the R to W circuit. Accurate amp draw measurements can be obtained at the thermostat subbase terminals R and W.

Fig. 16 illustrates an easy method of obtaining these measurements. The amp reading should be taken after the blower motor has started. See the thermostat manufacturer’s instructions for adjusting the heat anticipator and for varying the heating cycle length.

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED

HOOK-AROUND

VOLT/AMMETER

R Y W G

Fig. 16—Amp Draw Check with Ammeter

10 TURNS

CHECK SAFETY CONTROLS

1. Check primary limit control.

The control shuts off the combination control system and energizes

EXAMPLE:

the circulating-air blower motor if the furnace overheats.

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

FROM UNIT 24-VOLT TERMINAL BLOCK

= 0.5 AMPS FOR THERMOSTAT SETTING

The recommended method of checking this limit control is to gradually block off the return air after the furnace has been operating for a period of at least 5 minutes. As soon as the limit control has shut off the burners, the return-air opening should be unblocked to permit normal air circulation. By using this method to check the limit control, it can be established that the limit is functioning properly and will operate if there is a restricted circulating-air supply or motor failure. If the limit control does not function during this test, the cause must be determined and corrected.

2. Check pressure switch P1 (blocked-vent shutoff switch).

A80201

Page 15

This control proves operation of the draft inducer. Check switch operation as follows.

a. Turn off 115-v power to furnace. b. Remove control box cover and disconnect inducer motor

lead wires from control board. c. Turn on 115-v power to furnace. d. Set thermostat to "call for heat." When the pressure switch

is functioning properly, the ignitor should not spark. If the

ignitor sparks when the inducer motor is disconnected, shut

down the furnace immediately. Determine the reason the

pressure switch did not function properly and correct the

condition. e. Turn off 115-v power to furnace. f. Reconnect inducer motor lead, reinstall control box cover,

and turn on 115-v power supply.

3. Check pressure switch P2 (blocked drain safety switch).

This control ensures the condensate drain is open to allow condensate flow and that combustion air is flowing through the unit prior to starting the ignition cycle. The blocked drain safety switch has only 1 tube connected to it. Check switch operation as follows.

a. Place unit into operation with burners on. b. Pinch off tube leading to pressure switch P2. The burners

should shut off.

c. Release the restriction on tube and furnace should begin an

ignition trial.

d. If burners do not shut off, determine reason pressure switch

did not function properly and correct condition.

CHECKLIST

1. Put away tools and instruments. Clean up debris. Verify that blower and control access panels are properly installed.

2. Cycle test furnace with room thermostat.

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

4. Review User’s Manual with owner.

5. Leave literature packet near furnace.

Page 16

CIRCULATION

FAN

MED

LOW

50, 75

100,125

HEAT

FOR 75, 100, 125

115 VAC 1 0 60 HZ POWER SUPPLY

(FUSED DISCONNECT ON HOT LEG)

GND

L1(H) L2(N)

COOL

K1K2

N3D1

INDUCER MOTOR

TRANSFORMER

24VAC

(115 VAC)

CONDENSING

UNIT

ST912081005

ELECTRONIC

CN23-1

RYC

FAN TIMER

CN23-6

LIMIT

CONTROL

TSTAT

PILOT

CN23-2

GAS VALVE

HONEYWELL VR8204

GNO

MV PV

MV\PV

PS1 PS2 V1

N.O. N.C.

CN23-3 CN23-5

COM.

ROS

24V (GNO)

GNO (BURNER)

MV MV\PV PV

24V

PRESSURE SW.

IGNITION MODULE

HONEYWELL S8600

SPARK

OR 8660

A91349

with orange wire nuts.

and local codes.

replaced, it must be replaced with wiring material having a temperature

rating of at least 185 C and be a minimum of 16 GA. AWG copper

strand wire.

a temperature rise within the range specified on the rating plate.

Connect unused motor leads to the "M1 & M2" terminals.

(1) Make field power supply connections to black and white wires capped

(2) WARNING --- Unit must be grounded. Wiring must conform to N.E.C.

(3) If any of the original wire, as supplied with the furnace, must be

(4) Connect required motor lead to heat terminal on circuit board to deliver

NOTES:

LIMIT

LPROS

BLACK

BLUE

BROWN

BK

BL

BR

LEGEND

PRINTED CIRCUIT

BOARD WIRING

FACTORY WIRING

LINE Y 

24 V

PRESSURE SWITCH

ROLL OUT SWITCH

BLOWER INTERLOCK

CONDENSING UNIT

BI

CU

GREEN

ORANGE

RED

RED/BLACK STRIPE

VIOLET

WHITE

YELLOW

GR

OR

RD

RD/BK

VI

WH

FIELD WIRING

POWER SUPPLY

115 VAC 10 60 HZ

(FUSED DISCONNECT

ON HOT LEG)

L1 (H)

L2 (N)

GND

ORANGE WIRE NUT GROUND

ROS P

I.D.

150 SEC

DELAY OFF SCREW SETTINGS

60 SEC 90 SEC 120 SEC

BLOWER

S8600

SPARK

TH-W (OPT) 24V 24V (GNO)

GNO (BURNER)

PV MV/PV MV

CAP.

INDOOR

BLOWER

MOTOR

1 2 3 4 5 6 7 8 9

WH BL

RD/

3 4

M H

G.V.

MV/PV

GND

Fig. 17—Wiring Diagram

PILOT

HONEYWELL

1 2 3 4 D1

L O

O C

1 2 3 4 5 6

T A E H

M1 M2

SELECT

DELAY OFF

A B

LEADS

MOTOR UNUSED

100, 125K INPUT

50, 75K INPUT

R Y W G

G H COY R

X X Y

C C

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

Book 1 4 Tab 6a 8a

PC 101 Catalog No. 535-869 Printed in U.S.A. Form 58EJB-1SI Pg 16 2-94 Replaces: 58EJA-3SI