Carrier 58MCA, 58MCA040, 58MCA060, 58MCA080, 58MCA100 Installation, Start-up, And Operating Instructions Manual

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Page 1

4-Way Multipoise Fixed-Capacity

Direct-Vent Condensing Gas Furnace

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Installation, Start-Up, and Operating Instructions

For Sizes 040-140, Series 140 (LIMITED)

58MCA

A93040

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

Index Page

DIMENSIONAL DRAWING........................................................2

SAFETY CONSIDERATIONS.....................................................3

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........4

INTRODUCTION..........................................................................4

APPLICATIONS ......................................................................5-12

General......................................................................................5

Upflow Applications..............................................................5-7

Downflow Applications.........................................................7-8

Horizontal Left (Supply-Air Discharge) Applications.......8-10

Horizontal Right (Supply-Air Discharge) Applications...10-12

LOCATION ............................................................................12-13

General....................................................................................12

Furnace Location Relative to Cooling Equipment................13

Hazardous Locations...............................................................13

INSTALLATION....................................................................13-17

Leveling Legs (If Desired).....................................................13

Installation In Upflow and Downflow Applications........13-15

Installation In Horizontal Applications..................................15

Filter Arrangement..................................................................16

Bottom Closure Panel.............................................................16

Gas Piping..........................................................................16-17

AIR DUCTS............................................................................17-18

General Requirements.............................................................17

Ductwork Acoustical Treatment.............................................18

Supply Air Connections..........................................................18

Return Air Connections..........................................................18

ELECTRICAL CONNECTIONS...........................................18-19

115-v Wiring......................................................................18-19

24-v Wiring.............................................................................19

Accessories..............................................................................19

DIRECT VENTING ...............................................................19-29

Removal of Existing Furnaces from

Common Vent Systems................................................19-21

Combustion-Air and Vent Piping .....................................21-27

Concentric Vent and Combustion-Air Termination

Kit Installation...................................................................28

Multiventing and Vent Termination.......................................28

CONDENSATE DRAIN........................................................30-32

General....................................................................................30

ama

CERTIFIED

As an ENERGY STAR® Partner, Carrier Corporation has determined that this product meets the ENERGY STAR® guidelines for energy efficiency.

HORIZONTAL

LEFT

AIRFLOW

Fig. 1—Multipoise Orientations

Application..............................................................................30

Condensate Drain Protection..................................................32

SEQUENCE OF OPERATION..............................................32-34

Heating Mode..........................................................................32

Cooling Mode .........................................................................32

Continuous Blower Mode.......................................................33

Heat Pump Mode....................................................................33

Component Test......................................................................33

START-UP PROCEDURES ..................................................34-42

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

Prime Condensate Trap With Water......................................34

Purge Gas Lines......................................................................34

Adjustments .......................................................................35-42

Set Gas Input Rate ............................................................35-41

Set Temperature Rise........................................................41-42

Blower Off Delay (Heat Mode).............................................42

Set Thermostat Heat Anticipator............................................42

CHECK SAFETY CONTROLS..................................................42

Check Primary Limit Control.................................................42

Check Pressure Switch ...........................................................42

CHECKLIST................................................................................43

REGISTERED QUALITY SYSTEM

AIRFLOW

UPFLOW

HORIZONTAL

DOWNFLOW

AIRFLOW

RIGHT

AIRFLOW

A93041

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. 535-758 Printed in U.S.A. Form 58MCA-7SI Pg 1 1-00 Replaces: New

Page 2

A99112

⁄

19"

⁄

OUTLET

⁄

AIRFLOW

⁄

TYP

OUTLET

CONDENSATE DRAIN

TRAP LOCATION

2-IN. COMBUSTION-

TRAP LOCATION

CONDENSATE DRAIN

(DOWNFLOW &

HORIZONTAL LEFT)

⁄2-IN. DIA

GAS CONN

AIR CONN

(DOWNFLOW &

OR ALTERNATE

-IN. DIA GAS CONN

⁄

HORIZONTAL RIGHT)

⁄8-IN. DIA

POWER CONN

⁄8-IN. DIA

POWER CONN

⁄

TYP

⁄2-IN. DIA

⁄

TYP

⁄

2-IN. VENT CONN

THERMOSTAT ENTRY

⁄

TYP

⁄

⁄8-IN. DIA

ACCESSORY

POWER ENTRY

⁄

TYP

CONDENSATE

DRAIN TRAP

LOCATION

(ALTERNATE

SIDE INLET

⁄

UPFLOW)

⁄

TYP

" TYP

⁄

CONDENSATE

INLET

DRAIN LOCATION

CONDENSATE

DRAIN LOCATION

(UPFLOW)

⁄

BOTTOM INLET

DIMPLE LOCATORS

(UPFLOW)

HANGING

FOR HORIZONTAL

/2-in. rectangle.

/4-in. rectangle.

/2 x 19

/2 x 23

/2 x 12-in. rectangle.

c. For 1600 CFM–22-in. round or 14

b. For 1200 CFM–20-in. round or 14

see flex duct manufacturer’s recommendations for equivalent diameters.

a. For 800 CFM–16-in. round or 14

2. Minimum return-air opening at furnace:

NOTES: 1. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,

Dimensions (In.)

literature for specific use of single side inlets. The use of both side inlets, a

combination of 1 side and the bottom, or the bottom only will ensure adequate

return air openings for airflow requirements above 1800 CFM.

d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data

Fig. 2—Dimensional Drawing

⁄

2-IN. COMBUSTION-

AIR CONN

⁄2-IN. DIA

GAS CONN

2-IN. VENT CONN

ENTRY

⁄

⁄2-IN. DIA THERMOSTAT

SIDE INLET

⁄

TYP

⁄

" TYP

⁄

SIDE INLET

" TYP

⁄

040-08 17-1/2 15-7/8 16

040-12 17-1/2 15-7/8 16

060-08 17-1/2 15-7/8 16

060-12 17-1/2 15-7/8 16

060-16 17-1/2 15-7/8 16

080-12 17-1/2 15-7/8 16

080-16 17-1/2 15-7/8 16

080-20 21 19-3/8 19-1/2

100-16 21 19-3/8 19-1/2

100-20 21 19-3/8 19-1/2

120-20 24-1/2 22-7/8 23

UNIT SIZE A D E

140-20 24-1/2 22-7/8 23

Page 3

SAFETY CONSIDERATIONS

In Canada, refer to the current edition of the CAN/CGA-B149.1and .2-M95 National Standard of Canada, Natural Gas and

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 literature, on tags, and on labels attached to or shipped with 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. 54-1999/ANSI Z223.1-1999 and the Installation Standards, Warm Air Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B.

Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have a 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 unit or in instructions and manuals, be alert to potential for personal injury.

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

INSTALLATION

This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size Furnaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m). An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications. This furnace is for indoor installation in a building constructed on site. This furnace may be installed in a manufactured (mobile) home when stated on rating plate and using factory authorized kit. This furnace may be installed on combustible flooring in alcove or closet at minimum clearance from combustible material. This appliance requires a special venting system. Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC, PVC-DWV, CPVC or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).

Furnace must be installed level, or pitched forward within 1/2 inch of level for proper drainage. Failure will result in equipment or property damage. See Installation Manual for IMPORTANT unit support details on horizontal applications

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

ALL POSITIONS:

Mimimum front clearance for service 30 inches (762mm).

140 size furnaces require 1 inch back clearance to combustible

††

materials.

DOWNFLOW POSITIONS:

For installation on combustible floors only when installed on

†

special base No. KGASB0201ALL, Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

HORIZONTAL POSITIONS:

Line contact is permissible only between lines formed by intersections of top and two sides of furnace jacket, and building joists, studs, or framing.

Clearance shown is for air inlet and air outlet end.

120 and 140 size Furnaces require 1 inch bottom clearance to

combustible materials.

324999-201 REV. B (LIT)

LEVEL (0")

1/2" MAX

UPFLOW OR DOWNFLOW

LEVEL (0")

1/2" MAX

FRONT

This furnace is approved for UPFLOW, DOWNFLOW and HORIZONTAL installations.

FRONT

HORIZONTAL

††

SIDE

Clearance in inches

TOP/PLENUM

FURNACE

BOTTOM

†

FRONT

Vent clearance to combustibles 0”.

SIDE

MIN

A99230

Fig. 3—Clearances to Combustibles

Page 4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. DO NOT TOUCH THE

CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity (for example; DO NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).

4. If you touch ungrounded objects (recharge your body with static electricity), firmly touch furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 5 before bringing the control or yourself into contact with the furnace. Put all used AND new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

INTRODUCTION

The 58MCA Multipoise Condensing Gas-Fired Series 140 Limited Furnaces are A.G.A./C.G.A. design certified for natural and propane gases and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. An A.G.A./C.G.A. listed gas conversion kit is required to convert furnace for use with propane gas. The 58MCA 040 through 120 size units are A.G.A./C.G.A. approved for use in manufactured (mobile) homes when factory accessory conversion kit is used. The 140 size unit is NOT approved for use in manufactured (mobile) homes. These furnaces are suitable for installation in a residence built on site or a manufactured residence completed at final site. The design of this furnace line is NOT A.G.A./C.G.A. certified for installation in recreation vehicles or outdoors.

These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used.

These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGHT, or

HORIZONTAL LEFT (supply-air discharge direction) applications as shown in Fig. 1. See details in Applications section.

These furnaces are shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main blower compartment.

Installer Packet includes:

Installation, Start-Up, and Operating Instructions Service and Maintenance Instructions User’s Information Manual Warranty Certificate

Loose Parts Bag includes: Quantity

Pressure tube extension 1 Collector box or condensate trap extension tube 1 Inducer housing drain tube 1 1/2-in. CPVC street elbow 2 Drain tube coupling 1 Drain tube coupling grommet 1 Vent and combustion-air pipe support 2 Combustion-air pipe perforated disk assembly 1

Vent Pipe Extension 1*

* ONLY supplied with some furnaces. This furnace must be installed with a direct-vent (combustion air

and flue) system and a factory accessory termination kit. In a direct-vent system, all air for combustion is taken directly from the outside atmosphere and all flue products are discharged to the outside atmosphere. See furnace and factory accessory termination kit instructions for proper installation.

Before installing the furnace in the United States, refer to the current edition of the NFGC and the NFPA 90B.

For copies of the NFGC and NFPA 90B, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC contact the American Gas Association, 400 N. Capitol St., NW, Washington DC 20001.

Before installing the furnace in Canada, refer to the NSCNGPIC. For a copy of the NSCNGPIC, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke, (Toronto) Ontario, Canada M9W 1R3.

Installation must comply with regulations of serving gas supplier and local building, heating, plumbing or other codes in effect in the area in which installation is made. In the absence of local building codes, installation must conform with the NFGC in the United States and the NSCNGPIC and all authorities having jurisdiction in Canada.

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, unit leveling, and unit sizing. Improper installation or misapplication of furnace can require excessive servicing or cause premature component failure.

Page 5

BLOWER SHELF

CONDENSATE TRAP (INSIDE)

ALTERNATE DRAIN TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

FURNACE DOOR

FIELD

DRAIN

CONN

EXTERNAL UPFLOW APPLICATIONS

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

WIRE TIE GUIDES (WHEN USED)

CONDENSATE TRAP

FURNACE

SIDE

FURNACE DOOR

FIELD

DRAIN

CONN

FURNACE SIDE

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

⁄4 OD COLLECTOR BOX TO TRAP RELIEF PORT

⁄2 OD INDUCER HOUSING DRAIN CONNECTION

⁄8 OD COLLECTOR BOX DRAIN CONNECTION

SCREW HOLE FOR UPFLOW OR DOWN- FLOW APPLICATIONS (OPTIONAL)

⁄2-IN. PVC OR CPVC

HORIZONTAL

APPLICATIONS

FRONT VIEW SIDE VIEW

Fig. 4—Condensate Trap

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

For accessory installation details, refer to applicable installation literature.

APPLICATIONS

Step 1—General

Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 1. All drain and pressure tubes are connected as shown in Fig. 5. See appropriate application instructions for these procedures.

Step 2—Upflow Applications

An upflow furnace application is where furnace blower is located below combustion and controls section of furnace, and conditioned air is discharged upwards.

A93026

CONDENSATE TRAP LOCATION (FACTORY-SHIPPED ORIENTATION)

The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications. A factory-supplied tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment. See Condensate Trap Tubing (Factory-Shipped Orientation) section for drain tube extension details.

CONDENSATE TRAP TUBING (FACTORY-SHIPPED ORIENTATION) NOTE: See Fig. 5 or tube routing label on main furnace door to confirm location of these tubes.

1. Collector Box Drain, Inducer Housing Drain, Relief Port, and Pressure Switch Tubes

These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications. These tubes can be identified by their connection location and also by a color label on each tube. These tubes are identified as follows: collector box drain tube (blue label), inducer housing drain tube (violet label or molded), relief port tube (green label), and pressure switch tube (pink label).

2. Condensate Trap Drain Tube The condensate trap drain connection must be extended for

field attachment by doing the following: a. Determine location of field drain connection. (See Fig. 2 or

5.)

Page 6

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING 

(MOLDED) DRAIN 

TUBE (BEHIND 

COLLECTOR BOX 

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄2-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE  TRAP

DRAIN TUBE

DRAIN OPTION)

Fig. 5—Factory-Shipped Upflow Tube

Configuration

(Shown With Blower Access Panel Removed)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

CONDENSATE

TRAP

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

A94163

A94164

Fig. 6—Alternate Upflow Tube Configuration and

Trap Location

NOTE: If internal filter is used, drain tube should be located to

opposite side of casing of return duct attachment to assist in filter removal.

b. Remove and discard casing drain hole plug button from

desired side.

c. Install drain tube coupling grommet (factory-supplied in

loose parts bag) in selected casing hole.

d. Slide drain tube coupling (factory-supplied in loose parts

bag) through grommet ensuring long end of coupling faces blower.

e. Cement 2 factory-supplied 1/2-in. street CPVC elbows to

the rigid drain tube connection on the condensate trap. (See Fig. 5.) These elbows must be cemented together and cemented to condensate trap drain connection.

NOTE: Failure to use CPVC elbows may allow drain to kink and prevent draining.

f. Connect larger diameter drain tube and clamp (factory-

supplied in loose parts bag) to condensate trap and clamp

securely. g. Route tube to coupling and cut to appropriate length. h. Attach tube to coupling and clamp securely.

CONDENSATE TRAP LOCATION (ALTERNATE UPFLOW ORIENTATION)

An alternate location for the condensate trap is the left-hand side of casing. (See Fig. 2 and 6.)

NOTE: If the alternate left-hand side of casing location is used, the factory-connected drain and relief port tubes must be disconnected and modified for attachment. See Condensate Trap Tubing (Alternate Upflow Orientation) section for tubing attachment.

To relocate condensate trap to the left-hand side, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2 or

6.)

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into left-hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

Page 7

CONDENSATE TRAP TUBING (ALTERNATE UPFLOW ORIENTATION)

NOTE: See Fig. 6 or tube routing label on main furnace door to confirm location of these tubes.

1. Collector Box Drain Tube Connect collector box drain tube (blue label) to condensate

trap.

NOTE: On 17-1/2-in. wide furnaces ONLY, cut tube between corrugated sections to prevent kinks from occurring.

2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing

drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label and

factory-supplied in loose parts bag) to connect LOWER

inducer housing drain connection to the condensate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube a. Connect relief port tube (green label) to condensate trap. b. Extend this tube (if required) by splicing to small diameter

tube (factory-supplied in loose parts bag).

c. Determine appropriate length, cut, and connect tube.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT Refer to Condensate Drain section for recommendations and

procedures. PRESSURE SWITCH TUBING The LOWER collector box pressure tube (pink label) is factory

connected to the pressure switch and should not require any modification.

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections.

UPPER COLLECTOR BOX AND INDUCER HOUSING (UNUSED) DRAIN CONNECTIONS

Upper Collector Box Drain Connection Attached to the UPPER collector box drain connection is a

factory-installed corrugated, plugged tube (blue and white striped label). This tube is plugged to prevent condensate leakage in this application. Ensure this tube is plugged.

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections.

Upper Inducer Housing Drain Connection Attached to the UPPER (unused) inducer housing drain connection

is a cap and clamp. This cap is used to prevent condensate leakage in this application. Ensure this connection is capped.

NOTE: See Fig. 5 or 6 or tube routing label on main furnace door to check for proper connections.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda-

tions and procedures.

Step 3—Downflow Applications

A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, and conditioned air is discharged downwards.

CONDENSATE TRAP LOCATION The condensate trap must be removed from the factory-installed

blower shelf location and relocated in selected application location as shown in Fig. 2, 7, or 8.

To relocate condensate trap from the blower shelf to desired location, perform the following:

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX 

EXTENSION TUBE

CONDENSATE

TRAP

INDUCER HOUSING 

DRAIN TUBE (VIOLET)

PLUG CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (PINK)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED)

COLLECTOR BOX  EXTENSION TUBE

INDUCER HOUSING  DRAIN TUBE  (VIOLET)

CONDENSATE TRAP

COLLECTOR BOX  EXTENSION  DRAIN TUBE

DRAIN TUBE COUPLING

Fig. 7—Downflow Tube Configuration

(Left-Hand Trap Installation)

A94165

A94166

Fig. 8—Downflow Tube Configuration

(Right-Hand Trap Installation)

Page 8

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2, 7, or 8.)

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into desired casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

CONDENSATE TRAP TUBING NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections.

1. Collector Box Drain Tube a. Remove factory-installed plug from LOWER collector box

drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector box

drain tube (blue label) which was connected to condensate trap.

c. Connect LOWER collector box drain connection to con-

densate trap. (1.) Condensate Trap Located on Left Side of Casing

(a.) Connect LOWER collector box drain tube (blue

and white striped label) to condensate trap. Tube does not need to be cut.

(b.) Clamp tube to prevent any condensate leakage.

(2.) Condensate Trap Located on Right Side of Casing

(a.) Install drain tube coupling (factory-supplied in

loose parts bag) into collector box drain tube (blue and white striped label) which was previously plugged.

(b.) Connect larger diameter drain tube (factory-

supplied in loose parts bag) to drain tube coupling, extending collector box drain tube for connection to condensate trap.

(c.) Route extended collector box drain tube directly

from collector box drain to condensate trap as

shown in Fig. 8. (d.) Determine appropriate length and cut. (e.) Connect to condensate trap. (f.) Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

d. Use inducer housing drain tube (violet label and factory-

supplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap.

e. Connect inducer housing drain connection to condensate

trap. (1.) Condensate Trap Located on Left Side of Casing

(a.) Determine appropriate length and cut. (b.) Connect tube to condensate trap. (c.) Clamp tube to prevent any condensate leakage.

(2.) Condensate Trap Located on Right Side of Casing

(a.) Route inducer housing drain tube (violet label)

directly from inducer housing to condensate trap

as shown in Fig. 8. (b.) Determine appropriate length and cut. (c.) Connect tube to condensate trap. (d.) Clamp tube to prevent any condensate leakage.

3. Relief Port Tube Refer to Pressure Switch Tubing section for connection

procedure.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT Refer to Condensate Drain section for recommendations and

procedures. PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL RIGHT applications.

NOTE: See Fig. 7 or 8 or tube routing label on main furnace door to check for proper connections.

Relocate tubes as described below.

1. Disconnect collector box pressure tube (pink label) attached to pressure switch.

2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in loose parts bag).

3. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.

4. Extend collector box pressure tube (pink label) which was previously connected to pressure switch by splicing to remaining small diameter tube (factory-supplied in loose parts bag).

5. Route this extended tube (pink label) to condensate trap relief port connection.

6. Determine appropriate length, cut, and connect tube.

7. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda-

tions and procedures.

Step 4—Horizontal Left (Supply-Air Discharge) Applications

A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace, and conditioned air is discharged to the left.

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling.

NOTE: In Canada, installations shall be in accordance with current NSCNGPIC and/or local codes.

NOTE: The auxiliary junction box (J-Box) MUST be relocated to opposite side of furnace casing. (See Fig. 9.) See Electrical Connection section for J-Box relocation.

Page 9

CONDENSATE TRAP LOCATION The condensate trap must be removed from the factory-installed

blower shelf location and relocated in selected application location as shown in Fig. 2 or 9.

To relocate condensate trap from the blower shelf to desired location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2 or

9.)

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

CONDENSATE TRAP TUBING NOTE: See Fig. 9 or tube routing label on main furnace door to

check for proper connections.

1. Collector Box Drain Tube a. Install drain tube coupling (factory-supplied in loose parts

bag) into collector box drain tube (blue label) which was previously connected to condensate trap.

b. Connect large diameter drain tube and clamp (factory-

supplied in loose parts bag) to drain tube coupling, extending collector box drain tube.

c. Route extended tube (blue label) to condensate trap and cut

to appropriate length.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing

drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label and

factory-supplied in loose parts bag) to connect LOWER

inducer housing drain connection to the condensate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube a. Extend collector box tube (green label) which was previ-

ously connected to the condensate trap by splicing to small diameter tube (factory-supplied in loose parts bag).

b. Route extended collector box pressure tube to relief port

connection on the condensate trap. c. Determine appropriate length, cut, and connect tube. d. Clamp tube to prevent any condensate leakage.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT Refer to Condensate Drain section for recommendations and

procedures. PRESSURE SWITCH TUBING

The LOWER collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected, extended, rerouted, and then reconnected to the pressure switch in HORIZONTAL LEFT applications.

PLUG

CAP

AUXILIARY "J" BOX

RELOCATED HERE

CONDENSATE

TRAP

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040, 060, AND 080 HEATING INPUT FURNACES

COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED)

Fig. 9—Horizontal Left Tube Configuration

COLLECTOR BOX TUBE (GREEN)

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOX DRAIN TUBE (BLUE)

A93302

Page 10

MANUAL

SHUTOFF

GAS VALVE

COMBUSTION – AIR

SEDIMENT TRAP

INTAKE

5 3⁄4″

CONDENSATE TRAP

VENT



30″ MIN

WORK AREA

DRAIN

A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE.

ACCESS OPENING FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS.

Fig. 10—Attic Location and Working Platform

NOTE: See Fig. 9 or tube routing label on main furnace door to

check for proper connections. Modify tube as described below.

1. Disconnect collector box pressure tube (pink label) attached to pressure switch.

2. Use smaller diameter tube (factory-supplied in loose parts bag) to extend tube disconnected in item 1.

3. Route extended tube: a. Behind inducer housing. b. Between blower shelf and inducer housing. c. Behind inducer motor bracket. d. Between inducer motor and pressure switch.

4. Determine appropriate length, cut, and reconnect tube to pressure switch connection labeled COLLECTOR BOX.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda-

tions and procedures. CONSTRUCT A WORKING PLATFORM Construct working platform where all required furnace clearances

are met. (See Fig. 3 and 10.)

The condensate trap MUST be installed below furnace. See Fig. 4 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 6.)

A93031

NOTE: A 12-in. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 10 or 28.)

Step 5—Horizontal Right (Supply-Air Discharge) Applications

A horizontal right furnace application is where furnace blower is located to the left of combustion and controls section of furnace, and conditioned air is discharged to the right.

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in attic application or over a finished ceiling.

NOTE: In Canada, installations shall be in accordance with current NSCNGPIC Installation Codes and/or local codes.

CONDENSATE TRAP LOCATION The condensate trap must be removed from the factory-installed

blower shelf location and relocated in selected application location as shown in Fig. 2 or 11.

To relocate condensate trap from the blower shelf to desired location, perform the following:

1. Remove 3 tubes connected to condensate trap.

2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2 or

11.)

Page 11

CAP

PLUG

COLLECTOR BOX DRAIN TUBE 

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 11—Horizontal Right Tube Configuration

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

CONDENSATE TRAP

A93303

4. Install casing hole filler cap into blower shelf hole where trap was removed.

5. Install condensate trap into casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

CONDENSATE TRAP TUBING NOTE: See Fig. 11 or tube routing label on main furnace door to check for proper connections.

1. Collector Box Drain Tube a. Remove factory-installed plug from LOWER collector box

drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector box

drain tube (blue label) which was previously connected to condensate trap.

c. Connect LOWER collector box drain tube (blue and white

striped label) to condensate trap. Tube does not need to be cut.

d. Clamp tube to prevent any condensate leakage.

2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

d. Use inducer housing drain extension tube (violet label and

factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to condensate trap.

e. Determine appropriate length, cut, and connect tube to

condensate trap.

f. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube Refer to Pressure Switch Tubing section for connection

procedure.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT Refer to Condensate Drain section for recommendations and

procedures. PRESSURE SWITCH TUBING

NOTE: See Fig. 11 or tube routing label on main furnace door to check for proper connections.

Relocate tubes as described below:

1. Disconnect collector box pressure tube (pink label) attached to pressure switch.

2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in loose parts bag).

3. Route extended collector box pressure tube behind inducer motor bracket then between inducer motor and pressure switch.

4. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.

5. Use remaining smaller diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch.

Page 12

6. Route this extended tube (pink label) to condensate trap relief port connection.

7. Determine appropriate length, cut, and connect tube.

8. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda-

tions and procedures. CONSTRUCT A WORKING PLATFORM Construct working platform where all required furnace clearances

are met. (See Fig. 3 and 10.)

The condensate trap MUST be installed below furnace. See Fig. 4 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

FRONT

°F °F

RETURN AIR

MAX 85°F MIN 55°F

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 6.)

LOCATION

Step 1—General

When a furnace is installed so that supply ducts carry air to areas outside the space containing the furnace, return air must also be handled by ducts sealed to furnace casing. The ducts terminate outside the space containing the furnace to ensure there will not be a negative pressure condition within equipment room or space. Furnace may be located in a confined space without special provisions for dilution or ventilation air. This furnace must be installed so electrical components are protected from water.

LEVEL (0″)

TO

⁄2″ MAX

UPFLOW OR DOWNFLOW HORIZONTAL

FRONT

LEVEL (0″)

TO

⁄2″ MAX

FRONT

A93025

NOTE: For proper furnace operation, install furnace so that it is level or pitched forward within 1/2 in. to ensure proper condensate drainage from secondary heat exchangers.

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

Locate furnace so combustion-air pipe maximum lengths are not exceeded. Refer to Table 6.

A93042

NOTE: These furnaces are designed for a minimum continuous return-air temperature of 60°F or intermittent operation down to 55°F such as when used with a night setback thermostat. Return-air temperature must not exceed a maximum of 85°F. Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls.

FRONT

B A C K

BACK

FRONT

A93043

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

If these furnaces are 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 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 heat exchangers. Some of these compounds are found in paneling, dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems.

Page 13

32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED

A93058

INSTALLATION

Step 1—Leveling Legs (If Desired)

When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 12.) Install field-supplied, corrosion-resistant 5/16-in. machine bolts and nuts.

⁄16″

1 3⁄4″

⁄4″

If these furnaces are installed in an unconditioned space where ambient temperatures may be 32°F or lower, freeze protection measures must be taken.

Provide ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on unit’s clearance to combustibles label. (See Fig. 3.) Locate furnace where available electric power and gas supplies meet specifications on furnace rating plate.

Step 2—Furnace Location Relative to Cooling Equipment

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

Step 3—Hazardous Locations

18-IN. MINIMUM

TO BURNERS

A93044

When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18 in. above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, unit must be installed in accordance with requirements of National Fire Protection Association, Inc.

⁄16″

1 3⁄4″

A89014

Fig. 12—Leveling Legs

NOTE: The maximum length of bolt should not exceed 1-1/2 in.

1. Position furnace on its back. Locate and drill a 5/16-in. diameter hole in each bottom corner of furnace. (See Fig. 12.) Holes in bottom closure panel may be used as guide locations.

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

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

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

NOTE: Bottom closure must be used when leveling legs are used. See Bottom Closure Panel section.

Step 2—Installation in Upflow or Downflow Applications

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when special base (available from manufacturer) Part No. KGASB0201ALL is used. Special base in not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is used.

1. Determine application being installed from Table 1.

2. Construct hole in floor per dimensions specified in Table 1 and Fig. 13.

3. Construct plenum to dimensions specified in Table 1 and Fig.

13.

4. If downflow subbase (KGASB) is used, install as shown in Fig. 14.

If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No. KCAKC is used, install as shown in Fig. 15.

NOTE: Remove furnace perforated, discharge duct flanges when they interfere with mating flanges on coil on downflow subbase. To remove furnace perforated, discharge duct flange, use wide

Page 14

PLENUM

OPENING

FLOOR

OPENING

A96283

Fig. 13—Floor and Plenum Opening Dimensions

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 14—Furnace, Plenum, and Subbase

Installed on a Combustible Floor

Table 1—Opening Dimensions (In.)

FURNACE

CASING

WIDTH

17-1/2

24-1/2

Downflow Applications on Non-Combustible Flooring 15-7/8 19 16-1/2 19-5/8

Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Non-Combustible Flooring 19-3/8 19 20 19-5/8

Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Non-Combustible Flooring 22-7/8 19 23-1/2 19-5/8

Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

APPLICATION

Upflow Applications 16 24-1/8 16-5/8 24-3/4

Upflow Applications 19-1/2 24-1/8 20-1/8 24-3/4

Upflow Applications 23 24-1/8 23-5/8 24-3/4

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96284

Fig. 15—Furnace, Plenum, and Coil

Assembly or Coil Box Installed

on a Combustible Floor

PLENUM OPENING FLOOR OPENING

ABCD

15-1/8 19 16-3/4 20-3/8

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

18-5/8 19 20-1/4 20-3/8

19 19 20 20

22-1/8 19 23-3/4 20-3/8

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

Page 15

PERFORATED DISCHARGE DUCT FLANGE

210° MIN

YES

duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 16.)

Do not bend duct flanges inward as shown in Fig. 16. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 16.

NOTE: For 140 size unit when installed in downflow orientation, cut the white jumper wire off between terminals PL1-6 and PL1-9. Refer to Fig. 24 for location of jumper. Cut jumper close to connector and remove wire to avoid a short circuit.

Step 3—Installation in Horizontal Applications

These furnaces can be installed horizontally in either horizontal left or right discharge position. In a crawlspace, furnace can either be hung from floor joist or installed on suitable blocks or pad. Furnace can be suspended from each corner by hanger bolts and angle iron supports. (See Fig. 17.) Cut hanger bolts (4 each 3/8-in. all-thread rod) to desired length. Use 1 X 3/8-in. flat washers, 3/8-in. lockwashers, and 3/8-in. nuts on hanger rods as shown in Fig. 17. Dimples are provided for hole locations. (See Fig. 2.)

Fig. 16—Duct Flanges

ANGLE IRON OR EQUIVALENT

(B)

A93029

(A)

5 3⁄4″

DRAIN

⁄8-IN. ROD

ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX

(A) ROD LOCATION

USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS)

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

(A)

(B)

/8-IN. HEX NUT

& WASHER (4)

REQD PER ROD

NOTES:

(A)

1. A 1 In. clearance minimum between top of furnace and combustible material. 

2. The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage.

(B)

/16-IN. MAX ALTERNATE SUPPORT LOCATION FROM BACK

Fig. 17—Crawlspace Horizontal Application

A93304

Page 16

The entire length of furnace MUST be supported when furnace is used in a horizontal position to ensure proper draining. When suspended, bottom brace supports sides and center blower shelf. When unit is supported from the ground, blocks or pad should support sides and center blower shelf area.

Step 4—Filter Arrangement

Never operate unit without a filter or with blower access panel removed.

Factory-supplied washable framed filters are shipped in blower compartment. Determine location for filter and relocate filter retaining wire if necessary. See Table 2 to determine correct filter size for desired filter location. Table 2 indicates filter size, location, and quantity shipped with this furnace. See Fig. 2 for location and size of bottom and side return-air openings.

Table 2—Filter Information

FURNACE

CASING

WIDTH (IN.)

17-1/2 (1) 16 X 25 X 1† (1) 16 X 25 X 1 Cleanable

21 (1) 16 X 25 X 1 (1) 20 X 25 X 1† Cleanable

24-1/2 (2) 16 X 25 X 1† (1) 24 X 25 X 1 Cleanable

* Filters can be field modified by cutting frame as marked and folding to

desired size. Alternate sizes can be ordered from your distributor or dealer.

† Factory-provided with furnace.

FILTER SIZE (IN.)*

Side Return Bottom Return

FILTER TYPE

FRAMED

171⁄2-IN. WIDE  CASINGS ONLY:

INSTALL FIELD-SUPPLIED FILTER FILLER STRIP UNDER FILTER.

3″

/2″

1″

241⁄2-IN. WIDE  CASINGS ONLY:

CUT AND FOLD FACTORY-PROVIDED FILTERS AS SHOWN TO DESIRED SIZE.

WASHABLE FILTER

Air delivery above 1800 CFM requires that both sides, a combination of 1 side and bottom, or bottom only of furnace be used for return air.

NOTE: Side return-air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 18.

WASHABLE

FILTER

FILTER RETAINER

A93045

Fig. 18—Filter Installed for Side Inlet

Bottom return-air opening may be used with all 4 orientations. Filter may need to be cut to fit some furnace widths. Install filter as shown in Fig. 19.

NOTE: Remove and discard bottom closure panel when bottom inlet is used.

Step 5—Bottom Closure Panel

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

FILTER SUPPORT

FILTER RETAINER

Fig. 19—Bottom Filter Arrangement

To remove bottom closure panel, perform following:

1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 20.)

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

3. Remove bottom closure panel.

4. Reinstall front filler panel and screws.

Step 6—Gas Piping

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC. Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction. Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 3 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.

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

A96030

Page 17

BOTTOM CLOSURE PANEL

FRONT FILLER PANEL

Fig. 20—Removing Bottom Closure Panel

A93047

GAS SUPPLY

MANUAL SHUTOFF VALVE (REQUIRED)

SEDIMENT TRAP

UNION

Fig. 21—Typical Gas Pipe Arrangement

A93324

Gas valve shutoff switch MUST be facing forward or tilted upward. Failure to follow this warning could result in property damage or death.

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

Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this warning could result in a gas leak resulting in fire, explosion, personal injury, or death.

Table 3—Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE SIZE

(IN.)

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

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

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and

a pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table 10-2 NFPA 54-1999.

INTERNAL

DIAMETER

(IN.)

Install a sediment trap in riser leading to furnace. Trap can be installed by connecting a tee to riser leading to furnace so straight-through section of tee is vertical. Then connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and manual gas shutoff valve. (See Fig. 21.)

LENGTH OF PIPE (FT)

10 20 30 40 50

If a flexible connector is required or allowed by authority having jurisdiction, black iron pipe shall be installed at gas valve and extend a minimum of 2 in. outside furnace casing.

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

NOTE: The gas valve inlet press tap connection is suitable to use as test gage connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. wc) stated on gas valve. (See Fig. 44.) Piping should be pressure tested in accordance with local and national plumbing and gas codes before furnace is attached. In Canada, refer to current edition of NSCNGPIC. If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14-in. wc), turn off electric shutoff switch located on gas valve before test. It is recommended that ground joint union be loosened before pressure testing. After all connections have been made, purge lines and check for leakage.

AIR DUCTS

Step 1—General Requirements

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE). Or consult factory The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design static pressure.

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 a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

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

Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing

Page 18

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

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

Step 2—Ductwork Acoustical Treatment

Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take-off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Step 3—Supply Air Connections

UPFLOW FURNACES Connect supply-air duct to 3/4-in. flange on furnace supply-air

outlet. The supply-air duct attachment must ONLY be connected to furnace supply-/outlet-air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

DOWNFLOW FURNACES Connect supply-air duct to supply-air opening on furnace. The

supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used), when installed on non-combustible material. When installed on combustible material, supply-air duct attachment must ONLY be connected to an accessory subbase or factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

HORIZONTAL FURNACES Connect supply-air duct to supply air opening on furnace. The

supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

Step 4—Return Air Connections

UPFLOW FURNACES The return-air duct must be connected to bottom , sides (left or

right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 1. Bypass humidifier may be attached into unused side return air portion of the furnace casing. DO NOT connect any portion of return-air duct to back of furnace casing.

DOWNFLOW AND HORIZONTAL FURNACES The return-air duct must be connected to return-air opening

provided as shown in Fig. 1. DO NOT cut into casing sides or back to attach any portion of return-air duct. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

ELECTRICAL CONNECTIONS

See Fig. 22 for field wiring diagram showing typical field 115-v and 24-v wiring. Check all factory and field electrical connections for tightness.

Blower access panel door switch opens 115-v power to control center. No component operation can occur. Do not bypass or close switch with panel removed. Failure to follow this warning could result in personal injury or death.

Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw.

Step 1—115-v Wiring

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

Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70-1999 and any local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with Canadian Electrical Code CSA C22.1 or subauthorities having jurisdiction.

TERMINAL

FURNACE

NOTE 2

BLOCK

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

BLK

WHT

115-V FIELD-

SUPPLIED

DISCONNECT

GND

BLK

WHT

AUXILIARY J-BOX

FIVE WIRE

GND

Fig. 22—Heating and Cooling Application Wiring Diagram

WCR GY

O N T

R O

COM

24-V

NOTES: Connect Y-terminal in furnace as shown for proper blower operation.

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

THERMOSTAT TERMINALS

NOTE 1

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

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

CONDENSING UNIT

TWO WIRE

FIELD-SUPPLIED DISCONNECT

GND

208/230- OR 460-V THREE PHASE

208/230-V SINGLE PHASE

A99408

Page 19

ELECTRIC

DISCONNECT

SWITCH

COPPER

WIRE ONLY

ALUMINUM

WIRE

A93033

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

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

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

The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-1999 and Canadian Electrical Code CSA C22.1 or local codes to miniize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground. Failure to follow this warning could result in electrical shock, fire, or death.

J-Box Relocation

1. Remove 2 screws holding auxiliary J-box. (See Fig. 23.)

2. Rotate J-box 180° and attach box to right side, using holes provided.

FACTORY

INSTALLED

LOCATION

Fig. 23—Relocating J-Box

ALTERNATE FIELD LOCATION

A93051

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

Step 2—24-v Wiring

Make field 24-v thermostat connections at 24-v terminal block on control center. For proper cooling operation, Y wire from thermostat MUST be connected to Y terminal on control center, as shown in Fig. 22. The 24-v terminal board is marked for easy connection of field wiring. (See Fig. 24.) The 24-v circuit contains a 3-amp, automotive-type fuse located on control center. (See Fig. 25.) Any electrical shorts of 24-v wiring during installation, service, or maintenance may cause fuse to blow. If fuse replacement is required, use only a fuse of identical size (3 amp).

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.

Step 3—Accessories

1. Electronic Air Cleaner (EAC) Two quick-connect terminals marked EAC-1 and EAC-2 are

provided for EAC connection. (See Fig. 25.) These terminals are energized with 115v (1.5-amp maximum) during blower motor operation.

2. Humidifier (HUM) A quick-connect terminal (HUM) and screw terminal (C

OM)

are provided for 24-v humidifier connection. (See Fig. 24.) HUM terminal is energized with 24-v (0.5-amp maximum) after pressure switch closes.

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

DIRECT VENTING

The 58MCA Furnaces require a dedicated (one 58MCA furnace only) direct-vent system. In a direct-vent system, all air for combustion is taken directly from outside atmosphere, and all flue products are discharged to outside atmosphere.

Step 1—Removal of Existing Furnaces from Common Vent Systems

If furnace being replaced was connected to a common vent system with other appliances, the following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch as required in the NFGC or NSCNGPIC and these instructions. Determine that there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition.

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

4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously.

Page 20

325768-101 REV. B

TRIALS-FOR-IGNITION. CONTR OL WILL A UT O-RESET A FT ER THREE HO URS .

10. IGNITION-LOCKOUT WILL OCCUR AFTER FOUR CONSECUTIVE UNSUCCESSFUL

FIELD SPLICE

PLUG RECEPTACLE

A99405

Fig. 24—Wiring Diagram

EAC-2

CAP-1

BLWM

SCHEM AT IC DIAGR AM

START

(NA TU R AL GAS & PROPANE)

MED LO

MED HI

EQUIPMENT GROUND

HEAT

SPARE-2

GND

ILK

NOTE #4

TO 115VAC FIELD DISCONNECT

YEL

LGPS

(WHEN USED)

PRS

NOTE #6

COM

COOL

SPARE-1

HI/LO

BLWR

BLU

FRS

IDM

1HSI

PL5 1

EAC-1

HSIR

IDR

NOTE #5

GRN

RED

FSE

PL6

PL2

115VAC

PR1

BLK

BLU

BRN

AUX

BRN

PL4

PL3

24VAC

TRAN

BRN

WHT

CAP -2

TRAN

BRN

WHT

RED

CAP - 2

WHT

PL4

PL3

NOTE #7

F U 1

TEST/TWIN

IDM

AUX

GRN

321

NOTE #5

(WHEN USED)

FRS

SEC-2

SEC-1

WHT

PL6

BLK

NOTE #6

LGPS

WHT

PL5

PRS

PL7

PL1

GVR

HI/LO

BLWR

IDR

HSIR

HUM

HSI

FUSED OR CIRCUIT BREAKER

BLK

DISCONNECT SWITCH (WHEN REQ'D)

WHT

BLK

GVR-1

CPU

NEUTRAL

NOTE #4

FU2

BLK

WHT

FSE

GRN

GND

GRN

PL1 10-CIRCUIT PCB CONNECTOR

PL2 2-CIRC UIT PCB CONNECTOR

PL3 3-CIRCUIT ADAPTER CONNECTOR

PL4 3-CIRCUIT IDM CONNECTOR

PL5 2-CIRCUIT ADAPTER CONNECTOR

PL6 2-CIRCUIT HSI, PCB CONNECTOR

PL7 9-CIRCUIT ADAPTER CONNECTOR

AUTO-RESET THERMAL OVERLOAD SWITCHES (OL).

INSTRUCTIONS FOR DETAILS ON OPTIMUM SPEED SELECTION.

FURNACE JUNCTION BOX (JB).

NOTES:

1. IF ANY OF THE ORIGINAL EQUIPMENT WIRE IS REPLACED USE WIRE RATED FOR 105°C.

2. INDUCER (IDM) AND BLOWER (BLWM) MOTORS CONTAIN INTERNAL

3. BLOWER MOTOR SPEED SELECTIONS ARE FOR AVERAGE CONDITIONS, SEE INSTALLATION

JUNCTION

UNMARKED TERMINAL

PRS PRESSURE SWITCH, SPST-(N.O.)

TEST/TWIN COMPONENT TEST & TWIN TERMINAL

TRAN TRANSFORMER-115VAC/24VAC

FLAME.

4. USE ONLY COPPER WIRE BETWEEN THE DISCONNECT SWITCH AND THE

5. THIS WIRE MUST BE CONNECTED TO FURNACE SHEET METAL FOR CONTROL TO PROVE

PCB TERMINAL

FACTORY WIRING (115VAC)

FACTORY WIRING (24VAC)

FIELD WIRING (115VAC)

FIELD WIRING (24VAC)

HEAT PUMP 90 SECONDS.

6. FACTORY CONNECTED WHEN LGPS NOT USED.

7. REPLACE ONLY WITH A 3 AMP FUSE.

8. BLOWER-ON DELAY, GAS HEATING 60 SECONDS, COOLING OR HEAT PUMP 2 SECONDS.

9. BLOWER-OFF DELAY, GAS HEATING 90, 135, 180 OR 225 SECONDS, COOLING OR

CONDUCTOR ON PCB

FIELD WIRING TERMINAL

FIELD EARTH GROUND

EQUIPMENT GROUND

WHT

RED RED

WHT

PL7

5 6

987

321

RED

BLU

225

180

24V

ORN

WHT

HUM

TEST/TWIN

FU1

SEC-1

SEC-2

YEL

RED

GRN

WHT

EAC-2

LED 1

BLOWER OFF DELA Y

JUMPER SELECT

ORN

PCB

135

BLK

WHT (COM)

BLK

PL2

GRN

PL1

12345678910

PR1

EAC-1

SPARE 1 SPARE 2

COOL

HEAT

GRN

BRN

BLWM

BLK (HI)

YEL

(MED HI)

WHT

(COM)

ILK

BLK

WHT

CAP -1

BRN

START

RED (LO)

BLU

(ME D LO)

BLWR BLOWER MOTOR RELAY, SPST-(N.O.)

BLWM BLO W ER MOT OR

CAP CAPACITOR

CPU MICROPROCESSOR AND CIRCUITRY

LEGEND

EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.)

(FIELD INSTALLED & SUPPLIED)

EAC-2 ELECTRO NIC AIR CLEANER CONNECTION (COMMON)

FRS FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)

FSE FLAME PROVING ELECTRODE

FU1 FUSE, 3 AMP, A UTO MO TIVE BLADE TYPE, FACTORY INSTALLED

FU2 FUSE OR C IRCUIT BREAKER CURRENT INTERRUPT DEVICE

GND EQUIPMENT GROUND

GV GAS VALVE-REDUNDANT OPERATORS

GVR GAS VALVE RELAY, DPST-(N.O.)

HI/LO BLOWER MOTOR SPEED CHANGE RELAY, SPDT

HSI HOT SURFACE IGNITOR (115 VAC)

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

HUM 24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)

IDM INDUCED DRAFT MOTOR

IDR INDUCED DRAFT RELAY, SPST-(N.O.)

ILK BLOW ER A CCESS PANEL INTERLOCK SWITCH, SPST -(N.O.)

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STATUS CODES

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

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

OL AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.

PCB PRINTED CIRCUIT BOARD

Page 21

Table 4—Electrical Data

UNIT SIZE

VOLTS— HERTZ—

PHASE

OPERATING

VOLTAGE RANGE

Max* Min*

MAX UNIT

AMPS

UNIT

AMPACITY†

040-08 115—60—1 127 104 6.1 8.4 14 44 15 040-12 115—60—1 127 104 7.3 10.0 14 37 15 060-08 115—60—1 127 104 6.1 8.4 14 44 15 060-12 115—60—1 127 104 7.1 9.8 14 38 15 060-16 115—60—1 127 104 9.5 12.8 14 29 15 080-12 115—60—1 127 104 7.6 10.4 14 36 15 080-16 115—60—1 127 104 10.0 13.4 14 28 15 080-20 115—60—1 127 104 14.1 18.4 12 31 20 100-16 115—60—1 127 104 10.2 13.5 14 27 15 100-20 115—60—1 127 104 14.8 19.3 12 30 20 120-20 115—60—1 127 104 14.6 19.1 12 30 20 140-20 115—60—1 127 104 14.3 18.8 12 30 20

* Permissible limits of voltage range at which unit will operate satisfactorily. † Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full

load amps. ‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. ** Time-delay type is recommended.

MIN

WIRE

SIZE

MAX WIRE

LENGTH

(FT)‡

MAX FUSE

OR CKT BKR

AMPS**

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

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

7. If improper venting is observed during any of above tests, the venting system must be corrected.

COOLING OFF DELAY DEFEAT JUMPER-J2

135

EAC-2

180 225

SEC-1

24-V THERMOST AT

TERMINALS

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX)

24-V TRANSFORMER SEC-2

LED OPERATION &

DIAGNOSTIC LIGHT

GYW

24V

Com

Vent system or vent connectors may need to be resized. For any other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSCNGPIC.

Step 2—Combustion-Air and Vent Piping

GENERAL Combustion-air and vent pipe fittings must conform to American

National Standards Institute (ANSI) standards and American

BLOWER OFF DELAY JUMPER SELECT

1 2 3 4 5

TEST/TWIN

HUM

3-AMP FUSE

HARNESS CONNECTOR

115-VAC (L2) NEUTRAL

CONNECTION

COOL

BLOWER SPEED

SELECTION TERMINALS

HEAT

1234567891011

SP ARE-1

SP ARE-2

EAC-1 ELECTRONIC AIR CLEANER TERMINALS (115-VAC 1.0 AMP MAX)

Fig. 25—Control Center

PRI

115-VAC (L1)

POWER SUPPLY

HOT SURFACE

IGNITOR CONNECTOR

INDUCER MOTOR CONNECTOR

A99416

Page 22

Society for Testing and Materials (ASTM) standards D1785 (schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and SDR-26 PVC), D2661 (ABS-DWV), F628 (schedule-40 ABS), F891 (PVC-DWV cellular core) or F441 (schedule-40 CPVC pipe) and F438 (schedule-40 CPVC fittings). Pipe cement and primer must conform to ASTM standards D2564 or F493 (PVC or CPVC) or D2235 (ABS). See Table 6 for maximum pipe lengths and Fig. 30, 31, 32, 33, and 34 for exterior piping arrangements.

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

NOTE: Furnace combustion-air and vent pipe connections are sized for 2-in. pipe. Any pipe size change should be made outside furnace casing in vertical pipe. (See Fig. 26.) This allows proper drainage of vent condensate.

FURNACE

NOT IN HORIZONTAL SECTION

PIPE DIAMETER

TRANSITION IN

VERTICAL SECTION

A93034

Fig. 26—Combustion-Air and Vent Pipe Diameter

Transition Location and Elbow Configuration

Combustion-air and vent pipes must terminate together in same atmosphere pressure zone, either through roof or sidewall (roof termination preferred), using accessory termination kit. See Table 5 for required clearances.

Furnace combustion-air and vent pipe connections must be attached as shown in Fig. 27. Combustion-air intake plug fitting and inducer housing alternate vent cap may need to be relocated in some applications.

NOTE: Slope combustion-air and vent pipes a minimum of 1/4 in. per linear ft with no sags between hangers.

Table 5—Combustion-Air and Vent Pipe

Termination Clearances

LOCATION

Above grade level or above anticipated snow depth

Dryer vent 33 From plumbing vent stack 33 From any mechanical fresh air intake 16 For furnaces with an input capacity

less than 100,000 Btuh—from any nonmechanical air supply (windows or doors which can be opened) or combustion-air opening

From service regulator vent, electric and gas meters, and relief equipment

Above grade when adjacent to public walkway

* Horizontal distance. † 18 in. above roof surface in Canada. ‡ 36 in. to electric meter in Canada only.

NOTES:

1. If installing 2 adjacent 58MCA Furnaces, refer to Multiventing and Vent Terminations section for proper vent configurations.

2. When locating combustion-air and vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recirculation of the appliance’s own flue products or the flue products of adjacent vents. Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of heat exchangers.

3. Vent termination cannot terminate less than 2 ft horizontal and 7 ft above public walkway or where condensate vapor or droplets may be a hazard.

Combustion air must not be taken from inside structure because inside air is frequently 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. Locate combustion-air inlet as far as possible from swimming pool and swimming pool pump house. Excessive exposure to contaminated combustion air will result in safety and performance related problems.

CLEARANCE (FT)

U.S.A. Canada

11†

4* 6‡

Note 3 Note 3

When combustion-air pipe is installed above a suspended ceiling, pipe must be insulated with 3/8-in. thick Armaflextype insulation. Combustion-air pipe should also be insulated when it passes through warm, humid space.

When 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, pipe must be insulated as shown in Table 7 with Armaflex-type insulation.

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

All combustion-air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 30, 31, 32, 33, or 34. Failure to follow this warning could result in property damage, personal injury, or death.

NOTE: The minimum combustion-air and vent pipe length (each) for these furnaces is 5 ft. Short pipe lengths (5-8 ft) may discharge water droplets. These droplets may be undesirable, and a 12-in. minimum offset pipe section is recommended, as shown in Fig. 28,

Page 23

Select 1 vent pipe connection and

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

AIR

COMBUSTION-

AIR

VENT

COMBUSTION-

AIR

FLOW

HORIZONTAL-LEFT DISCHARGE HORIZONTAL-RIGHT DISCHARGE

FLOW

COMBUSTION-

UPFLOW DOWNFLOW

AIR

VENT

AIR

VENT

NOTE:

1 combustion-air pipe connection.

VENT

COMBUSTION-

AIR

AIR

FLOW

COMBUSTION-

VENT

COMBUSTION-

AIR

AIR

FLOW

A96187

Fig. 27—Combustion-Air and Vent Pipe

Connections

to reduce excessive droplets from exiting vent pipe outlet. COMBUSTION-AIR AND VENT PIPE DIAMETER Determine combustion-air and vent pipe diameter.

1. Using Table 6, individually determine the combustion-air and vent pipe diameters. Pick the larger of these 2 pipe diameters and use this diameter for both combustion-air and vent pipes.

2. When installing vent systems of short pipe length, use the smallest allowable pipe diameter. Do not use pipe size greater than required or incomplete combustion, flame disturbance, or flame sense lockout may occur.

NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 30, 31, 32, 33, and 34.

EXAMPLE: An 080-12 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed in an application requiring 3 elbows and 32 ft of vent pipe, along with 5 elbows and 34 ft of combustion-air pipe. Table 6 indicates this application would allow a 2-in. diameter vent pipe, but require a 2-1/2 in. diameter combustion air pipe (2-in. pipe is good for 35 ft with 3 elbows, but only 30 ft with 5 elbows). Therefore, 2-1/2 in. diameter pipe must be used for both vent and combustion-air pipes since larger required diameter must always be used for both pipes. If same installation were in Albuquerque, elevation 5250 ft above sea level, installation would require 2-1/2 in. vent pipe and combustion-air pipe. At 5001- to 6000-ft elevation, 2-in. pipe is only good for 17 ft with 5 elbows, and 2-1/2 in. pipe is good for 70 ft with 5 elbows.

COMBUSTION-AIR AND VENT PIPE ATTACHMENT NOTE: All pipe joints must be watertight except attachment of

combustion-air pipe to inlet housing connection, since it may be necessary to remove pipe for servicing.

1. Attach combustion-air pipe as follows: a. Determine location of combustion-air intake pipe connec-

tion to combustion-air intake housing as shown in Fig. 27 for application.

b. Reposition combustion-air intake housing plug fitting in

appropriate unused intake housing connection.

c. If required, insert perforated disk assembly (factory-

supplied in loose parts bag) in intake housing where combustion-air intake pipe will be connected. If half disk set is required, install with shoulder of disk against stop in combustion-air inlet.

d. Install pipe support (factory-supplied in loose parts bag)

into selected furnace casing combustion-air pipe hole. Pipe support should be positioned at bottom of casing hole.

e. Insert 2-in. diameter pipe into intake housing.

NOTE: A 2-in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing.

f. Drill a 1/8-in. hole in 2-in. combustion-air pipe using hole

in intake housing as a guide.

g. Install a field-supplied No. 6 or No. 8 sheet metal screw

into combustion-air pipe.

NOTE: DO NOT OVER TIGHTEN SCREW. Breakage to intake housing or fitting may cause air leakage to occur.

NOTE: Do not attach combustion-air intake pipe permanently to combustion-air intake housing since it may be necessary to remove pipe for service of ignitor or flame sensor.

COMBUSTION-AIR INTAKE HOUSING PLUG FITTING

The combustion-air intake plug fitting must be installed in unused combustion-air intake housing. This fitting must be attached by using RTV sealant, or by drilling a 1/8-in. hole in fitting, using hole in intake housing as a guide. Install a field-supplied No. 6 or No. 8 sheet metal screw.

NOTE: DO NOT OVER TIGHTEN SCREW. Breakage to intake housing or fitting may cause air leakage to occur.

A plugged drain connection has been provided on this fitting for use when moisture is found in combustion-air intake pipe and combustion box.

Page 24

12″ MIN

VENT PIPE

HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL

COMBUSTION-AIR PIPE

12″ MIN

VENT PIPE

COMBUSTION-AIR PIPE COMBUSTION-AIR PIPE

COMBUSTION-AIR PIPE

VENT PIPE

12″ MIN

VENT PIPE

VERTICAL TO SIDEWALLVERTICAL TO ROOF

NOTE: A 12 In. minimum offset pipe section is recommended with

short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe.

Fig. 28—Short Vent (5 to 8 Ft) System

NOTE: Moisture in combustion-air intake may be result of

improper termination. Ensure combustion-air intake pipe is similar to that shown in Fig. 30, 31, 32, 33, or 34 so it will not be susceptible to areas where light snow or other sources of moisture could be pulled in.

If use of this drain connection is desired, drill out fitting’s tap plug with a 3/16-in. drill and connect a field-supplied 3/8-in. tube. This tube should be routed to open condensate drain for furnace and A/C (if used), and should be trapped. (See Fig.

29.)

2. Attach vent pipe as follows: a. Determine location of vent pipe connection to inducer

housing as shown in Fig. 27 for application.

b. Reposition elastomeric (rubber) inducer housing outlet cap

and clamp to appropriate unused inducer housing connection. Tighten clamp.

Inducer housing outlet cap must be installed and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

c. Install pipe support (factory-supplied in loose parts bag)

into selected furnace casing vent pipe hole. Pipe support should be positioned at bottom of casing hole.

A96230

d. Be certain that mating surfaces of inducer housing connec-

tion, elastomeric (rubber) coupling, and 2-in. diameter vent pipe are clean and dry. Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps) onto inducer housing connection. Insert the 2-in. diameter vent pipe through the elastomeric (rubber) coupling and fully into inducer housing connection until it bottoms on the internal stop. Tighten both clamps to secure the pipe to inducer housing. Tighten the clamp screws to 15 in.-lb of torque.

Vent pipe must be installed and fully seated against inducer housing internal stop. Clamp must be tightened to prevent any condensate leakage. Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

NOTE: A 2-in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing.

VENT EXTENSION PIPE Furnaces with 100,000 Btuh and larger inputs are supplied

with a PVC vent extension pipe (2-in. diameter by 12-in. long). This pipe has a built-in channel to assist vent condensate disposal. When this vent extension pipe is supplied, it must be used to connect the field vent pipe to furnace inducer housing on ALL upflow and downflow applications.

Page 25

ALTITUDE UNIT SIZE

0 to 2000

ALTITUDE UNIT SIZE

2001 to 3000

ALTITUDE UNIT SIZE

3001 to 4000

See notes on page 27.

040-08 040-12

060-08 060-12 060-16

080-12 080-16 080-20

100-16 100-20

120-20

140-20

040-08 040-12

060-08 060-12 060-16

080-12 080-16 080-20

100-16 100-20

120-20

140-20

040-08 040-12

060-08 060-12 060-16

080-12 080-16 080-20

100-16 100-20

120-20

140-20

Table 6—Maximum Allowable Pipe Length (Ft)

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIA

(IN.)*

1 5 NA NA NA NA NA

1-1/2 70 70 65 60 60 55

2 707070707070

1-1/2 20 15 10 5 NA NA

2 707070707070

1-1/2 10 NA NA NA NA NA

2 555035303020

2-1/2 70 70 70 70 70 70

2 5 NA NA NA NA NA

2-1/2 40 30 20 20 10 NA

3 707070707070

2-1/2 one

disk

3† 45 40 35 30 25 20 3† no disk 70 70 70 70 70 70 4† no disk 70 70 70 70 70 70

2-1/2 one

disk

3† one disk 40 35 30 25 20 15

3† no disk 60 56 52 48 44 40 4† no disk 70 70 70 70 70 70

PIPE DIA

(IN.)*

1-1/2 67 62 57 52 52 47

2 707070707070

1-1/2 17 12 7 NA NA NA

2 706766616161 2 494430252515

2-1/2 70 70 70 70 70 70 2-1/2 35 26 16 16 6 NA

3 707070706661

3 14 9 NANANANA 3† no disk 70 70 63 56 50 43 4† no disk 70 70 70 70 70 70

3† one disk 20 15 10 5 NA NA

3† no disk 39 35 31 27 23 19 4† no disk 70 70 70 70 70 70

PIPE DIA

(IN.)*

1-1/2 64 59 54 49 48 43

2 707070707070

1-1/2 16 11 6 NA NA NA

2 686362575756

2 464128232213

2-1/2 70 70 70 70 70 70 2-1/2 33 24 15 14 5 NA

3 707070666156 3† no disk 65 58 51 44 38 31 4† no disk 70 70 70 70 70 70

3† one disk 11 6 NA NA NA NA

3† no disk 30 26 22 18 14 10 4† no disk 70 70 70 70 70 70

123456

10 NA NA NA NA NA

5 NANANANANA

123456

NUMBER OF 90° ELBOWS

Page 26

ALTITUDE UNIT SIZE

4001 to 5000‡

ALTITUDE UNIT SIZE

5001 to 6000‡

ALTITUDE UNIT SIZE

6001 to 7000‡

ALTITUDE UNIT SIZE

7001 to 8000‡

See notes on page 27.

Table 6—Maximum Allowable Pipe Length (Ft) Continued

TERMINATION

TYPE

040-08 040-12

060-08 060-12 060-16

080-12 080-16 080-20

100-16 100-20

120-20

140-20

040-08 040-12

060-08 060-12 060-16

080-12 080-16 080-20

100-16 100-20

120-20

140-20

040-08 040-12

060-08 060-12 060-16

080-12 080-16 080-20

100-16 100-20

120-20

140-20

040-08 040-12

060-08 060-12 060-16

080-12 080-16 080-20

100-16 100-20

120-20 140-20 NA

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3 In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIA

(IN.)*

1-1/2 60 55 50 45 44 39

2 70707070 70 70

1-1/2 15 10 5 NA NA NA

2 64595853 52 52 2 44392621 20 11

2-1/2 70 70 70 70 70 70 2-1/2 31 22 13 12 NA NA

3 70706762 57 52 3† no disk 53 46 40 33 26 20 4† no disk 70 70 70 70 70 70 3† no disk 21 17 13 9 5 NA 4† no disk 69 64 59 54 49 44

PIPE DIA

(IN.)*

1-1/2 57 52 47 42 40 35

2 707070707070

1-1/2 14 9 NA NA NA NA

2 605554494847

2 4136231817 8

2-1/2 70 70 70 70 70 70 2-1/2 29 21 12 11 NA NA

3 706762575247 3† no disk 42 35 29 22 15 9 4† no disk 70 70 70 70 70 70 3† no disk 12 8 NA NA NA NA 4† no disk 42 37 32 27 22 17

PIPE DIA

(IN.)*

1-1/2 53 48 43 38 37 32

2 707068676664

1-1/2 13 8 NA NA NA NA

2 575250454443

2 3833211615 6

2-1/2 70 70 68 67 66 64 2-1/2 27 19 10 9 NA NA

3 686358534843 3† no disk 31 24 18 11 NA NA 4† no disk 70 70 70 70 67 62

4† no disk 17 12 7 NA NA NA

PIPE DIA

(IN.)*

1-1/2 49 44 39 34 33 28

2 666563626059

1-1/2 12 7 NA NA NA NA

2 534846414038

2 3631191412NA

2-1/2 66 65 63 62 60 59 2-1/2 25 17 8 7 NA NA

3 635853484338 3† no disk 20 13 7 NA NA NA 4† no disk 61 56 51 46 41 36

1234 5 6

123456

NUMBER OF 90° ELBOWS

Page 27

Table 6—Maximum Allowable Pipe Length (Ft) Continued

ALTITUDE UNIT SIZE

040-08 040-12

060-08 060-12 060-16

8001 to

9000‡

ALTITUDE UNIT SIZE

9001 to

10,000‡

* Disk usage—Unless otherwise specified, use perforated disk assembly (factory-supplied in loose parts bag). If one disk is stated, separate 2 halves of perforated disk

assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box. † Wide radius elbow. ‡ Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction. NA—Not Allowed; pressure switch will not make.

NOTES:

1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.

2. Size both the combustion-air and vent pipe independently, then use the larger diameter for both pipes.

3. Assume two 45° elbows equal one 90° elbow. Long radius elbows are desirable and may be required in some cases.

4. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.

5. The minimum pipe length is 5 ft for all applications.

6. Use 3-in. diameter vent termination kit for installations requiring 4-in diameter pipe.

080-12 080-16 080-20

100-16 100-20

120-20 140-20 NA

040-08 040-12

060-08 060-12 060-16

080-12 080-16 080-20

100-16 100-20

120-20 140-20 NA

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIA

(IN.)*

1-1/2 46 41 36 31 29 24

2 626058565553

1-1/2 11 6 NA NA NA NA

2 494442373534 2 3328171210NA

2-1/2 62 60 58 56 55 53 2-1/2 23 15 7 5 NA NA

3 595449443934 3† no disk 10 NA NA NA NA NA 4† no disk 35 30 25 20 15 10

PIPE DIA

(IN.)*

1-1/2 42 37 32 27 25 20

2 575553514947

2 454038333129

230251497NA

2-1/2 57 55 53 51 49 47 2-1/2 21 13 5 NA NA NA

3 544944393429 4† no disk 10 5 NA NA NA NA

123456

NUMBER OF 90° ELBOWS

COMBUSTION – AIR

3/8" ID TUBE

3/16"

DRILL

TRAP

TO OPEN

DRAIN

4″

MIN

INTAKE HOUSING

Fig. 29—Intake Housing Plug Fitting Drain

NOTE: See label on vent extension pipe for proper installation.

This pipe may be shortened if an elbow is used to connect vent extension tube to field-installed vent pipe.

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.

BURNER BOX

COMBUSTION – AIR PIPE 

A93035

6. Clean and dry all surfaces to be joined.

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

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

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 a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat.

9. While cement is still wet, twist pipe into socket with 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 perimeter of a properly made joint.

11. Handle pipe joints carefully until cement sets.

12. Support combustion-air and vent piping a minimum of every 5 ft (3 ft for SDR-21 or -26 PVC) using perforated metal hanging strap.

13. Slope combustion-air and vent pipes toward furnace a minimum of 1/4 in. per linear ft with no sags between hangers.

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

Page 28

Step 3—Concentric Vent and Combustion-Air Termination Kit Installation

NOTE: If these instructions differ from those packaged with

termination kit, follow kit instructions. Combustion-air and vent pipes must terminate outside structure. A

factory accessory termination kit must be installed in 1 of the installations shown in Fig. 30, 31, 32, 33, or 34. Four termination kits are available.

1. The 2-in. termination bracket kit is for 1-in., 1-1/2 in., and 2-in. diameter 2-pipe termination systems.

2. The 3-in. termination bracket kit is for 2-1/2 in., 3-in., and 4-in. diameter 2-pipe termination systems.

3. The 2-in. concentric vent/air termination kit is for 1-in., 1-1/2 in., 2-in., and 2-1/2 in. diameter pipe systems when single penetration of wall or roof is desired.

4. The 3-in. concentric vent/air termination kit is for 2-1/2 in., 3-in., and 4-in. diameter pipe systems when single penetration of wall or roof is desired.

NOTE: Shaded parts in Fig. 30, 31, 32, 33, and 34 are considered to be termination. These components should NOT be counted when determining pipe diameter. Roof termination is preferred since it is less susceptible to damage, has reduced chances to take in contaminants, and has less visible vent vapors. (See Fig. 30 or

31.) Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system.

EXTENDED EXPOSED SIDEWALL PIPES Sidewall combustion-air and vent pipe terminations may be

extended beyond area shown in Fig. 33 or 34 in outside ambient by insulating pipes as indicated in Table 7.

1. Determine combustion-air and vent pipe diameters, as stated above, using total pipe length and number of elbows.

2. Using winter design temperature (used in load calculations), find appropriate temperature for your application and furnace model.

3. Determine required insulation thickness for exposed pipe lengths.

NOTE: Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 6.

TWO-PIPE TERMINATION KIT

1. Determine location for termination. Consideration of the following should be made when deter-

mining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in Table

b. Termination kit should be positioned where vent vapors

will not damage plants/shrubs or air conditioning equipment.

c. Termination kit should be positioned so that it will not be

affected by wind eddy (such as inside building corners) or allow recirculation of flue gases, airborne leaves, or light snow.

d. Termination kit should be positioned where it will not be

damaged by or subjected to foreign objects, such as stones, balls, etc.

e. Termination kit should be positioned where vent vapors are

not objectionable.

2. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size being used.

3. Loosely install elbow in bracket and place assembly on combustion-air pipe.

Roof terminations—Loosely install pipe coupling on properly cut vent pipe. Coupling must be positioned so bracket will mount as shown in Fig. 30.

For applications using combustion-air pipe option, indicated by dashed lines in Fig. 30, install 90° street elbow into 90° elbow, making U-fitting. A 180° U-fitting may be used.

Sidewall terminations—Install bracket as shown in Fig. 33 or

34. For applications using vent pipe option indicated by dashed

lines in Fig. 33, rotate vent elbow 90° from position shown in Fig. 33.

4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping.

5. Check required dimensions as shown in Fig. 30, 33, or 34.

CONCENTRIC VENT/AIR TERMINATION KIT

1. Determine location for termination. Consideration of the following should be made when deter-

mining an appropriate location for termination kit. a. Comply with all clearance requirements as stated in Table

b. Termination kit should be positioned where vent vapors

will not damage plants/shrubs or air conditioning equipment.

c. Termination kit should be positioned so it will not be

affected by wind eddy (such as inside building corners) or that may allow recirculation of flue gases, airborne leaves, or light snow.

d. Termination kit should be positioned where it will not be

damaged by or subjected to foreign objects, such as stones, balls, etc.

e. Termination kit should be positioned where vent vapors are

not objectionable.

2. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in. diameter hole for 3-in. kit.

3. Loosely assemble concentric vent/air termination components together using instructions in kit.

4. Slide assembled kit with rain shield REMOVED through hole.

NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.

Roof terminations—Locate assembly through roof to appropriate height as shown in Fig. 31.

Sidewall terminations—Locate assembly through sidewall with rain shield positioned no more than 1-in. from wall as shown in Fig. 32.

5. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping.

6. Check required dimensions as shown in Fig. 31 or 32.

Step 4—Multiventing and Vent Terminations

When 2 or more 58MCA Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent 58MCA furnaces. When 2 or more 58MCA furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 35, 36, 37, 38, or 39, but next vent termination must be at least 36 in. away from first 2 terminations. It is important that vent terminations be made as shown to avoid recirculation of flue gases. Dimension "A" in Fig. 35, 36, 37, 38, and 39 represents distance between pipes or rain shields, as touching or 2-in. maximum separation.

Page 29

VERTICAL SEPARATION

BETWEEN COMBUSTION

MAXIMUM OF 24 IN. ABOVE ROOF.

AIR AND VENT 8 3/4″ FOR 3″ KIT 6 3/4″ FOR 2″ KIT

MAINTAIN 12 IN. MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL.

COUPLING

VENT

ROOF

18″ MAXIMUM

BRACKET

COMBUSTION AIR

Fig. 30—Roof Termination (Preferred)

VENT

COMBUSTION AIR

MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

A93054

Fig. 31—Concentric Vent and Combustion-Air Roof

Termination (Preferred)

OVERHANG OR ROOF

A87224

OVERHANG OR ROOF

12″ MINIMUM

1″ MAXIMUM

COMBUSTION-AIR

VENT

MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.

A93055

Fig. 32—Concentric Vent and Combustion-Air Side

Termination

OVERHANG OR ROOF

12″ MINIMUM

VENT

BRACKET

90°

COMBUSTION-AIR

12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT

MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.

Fig. 33—Sidewall Termination of 12 in. or More

A87225

12″ MINIMUM

VENT

BRACKET

COUPLING

90°

COMBUSTION-AIR (ELBOW PARALLEL TO WALL)

12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT

MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER.

Fig. 34—Sidewall Termination of Less than 12 in.

A87226

Page 30

Table 7—Maximum Allowable Exposed Vent Pipe Length (Ft) With and Without Insulation

in Winter Design Temperature Ambient*

UNIT

SIZE

040

060

080

100

120

140

* Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length

as specified in Table 6.

† Insulation thickness based on R value of 3.5 per in.

WINTER DESIGN

TEMPERATURE

(°F)

20 2 45 70

0 2 28 70

-20 2 10 58 20 2 65 70

0 2 35 70

-20 2 20 70 20 2-1/2 70 70

0 2-1/2 47 70

-20 2-1/2 28 70 20 3 70 70

0 3 50 70

-20 3 28 70 20 4 70 70

0 4 48 70

-20 4 23 70 20 4 70 70

0 4 57 70

-20 4 30 70

MAX PIPE

DIAMETER

(IN.)

WITHOUT

INSULATION

WITH 3/8-IN. OR

THICKER INSULATION†

CONDENSATE DRAIN

Step 1—General

Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications.

Condensate trap MUST be used for all applications. An external trap is not required when connecting the field drain to

this condensate trap. The field drain connection (condensate trap or drain tube coupling)

is sized for 1/2-in. CPVC, 1/2-in. PVC, or 5/8-in. ID tube connection.

Drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or F493. In Canada, use CSA or ULC certified schedule 40 CPVC or PVC drain pipe, fittings, and cement.

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

Furnace condensate is mildly acidic, typically in the pH range of

3.2 to 4.5. Due to corrosive nature of this condensate, a condensate pH neutralizing filter may be desired. Check with local authorities to determine if a pH neutralizer is required.

Step 2—Application

The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, fieldsupplied trap prior to the furnace drain connection. All drain connections (furnace, A/C, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible to prevent siphoning of the equipment’s drain.

See Fig. 40 for example of possible field drain attachment using 1/2-in. CPVC or PVC tee for vent and A/C or humidifier drain connection.

32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED

Unit must not be installed, operated, and then turned off and left in an unoccupied structure during cold weather when temperature drops to 32°F and below unless drain trap and drain line have adequate freeze protection. See Service and Maintenance Instructions for winterizing procedure.

Outdoor draining of the furnace is permissible if allowed by local codes. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining.

A93058

Page 31

A96128

Fig. 35—Rooftop Termination

(Dimension "A" is Touching or 2-In. Maximum Separation)

VENT

COMBUSTION AIR

A93056

Fig. 36—Concentric Vent and Combustion-Air

Roof Termination

(Dimension "A" is Touching or 2-In. Maximum Sepa-

ration)

VENT

1″ MAXIMUM (TYP)

COMBUSTION AIR

VENT

A93057

Fig. 37—Concentric Vent and Combustion-Air

Side Termination

(Dimension "A" is Touching or 2-In.

Maximum Separation)

VENT

COMBUSTION AIR

Fig. 38—Sidewall Termination of 12 in. or Less

(Dimension "A" is Touching or 2-In.

Maximum Separation)

COMBUSTION AIR

A96129

COMBUSTION AIR

Fig. 39—Sidewall Termination of More Than 12 in.

(Dimension "A" is Touching or 2-In.

Maximum Separation)

A96130

Page 32

OPEN STAND

PIPE FOR

A/C OR

HUMIDIFIER

DRAIN

CONDENSATE TRAP

WIRE TIE(S)

TEE

TO OPEN DRAIN

A94054

Fig. 40—Example of Field Drain Attachment

Caution should be taken to prevent draining where slippery conditions may cause personal injuries. Excessive condensate draining may cause saturated soil conditions which may result in damage to plants.

Step 3—Condensate Drain Protection

Freezing condensate left in condensate trap and drain line may cause cracks, and possible water damage may occur. If freeze protection is required, use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120v and 40°F self-regulating, shielded, and waterproof heat tape. See Installation Instructions supplied with accessory or heat tape manufacturer’s recommendations.

1. Fold heat tape in half and wrap on itself 3 times.

2. Locate heat tape between sides of condensate trap back. (See Fig. 41.)

3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig. 41.)

4. Wrap field drain pipe with remaining heat tape, approximately 1 wrap per ft.

5. When using field-supplied heat tape, follow heat tape manufacturer’s instructions for all other installation guidelines.

SEQUENCE OF OPERATION

Furnace control must be grounded for proper operation, or control will lock out. Control is grounded through green wire routed to gas valve and burner box screw.

Using schematic diagram, follow sequence of operation through different modes. (See Fig. 24.) Read and follow wiring diagram carefully.

NOTE: If 115-v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates for 90 sec when power is restored before heating cycle is resumed.

(3 WRAPS MINIMUM)

HEAT TAPE

Fig. 41—Condensate Trap Heat Tape

Step 1—Heating Mode

When wall thermostat calls for heat, R-W circuit closes. Furnace control performs a self-check, verifies pressure switch contacts are open, and starts inducer motor.

1. Prepurge period—As inducer motor comes up to speed,

pressure switch contacts close to begin a 15-sec prepurge period.

HUM terminal on control center is energized through pressure switch curcuit. See Accessories — Humidifier section.

2. Ignitor warm up—At end of prepurge period, ignitor is

energized for a 17-sec ignitor warm-up period.

3. Ignition sequence—When ignitor warm-up period is com-

pleted, gas valve opens, permitting gas flow to burners where it is ignited. After 5 sec, ignitor is de-energized and a 2-sec flame-sensing period begins.

4. Flame sensing—When burner flame is sensed, control begins

blower on delay period and continues holding gas valve open. If burner flame is not sensed, control center de-energizes gas

valve and ignition sequence is repeated.

NOTE: Ignition sequence repeats 3 additional times before a lockout occurs. Lockout automatically resets after 3 hr or can be manually reset by turning off 115v (not at thermostat) for 3 sec minimum, then turning it on again.

5. Blower on delay—Sixty sec after burner flame is proven (40

sec if jumper has been cut for 140 size unit in downflow orientation), blower motor is energized on heating speed. Simultaneously, electronic air cleaner terminal EAC-1 is energized.

6. Blower off delay—When thermostat is satisfied, circuit be-

tween R-W is opened, de-energizing gas valve (stopping gas flow to burners) and humidifier. Blower motor and electronic air cleaner remain energized for selected OFF delay. See figure 25.

7. Post purge—Inducer motor remains energized 15 sec after

burners are extinguished (5 sec if jumper has been cut for 140 size unit in downflow orientation).

Step 2—Cooling Mode

When thermostat calls for cooling, R-G and R-Y circuits close. R-Y circuit starts outdoor condensing unit, and combined R-Y and R-G circuit starts furnace blower motor on cooling speed. Electronic air cleaner EAC-1 terminal is energized with 115v whenever blower is operating.

A93036

Page 33

When thermostat is satisfied, R-G and R-Y circuits are opened, furnace blower continues operating on cooling speed for an additional 90 sec. Cooling OFF delay can be set to 3 sec by cutting jumper J2 on control board. See figure 25.

Step 3—Continuous Blower Mode

When R-G circuit is made, blower motor operates on heating speed.

NOTE: Electronic air cleaner EAC-1 terminal is energized with 115v whenever blower is operating.

If a call for heat (R-W) occurs while thermostat is in continuous blower mode, blower stops to allow furnace heat exchangers to heat up more quickly, then restarts at end of blower on delay period of 60 sec (40 sec if jumper has been cut for 140 size unit in downflow orientation).

Blower reverts to continuous operation after heating cycle is completed.

If a call for cooling (R-Y) occurs while thermostat is in continuous blower mode, blower changes from continuous blower speed (heating speed) to cooling speed.

When thermostat cooling call is satisfied, R-Y opens and blower operates for cooling blower OFF delay at cooling speed before reverting back to continuous operation (heating speed).

Step 4—Heat Pump Mode

When installed with a heat pump, furnace control automatically changes blower on delay timing sequence to avoid no blower operation time during demand defrost cycles. When R-W and R-Y or R-W, R-Y, and R-G thermostat inputs are received at the same time at furnace control center, control starts blower in heating speed. Then a gas heat mode begins. Blower remains operating at heating speed for 15 sec or until end of prepurge period, then blower shuts off until end of ignitor warm up and trial for ignition periods (a total of 24 sec). Blower restarts at heating speed.

When R-W thermostat call disappears, control completes inducer post-purge period of 15 sec (5 sec if jumper has been cut for 140 size unit in downflow orientation) and changes to cooling speed after a 2-sec delay.

If R-W, R-Y, and R-G thermostat signals should disappear simultaneously, blower remains on for heating blower off delay period of 135, and the inducer goes through 15 sec post-purge period (5 sec if jumper has been cut for 140 size unit in downflow orientation). If R-W and R-Y thermostat signals should disappear, leaving R-G thermostat signal, blower remains on in heating speed and inducer remains on for 15 sec to complete post-purge period (5 sec if jumper has been cut for 140 size unit in downflow orientation).

Control initiates a 90-sec blower only on period before starting another heat pump cycle if there is a power interruption. Anytime control senses false flame, control locks out of heating mode. This reaction occurs because control ignores W input due to false flame signal and, as a result, sees only Y input and goes into cooling mode blower off delay. All other control functions remain in standard format.

Step 5—Component Test

COMPONENT TEST SEQUENCE NOTE: All components are functionally operated except the gas

valve. When component test is initiated, the following sequence of events

occurs:

1. LED flashes a status code 4 times.

2. Inducer motor starts and continues to run for remainder of component test.

3. Hot surface ignitor is energized for 15 sec, then de-energized.

4. Main blower operates at HEAT speed for 10 sec, then turns off.

5. Main blower operates at COOL speed for 10 sec, then turns off.

6. Inducer motor stops.

Component test can be initiated by one of the following procedures.

INITIATING COMPONENT TEST BY REMOVING MAIN LIMIT SWITCH WIRE

NOTE: NO thermostat signal may be present at control center and all blower time delay off periods must be completed.

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

2. Remove main furnace door.

3. Look into blower access panel sight glass for current LED status.

NOTE: Leave blower access panel installed to maintain power to control center to view current LED status.

4. BRIEFLY remove either wire from the main limit switch until the LED goes out, then reconnect it.

Make sure limit switch wire does not contact any metallic component such as the gas valve. If wire is shorted, 3-amp fuse on control center will blow.

NOTE: If wire to main limit is disconnected longer than 4 sec, the control senses limit circuit is open. Main blower will start and status retrieval request will be ignored.

5. When above items have been completed, the component test sequence will occur as described in the Component Test Sequence section above.

NOTE: Be sure to record the status code which is flashed 4 times at start of component test for further troubleshooting.

6. After component test is completed and LED is ON continuously indicating the furnace is ready to operate when a signal from the thermostat is received, replace main furnace door.

INITIATING COMPONENT TEST BY JUMPERING CONTROL TEST TERMINAL

1. Remove main furnace door.

2. Remove blower access panel.

3. Manually close blower access panel door switch. Use a piece of tape to hold switch closed.

Blower access panel door switch opens 115-v power to control center. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death.

4. BRIEFLY short (jumper) TEST, 3/16-in. quick-connect terminal on control center (behind the Y terminal) and the C

terminal on thermostat connection block. (See Fig. 25.)

NOTE: If TEST to C

OM terminals are jumpered longer than 2 sec,

LED will flash rapidly, and retrieval request will be ignored.

5. When above items have been completed, the component test sequence will occur as described in the Component Test Sequence section above.

NOTE: Be sure to record the status code which is flashed 4 times at start of component test for further troubleshooting.

Page 34

Fig. 42—Inducer Housing Drain Tube

A99118

A99119

Fig. 43—Filling Condensate Trap

6. After component test is completed and furnace is operating properly, release blower access panel door switch, replace blower access panel, and replace main furnace door.

START-UP PROCEDURES

Step 1—General

1. Furnace must have a 115-v power supply properly connected and grounded. Proper polarity must be maintained for correct operation.

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

2. Thermostat wire connections at terminals R, W, G, and Y must be made at 24-v terminal block on control center.

3. Natural 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).

4. Blower access panel must be in place to complete 24-v electrical circuit to furnace.

These furnaces are equipped with a manual reset limit switch in burner box. This switch will open if an overheat condition (rollout) occurs in burner enclosure. Correct inadequate combustion-air supply or improper venting condition and reset switch. DO NOT jumper this switch.

Step 2—Prime Condensate Trap with Water

Condensate trap must be PRIMED or proper draining may not occur. The condensate trap has 2 internal chambers which can ONLY be primed by pouring water into the inducer drain side of condensate trap.

1. Remove upper inducer housing drain connection cap. (See Fig. 42.)

2. Connect field-supplied 1/2-in. ID tube to upper inducer housing drain connection.

3. Insert field-supplied funnel into tube.

4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 43.)

5. Remove funnel and tube from inducer housing and replace drain connection cap and clamp.

Step 3—Purge Gas Lines

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

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

Page 35

Step 4—Adjustments

SET GAS INPUT RATE Furnace gas input rate on rating plate is for installations at altitudes

up to 2000 ft. In the U.S.A., the input ratings for altitudes above 2000 ft must be

reduced by 2 percent for each 1000 ft above sea level. In Canada, the input ratings must be derated by 5 percent for

altitudes of 2000 ft to 4500 ft above sea level. Furnace input rate must be within ±2 percent of input on furnace

rating plate adjusted for altitude.

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

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

local gas supplier.

b. Obtain average yearly specific gravity from local gas

supplier.

c. Verify furnace model. Table 8 can only be used for model

58MCA furnaces with heating sizes of 040 through 120. Table 9 can only be used for model 58MCA furnaces with a 140 heating size.

d. Find installation altitude in Table 8 or 9.

NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 8 or 9.

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

Table 8 or 9.

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

intersection to find orifice size and manifold pressure settings for proper operation.

EXAMPLE: (0—2000 ft altitude using Table 8) Heating value = 1050 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 45

Manifold pressure 3.6-in. wc * Furnace is shipped with No. 45 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain the proper input rate.

Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY.

2. Adjust manifold pressure to obtain input rate.

NOTE: Manifold pressure must always be measured with burner enclosure front REMOVED. Gas meter must always be clocked with burner enclosure front INSTALLED.

a. Remove burner enclosure front. b. Remove cap that conceals adjustment screw for gas valve

regulator. (See Fig. 44.)

c. Turn adjusting screw, counterclockwise (out) to decrease

manifold pressure or clockwise (in) to increase manifold pressure.

NOTE: This furnace has been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft. For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 in. wc to 3.8 in. wc.

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

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

d. Replace gas valve regulator adjustment screw cap. e. Replace burner enclosure front and verify adjusted gas

input rate using method outlined in item 3.

f. Look through sight glass in burner enclosure and check

burner flame. Burner flame should be clear blue, almost transparent. (See Fig. 45.)

3. Verify natural gas input rate by clocking gas meter.

NOTE: Be sure all pressure tubing, combustion-air and vent pipes, and burner enclosure front are in place when checking input by clocking gas meter.

a. Calculate high-altitude adjustment (if required).

UNITED STATES At altitudes above 2000 ft, this furnace has been approved

for a 2% derate for each 1000 ft above sea level. See Table 10 for derate multiplier factor.

EXAMPLE: 100,000 Btuh input furnace installed at 4300 ft.

Furnace Input Rate

at Sea Level

100,000 X 0.91 = 91,000

Derate

Multiplier

Factor

Furnace Input Rate

at Installation

Altitude

Page 36

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

For Use with 040 through 120 Size Furnaces Only

(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

0 925 44 3.5 44 3.7 44 3.8 43 3.4 43 3.5

to 975 44 3.2 44 3.3 44 3.4 44 3.5 44 3.6

2000 1025 45 3.5 45 3.6 45 3.7 44 3.2 44 3.3

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

U.S.A. 775 43 3.8 42 3.2 42 3.3 42 3.4 42 3.5

Altitudes 800 43 3.5 43 3.7 43 3.8 42 3.2 42 3.3

2001 825 44 3.8 43 3.4 43 3.6 43 3.7 43 3.8

to 850 44 3.6 44 3.7 44 3.8 43 3.5 43 3.6

3000 875 44 3.4 44 3.5 44 3.6 44 3.7 43 3.4

or 900 44 3.2 44 3.3 44 3.4 44 3.5 44 3.6

Canada 925 45 3.7 45 3.8 44 3.2 44 3.3 44 3.4

Altitudes 950 45 3.5 45 3.6 45 3.7 45 3.8 44 3.3

U.S.A. and Canada

2000 975 45 3.3 45 3.4 45 3.5 45 3.6 45 3.8

to 1000 45 3.1 45 3.2 45 3.4 45 3.5 45 3.6

4500 1025 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

ALTITUDE

RANGE

(FT)

3001 825 44 3.5 44 3.6 44 3.8 43 3.4 43 3.5

to 875 45 3.8 44 3.2 44 3.3 44 3.5 44 3.6

U.S.A. Only

4000 925 45 3.4 45 3.5 45 3.6 45 3.7 44 3.2

* Orifice numbers shown in BOLD are factory installed.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

850 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4 875 43 3.5 43 3.6 43 3.7 43 3.8 42 3.2 900 44 3.7 43 3.4 43 3.5 43 3.6 43 3.7

950 44 3.4 44 3.5 44 3.6 44 3.7 44 3.8

1000 45 3.7 45 3.8 44 3.2 44 3.4 44 3.5

1050 45 3.3 45 3.4 45 3.6 45 3.7 45 3.8 1075 45 3.2 45 3.3 45 3.4 45 3.5 45 3.6 1100 47 3.6 47 3.7 45 3.2 45 3.4 45 3.5

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

750 43 3.7 43 3.8 42 3.3 42 3.4 42 3.5 775 43 3.5 43 3.6 43 3.7 43 3.8 42 3.2 800 44 3.7 43 3.4 43 3.5 43 3.6 43 3.7

850 44 3.3 44 3.4 44 3.5 44 3.7 44 3.8

900 45 3.6 45 3.7 45 3.8 44 3.3 44 3.4

950 45 3.2 45 3.3 45 3.4 45 3.5 45 3.7 975 45 3.0 45 3.2 45 3.3 45 3.4 45 3.5

1000 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 37

Table 8—Model 58MCA Orifice Size and Manifold Pressure for Correct Input (Continued)

For Use with 040 through 120 Size Furnaces Only

(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

4001 800 44 3.5 44 3.6 44 3.7 44 3.8 43 3.4

to 850 45 3.7 45 3.8 44 3.3 44 3.4 44 3.5

U.S.A. Only

5000 900 45 3.3 45 3.4 45 3.5 45 3.6 45 3.8

ALTITUDE

RANGE

(FT)

5001 800 44 3.2 44 3.3 44 3.4 44 3.5 44 3.6

to 850 45 3.4 45 3.5 45 3.6 45 3.8 44 3.2

U.S.A. Only

6000 900 45 3.0 45 3.1 45 3.3 45 3.4 45 3.5

ALTITUDE

RANGE

(FT)

6001 725 44 3.6 44 3.7 44 3.8 43 3.4 43 3.5

to 775 45 3.8 44 3.2 44 3.3 44 3.4 44 3.5

U.S.A. Only

7000 825 45 3.3 45 3.4 45 3.6 45 3.7 45 3.8

* Orifice numbers shown in BOLD are factory installed.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4 750 43 3.4 43 3.5 43 3.7 43 3.8 42 3.2 775 44 3.7 44 3.8 43 3.4 43 3.5 43 3.7

825 44 3.2 44 3.4 44 3.5 44 3.6 44 3.7

875 45 3.5 45 3.6 45 3.7 44 3.2 44 3.3

925 45 3.1 45 3.2 45 3.3 45 3.4 45 3.6 950 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

700 43 3.6 43 3.7 42 3.2 42 3.3 42 3.4 725 43 3.4 43 3.5 43 3.6 43 3.7 43 3.8 750 44 3.6 44 3.7 43 3.4 43 3.5 43 3.6 775 44 3.4 44 3.5 44 3.6 44 3.7 43 3.4

825 45 3.6 45 3.7 44 3.2 44 3.3 44 3.4

875 45 3.2 45 3.3 45 3.4 45 3.6 45 3.7

925 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3 950 45 2.7 45 2.8 45 2.9 45 3.0 45 3.1 975 45 2.6 45 2.7 45 2.8 45 2.9 45 2.9

1000 45 2.5 45 2.5 45 2.6 45 2.7 45 2.8

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6 675 43 3.6 43 3.7 43 3.8 42 3.2 42 3.3 700 44 3.8 43 3.4 43 3.6 43 3.7 43 3.8

750 44 3.3 44 3.4 44 3.6 44 3.7 44 3.8

800 45 3.5 45 3.7 45 3.8 44 3.2 44 3.3

850 45 3.1 45 3.2 45 3.4 45 3.5 45 3.6 875 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

0.58 0.60 0.62 0.64 0.66

Orifice

No.

0.58 0.60 0.62 0.64 0.66

Orifice

No.

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 38

Table 8—Model 58MCA Orifice Size and Manifold Pressure for Correct Input (Continued)

For Use with 040 through 120 Size Furnaces Only

(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

7001 700 44 3.5 44 3.6 44 3.8 43 3.4 43 3.5

to 750 45 3.7 45 3.8 44 3.3 44 3.4 44 3.5

U.S.A. Only

8000 800 45 3.3 45 3.4 45 3.5 45 3.6 45 3.7

ALTITUDE

RANGE

(FT)

8001 650 44 3.7 43 3.4 43 3.5 43 3.6 43 3.7

to 700 44 3.2 44 3.3 44 3.4 44 3.6 44 3.7

U.S.A. Only

9000 750 45 3.4 45 3.5 45 3.6 45 3.8 44 3.2

ALTITUDE

RANGE

(FT)

9001 625 44 3.7 44 3.8 43 3.5 43 3.6 43 3.7

to 675 45 3.8 44 3.3 44 3.4 44 3.5 44 3.6

U.S.A. Only

10,000 725 45 3.3 45 3.4 45 3.6 45 3.7 45 3.8

Orifice numbers shown in BOLD are factory installed.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

625 43 3.8 42 3.3 42 3.4 42 3.5 42 3.6 650 43 3.5 43 3.7 43 3.8 42 3.2 42 3.3 675 44 3.8 43 3.4 43 3.5 43 3.6 43 3.7

725 44 3.3 44 3.4 44 3.5 44 3.6 44 3.7

775 45 3.5 45 3.6 45 3.7 45 3.8 44 3.3

825 45 3.1 45 3.2 45 3.3 45 3.4 45 3.5 850 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

600 43 3.8 42 3.3 42 3.4 42 3.5 42 3.6 625 43 3.5 43 3.6 43 3.8 42 3.2 42 3.3

675 44 3.5 44 3.6 44 3.7 44 3.8 43 3.4

725 45 3.6 45 3.8 44 3.2 44 3.3 44 3.4

775 45 3.2 45 3.3 45 3.4 45 3.5 45 3.6 800 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

575 43 3.8 42 3.2 42 3.3 42 3.5 42 3.6 600 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3

650 44 3.4 44 3.5 44 3.7 44 3.8 43 3.4

700 45 3.6 45 3.7 45 3.8 44 3.3 44 3.4

750 45 3.1 45 3.2 45 3.3 45 3.4 45 3.5 775 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 39

Table 9—Model 58MCA Orifice Size and Manifold Pressure for Correct Input

For Use with 140 Size Furnaces Only

(Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

0 925 42 3.4 42 3.5 42 3.6 42 3.7 42 3.8

to 975 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4

2000 1025 43 3.3 43 3.4 43 3.6 43 3.7 43 3.8

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

U.S.A. 775 41 3.7 41 3.8 40 3.6 40 3.7 39 3.6

Altitudes 800 42 3.8 41 3.6 41 3.7 41 3.8 40 3.6

2001 825 42 3.6 42 3.7 41 3.5 41 3.6 41 3.7

to 850 42 3.4 42 3.5 42 3.6 42 3.7 41 3.5

3000 875 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6

or 900 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4

Canada 925 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3

Altitudes 950 43 3.3 43 3.4 43 3.5 43 3.7 43 3.8

U.S.A. and Canada

2001 975 43 3.1 43 3.3 43 3.4 43 3.5 43 3.6

to 1000 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4

4500 1025 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

ALTITUDE

RANGE

(FT)

3001 825 42 3.3 42 3.4 42 3.6 42 3.7 42 3.8

to 875 43 3.6 43 3.7 42 3.2 42 3.3 42 3.4

U.S.A. Only

4000 925 43 3.2 43 3.3 43 3.5 43 3.6 43 3.7

* Orifice numbers shown in BOLD are factory installed.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

850 41 3.6 41 3.7 41 3.8 40 3.6 40 3.8 875 42 3.8 41 3.5 41 3.6 41 3.7 41 3.8 900 42 3.5 42 3.7 42 3.8 41 3.5 41 3.6

950 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6

1000 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3

1050 43 3.2 43 3.3 43 3.4 43 3.5 43 3.6 1075 44 3.5 44 3.6 43 3.2 43 3.3 43 3.4 1100 44 3.3 44 3.4 44 3.5 43 3.2 43 3.3

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

750 41 3.6 41 3.8 40 3.6 40 3.7 40 3.8 775 42 3.8 41 3.5 41 3.6 41 3.7 40 3.6 800 42 3.5 42 3.7 42 3.8 41 3.5 41 3.6

850 43 3.8 42 3.2 42 3.4 42 3.5 42 3.6

900 43 3.4 43 3.5 43 3.6 43 3.8 42 3.2

950 43 3.1 43 3.2 43 3.3 43 3.4 43 3.5 975 43 2.9 43 3.0 43 3.1 43 3.2 43 3.3

1000 43 2.8 43 2.9 43 3.0 43 3.0 43 3.1

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 40

Table 9—Model 58MCA Orifice Size and Manifold Pressure for Correct Input (Continued)

For Use with 140 Size Furnaces Only

(Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

4001 775 42 3.5 42 3.6 42 3.7 42 3.8 41 3.6

to 825 43 3.7 42 3.2 42 3.3 42 3.4 42 3.5

5000 875 43 3.3 43 3.4 43 3.6 43 3.7 43 3.8

U.S.A. Only

ALTITUDE

RANGE

(FT)

5001 800 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4

to 850 43 3.3 43 3.4 43 3.5 43 3.6 43 3.7

U.S.A. Only

6000 900 43 2.9 43 3.0 43 3.1 43 3.2 43 3.3

ALTITUDE

RANGE

(FT)

6001 700 42 3.6 42 3.7 41 3.5 41 3.6 41 3.7

to 750 43 3.8 42 3.3 42 3.4 42 3.5 42 3.6

7000 800 43 3.4 43 3.5 43 3.6 43 3.7 43 3.8

U.S.A. Only

* Orifice numbers shown in BOLD are factory installed.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

725 41 3.6 41 3.7 41 3.8 40 3.6 40 3.8 750 42 3.7 42 3.8 41 3.6 41 3.7 41 3.8

800 42 3.3 42 3.4 42 3.5 42 3.6 42 3.7

850 43 3.5 43 3.6 43 3.8 42 3.2 42 3.3

900 43 3.1 43 3.3 43 3.4 43 3.5 43 3.6 925 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4 950 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

700 41 3.5 41 3.7 41 3.8 40 3.6 40 3.7 725 42 3.7 42 3.8 41 3.5 41 3.6 41 3.8 750 42 3.4 42 3.5 42 3.7 42 3.8 41 3.5 775 42 3.2 42 3.3 42 3.4 42 3.5 42 3.7

825 43 3.5 43 3.6 43 3.7 43 3.8 42 3.2

875 43 3.1 43 3.2 43 3.3 43 3.4 43 3.5

925 43 2.7 43 2.8 43 2.9 43 3.0 43 3.1 950 43 2.6 43 2.7 43 2.8 43 2.9 43 3.0 975 43 2.5 43 2.6 43 2.6 43 2.7 43 2.8

1000 43 2.3 43 2.4 43 2.5 43 2.6 43 2.7

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

650 41 3.8 40 3.6 40 3.7 40 3.8 39 3.7 675 41 3.5 41 3.6 41 3.7 40 3.6 40 3.7

725 42 3.4 42 3.5 42 3.6 42 3.7 42 3.8

775 43 3.6 43 3.7 43 3.8 42 3.3 42 3.4

825 43 3.2 43 3.3 43 3.4 43 3.5 43 3.6 850 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4 875 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

0.58 0.60 0.62 0.64 0.66

Orifice

No.

0.58 0.60 0.62 0.64 0.66

Orifice

No.

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 41

ON AND OFF SWITCH

GAS PRESSURE REGULATOR ADJUSTMENT

BURNER ENCLOSURE REFERENCE PRESSURE TAP

INLET PRESSURE TAP

MANIFOLD PRESSURE TAP

Fig. 44—Redundant Automatic Gas Valve

A95622

Table 10—Altitude Derate Multiplier for U.S.A.

ALTITUDE

(FT)

0—2000 0 1.00 2001—3000 4—6 0.95 3001—4000 6—8 0.93 4001—5000 8—10 0.91 5001—6000 10—12 0.89 6001—7000 12—14 0.87 7001—8000 14—16 0.85 8001—9000 16—18 0.83

9001—10,000 18—20 0.81

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

CANADA At installation altitudes from 2000 to 4500 ft, this furnace

must be derated 5% by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example above and use 0.95 as derate multi-

plier factor. b. Turn off all other gas appliances and pilots. c. Start furnace and let operate for 3 minutes. d. Measure time (in sec) for gas meter test dial to complete 1

revolution.

e. Refer to Table 11 for cu ft of gas per hr.

%OF

DERATE

DERATE MULTIPLIER

FACTOR FOR U.S.A.*

BURNER 

ORIFICE

A93059

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

BURNER FLAME

BURNER

MANIFOLD

A89020

Fig. 45—Burner Flame

f. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft) using

natural gas heating value from local gas utility/supplier.

EXAMPLE: (0—2000 ft altitude) Furnace input from rating plate is 100,000 Btuh. Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 975 Btu/cu ft Time for 1 revolution of 2-cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 11) Btu heating input = 103 X 975 = 100,425 Btuh In this example, the orifice size and manifold pressure adjustment is within ±2 percent of the furnace input rate.

SET TEMPERATURE RISE

Temperature rise must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise or above. Failure to follow this caution may result in condensing or overheating the heat exchangers.

Determine and adjust air temperature rise as follows:

1. Place thermometers in return and supply ducts as close to 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.

2. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.

3. Adjust temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.

Page 42

Disconnect 115-v electrical power before changing speed tap. Failure to follow this warning could result in personal injury.

4. To change blower motor speed selections for heating mode, remove blower motor lead from control center HEAT terminal. (See Fig. 25.) Select desired blower motor speed lead from 1 of the other terminals and relocate it to HEAT terminal. See Table 12 for lead color identification. Reconnect original lead on SPARE terminal.

Follow this same procedure for proper selection of COOL speed selection.

Table 11—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 1000

947 900

857 818 783 750

720 692 667 643 621

600 581 563 545 529

514 500 486 474 462

450 439 429 419 409

400 391 383 375 367

327 300 277 257

240 225 212 200 189

180 171 164 157 150

144 138 133 129 124

120 116 113 109 106

103 100

97 95 92

90 88 86 84 82

80 78 76 75 73

SECONDS

FOR 1

REVOLUTION

50 51 52 53 54

55 56 57 58 59

60 62 64 66 68

70 72 74 76 78

80 82 84 86 88

90 92 94 96 98

100 102 104 106 108

110 112 116 120

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

144 141 138 136 133

131 129 126 124 122

120 116 112 109 106

103 100

97 95 92

90 88 86 84 82

80 78 76 75 74

72 71 69 68 67

65 64 62 60

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

71 69 68 67

65 64 63 62 61

60 58 56 54 53

51 50 48 47 46

45 44 43 42 41

40 39 38 38 37

36 35 35 34 33

33 32 31 30

Table 12—Speed Selector

COLOR SPEED

Black High Cool Yellow (When

Present)

Medium High Spare

Blue Medium Low Heat Red Low Spare White Common L2

BLOWER OFF DELAY (HEAT MODE) The main blower off time delay period is factory-set at 135 sec and

can be adjusted. See figure 25.

FACTORYSHIPPED CONNECTION

SET THERMOSTAT HEAT ANTICIPATOR Thermostat heat anticipator must be set to match amp draw of

components in R-W circuit. Accurate amp draw measurements can be obtained at thermostat subbase terminals R and W.

Fig. 46 illustrates an easy method of obtaining these measurements. Amp reading should be taken after blower motor has started. See thermostat manufacturer’s instructions for adjusting heat anticipator and for varying heating cycle length.

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED

HOOK-AROUND

VOLT/AMMETER

R Y W G

10 TURNS

FROM UNIT 24-VOLT TERMINAL BLOCK

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

= 0.5 AMPS FOR THERMOSTAT SETTING

Fig. 46—Amp Draw Check with Ammeter

CHECK SAFETY CONTROLS

Step 1—Check Primary Limit Control

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

Step 2—Check Pressure Switch

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

1. Turn off 115-v power to furnace.

2. Remove main furnace door and disconnect inducer motor lead wires from wire harness.

3. Turn on 115-v power to furnace.

4. Set thermostat to call for heat and wait 1 minute. When pressure switch is functioning properly, hot surface ignitor should NOT glow, and control center diagnostic light flashes a Status Code 31. If hot surface ignitor glows when inducer motor is disconnected, shut furnace down immediately. Determine reason pressure switch did not function properly and correct condition.

5. Turn off 115-v power to furnace.

6. Reconnect inducer motor leads, reinstall main furnace door, and turn on 115-v power supply.

A80201

Page 43

CHECKLIST

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

2. Verify manual reset switch has continuity.

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

4. Cycle test furnace with room thermostat.

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

6. Review User’s Guide with owner.

7. Leave literature packet near furnace.

Page 44

LOAD CALCULATION

____________ Heating Load (Btuh)

____________ Cooling Load (Btuh)

____________ Furnace Model Selection

CHECKLIST—INSTALLATION

Condensate Drain

________ Unit Level or Pitched Forward

________

Internal Tubing Connections Free of Kinks and Traps

COMBUSTION AND VENT PIPING

Termination Location

________ Roof or Sidewall

________ Termination Kit — 2 Pipe or Concentric

________ Combustion-Air Pipe Length

________ Combustion-Air Pipe Elbow Quantity

________ Vent Pipe Length

________ Vent Pipe Elbow Quantity

________ Pipe Diameter Determined from Sizing Table

________ Pipe Sloped To Furnace

Pipe Insulation

________ Over Ceilings

________ Low-Ambient Exposed Pipes

________

External Drain Connection Leak Tight and Sloped

________ Condensate Trap Primed before Start-Up

________ Heat Tape Installed if Required

CHECKLIST—START-UP

________

Gas Input Rate (Set Within 2 percent of Rating Plate)

________ Temperature Rise Adjusted

Thermostat Anticipator

________ Anticipator Setting Adjusted or

________ Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Check Operation

________ Primary Limit

________ Pressure Switch

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. 535-758 Printed in U.S.A. Form 58MCA-7SI Pg 44 1-00 Replaces: New