Carrier 58MTB100F10116, 58MTB100F10120, 58MTB120F10120, 58MTB060F10112, 58MTB080F10112 Installation Guide

...

Installation, Start-up, and Operating Instructions

Sizes 060-120, Series 110

Visit www.Carrier.com

NOTE: Read the entire instruction manual before starting the installation. Please retain these instructions with the furnace

after installation for future reference.

NOTE: This furnace can be installed as a (2-pipe) direct vent or (1-pipe) non-direct vent condensing gas furnace.

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ISO 9001:2000

Special Venting Requirements for Installations in Canada

Installation in Canada must conform to the requirements of CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC $636. The special vent

fittings and accessory concentric vent termination kits and accessory external drain trap have been certified to ULC $636 for

use with those IPEX PVC vent components which have been certified to this standard. In Canada, the primer and cement must

be of the same manufacturer as the vent system - IPEX System 636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and IPEX System 636(1) TM , PVC Cement for Flue Gas Venting, rated

Class IIA, 65 deg C. must be used with this venting system - do not mix primers and cements from one manufacturer with a vent

system from a different manufacturer. Follow the manufacturer's instructions in the use of primer and cement and never use primer

or cement beyond its expiration date. The safe operation, as defined by ULC $636, of the vent system

is based on following these installation instructions, the vent system manufacturer's installation instructions, and proper use of primer and cement. All fire stop and roof flashing used with this

system must be UL listed material. Acceptability under Canadian standard CSA B149 is dependent upon full compliance with all installation instructions. Under this standard, it is recommended

that the vent system be checked once a year by qualified service personnel.

The authority having jurisdiction (gas inspection authority, municipal building department, fire department, etc) should be

consulted before installation to determine the need to obtain a permit.

Consignes sp_ciales pour l'installation de ventillation au Canada

Uinstallation faite au Canada doit se conformer aux exigences du code CSA B149. Ce syst_me de ventillation doit se composer de

tuyaux, raccords, ciments et appr_ts conformes au ULC $636. La tuyauterie de ventillation des gaz, ses accessoires, le terminal

concentrique mural ainsi que l'ensemble du drain de condensat ext_rieur ont _t_ certifies ULCS 636 pour l'application des composantes IPEX PVC qui sont certifi_es fi ce standard. Au

Canada l'appr_t et le ciment doivent _tre du m_me manufacturier

que le syst_me de ventillation - IPEX Syst_me 636, Appr_t PVC/CPVC. Mauve Violette pour conduit en _vacuation des gaz et IPEX Syst_me 636(1) TM, ciment pour PVC pour conduit en

_vacuation des gaz, _valu_ CLASSE IIA, 65 deg. C. doit _tre utilis_ avec ce syst_eme d'_vacuation - ne pas m_langer l'appr_t

et le ciment d'un manufacturier avec le syst_me de ventillation d'un autre manufacturier. Bien suivre les indications du

manufacturier lors de l'utilisation de l'appr_t et du ciment et ne pas utiliser ceux-ci si la date d'expiration est atteinte.

Uop_ration s_curitaire, tel que d_finit par ULC $636, du syst_me de ventilation est bass sur les instructions d'installation suivantes,

ainsi que l'usage appropri_ de l'appr_t et ciment. Tout arr_t feu et

solin de toit utilis_s avec ce syst_me doivent _tre des mat_riaux list,s UL. Uacceptation du standard Canadien CSA B419 est

directement reli_ fi l'installation conforme aux instructions ci- haut mentionn_es. Le standard Canadien recommande 1'

inspection par un personel qualifi_ et ce, une fois par annie. Les autorit_es ayant juridiction (inspecteurs de gas, inspecteurs

en bfitiments, d@artement des incendies, etc) devraient _tre consult_es avant l'installation afin de d_terminer si un permis est requis.

(1) System 636 is a trademark of IPEX Inc.

Required Notice for Massachusetts Installations

IMPORTANT

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:

5.08: Modifications to NFPA-54, Chapter 10

2) Revise 10.8.3 by adding the following additional requirements: a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used

in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,

including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an

alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is

installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for

the installation of hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard

wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner

shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a

minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "(}AS

VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve

the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in

accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

(1.) The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of

NFPA 54 as adopted by the Board; and

(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from

the dwelling, building or structure used in whole or in part for residential purposes.

c. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

d. MANUFACTURER REQUIREMENTS - (}AS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When

the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be

satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled

equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

For questions regarding these requirements, please contact the Commonwealth of Massachusetts Board of State Examiners of Plumbers

and Gas Fitters, 239 Causeway Street, Boston, MA 02114. 617-727-9952.

TABLE OF CONTENTS

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

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

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

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

Combustion and Ventilation Air ........................ 7

Duct Systems ...................................... 7

Acoustical Lining and Fibrous Glass Duct ................ 7

Gas Piping and Gas Pipe Pressure Testing ................ 7

Electrical Connections ............................... 7

Venting ........................................... 8

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ... 8

INTRODUCTION .................................... 8

APPLICATIONS ..................................... 8

General ........................................... 8

Upflow Applications ................................. 8

Downflow Applications ............................. 10

Horizontal Left (Supply-Air Discharge) Applications ...... 12

Horizontal Right (Supply-Air Discharge) Applications ..... 13

LOCATION ........................................ 16

General .......................................... 16

Furnace Location Relative to Cooling Equipment ......... 17

Hazardous Locations ............................... 17

Furnace Location and Application ..................... 17

AIR FOR COMBUSTION AND VENTILATION .......... 18

INSTALLATION .................................... 21

Leveling Legs (If Desired) ........................... 21

Installation in Upflow and Downflow Applications ....... 21

Installation in Horizontal Applications ................. 21

Air Ducts ......................................... 21

General Requirements ............................. 21

Ductwork Acoustical Treatment ..................... 23

Supply Air Connections ........................... 23

Return Air Connections ............................ 24

Filter Arrangement ................................. 25

Bottom Closure Panel ............................... 26

Gas Piping ........................................ 26

Electrical Connections .............................. 27

115-v Wiring .................................... 27

24-v Wiring ..................................... 29

Accessories ..................................... 29

Removal of Existing Furnaces from

Common Vent Systems .............................. 30

Combustion Air and Vent Pipe Systems ................. 30

Condensate Drain .................................. 45

General ........................................ 45

Application ..................................... 45

Condensation Drain Protection ...................... 46

START-UR ADJUSTMENTS, AND SAFETY CHECK ..... 46

General .......................................... 46

Prime Condensate Trap With Water .................... 47

Purge Gas Lines ................................... 47

Sequence of Operation .............................. 47

Two-Stage Heating With Single-Stage Thermostat

(Adaptive Mode) ................................. 48

Two-Stage Heating With Two-Stage Thermostat

(Non-Adaptive Heating Mode) ...................... 48

Cooling Mode ................................... 49

Thermidistat Mode ............................... 49

Continuous Blower Mode .......................... 53

Heat Pump Mode ................................. 53

Component Self-Test .............................. 53

Operate Furnace ................................. 54

Furnace Restart .................................. 54

Set Gas Input Rate ................................ 54

Set Temperature Rise .............................. 59

Adjust Blower Off Delay (Heat Mode) ................ 60

Set Thermostat Heat Anticipator ..................... 60

Check Safety Controls .............................. 60

Checklist ......................................... 61

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SAFETY CONSIDERATIONS

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

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

Improper installation, adjustment, alteration, service, maintenance, or use could cause carbon monoxide

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

A93041

FURNACERELIABILITYHAZARD

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

failure. Application of this furnace should be indoors with special

attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

hnproper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or

property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The

qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these

instructions thoroughly and follow all warnings or cautions include in literature and attached to the unit. Consult local

building codes, the current editions of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical

Code (NEC) NFPA 70. In Canada, refer to the current editions of the National Standards of Canada CAN/CSA-B149.1 and .2 Natural Gas and Propane

Installation Codes, and Canadian Electrical Code CSA C22.1

Recognize safety information. This is the safety-alert symbol/_. When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and

CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in

severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is

used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used

to highlight suggestions which will result in enhanced installation, reliability, or operation.

ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental

pollution. Remove and recycle all components or materials (i.e., oil,

refrigerant, control boards, etc.) before unit final disposal.

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing furnaces.

The model 58MTB, 2-Stage, 4-way Multipoise, Gas-Fired, Category IV, condensing furnace is available in model sizes

ranging in high-stage gas input rates of 60,000 to 120,000 Btuh.

This furnace is CSA (formerly AGA and CGA) design-certified for natural and propane gases (see furnace rating plate) and for

installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. This furnace is factory-shipped for use with natural gas. A CSA listed gas conversion kit is required to

convert furnace for use with propane gas.

See Fig. 3 for required clearances to combustibles.

This furnace SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. For

downflow installations, a factory accessory floor base must be used when installed on combustible materials and wood flooring.

Special base is not required when this furnace is installed on the

manufacturer's coil assembly or when the manufacturer's coil box is used. The design of the 58MTB furnace is not CSA certified for installation in mobile homes, recreational vehicles, or outdoors. This furnace is suitable for installation in a structure

built on site or a manufactured building completed at final site. This furnace is designed for continuous return-air minimum

temperature of 60°F (16°C) db or intermittent operation down to 55°F (13°C)db such as when used with a night setback

thermostat. Return-air temperature must not exceed 80°F (27°C) db. Failure to follow these return air limits may affect reliability

of heat exchangers, motors and controls. (See Fig. 4.) This furnace is 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. Install this furnace only in a location and position as specified in

LOCATION and INSTALLATION sections of these instructions. Always provide adequate combustion and ventilation air as

specified in section Combustion Air and Vent Pipe Systems of these instructions to furnace.

Combustion products must be discharged outdoors. Connect this

furnace to an approved vent system only, as specified in the

Combustion Air and Vent Piping sections of these instructions.

Never test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of

leaks to check all connections, as specified in the GAS PIPING section of these instructions.

Always install furnace to operate within the furnace's intended rise range with a duct system which has an external static

pressure within the allowable range, as specified in the SET TEMPERATURE RISE section of these instructions and furnace

rating plate. When a furnace is installed so that supply ducts carry air

circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to

the furnace casing and terminating outside the space containing the furnace.

A gas-fired furnace for installation in a residential garage must be installed as specified in the Hazardous Locations section of these

instructions. The furnace may be used for construction heat provided that the

furnace installation and operation complies with:

• The furnace is permanently installed with all electrical wiring, piping, air filters, venting and ducting installed according to

these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space

containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a

flame rollout and/or drawing combustion products into the structure.

• The furnace is controlled by a thermostat. It may not be "hot wired" to provide heat continuously to the structure without

thermostatic control.

• Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other

construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

• The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), with no evening

setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per

our installation instructions.

• The air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the

nameplate value.

• The filters used to clean the circulating air during the construction process must be either changed or thoroughly

cleaned prior to occupancy.

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

This furnace is shipped with the following materials to assist in proper furnace installation. These materials are shipped in the

main blower compartment.

Installer Packet includes:

Installation, Startup, 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

Condensate trap hole filler plug 3

Vent and combustion-air intake hole filler plug 2

Combustion-air intake pipe perforated disk assembly 1 Gas line grommet 1

Vent pipe grommet 1

Combustion-air pipe grommet 1 Power entry hole filler plug 2

Vent Pipe Extension 1"

CODES AND STANDARDS

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

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

all authorities having jurisdiction.

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

Step 1 - Safety

• US: National Fuel (;as Code (NFGC) NFPA 54-2006/ANSI Z223.1-2006 and the Installation Standards, Warm Air Heating

and Air Conditioning Systems ANSI/NFPA 90B

• CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-05

Step 2 - General Installation

• US: NFGC and the NFPA 90B. For copies, 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, N.W., Washington DC 20001

• A manufactured (Mobile) home installation must conform with

the Manufactured Home Construction and Safety Standard,

Title 24 CFR, Part 3280, or when this standard is not applicable, the Standard for Manufitctured Home Installation

(Manufactured Home Sites, Communities, and Set-Upsg,

ANSI/NCS A225.1, and/or CAN/CSA-Z240, MH Series

Mobile Homes

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,

CSA International, 178 Rexdale Boulevard, Etobicoke

(Toronto), Ontario, M9W 1R3, Canada.

*ONLY supplied with some furnaces.

The furnace shall be installed so that the electrical components are protected from water.

For accessory installation detail, refer to the accessory installation instruction.

NOTE: Remove all shipping materials before operating furnace.

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A05053

NSTALLATION

e This forced air fumace 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 fL

(0- Z135m).

• An accessory kit, supplied by the manufacturer, shah be used to convert to propane gas use or may be required for some natural gas applications.

• This famace 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 instated on combustible floodng in alsove or closet at Minimum Inches Clearance To Combustible Construction as described below.

e This _mace requires a special venting system. Refer to the installation instructions for parts list and method of installation. In the US this furnace is for use with

schedule=40 PVC, PVC-DWV, CPVC, or AB,S-DWV pipe, and must not be vented in common with other gas-fired appliances. In Canada, refer to installation instructions for vent materiaN. Construction through which vent/air intake pipes may be installed is maximum 24 inches (610 ram), minimum 3/4 inches (19 mm) thickness (including

roofing materials).

e Cette foumaise _ air puls6 est 6quip6e pour utilisation avec gaz naturem et altitudes comprises entre 0 - 3,050m (0 - 10,000 pi),except6 queles foumaises de 140 taifle

sont pour altitudes comprises entre 0 - 2,135m (0 - 7,000pi).

® Utiiiser une trousse de conversion, foumie par le fabdcent, pour passer au gaz propane ou pour certaines installations au gaz natureL e Cette foumaise _ air pulse est pour installation a Fintedeur dans un b_timent construit sur place. Cette foumaise a air puNe peut 6tre install6e dans une maison

prCfabdqu6e (maison mobile) si prescrit par la plaque signal6tique et si'l on utilise une trousse specifi6e par le fabricent.

• C.ette foumaise pout 6tre install6e sur un piancher combustible dans un enfoncement ou un pmacerd en observant les D6gagernent Minimum En Pouces Avec EI6ments De Construction Combustibles.

• Cette foumaise n6cessite un syst_me d'6vacuation sp6cial. La m6thode d'instaliation et la liste des pi_ces n6cessaires figurent dana les instructions d'installation. Aux Etats-Unis, cette foumaise dolt s'utiliser avec la tuyautede des nomenclatures 40 PVC, PVC-DWV, CPVC, ou ,ABS-DWV et elle ne peut pas _tre ventii6e conjointment

avec d'autres appareils & gaz. Au Canada, referer aux instructions d'installation pour lax matedaux a ventiler. Epaisseur de la construction au travers de laquene il est possible de faire passer les tuyaux d'aeration (admission/evacuation): 24 po (610 mm) maximum, 3/4 pc (19mm) minimum (y compds la toiture).

For up&3w and downflow applications, furnace must be installed level, or pitched within 1/2" (12.7ram) of level. For a LEVEL 0" ( 0 ) TO _,. MIN 114"(6.35mm) TO horizontal appllaatiorl, the furnace must be pitched mirlimum 1/4" (6.35mm) to maximum of 1/2" (12.7mm) forward for 1/2" (12.7mm) MAX t ¢_L-_-_ 1/2" (12.7mm)MAX

proper drainage. See Installation Manual for IMPORTANT unit support details on horizontal applications.

Pour des applications de flux ascendant et descendant, la foumaise doit ¢¢e install6e de niveau ou indin6e _ T ............ !

pas plus de 1/2" (12.7mm) du niveau. Pour une applicetion hodzontale, lafoumaise dolt &,Ire inclin6e enli'e minimum UPFLOW OR F_0RONT_) 1/4" (6.35mm) et maximum 1/2" (12.7ram) du niveau pour ledrainage appropn6. En cas d'installation en position DOWN FLOW

hodzootale, consulter les renseignements mMPORTANTS sur le support dans le manuel d'instaHation. HORIZONTAL

MINIMUMINCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSiTiONS:

Minimum front clearance for service 24 inches (610mm).

t 1 140 size furnaces require I inch back clearance to combustible materials.

DOWNFLOW POSITIONS:

t For installation on combustible 11oors only when instated on special base No. KGASB0201ALL or

NAHA01101SB, CoilAssembly, Part No. CAR, CAP, CNPV, CNRV or Coil Casing, Part No. KCAKC,

or WENC or WTNC.

HORIZONTAL POSITIONSi

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 curet ends.

O 120 and 140 size furnaces require 1 inch bottom clearance to combustible materials.

DEGAGEMENT MNfl_UM EN POUCESAVEC I_LleMENTSDECONSTRUCTION COMBUSTIBLES

POUR TOUS LES POSITIONS:

D@jagement avant minimum de 24 po (610mm ) pour l'entretien.

1- t Pour les foumaises de 140 taifle, 1 pc (25mm) d6gagement des mat6riaux combustibles est

requis au-arriere.

POUR LA POSITION COURANT DESCENDANT:

1 Pour Ilnstaflation sur le plancher cembustible seulement quand on utilise la base sp_ciale, piece

n° KGASB0201ALL ou NAHA01101SB, I'ensemble serpentin, pi_:e n ° CAR, CAP, CNPV, CNRV, ou le carter de serpentin, piece n ° KCAKC ou WENC ou WTNC.

POUR LA POSmON HORIZONTALE:

Le contact n'est permis qOentre les lignes form6es par les intersec_ons du dessus et des deuxottes de la chemise de la foumaise, et des solives, des montants ou de la charpente du

batiment.

§ La distance indiqu_e conceme I'extr_mit6 du tuyau d'ardv_e d'air et I'extr_mit_ du tuyau de sortie d'aic Pour les foumaises de 120 et 140 taifie, 1 pc (25mm) d6gagement des materiaux combustibles

est requis au-dessous.

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

Cette foumaise est approuv_e pour I'installation HORIZONTALE et la circulation d'air VERS LE HAUT et VERS LE BAS.

Clearance arrows Les _hes de degagement do not change with ne change pas avec

furnace orientation, gen_rateur d'air chaud.

Clearanceininches 0 (pc) D_Jagement D6gagement(pc). d'_ventaveccombustibles.

I'orientation de la

Vent clearance to

combustibles 0".

Step 3 - Combustion and Ventilation Air

• US: Section 9.3 of the NFPA 54/ANSI Z223.1-2006, Air for Combustion and Ventilation

• CANADA: Part 8 of the CAN/CSA-B149.1-05, Venting Systems and Air Supply for Appliances

Step 4 - Duct Systems

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

Step 5 - Acoustical Lining and Fibrous Glass Duct

• US and CANADA: current edition of SMACNA, NFPA 90B as tested by UL Standard 181 for (?lass I Rigid Air Ducts

Step 6 - Gas Piping and Gas Pipe Pressure Testing

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

national plumbing codes.

• CANADA: CAN/CSA-B149.1-05 Parts 4, 5, and 6, A, B, E, G, and H.

In the state of Massachusetts:

• This product must be installed by a licensed plumber or gas fitter.

• When flexible connectors are used, the maximum length shall

not exceed 36 in. (914 mm)

• When lever type gas shutoffs are used they shall not exceed 36 in.

014 mm).

• The use of copper tubing for gas piping is not approved by the

state of Massachusetts.

Step 7 - Electrical Connections

• US: National Electrical (?ode (NEC) ANSI/NFPA 70-2008

• CANADA: Canadian Electrical (?ode CSA (722.1

Step 8 - Venting

• US: NFPA 54/ANSI Z223.1-2006 Chapters 12 and 13.

• CANADA: CAN/CSA-B149.1-05 Part 8 and Appendix C

MAX80°F (27° C)

INTRODUCTION

The model 58MTB 4-way multipoise, Gas-Fired, Category IV, condensing furnace is available in model sizes ranging from input

capacity of 60,000 to 120,000 Btuh as a direct vent (2-pipe)

application as well as a non-direct vent (1-pipe) application.

APPLICATIONS

FRONT

MIN 60°F (16o C)

Fig. 4 - Return-Air Temperature

A05004

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

UNIT DAMAGE HAZARD Failure to follow this caution may result in damage to unit

components. 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. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR

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

2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in

hand during grounding will be discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing to recharge your body (moving or shuffling feet, touching

ungrounded objects, etc.).

4. If you touch ungrounded objects, firmly touch a clean, unpainted metal surface of the furnace again before

touching control or wires.

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

6. Before removing a new control from its container, discharge your body's electrostatic charge to ground to

protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before

bringing the control or yourself in contact with the furnace. Put all used and new controls into containers

before touching ungrounded objects.

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

MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor property damage.

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.

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. 6. See appropriate application instructions for these procedures.

Step 2 - Upflow Applications

In an upflow application, the blower is located below the burner section, and conditioned air is discharged upwards.

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. (See Fig. 5.)

CONDENSATE TRAP TUBING (FACTORY-SHIPPED ORIENTATION)

NOTE: See Fig.6 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 robes 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:

f. Determine location of field drain connection. (See Fig.

2 or 6)

NOTE: If internal filter or side Filter/Media Cabinet is used, drain tube should be located to opposite side of casing from

return duct attachment to assist in filter removal.

g. Remove and discard casing drain hole plug button

from desired side.

h. Install drain tube coupling grommet (factory-supplied

in loose parts bag) in selected casing hole.

i. Slide drain tube coupling (factory-supplied in loose

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

BLOWERSRELF ACE ,--"CONDENSATE

,---CONDENSATE\ / TRAP

/TRAP(INSIDE) "k / FURNACE-7

\ / S,Dy

FIELD 261/4 1 /2

ALTERNATEDRAIN CONN TUBELOCATION

CONDENSATETRAP-- SIDE VIEW FRONT VIEW

DRAINTUBE LOCATION

UPFLOW APPLICATIONS EXTERNAL UPFLOW APPLICATIONS

DRAIN 667 mm 38 mm

DOWNFLOW AND ALTERNATE

SLOT oO SO2fW-7

11/2 3Smm /

71/8

__!/4 45 mm

GUIDES (WHEN USED)

181

RNACE

DOOR

102

FIELD

DRAIN

CONN

END VIEW FRONT VIEW

1/40D COLLECTOR BOX TO TRAP RELIEF PORT

1/2OD

INDUCER HOUSING

DRAIN CONNECTION

5/80D COLLECTOR BOX

DRAIN CONNECTION

SCREW HOLE FOR

UPFLOW OR DOWN-

FLOW APPLICATIONS

(OPTIONAL)

1/2-1N. PVC OR CPVC

-- FURNACE SIDE

146mm _4 146mm

26 /4 667mm 3/4 19mm

HORIZONTAL

APPLICATIONS

FRONT VIEW SIDE VIEW

Fig. 5 - Condensate Trap

j. Cement 2 factory-supplied 1/2-in. (13 mm) street CPVC

elbows to the rigid drain tube connection on the condensate trap. (See Fig. 6.) 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.

k. Connect larger diameter drain tube and clamp (factory

supplied in loose parts bag) to condensate trap and clamp securely.

1. Route tube to coupling and cut to appropriate length.

In. 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 7.)

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. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

A93026

CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury

or death. Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

4. 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.

5. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING (ALTERNATE

UPFLOW ORIENTATION) NOTE: See Fig.7 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. (445 mm) wide furnaces ONLY, cut tube between corrugated sections to prevent kinks from occurring.

PLUG

CAP

COLLECTOR

DRAIN TUBE (BLUE

&WHITE STRIPED)

COLLECTOR

TUBE (PINK)

PLUG

COLLECTOR BOX

DRAIN TUBE (BLUE

&WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK) N

CAP

COLLECTOR BOX

TUBE (GREEN)

INDUCER

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR

DRAIN TUBE (BLUE)

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIE LD-INSTALLED FIELD- IN STALLED

FACTORY-SUPPLIED FACTORY-SUPPLIED

%-IN. (13 mm) CPVC STREET DRAIN TUBE

Fig. 6 - Factory-Shipped Upflow Tube Configuration

2. Inducer Housing Drain Tube

3. Relief Port Tube

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and procedures.

ELBOWS (2) FOR COUPLING (RIGHT

LEFT DRAIN OPTION DRAIN OPTION)

(Shown with Blower Access Panel Removed)

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.

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.

A01030

COLLECTOR BOX --

TUBE (GREEN)

COLLECTOR BOX --

DRAIN TUBE (BLUE)

O O

CONDENSATETRAP.,.-,.*,,,.b__

INDUCER J

HOUSING

DRAIN TUBE

(VIOLET)

A01031

Fig. 7 - Alternate Upflow Configuration and Trap Location

PRESSURE SWITCH TUBING

The LOWER collector box pressure tube (pink label) is factory connected to the High Pressure Switch and should not require

any modification.

NOTE: See Fig.6 or 7 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.6 or 7 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.6 or 7 or tube routing label on main furnace door to check for proper connections.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

Step 3 - Downflow Applications

In a downflow furnace application, the blower is located above the burner section, 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, 8, or 9.

DRAIN TUBE (BLUE)

COLLECTOR

TUBE (GREEN)

COLLECTOR

EXTENSION TUBE

COLLECTOR

TUBE (PINK)

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX_

EXTENSION TUBE

TRAP

INDUCER HOUSING

DRAIN TUBE (VIOLET)

Fig. 8 - Downflow Tube Configuration

(Left-Hand Trap Installation)

A01023

O O

'DRAIN TUBE 8

COUPLING "_

Fig. 9 - Downflow Tube Configuration

(Right-Hand Trap Installation)

DRAIN TUBE (BLUE)

BOX

TUBE (PINK)

)R BOX

TUBE (GREEN)

)R BOX

EXTENSION TUBE

BOX DRAIN TUBE (BLUE & WHITE STRIPED)

)R BOX

EXTENSION TUBE INDUCER HOUSING

DRAIN TUBE

(VIOLET)

TRAP

)R BOX

EXTENSION DRAINTUBE

A01024

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, 8, or 9.)

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

CARBON MONOXIDE POISONING HAZARD

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

Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

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. 8 or 9 or robe routing label on main fi_rnace

door to check for proper connections. Relocate robes as described below.

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

condensate trap.

(3.) 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.

(4.) 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. 9. 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. 9.

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 High 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

High Pressure Switch in DOWNFLOW or HORIZONTAL RIGHT applications

NOTE: See Fig. 8 or 9 or robe routing label on main furnace door to check for proper connections.

1. Disconnect collector box pressure tube (pink label) attached to High 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 High Pressure Switch connection labeled COLLECTOR BOX.

4. Extend collector box pressure tube (pink label) which was previously connected to High Pressure Switch by splicing to remaining small diameter tube (factory-supplied in

loose parts bag).

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

Determine appropriate length, cut, and connect tube.

7. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section

recommendations and procedures.

for

Step 4 - Horizontal Left (Supply-Air Discharge)

Applications

In a horizontal left furnace application, the blower is located to the right of the burner section, and conditioned air is discharged

to the left.

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 10. 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. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

CARBON MONOXIDE POISONING HAZARD

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

Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

4. 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.

5. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING

NOTE: See Fig. 10 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.

PLUG--

AUXILIARY

CONDENSATE

"J" BOX COLLECTORBOX

_t I CAP

TRAP

COLLECTC \ DRAINTUBE (VIOLET)

BOX EXTENSION \\

DRAINTUBE \_'- COLLECTOR BOX

COLLECTOR BOX

DRAINTUBE (BLUEAND WHITE STRIPED)

_ O

\ DRAINTUBE (BLUE)

EXTE.S,O. O E

DRAINTUBE COUPLING _

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040,060, AND 080 HEATING INPUT FURNACES

Fig. 10 - Horizontal Left Tube Configuration

COLLECTOR BOXTUBE (PINK)

UCER HOUSING

A01029

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

previously 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 ATTACHMENTS

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 High 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 for 060 and 080 heating input furnaces.

NOTE: See Fig. 10 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 High 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.

4. Determine appropriate length, cut, and reconnect tube to High Pressure Switch connection labeled

COLLECTOR BOX.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

CONSTRUCT A WORKING PLATFORM Construct working platform where all required furnace clearances

are met. (See Fig. 3 and 11 or 12.)

UNIT MAY NOT OPERATE

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

The condensate trap MUST be installed below furnace. See Fig. 5 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. (2 M)(See Table 13.)

NOTE: A 12-in. (305 mm) minimum offset pipe section is recommended with short (5 to 8 ft or 2 to 3 M)) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12 or 43.)

Step 5 - Horizontal Right (Supply-Air Discharge)

Applications

In a horizontal right furnace application, the blower is located to the left of the burner section, and conditioned air is discharged to

the right.

MAN1

SHUTOFF

GAS VALVE

SEDIMENT TRAP

COMBUSTION -

INTAKE

(146 mm)

CONDENSATE

TRAP

30" (762 mm)MIN

DRAIN

A 12-1N. (305 mm) MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH

SHORT (5 TO 8 FT / 1.5 TO 2.4 M) 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. 11 - Attic Location and Working Platform for Direct Vent (2-Pipe) Applications

MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor property damage.

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: The auxiliary junction box (J-Box) MUST be relocated to opposite side of furnace casing. (See Fig. 13.) See Electrical

Connection section for J-Box relocation. 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 13. 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. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

A93031

CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury

or death. Casing hole filler cap must be installed in blower shelf hole

when condensate trap is relocated to prevent combustion products being drawn in from appliances in the

equipment room.

4. Install condensate trap into right-hand side casing hole by inserting tube connection stubs through casing hole and

rotating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

CONDENSATE TRAP TUBING

NOTE: See Fig. 13 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.

A 3-1N.(76mm) MINIMUM CLEARANCE TO COMBUSTION-AIR INTAKE

IS REQUIRED.

COMBUSTION

INTAKE

A 12-IN. (305mm) MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH

SHORT (5 TO 8 FT / 1.5 TO 2.4M) VENT CONDENSATE DROPLETS FROM

EXITING THE VENT PIPE.

30-1N.(762mm) MIN WORKAREA

IN. (146mm)

MAN[

SHUTOFF

GAS VALVE

SEDIMENT TRAP

DRAIN

CONDENSATE

ACCESS OPENING

FOR TRAP

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. 12 - Attic Location and Working Platform for Non-Direct Vent (1-pipe) Applications

TO REDUCE EXCESSIVE

A96184

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

One collector box pressure tube (pink label) is factory connected to the High 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 High Pressure Switch in DOWNFLOW or HORIZONTAL

RIGHT applications.

NOTE: See Fig. 12 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 High 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 High

Pressure Switch connection labeled COLLECTOR BOX.

4. Use remaining smaller diameter tube (factory-supplied in

loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to High Pressure Switch. Route this extended tube (pink label) to

condensate trap relief port connection.

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

6. Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

CONSTRUCT A WORKING PLATFORM

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 11 or 12.)

PLUG

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAINTUBE(VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 13 - Horizontal Right Tube Configuration

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TU BE (GREEN)

BOX EXTENSION TUBE

COLLECTOR BOXTUBE (PINK)

"J" BOX RELOCATED HERE

TRAP

A01028

UNIT MAY NOT OPERATE

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

The condensate trap MUST be installed below furnace. See Fig. 5 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: Combustion-air pipe (when applicable) and vent pipe(s) are restricted to a minimum length of 5 ft. (2 M). (See Table 13.)

NOTE: A 12-in. (305 mm) minimum offset pipe section is recommended with short (5 to 8 ft or 2 to 3 M) vent systems. This

recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12 or 43.)

LOCATION

Step 1 - General

This furnace must

• be installed so the electrical components are protected from water.

• not be installed directly on any combustible material other than wood flooring (refer to SAFETY CONSIDERATIONS).

• be located so combustion-air and vent pipe maximum lengths are not exceeded. Refer to Table 13.

• be located where available electric power and gas supplies meet specifications on the furnace rating plate.

• be attached to an air distribution system and be located as close to the center of the distribution system as possible. Refer to Air

Ducts section.

• be provided with ample space for servicing and cleaning. Always comply with minimum fire protection clearances

shown on the furnace clearance to combustibles label.

NOTE: For upflow/downflow applications install furnace so that it is level or pitched forward within 1/2-in. (13 mm) for proper furnace operation. For horizontal applications pitch 1/4-in. (6 mm) minimum to 1/2-in. (13 mm) maximum forward to ensure proper condensate drainage from secondary heat exchangers. (See Fig. 14.)

When a furnace is installed so that supply ducts carry air circulated by the furnace 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 a negative pressure condition will not occur within equipment room or space.

FIRE, INJURY OR DEATH HAZARD

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

Do not install furnace on its back. (See Fig. 15.) Safety control operation will be adversely affected. Never connect return-air

ducts to back of furnace.

UPFLOW OR DOWNFLOW

F FRONT

I_"MAX

(6to13mm)

HORIZONTAL

A02146

Fig. 14 - Proper Condensate Drainage

UNIT DAMAGE HAZARD

This gas fllmace may be used for construction heat provided that:

-The furnace is permanently installed with all electrical

wiring, piping, air filters, venting and ducting installed

according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a

negative pressure condition as created by the circulating air blower, causing a flame rollout and/ or drawing combustion

products into the structure.

-The furnace is controlled by a thermostat. It may not be "hot

wired" to provide heat continuously to the structure without thermostatic control.

-Clean outside air is provided for combustion. This is to

minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling

and plugging of furnace components.

-The temperature of the return air to the furnace is

maintained between 55°F (13°C) and 80°F (27°C), with no evening setback or shutdown. The use of the furnace while

the structure is under construction is deemed to be intermittent operation per our installation instructions.

-The air temperature rise is within the rated rise range on the

furnace rating plate, and the firing rate has been set to the nameplate value.

-The filters used to clean the circulating air during the

construction process must be either changed or thoroughly cleaned prior to occupancy.

-The furnace, ductwork and filters are cleaned as necessary

to remove drywall dust and construction debris from all HVAC system components after construction is completed.

- After construction is complete, verify furnace operating

conditions including ignition, input rate, temperature rise and venting, according to the manufacturer's instructions.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in minor property or unit damage.

If this furnace is installed in an unconditioned space where the ambient temperatures may be 32°F (0°C)or lower, freeze protection measures must be taken. (See Fig. 16.)

BACK

A93043

Fig. 15 - Prohibit Installation on Back

Step 3 - Hazardous Locations

FIRE, EXPLOSION, INJURY OR DEATH HAZARD

Improper location or inadequate protection could result in fire or explosion.

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 in.

(457 mm) above the floor. The furnace must be located or protected to avoid physical damage by vehicles. When the

furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be

installed in accordance with current edition of the NFGC or NSCNGPIC. (See Fig. 17.)

Step 4 Furnace Location and Application

DIRECT VENT (2-PIPE) APPLICATION

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

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 shall be adequate to 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

the damper is in full-heat or full-cool position.

32° F/0 ° C MINIMUM INSTALLED AMBIENT OR FREEZE

PROTECTION REQUIRED

A07911

Fig. 16 - Freeze Protection

18-1N.(457.2mm)

MINIMUMTOBURNERS

A93044

Fig. 17 - Installation in a Garage

NON-DIRECT VENT (1-PIPE) APPLICATION

UNIT DAMAGE HAZARD Failure to follow this caution may result in intermittent

unit operation. Do not install furnace in a corrosive or contaminated

atmosphere. Make sure all combustion and circulating air

requirements are met.

Refer to the AIR FOR COMBUSTION AND VENTILATION section for details.

AIR FOR COMBUSTION AND

VENTILATION

Provisions for adequate combustion, ventilation, and dilution air

must be provided in accordance with:

• U.S. Installations: Section 9.5 of the NFPA 54/ANSI Z223.1-2006, Air for Combustion and Ventilation and

applicable provisions of the local building codes.

• Canadian Installations: Part 8 of the CAN/CSA-B149.1-05, Venting Systems and Air Supply for Appliances and all

authorities having jurisdiction.

FURNACE CORROSION HAZARD Failure to follow this warning could result in reduced furnace

component life. Air for combustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and iodide. These elements could corrode heat exchangers and

shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air

fresheners, and other household products.

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

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas

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

for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be

made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and from draft

safeguard opening.

CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury

or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a

NEGATIVE PRESSURE CONDITION at the furnace. Make-up air MUST be provided for the ventilation devices, in

addition to that required by the furnace. Refer to the Carbon Monoxide Poisoning Hazard warning in the venting section of

these instructions to determine if an adequate amount of make-up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume

of at least 50 cubic feet per 1,000 Btuh input rating for all gas

appliances installed in the space.

• Spaces having less than 50 cubic feet per 1,000 Btuh require the OUTDOOR COMBUSTION AIR METHOD.

• Spaces having at least 50 cubic feet per 1,000 Btuh may use the INDOOR COMBUSTION AIR, STANDARD or

KNOWN AIR INFILTRATION METHOD.

Outdoor Combustion Air Method

Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using

permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

Fig. 18 illustrates how to provide TWO OUTDOOR

OPENINGS, one inlet and one outlet combustion and

ventilation air openings to the outdoors.

a. One opening MUST commence within 12 in.(305 mm)

of the ceiling and the second opening MUST commence within 12 in. (305 mm) of the floor.

b. Size openings and ducts per Fig. 18 and Table 1. c. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btt h (1,100 mm /kW) of combined input for all gas appliances in the space per Fig. 18 and

Table 1.

Table1 - Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

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

FURNACE (1SQ. INJ2,000 BTUH)(1,100SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/K3/V) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

INPUT Free Area of Round Duct Free Area of Opening Round Duct Free Area of Opening Round Duct

(BTUH) Opening and Duct Dia. and Duct Dia. and Duct Dia.

44,000 22 (14194) 6 (152) 14.7 (9494) 5 (127) 11 (7097) 4 (102) 66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127) 88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152)

110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17741) 6 (152) 132,000 66 (42581) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (198) 154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24838) 8 (203)

EXAMPLE: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

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

66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening 88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

ACH Space Volume Ft3 (M3)

0.60 (29.7) (39.6) (49.5) (31.1) (46.7) (62.2) (77.8) (93.4) (109.0)

0.50 (35.6) (47.5) (59.4) (37.3) (56.0) (74.7) (93.4) (112.1) (130.8)

0.40 (44.5) (59.4) (74.3) (46.7) (70.0) (93.4) (116.8) (140.1) (163.5)

0.30 (59.4) (79.2) (99.1) (62.2) (93.4) (124.5) (155.7) (186.8) (218.0)

0.20 (89.1) (118.9) (148.6) (93.4) (140.1) (186.8) (233.6) (280.3) (327.0)

O.10 (178.3) (237.8) (297.3) (186.8) (280.3) (373.7) (467.2) (560.6) (654.1)

0.00 NP NP NP NP NP NP NP NP NP

d. TWO OPENINGS OR VERTICAL DUCTS require 1

square inch of free area per 4,000 Btuh (550 mm2/kW) for combined input of all gas appliances in the space per Fig. 18 and Table 1.

3. ONE OUTDOOR OPENING requires: a. 1 square inch of free area per 3,000 Btuh (734 mm2/kW)

for combined input of all gas appliances in the space per Table 1 and 13.

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

connectors in the space. The opening shall commence within 12 in. (305 mm)

of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and

back and 6 in. (152 mm) from the front. The opening shall directly communicate with the outdoors or shall

communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely

communicate with the outdoors.

CARBON MONOXIDE POISONING HAZARD Failure to supply outdoor air via grilles or ducts could result in

death and/or personal injury. Many homes require air to be supplied from outdoors for

furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in

accordance with this instruction manual.

Sq. In. (mm) In. (mm) Sq. In (mm) In. (mm) Sq. In (mm) In. (mm)

Table 2 - Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors

(1,000'S BTUH GAS INPUT RATE) (1,000'S BTUH GAS INPUT RATE)

30 ! 40 ! 50 44 ! 66 ! 88 ! 110 ! 132 ! 154

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

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

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

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

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

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

Indoor Combustion Air© NFPA & AGA

Standard and Known-Air-Infiltration Rate Methods

Indoor combustion air is permitted for combustion, ventilation,

and dilution, if the Standard or Known-Air-Infiltration Rate

Method is used. The Standard Method:

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

installed in the space and

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

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of

ACH and shall be determined per Table 2 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum

required volume for the space. Table 2 - Minimum Space Volumes were determined by using

the following equations from the National Fuel Gas Code ANSI

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

CIRCULATING AIR

DUCTS

OUTDOORS BTUH*

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

A&BC&DD&EF&G

A03174

Fig. 18 - Air for Combustion, Ventilation, and Dilution for

Outdoors

1. For other than fan-assisted appliances, such as a draft

hood-equipped water heater:

Volume _ 21ft 3 _ !other 3

Other ACH _000 Btu/hr d

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

Volume Fan ACH 00(J Btu/hr

If:

Io_her=combined input of all ether than fan-assisted

appliances in Btu/hr

If_,,= combined input of all fan-assisted appliances in Btu/hr

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

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

1. Adjoining rooms can be considered part of a space if: a. There are no closable doors between rooms.

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW) of the total input rating of all gas

appliances in the space, but not less than 100 in. 2 (0.06 m2). One opening shall commence within 12 in.

(305 mm) of the ceiling and the second opening shall commence within 12 in. (305 mm) of the floor. The

minimum dimension of air openings shall be at least 3 in. (76 mm). (See Fig. 19.)

A04002

A04003

I I I I I

INTERIOR

HEATED

SPACE

i i

CIRCULATING AIR DUCTS

_'Minimum opening size is 100 sq in. (64516 mm 2) with minimum dimensions of 3 in. (76 mm) t Minimum of 3 in. (76 mm) when type-B1 vent is used.

I I

_: 12" MAX (305mm)

------1 SQ IN,

O_ OR WALL O UNCONFINED

O SPACE

z (FRONT)0

<_ PER 1000 <_ -- OR WALL

PER 1000 BTUH* IN DOOR

6" MIN (152mm)

1 SQ IN,

BTUH* IN DOOR

L 12" MAX (305rnm)

A03175

Fig. 19 - Air for Combustion, Ventilation, and Dilution from

Indoors

c. Combining space on different floor levels. The

volumes of spaces on different floor levels shall be considered as communicating spaces if connected by

one or more permanent openings in doors or floors having free area of at least 2 in.2/1,000 Btuh

(4,400 mm2/kW) of total input rating of all gas appliances.

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are

adequate permanent ventilation openings directly to outdoors having free area of at least 1-in.2/4,000 Btuh of total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for

combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight

construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air

Method section. Unusually tight construction is defined as

Construction with:

a. Walls and ceilings exposed to the outdoors have a

continuous, sealed vapor barrier. Openings are

gasketed or sealed and b. Doors and openable windows are weatherstripped and c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole

plates and floors, between wall-ceiling joints, between

wall panels, at penetrations for plumbing, electrical

and gas lines, etc.

NOTE: In determining the free area of an opening, the blocking effect of the louvers, grilles, and screens must be considered. If the free area of a louver or grille design is unknown, it may be

assumed that wood louvers have a 20 percent free area, and metal

louvers or grilles have a 60 percent free area. Screens, when used,

mustnotbesmallerthan1/4-in.(6mm)mesh.Louversand grillesmustbeconstructedsotheycannotbeclosed.

Whencombustionairductsareused,theymustbeofthesame crosssectionalareaasthefreeareaoftheopeningstowhichthey

connect.Theminimumdimensionofductsmustnotbelessthan 3in.(76mm).

CombinationofIndoorandOutdoorAir

1.Indooropeningsshall complywith the Indoor CombustionAirMethodbelowand,

2.Outdooropeningsshallbe locatedas requiredin theOutdoorCombustionAir Methodmentioned

previouslyand,

3.Outdooropeningsshallbesizedasfollows:

a.CalculatetheRatioofallIndoorSpacevolumedivided

byrequiredvolumeforIndoorCombustionAir Methodbelow.

b.OutdooropeningsizereductionFactoris1minusthe

Ratioina.above.

c.MinimumsizeofOutdooropeningsshallbethesize

requiredinOutdoorCombustionAirMethodabove multipliedbyreductionFactorinb.above.The

minimumdimensionofairopeningsshallbenotless than3in.(76mm).

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. 20.) Install field-supplied,

corrosion-resistant 5/16-in. (8 mm) machine bolts and nuts. 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. (8 mm) diameter hole in each bottom corner of furnace. (See

Fig. 20.) 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 and 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 is 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 3.

2. Construct hole in floor per dimensions specified in Table 3 and Fig. 21.

3. Construct plenum to dimensions specified in Table 3 and Fig. 21.

4. If downflow subbase (KGASB) is used, install as shown in Fig. 22. If Coil Assembly Part No. CD5 or CK5 or Coil

Box Part No. KCAKC is used, install as shown in Fig. 23.

NOTE: Remove furnace perforated, supply-air duct flanges when they interfere with mating flanges on coil or downflow subbase. To remove perforated, supply-air duct flanges, use wide duct pliers, duct flange tool, or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 24.)

(8mm)

1 3/4'

(44ram)

)

1 3/4"

(44ram)

(8mrn)

5/16"

(44mm) 1 3/4"

(44mm) 1

A89014

Fig. 20 - Leveling Legs

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation or performance satisfaction.

Do not bend duct flanges inward as shown in Fig. 21. 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. 24.

Step 3 - Installation in Horizontal Applications

These furnaces can be installed horizontally in either horizontal left or right discharge position. In a crawlspace, the 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. 25.) Cut hanger bolts (4 each 3/8-in. (10 mm) all-thread rod) to desired length. Use 1 X 3/8-in. flat washers, 3/8-in. lock washers, and 3/8-in. nuts on hanger rods as

shown in Fig. 25. Dimples are provided for hole locations. (See Fig. 2.)

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation or performance satisfaction.

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 - Air Ducts

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 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.

FURNACE

(OR OTHER MANUFACTURER'S

COILCASING WHEN USED)

COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL ...._

PLENUM

FLOOR

OPENING

Fig. 21 - Floor and Plenum Opening Dimensions

Fig. 23 - Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor

A96283

FU RNACE

APPROVED

COIL ASSEMBLY

COIL BOX

COMBUSTIBLE --\

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A07585

Fig. 22 - Furnace, Plenum, and Subbase Installed

on a Combustible Floor

A08556

Table 3 - Opening Dimensions - In. (mm)

FURNACE

CASING

WIDTH

APPLICATION

A B

16 24-1/8

Upflow Applications (422) (629)

(406) (613)

15-7/8 19

Downflow Applications on Non-Combustible Flooring (419) (498)

17-1/2 Downflow Applications on Combustible Flooring Using KGASB 16-3/4 20-3/8

(445) Subbase Furnace with or without CAP, CAR, CNPV, CNRV Coil

Assembly or KCAKC Coil Box (425) (518)

Downflow Applications on Combustible Flooring NOT Using 16-1/2 20

KGASB Subbase Furnace with CAP, CAR, CNPV, CNRV Coil As-

sembly or KCAKC Coil Box (419) (508)

(403) (483)

15-1/8 19

(384) (483)

15-1/2 19

(394) (483)

19-1/2 24-1/8

Upflow Applications (511) (629)

(495) (613)

19-3/8 19

Downflow Applications on Non-Combustible Flooring (508) (498)

21 Downflow Applications on Combustible Flooring Using KGASB 20-1/4 20-3/8

(533) Subbase Furnace with or without CAP, CAR, CNPV, CNRV Coil

Assembly or KCAKC Coil Box (514) (518)

Downflow Applications on Combustible Flooring NOT Using 20 20

KGASB Subbase Furnace with CAP, CAR, CNPV, CNRV Coil As-

sembly or KCAKC Coil Box (508) (508)

(492) (483)

18-5/8 19

(473) (483)

19 19

(483) (483)

23 24-1/8

Upflow Applications (600) (629)

(584) (613)

22-7/8 19

Downflow Applications on Non-Combustible Flooring (597) (498)

24-1/2 Downflow Applications on Combustible Flooring Using KGASB 23-3/4 20-3/8

(622) Subbase Furnace with or without CAP, CAR, CNPV, CNRV Coil

Assembly or KCAKC Coil Box (603) (518)

Downflow Applications on Combustible Flooring NOT Using 23-1/2 20

KGASB Subbase Furnace with CAP, CAR, CNPV, CNRV Coil As-

sembly or KCAKC Coil Box (597) (508)

(581) (483)

22-1/8 19

(562) (483)

22-1/2 19

(572) (483)

FLOOR OPENINGPLENUM OPENING

C D

16-5/8 24-3/4

16-1/2 19-5/8

20-1/8 24-3/4

20 19-5/8

23-5/8 24-3/4

23-1/2 19-5/8

Flexible connections should be used between ductwork and

DISCHARGE DUCT FLANGE

furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated to enhance

system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1-in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (915 mm) horizontally from the furnace. See NFPA 90B or local code for

further requirements. For a furnace not equipped with a cooling coil, the outlet duct

shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of

such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for

sampling the air stream. The cover attachment shall prevent leaks. DUCTWORK ACOUSTICAL TREATMENT

210 DEG.

MIN

I--]

I I

YES

Metal duct systems that do not have a 90 degree elbow and 10 ft (3 M) of main duct to the first branch take-off may require

internal acoustical lining. As an alternative, fibrous ductwork

A93029

Fig. 24 - Duct Flanges

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

When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the

furnace, the return air 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.

air ducts.

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

supplysideair duct,humidifier,or otheraccessories.All accessoriesMUSTbeconnectedexternaltofurnacemaincasing.

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. Supply air opening duct flanges must be modified per Fig. 24.

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. RETURN AIR CONNECTIONS

The furnace and its return air system shall be designed and installed so that negative pressure created by the air circulating

fan cannot affect another appliance's combustion air supply or act to mix products of combustion with circulating air, and that the

air circulating fan of the furnace, if installed in an enclosure

communicating with another fuel-burning appliance not of the direct-vent type, shall be operable only when any door or panel

covering an opening in the furnace fan compartment or in a return

air plenum on ducts in the closed position.

FIRE HAZARD Failure to follow this warning could result in fire, personal

injury, or death. Never connect return-air ducts to the back of the furnace. Return-air duct connections on furnace side(s) permitted in

upflow applications only.

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. 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. 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.

COMBUSTION-AIR INTAKE (NON-DIRECT VENT

_COMBUSTION-AIR INTAKE IS REQUIRED"_ !1

(NON-DIRECTVENT/1-PIPE

APPLICATION,)

ANGLE IRON OR

(A) ROD LOCATION

USING DIMPLE LOCATORS

(SEE DIMENSIONAL DWG FOR

LOCATIONS)

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

& WASHER (4)

REQD PER ROD

NOTES: 1. A 1-in. (25.4 mm) clearance minimum

?ATION)

5 3/4" (146 ram)

COMBUSTION-AIRPIPE

DIRECTVENT/2-PIPE

(A)

(a)

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.

3. For non-direct vent/I-pipe application, bottom side combustion-air entry cannot be used when furnace is installed with hangers

as shown.

13/16-1N. (21 mm) MAX

ALTERNATESUPPORT LOCATIONFROMBACK

;)

3/8-1N. (10 mm) ROD

ALTERNATE SUPPORT

LOCATION 4qN. (102 mm) MIN 3-IN. (203 mm) MAX

Fig. 25 - Crawlspace Horizontal Application for Direct Vent/2-Pipe Installation

and for Non-Direct Vent/l-Pipe Installation

A05054

Step 5 - Filter Arrangement

FIRE, CARBON MONOXIDE AND

POISONING HAZARD

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

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

The air filter arrangement will vary due to application, furnace orientation, and filter type. The filter may be installed in an

external Filter/Media cabinet (if provided) or the furnace blower compartment.

If a factory-supplied external Filter/Media cabinet is provided, instructions for its application, assembly, and installation are

packaged with the cabinet. The Filter/Media cabinet can be used with a factory-specified washable filter or a factory-specified

high-efficiency disposable filter (see cabinet instructions). If installing the filter in the furnace blower compartment,

determine location for filter and relocate filter retaining wire if necessary. See Table 4 to determine correct filter size for desired

filter location. Table 4 indicates filter size and location for this furnace. See Fig. 2 for location and size of bottom and side

return-air openings.

Table 4 - Filter Information

171/2-1N.(444mm) WIDE CASINGS ONLY:

INSTALL FIELD-SUPPLIED FILTER FILLER STRIP UNDER FILTER.

21-IN. (533mm) WIDE

CASINGS ONLY: SUPPORT RODS (3)

EXTEND 1/4" (6mm)ON EACH SiDE OF FILTER AND

REST ON CASING FLANGE

FILTER

AiR FILTER LOCATED IN BLOWER COMPARTMENT

Furnace

Casing

Width

In. (mm)

17-1/2

(445)

(533)

24-1/2 (1 or2) 16X25 (1) 24X 25 X3/4

(622) (406 X 635 X 19) (609 X 635 X 19)

* Alternate sizes can be ordered from your distributor or dealer. 1-Upflow only. Alternate sizes and additional filters may be ordered from

your dealer.

Filter Size - In. (ram)

Side Return*t Bottom Return*

(1) 16X 25 X3/4 (1) 16X 25 X3/4 (406 X 635 X 19) (406 X 635 X 19)

(1) 16X25X3/4 (1) 20 X 25 X 3/4 (406 X 635 X 19) (508 X 635 X 19)

X 3/4

Filter Type

Framed

Washable

FILTER

FILTER RETAINER

FILTER

SUPPORT

RETAINER

Fig. 27 - Bottom Filter Arrangement

! I

| I |

BOTTOM CLOSURE

PANEL

A08605

Fig. 26 - Filter Installed for Side Inlet

A08587

PANEL

A93047

Fig. 28 - Removing Bottom Closure Panel

CUT HAZARD

Failure to follow this caution may result in minor personal injury.

Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves,

and appropriate protective clothing.

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation or performance satisfaction.

For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side

inlets. The use of both side inlets, a combination of I side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

NOTE: Side return-air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 26. 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. 27.

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

Step 6 - Bottom Closure Panel

This furnace is shipped with bottom closure panel installed in bottom return-air opening. This panel MUST be in place when

side return air is used. To remove bottom closure panel, perform the following:

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

filler panel. (See Fig. 28.)

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

3. Remove bottom closure panel.

4. Reinstall front filler panel and screws.

Table 5 - Maximum Capacity of Pipe*

NOMINAL

IRON PIPE

SIZE

IN. (MM)

1/2 (12.7)

3/4 (19.0)

1 (25.4)

1-1/4

(31.8)

1-1/2 1.610

(38.1) (40.9) 2100 1460 1180 990 900

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or tess and a pressure drop of O.5-in wc (based on a 0.60 specific gravity gas). Ref:

Table 9.2 NFGC.

INTERNAL LENGTH OF PIPE - FT (M)

DIA. 10 20 30 40 50

IN. (MM) (3.0) (6.0) (9.1 / (12.1) (15.21

0.622 (158) 175 120 97 82 73

0.824

(20.9) 360 250 200 170 151

1.049

(26.6) 680 465 375 320 285

1.380

(35.0) 1400 950 770 660 580

Step 7 - Gas Piping

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

United States. 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 5 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. (2 M). Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.

FIRE OR EXPLOSION HAZARD

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

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

-Gas valve shutoff switch MUST be facing forward or tilted upward.

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

leaks to check all connections.

-Use proper length of pipe to avoid stress on gas control manifold.

-If a flexible connector is required or allowed by authority having jurisdiction, black iron pipe shall be installed at furnace

gas valve and extend a minimum of 2 in. (51 mm) outside furnace casing.

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

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. 29.)

GAS _ " SUPPLY

MANUAL _/ II SHUTOFF _ _

VALVE

(REQUIRED)/ f

SEDIMENT ''1 [ TRAP

Fig. 29 - Typical Gas Pipe Arrangement

If local codes allow the use of a flexible gas appliance connector,

always use a new listed connector. Do not use a connector which

has previously served another gas appliance. An accessible manual shutoff valve MUST be installed external

to furnace casing and within 6 ft (2 M)of furnace. A 1/8-in. NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to

furnace and downstream of manual shutoff valve.

UNION ..-a

A93324

Table 6- Electrical Data

UNIT SIZE

HERTZ- PHASE

060-12/036060 115-60-1 8.4 11.3 14 33(10.0) 080-12/036080 115-60-1 8.1 10.8 14 34(10.3) 080-16/048080 115-60-1 11.6 15.3 12 37(11.2)

100-16/048100 115-60-1 11.6 15.4 12 37(11.2) 100-20/060100 115-60-1 13.3 17.5 12 33(10.0)

120-20/060120 115-60-1 12.9 16.8 12 34(10.3)

VOLTS-

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

Piping should be pressure tested in accordance with the current edition of the NFGC, local and national plumbing and gas codes

before the furnace has been connected. In Canada, refer to current edition of NSCNGPIC. If the pressure exceeds 0.5 psig (14-in.

wc), gas supply pipe must be disconnected from the furnace and

OPERATING VOLTAGE

RANGE

Max* Min*

127 104 127 104 127 104

MAX UNIT

AMPS

UNIT

AMPACITYI

MIN

WIRE

SIZE

MAX WIRE

LENGTH

FT (M):I:

Step 8 - Electrical Connections

See Fig. 31, 32, and 50-57 for field wiring diagram showing

typical field 115-v and 24-v wiring. Check all factory and field electrical connections for tightness.

MAX FUSE

OR CKT

BKR

AMPS**

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 furnace gas valve and accessible manual shutoff valve before test.

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

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115-v power to furnace

FIRE OR EXPLOSION HAZARD

control. No component operation can occur. Do not bypass or close switch with panel removed.

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

Never test for gas leaks with an open flame. Use a

Field-supplied wiring shall conform with the limitations of

63°F (3. C) rise.

commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion could result causing property damage, personal injury or loss

of life.

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent

Gas line grommet (factory-supplied loose parts bag) should be used when installing gas piping. Gas line entry hole filler plug

should be installed in unused gas line entry hole. (See Fig. 30.) NOTE: The gas valve inlet pressure tap connection is suitable to

use as test gauge connection providing test pressure DOES NOT

unit operation. Furnace control must be grounded for proper operation or

control will lock out. Control is grounded through green/yellow wire routed to gas valve C-terminal and burner box screw.

exceed maximum 0.5 psig (14-in. wc) stated on gas valve. (See Fig. 58.)

The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with

the furnace burners ON at HI-HEAT and OFF.

COMBUSTION-AIR PIPE GROMMET

l15-V WIRING

Before proceeding with electrical connections, make certain that voltage, frequency, and phase correspond to that specified on the

furnace rating plate. Also, check to be sure that service provided by power supply is sufficient to handle load imposed by this

equipment. Refer to rating plate or Table 6 for equipment

UNUSED 1÷3/4 -IN. (44 mm) DIAMETER GAS

HOLE

electrical specifications. The furnace must be electrically grounded in accordance with

local codes; or in the absence of local codes, with the National

2_6}'4-- GASL,NEENTRY

HOLE FILLER PLUG

Electric Code ANSI/NFPA 70 and/or the Canadian Electric Code,

CSA C22.1, Part I, if an external electrical source is utilized.

15 15 2O

2O 2O 2O

NOTE: PIPE GROMMETS AND ENTRY HOLE FILLER

PLUGS ARE INCLUDED IN FACTORY-SUPPLIED LOOSE PARTS BAG

Fig. 30 - Typical Gas Pipe Arrangement

A05057

.... FIELD 24-V WIRING

.... FIELD 115-,208/230-, 460-V WIRING

-- FACTORY 24-VWIRING FACTORY 115-V WIRING

115-VFUSED

DISCONNECT

SWITCH

(WHEN REQUIRED)

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

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

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

Fig. 31 - Typical Heating and Cooling Application Wiring Diagram 1-Stage Thermostat and Condensing Unit

A99071

.... FIELD 24-V WIRING

.... FIELD 115-, 208/230-, 460-V WIRING

-- FACTORY 24-VWIRING FACTORY 115-VWIRING

2-STAGE THERMOSTAT TERMINALS

FIELD-SUPPLIED

[ [ I I

THREE-WIRE__ I Ii II

HEATING- "_,,__

ONLY -"h_]]_ I T ', ', ',

BLK.__BLK

115-VFUSED

DISCONNECT

SWITCH

(WHEN REQUIRED)

Fig. 32 - Typical Heating and Cooling Application Wiring Diagram 2-Stage Thermostat and Condensing Unit

JUNCTION

BOX (_

CONTROL

BOX (_

24-V

TERMINAL

BLOCK

FURNACE

I I I I I I I

_1 I I I I I I

I I I I I I

.... p---l----+----[----4-- l

l l

.... [ I

....... II [--"OJ

-] Li--_

I j

NOTES: 1. Connect Y4ermina[ as shown for proper operation.

it;

[

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

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

OY2

2-SPEED CONDENSING

UNIT

FUSED DISCONNECT

-._E_®_ - - 1 208/230-V _ b / /SINGLE

T__:I::I PHASE

[ ----GND/

208/230- OR 460-V

PHASE

A99072

ELECTRIC

DISCONNECT

SWITCH

Fig. 33 - Disconnect Switch and Furnace

A93033

POWER ENTRY HOLE FILLER PLUG (FACTORY- SUPPLIED LOOSE PARTS BAG)

Fig. 34 - Factory Installed J-Box Location

UNUSED 7/SqN. (22 I DIAMETER POWER

ENTRY HOLES

INSTALLED LOCATION

A05113

Use a separate, fused branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace. See Table 6 for wire size and fuse specifications. A disconnecting means must

be located within sight from and readily accessible to furnace. NOTE: Proper polarity and proper grounding must be

maintained for l15-v wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

FIRE HAZARD

Failure to follow this warning could result in intermittent operation or performance satisfaction.

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. (See Fig. 33.)

ELECTRICAL SHOCK AND FIRE HAZARD

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

The furnace casing MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2008 and Canadian

Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may

consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical

codes. Do not use gas piping as an electrical ground.

Factory Installed J-Box Location Install electrical entry hole filler plugs (factory-supplied in loose

parts bag) in unused power entry holes. (See Fig. 34.) J-Box Relocation

1. Remove 2 screws holding auxiliary J-box. (See Fig. 35.)

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

3. Install electrical entry hole filler plugs (factory-supplied loose parts Bag) in unused power entry holes. (See Fig.

35.)

24-V WIRING

Make field 24-v connections at 24-v terminal block on furnace. (See Fig. 37.) Connect terminal Y/Y2 as shown in Fig. 31 and 32

for proper cooling operation. Use only AWG No. 18, color-coded,

copper thermostat wire for lengths up to 100 ft. (30 M). For wire lengths over 100 ft. (30 M), use AWG No. 16 wire.

The 24-v circuit contains an automotive-type, 3-amp fuse located on furnace control. (See Fig. 37.) Any direct shorts of 24-v wiring

during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp fuse

of identical size/type. The control will flash code 24 when fuse

needs replacement. ACCESSORIES

1. Electronic Air (.'leaner (EAC) Two male quick-connect terminals marked EAC-1 and EAC-2 are provided for

EAC connection. (See Fig. 37.) These terminals are energized with 115-v (1.0-amp maximum) during blower motor operation.

2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp maximum humidifier (if used) to the 1/4-in. male

quick-connect HUM terminal and COM-24V screw terminal on the control board thermostat strip. The HUM

terminal is energized when gas valve is energized. (See Fig. 36 or 37.)

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

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component damage.

DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidistaff M, Zone Controller or

similar device. See Thermidistat'M, Zone Controller, thermostat, or controller manufacturer's instructions for proper connection.

ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in intermittent unit

operation or performance satisfaction. 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.

ALTERNATE --

FIELD

LOCATION

POWER ENTRY HOLE ______n-u.. ....

FILLER PLUG (FACTORY .......

SUPPLIED LOOSE PARTS BAG)

UNUSED 7/8-1N. (22 mm) DIAMETER POWER ENTRY HOLES

Fig. 35 - Relocating J-Box

Step 9 - Removal of Existing Furnaces from Common Vent Systems

When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent

the remaining attached appliances. An improperly sized Category I venting system could cause the formation of

condensate in the furnace and vent, leakage of condensate and combustion products, spillage of combustion products into the living space, etc.

Step 10 - Combustion Air and Vent Pipe Systems GENERAL

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. The 58MTB can be vented as either a direct vent (all sizes) or as

a non-direct vent (except for 140 size) application. A direct vent system shall be installed in accordance with the direct vent

(2-pipe) procedures in the following Combustion Air and Vent Pipe Systems section. For non-direct vent (1-pipe)

applications, refer to the non-direct vent (1-pipe) procedures in the same section.

Multistory and common venting are prohibited. DIRECT VENT/2-PIPE SYSTEM

In a direct-vent (2-pipe) system, all air for combustion is taken directly from outdoor atmosphere, and all flue products are discharged to outdoor atmosphere. A factory accessory vent

termination kit MUST be used in a direct vent (2-pipe) system. NON-DIRECT VENT/I-PIPE SYSTEM

In a non-direct vent (1-pipe) system, all air for combustion is taken from the area adjacent to furnace, and all flue products are discharged to outdoor atmosphere. A factory-supplied perforated

disk assembly (in loose parts bag) MUST be used in combustion-air pipe elbow.

MATERIALS Combustion-air and vent pipe, fittings, primers, and solvents

must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards. See Table 7 for approved materials for use in

the U.S.A.

iNSTALLED

S ACTORY

CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance

connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for each appliance connected to the venting system being placed into operation,

while all other appliances connected to the venting system are

not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI

Z223.1-2006/NFPA 54-2006 or the CSA B149.1-05, Natural Gas and Propane Installation Code and these

instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies,

which could cause an unsafe condition.

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

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as

range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

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

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main

burner operation. Use the flame of a match or candle.

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

with the National Fuel Gas Code, ANSI

Z223.12006/NFPA 54-2006 and/or CSA B149.1-05, Natural Gas and Propane Installation Code.

9. After it has been determined that each appliance connected to the venting system properly vents when

tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning

appliance to their previous conditions of use.

LOCATION

POWER ENTRY HOLE

iiiiii:0 _,,_1,..-----.- FILLER PLUG (FACTORY-

SUPPLIED LOOSE PARTS BAG)

•_. UNUSED 7/8-1N. (22 ram) DIAMETER POWER ENTRY HOLES

A05058

tu E

8 i

z _

PRINTEDCIRCIUT BOARD

0_+o,I1"' °+"-_d¢

_o_ _ _ _ _ _ _ o _ _o _ <

_<zz

Fig. 36 - Wiring Diagram

<<._ _z_o_z

s_os-8_ 8

+Oo@mzzzm_zm_m

ommmmm99_

A02176

Table 7 - Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (USA only*)

ASTM

SPECIFICATION SOLVENT CEMENT

(MARKED ON AND PRIMERS

MATERIAL)

D1527 ABS Pipe .... Schedule-40

D1785 PVC Pipe .... Schedule-40

D2235 For ABS .... Solvent Cement For ABS

D2241 PVC Pipe .... SDR-21 & SDR-26

D2466 PVC - - Fittings - - Schedule-40 D2468 ABS - - Fittings - - Schedule-40

D2564 For PVC .... Solvent Cement For PVC

D2661 ABS Pipe Fittings - - DWV at Schedule-40 IPS sizes D2665 PVC Pipe Fittings - - DWV

F438 CPVC - - Fittings - - Schedule-40

F441 CPVC Pipe .... Schedule-40

F442 CPVC Pipe .... SDR

F493 For CPVC .... Solvent Cement For CPVC

F628 ABS Pipe .... IPS sizes

F656 For PVC .... Primer For PVC

F891 PVC Pipe .... Cellular Core Schedule-40 & DWV

1for Canadian installations.*Refer to

FIRE AND EXPLOSION HAZARD

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

In Canada, construct all combustion-air and vent pipes for this unit of CSA or ULC listed schedule-40 PVC, PVC-DWV or

ABS-DWV pipe and pipe cement. SDR pipe is NOT approved in Canada.

In direct vent (2-pipe) systems, combustion air and vent pipes must terminate together in same atmospheric pressure zone,

either through roof or sidewall (roof termination preferred), using accessory termination kit. See Table 8 for required clearances.

In non-direct vent (1-pipe) system, vent pipe termination must be installed with adequate clearances to building openings and equipment to comply with national and local codes. See Table 9

for required clearances.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in 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. 44 for direct vent (2-pipe) system and Fig. 45 for non-direct vent 0-pipe) system.

An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion-air (when

applicable) and vent pipes. Each furnace must have its own set of combustion-air and vent pipes and be terminated individually, as

shown in Fig. 44 for Direct Vent (2-Pipe) system and Fig. 45 for Non-Direct Vent (1-Pipe) system.

A furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.

MATERIAL PIPE FITTINGS DESCRIPTION

Other gas appliances with their own venting system may also use

the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code and

the vent or liner manufacturer's installation instructions. Care must be taken to prevent the exhaust gases from one appliance

from contaminating the combustion air of other gas appliances.

UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent

unit operation. 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 10 with Armaflex-type insulation.

Furnace combustion air and vent pipe connections are sized for 2-in. (51 mm) pipe. Any pipe size change should be made outside

furnace casing in vertical pipe. The transition has to be made as close to the furnace as reasonably possible.

COMBUSTION AIR PIPE General

Furnace combustion-air connection must be attached as shown in Fig. 38. Combustion-air intake housing plug may need to be

relocated in some applications. For Non-Direct Vent (1-Pipe) system, combustion-air must

terminate outside of furnace casing with 1 elbow. Orient elbow so that its opening faces down for upflow or downflow applications.

Orient elbow so that its opening faces sideways (left or right) for

horizontal left or horizontal right applications. Maintain a 3-in minimum clearance between the opening of the combustion-air

inlet pipe and any object.

Cellular Core DWV at Schedule-40

SETUP SWITCHES TWINNING AND/OR

LOW-HEAT ONLY AND COMPONENT TEST

BLOWER OFF-DELAY TERMINAL

/ O,S B,

I_1 TEST!TWIN >

:_f:_ '=' -ol _ ,/ -- -- TRANSFORMER 24-VAC

ACRDJ AIR CONDITIONING

CONNECT,ONS

(24-VAC 0.5 AMP MAX.) PLI- LOW VOLTAGE MAIN

sEo,%02"I 11 HARNESSCONNECTOR

DIAGNOSTIC LIGHT _ PL3

3-AMP FUSE _ ,g__ _;_:, _ _ o

LED OPERATION&_p,_= _= I

115-VAC (L2) NEUTRAL _

CO N N ECTtO NS BHi/LOR BLWR

HEAT--

i LO HEAT- _J[_Z[] _' - =

SPA _ spRE-1SPARE-2 EAC-1

S E LECTIO N :TgR_/I_I_ALS_ y \

BLOWER SPEEDIPX SPARE-2 COOL, _I_;_V_L_A_O(IN) L_Eo N PG:_T,oTi R_O:N_D_U:_T_OE

UNIT CORROSION HAZARD

Excessive exposure to contaminated combustion air may result in safety and performance related problems.

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.

NOTE: All pipe joints must have cemented attachment of combustion-air inlet pipe to inlet housing connection, since it may be necessary to remove pipe for servicing.

Assembly of Combustion Air Pipe (Non-Direct Vent/I-Pipe System ONLY)

1. Permanently install perforated disk assembly (factory-supplied in loose parts bag) in combustion-air

elbow using RTV or by cementing, as shown in Fig. 39. For 120,000 Btuh size units only: separate the 2 halves of

perforated disk assembly and use only the shouldered disk half.

2. Determine the length of straight portion of combustion-air inlet pipe from Fig. 39.

3. Cut field-supplied 2-in. (51 mm) diameter PVC pipe to length as determined per Fig. 39.

/ EAC-1

(115-VAC

Fig. 37 - Control Center

4. Permanently attach elbow/perforated disk assembly to straight portion of pipe using RTV or by cementing as

shown in Fig. 39.

Assembly of Combustion Air Pipe (Direct Vent-2-Pipe

System ONLY)

1. Using Table 13, determine the smallest combustion air diameter permitted. Pick the larger diameter and use it for

both combustion and vent pipe.

NOTE: Do not count elbows or pipe sections in terminations or within furnace (All elbows shown in Fig. 44 and Fig. 45 are not to be counted).

UNIT MAY NOT OPERATE Failure to follow this caution may result in incomplete

combustion, flame disturbance, or flame sense lockout. When installing combustion air and vent system of short pipe

length, the smallest allowable pipe diameter must be used.

NOTE: A 2-in. (51 mm) diameter pipe must be used within furnace casing. Make all pipe diameter transitions outside furnace

casing per Fig. 41.

2. If required per Table 13, insert perforated disk assembly (factory-supplied in loose parts bag) in intake housing

where combustion air pipe will be connected. If half disk

set is required, install only shouldered disk half.

A02017

/ i!

A .... "\ ..... .....

C _ to a _y ctosed_ow

t_m_lnal _tn a horl_ _s_ of 2 feet(61cm) f_om _e

F Cl_r_e _oa_ o_tstd_ ¢o_er

_I m_ter ot _ se_¢_ _U_ _s_b_ assembly rneter,rteg_l_ asserrd_ Clearar_e to _ _ulator ve_ _et 3 f_st (9_ _m)

J _ra_"_e to nor_-m_a_ a_r sut_;:)ty Inlet to bt_idi_ or 12 inches (30 cm) for applieances > 10,000 Btuh(3 kW)

_ ¢Om_o_ air |r_tet to _ _r ap_$e_;_ and < 100,000 Btuh(3OkW), 36 inches (91cm) for

appliances > 100,000 Btuh(3OkW)

50,000 BtL_h(i _, i 2 in_es (_)lot app_

.......... \

\ ..... \ ............

.................. 25-24_2

Table 8 - Direct Vent Termination Clearance

A08600

25-24-65-2

[_ VENTTERMINAL \\ _ AIR SUPPLY INLET

Item Clearance Descriptions Canadian Installation (1) U.S. Installation (2)

A Clearance above grade, veranda, porch, deck, balcony, or 12 inches (30cm) # 12 inches (30 cm)

anticipated snow level

B Clearance to a window or door that may be opened 6 inches (15 cm) for appliances _< 10,000 Btuh (3 kW) 4 feet(l.2 m) below or to the side of the opening, t foot (30 cm

C Clearance to a permanently closed window

D Vertical clearance to a ventilated soffit located above the

terminal within a horizontal distance of 2"(61cm) from the centerline of the terminal

E Clearance to an unventilated soffit

E Clearance to an outside corner

G Clearance to an inside corner

H Clearance to each side of the centerline extended above 3 feet (91 cm) within 15 feet(4.5 m) above the meter/regulator 3 feet (91 cm) _iithin 15 feet (4.5 m) above the meter/regulator

electrical meter or gas service regulator assembly assembly assembly

I Clearance to service regulator vent outlet 3 feet (91 cm)

J Clearance to non-mechanical air supply inlet to building or 6 inches (15 cm) for appliances -< 10,000 Btuh (3 kW) 4 feet(1.2 m) below or to the side of opening: 1 foot (30 cm)

the combustion air inlet to any other appliance 12 inches ( 30 cm) for appliances > 10,000 Btuh (3 kWO) above opening.

K Clearance to a mechanical air supply inlet 6 feet (1.83 m) 3 feet (91 cm) above if within 10 feet (3 m horizontally)

L Clearance under a veranda, porch, deck, or balcony t 2 inches(3O cm) +

Clearance to each side of the centerline extended above or below vent terminal of the furnace to a dryer or water heater

vent, or other appliance's direct vent intake or exhaust.

N Clearance to the vent terminal of a dryer vent, water heater

vent, or other appliances direct vent intake or exhaust.

O Clearance from a plumbing vent stack

p Clearance above paved sidewalk or paved 7 feet (2.13m)**

driveway located on public property

(1.) InaccordaecewiththecurrentCSABt49.1,NaturalGasandPropanelnstallationCode (2.) InaccordancewiththecurrentANSIZ223.1/NFPA54, NationalFuelGasCode

# 18" (46 cm) above roof surface + Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances shall be in accordance with local installation codes and the requirements of the gas supplier and the Manufacturer's installation instructions.

** A vent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. Notes:

1. The vent for this appliance shall not terminate a. Over public walkways; or

b. Nears__it_ents_rcraw_spacevents_r_therareaswherec_ndensate_rvap_rc_u_dcreateanusiance_rhazard_rpr_pertydamage;_r c. Wh_rec_ndensatevap_rc_u_dcausedamage_rc_u_dbedetrime_ta_t_t_e_p_rati_n_fregu_at_rs_r__iefva_ves__r_therequipme_t_

2. When locating vent terminations, consideration must be given to prevailing winds, location, and other c onditions which may cause recirculation of the combustiob products of adjacent vents. Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of the heat exchangers.

3 Avoid venting under a deck or large overhang. Recirculation could occur and cause performance or system problems.

12 inches ( 30 cm) for appliances > 10,000 Btuh (3 kW0) above the opening. and -< 100,000 Btuh (30 kW), 36 inches (91 cm) for

appliances > 100,000 Btuh (39 kW)

and < 100,900 Btuh (30 kW) 36 inches (91 cm) for appliances > t00,000 Btuh (30 kW)

AREA WHERE TERMINAL IS NOT PERMITED

7 feet (2.13m)

A08601

Table 9 - Other than Direct Vent Termination Clearance

Table 10 - Maximum Allowable Exposed Vent Pipe Length With and Without Insulation in

Winter Design Temperature Ambient*

UNIT SIZE DIAMETER INSULATION THICKER INSULATION

060 0 (-18) 2 (51) 21 (6) 70 (21)

080

100

120

* Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces= Pipes located length as specified in Table 11.

1-Insulation thickness based on R value of 3.5 per in.

WINTER DESIGN

TEMPERATURE °F (°C) IN. (mm) FT (i) FT (a)l

20 (-7) 2 (51) 44 (13) 70 (21)

-20 (-29) 2 (51) 20 (6) 57 (17) 20 (-7) 2 (51) 55 (17) 55 (17)

0 (-18) 2 (51) 30 (9) 55 (17)

-20 (-29) 2 (51) 16 (5) 55 (17) 20 (-7) 2.5 (64) 58 (18) 70 (21)

0 (-18) 2.5 (64) 29 (9) 70 (21)

-20 (-29) 2.5 (64) 14 (4) 67 (20) 20 (-7) 2.5 (64) 40 (12) 40 (12)

0 (-18) 2.5 (64) 38 (12) 40 (12)

-20 (-29) 2.5 (64) 21 (6) 40 (12) 20 (-7) 3 (76) 63 (19) 70 (21) 0 (-18) 3 (76) 30 (9) 70 (21)

-20 (-29) 3 (76) 12 (4) 70 (21) 20 (-7) 3 (76) 70 (21) 70 (21)

0 (-18) 3 (76) 38 (12) 70 (21)

-20 (-29) 3 (76) 19 (6) 70 (21) 20 (-7) 4 (102) 65 (20) 70 (21)

0 (-18) 4 (102) 26 (8) 70 (21)

-20 (-29) 4 (102) 5 (2) 65 (20)

Attachment of Combustion Air Pipe

1. Determine location of combustion air intake pipe connection to combustion air intake housing as shown in

Fig. 38 for application.

2. Reposition combustion air intake housing plug fitting in appropriate unused intake housing connection.

3. Install combustion-air pipe grommet (factory-supplied in loose parts bag) into selected furnace casing

combustion-air pipe hole. (See Fig. 40.)

4. Insert assembled combustion air inlet pipe into intake housing as shown in Fig. 38.

MAX PIPE WITHOUT WITH 3/8-1N. (10 mm) OR

in unconditioned space cannot exceed total allowable pipe

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, as shown in Fig. 42. NOTE: (Direct Vent/2-Pipe System ONLY). Moisture in

combustion air intake may be a result of improper termination. Ensure combustion air pipe termination is similar to those as shown in Fig. 44 so that it will not be susceptible to area where light snow or other sources of moisture could be pulled in.

VENT PIPE

General

Furnace vent connection must be attached as shown in Fig. 38.

5. Drill a I/S-in. (3 mm) hole in 2-in. (51 mm), combustion air pipe using the hole in intake housing as a guide.

6. Install a field-supplied No. 6 or No. 8 sheet metal screw into combustion air pipe.

7. Install casing hole filler cap (factory-supplied in loose parts bag) in unused combustion air pipe casing hole.

NOTE: Do not attach combustion air intake pipe permanently to combustion air intake housing since it may be necessary to

CARBON MONOXIDE POISONING AND PROPERTY DAMAGE HAZARD

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

Vent pipes must be airtight.

remove pipe for service of burner box components or flame sensor.

Attachment of 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. (3 mm) 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 OVERTIGHTEN SCREW. Breakage of 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. If use of this drain connection is desired, drill

NOTE: A 2-in. (51 mm) diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing per Fig. 41.

The minimum vent pipe length for these furnaces is 5 ft. (2 M).

Short pipe lengths (5-8 ft or 2-3 M) may discharge condensate

droplets. These condensate droplets may be undesirable. A 12-in. (305 mm) minimum offset pipe section is recommended to reduce

excessive condensate droplets from exiting vent pipe outlet. (See Fig. 43.)

Attachment of Vent Pipe

1. Determine vent pipe diameter and maximum pipe lengths using Table 13.

out fitting's tap plug with 3/16-in. drill and connect a

Table11 - Furnace Setup Switch Description

SETUP SWITCH NO. SWITCH NAME NORMAL POSITION DESCRIPTION OF USE

SW-1 Mode OFF Heat operation when R to W/W1 closes and High Heat operation

SW-2 delay ON or OFF See Table 9B.

SW-3 delay ON or OFF See Table 9B.

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

AIR

COMBUSTION-AIR _ COMBUSTION-AIR

Adaptive Heat thermostat. Turn on when using 2-stage thermostat to allow Low

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

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

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

When off, allows 2-stage operation with a single-stage

when R to W/W1 and W2 close.

_t[-F!'EL' ' ---F,ELD-SUPPL,ED

PVC 90° ELBOWJ 2-IN. (51 mm) DIA.

__ 4__ _ _

,z"

W TO

VENT

f A

COMBUSTION- _7 COMBUSTION-

AIR AIR

UPFLOW

COMBUSTION-

AIR

VENT

HORIZONTAL-LEFT DISCHARGE

* For Non-Direct Vent (1-Pipe) system, orient elbow so that its

opening faces down.

** For Non-Direct Vent (1-Pipe) system, orient elbow so that its

opening faces sideways.

1 An external trap kit (see furnace product data sheet) must be used.

t t Bottom combustion-air not allowed for non-direct vent

Fig. 38 - Combustion-Air and Vent Pipe Connections

Table 12 - Blower Off Delay Setup Switch (SW) 2-Stage Units

with PSC Blower Motors

DESIRED HEATING MODE

BLOWER-OFF DELAY (SEC)

120 150

180

HORIZONTAL-RIGHT DISCHARGE

AiR

FLOW

DOWNFLOW

COMBUSTION-

AIR

VENT

SETUP SWITCH

SW-2 SW-3

OFF OFF OFF ON

ON OFF ON ON

A05092

_LCOMBUSTION-AIR DISC

(FACTORY-SUPPLIED IN LOOSE PARTS BAG)

Length of Straight Pipe Portion of

Combustion-Air Inlet Pipe Assembly - In. (mm)

CASING WIDTH A

17-1/2 (445) 8-1/2 -+1/2(216 -+13)

21(533) 10-1/2 -+1/2 (287 -+13)

24-1/2 (622) 12 -+1/2 (318 -+13)

Fig. 39 - Combustion-Air Inlet Pipe Assembly

NOTE: (Direct Vent/2-pipe ONLY) vent pipe system has the

same diameter and same length as combustion air pipe mentioned in section "Assembly of Combustion Air Pipe (Direct Vent/2-Pipe system ONLY)."

NOTE: Do not count elbows or pipe sections in terminations or within furnace (all elbows shown in Fig. 44 and Fig. 45 are not be to counted).

2. Determine location of vent pipe connection to inducer housing as shown in Fig. 38 for application.

3. Install vent pipe grommet (factory-supplied in loose parts

bag) into selected furnace casing vent pipe hole. (See

Fig. 44.)

4. Reposition elastomeric (rubber) inducer housing outlet cap and clamp to appropriate unused inducer housing

connection. Tighten clamp.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component damage.

Inducer housing outlet cap must be installed and fully seated

against inducer housing. Clamp must be tightened to prevent any condensate leakage.

PVC PiPE

A96211

Table 13 - Maximum Allowable Pipe Length - Ft. (M)

ALTITUDE INPUT DIRECT VENT (2-PIPE)

UNIT MAX NUMBER OF 90° ELBOWS

FT (i) RATE ONLY

0 to 2000

(0 to 610)

2001 to

3000

(610 to 914)

3001 to

4000

(914 to

1219)

See notes at end of table

(BTUH) TERMINATI

ON TYPE 1 2 3 4 5 6

60,000

80,000

100,000

120,000

60,000

80,000

100,000

120,000

60,000

80,000

100,000

120,000

2 Pipe or 2-in.

(51 ram)

Concentric

2 Pipe or 2-in.

(51 ram)

Concentric

2 Pipe or 3-in.

(76 ram)

Concentric

2 Pipe or 3-in.

(76 ram)

Concentric

2 Pipe or 2-in.

(51 ram)

Concentric

2 Pipe or 2-in.

(51 ram)

Concentric

2 Pipe or 3-in.

(76 ram)

Concentric

2 Pipe or 3-in.

(76 ram)

Concentric

2 Pipe or 2-in.

(51 ram)

Concentric

2 Pipe or 2-in.

(51 ram)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

4t no disk

PIPE DIA

IN. (MM)*

1- 1/2 (38)

2 (51)

1- 1/2 (38)

2 (51)

2-1/2 (64)

2 (51)

2-1/2 (64)

3 (76)

2-1/2 (64) one

disk

3 (76)t

3 (76)t no

disk

1- 1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)t no

disk

4t no disk

1- 1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)t no

disk

4t no disk

NON-DIRE

CT VENT

(1 -PIPE)

ONLY

PIPE DIA

IN. (MM)*

1- 1/2 (38)

2 (51)

1- 1/2 (38)

2 (51)

2-1/2 (64)

2 (51)

2-1/2 (64)

3 (76)

2-1/2 (64)

3 (76)t

1- 1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)t

4t no disk

1- 1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)t

4t no disk

(6.1)

(21.3)

(3.0)

(16.7)

(21.3)

(1.5)

(12.1)

(21.3)

10 (3.0) NA NA NA NA NA

45 40 35 30 25 20

(13.7) (12.1) (10.6) (9.1) (7.6) (6.1)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

17 12 7

(5.1) (3.6) (2.1) NA NA NA

70 67 66 61 61 61

(21.3) (20.4) (20.1) (18.5) (18.5) (18.5)

49 44 30 25 25 15

(14.9) (13.4) (9.1) (7.6) (7.6) (4.6)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

35 26 16 16 6

(10.6) (7.9) (4.8) (4.8) (1.8) NA

70 70 70 70 66 61

(21.3) (21.3) (21.3) (21.3) (20.1) (18.5)

14 9

(4.2) (2.7) NA NA NA NA

63 62 62 61 61 61

(19.2) (18.8) (18.8) (18.5) (18.5) (18.5)

70 70 63 56 50 43

(21.3) (21.3) (19.2) (17.) (15.2) (13.1)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

16 11 6

(4.8) (3.3) (18.8) NA NA NA

68 63 62 57 57 56

(20.7) (19.2) (18.8) (17.3) (17.3) (17.0)

46 41 28 23 22 13

(14.0) (12.4) (8.5) (7.0) (6.7) (3.9)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

33 24 15 14 5

(10.0) (7.3) (4.6) (4.2) (1.5) NA

70 70 70 66 61 56

(21.3) (21.3) (21.3) (20.1) (18.5) (17.0)

65 58 51 44 38 31

(19.8) (17.6) (15.5) (13.4) (11.5) (9.4)

59 59 58 57 57 56

(17.9) (17.6) (17.6) (17.3) (17.3) (17.0)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

15 10 5

(4.6) (3.0) (1.5)

NA NA

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

NA NA NA NA NA 50 35 30 30 20

(15.2) (10.6) (9.1) (9.1) (6.1)

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

NA NA NA NA NA 30 20 20 10

(9.1) (6.1) (6.1) (3.0) NA

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

ALTITUDE INPUT

FT (a) RATE

UNIT MAX DIRECT VENT (2-PIPE) ONLY NUMBER OF 90 ° ELBOWS

(BTUH) TERMINATION

60,000

80,000

4001 to

5000

(1219 to

1524)*

100,000

120,000

80,000

5001 to 6000

(1524 to

1829)*

6001 to 7000

(1829 to

2134)*

See Notes at the end of table

100,000

120,000

60,000

80,000

100,000

120,000

Table 13--Maximum Allowable Pipe Length - Ft. (M) (Continued)

NON-DIRE

CT VENT

(1 -PIPE)

ONLY

TYPE 1 2 3 4 5 6

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in..

(76 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

PIPE DIA

(IN.)*

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1- no disk

41-no disk

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1- no disk

41-no disk

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1- no disk

41-no disk

PIPE DIA

(IN.)*

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

41- no disk

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

41- no disk

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

41- no disk

(4.6)

(19.5)

(13.4)

(21.3)

(9.4)

(21.3)

(18.1)

(17.0)

(21.3)

(4.2)

(18.2)

(12.4)

(21.3)

(8.8)

(21.3)

(12.8)

(18.1)

(21.3)

(3.9)

(17.3)

(11.5)

(21.3)

(8.2)

(20.7)

(9.4)

(14.9)

(21.3)

(3.0)

(17.9)

(11.8)

(21.3)

(6.7)

(21.3)

(14.0)

(16.7)

(21.3)

(2.7)

(16.7)

(10.9)

(21.3)

(6.4)

(20.4)

(10.6)

(15.8)

(21.3)

(2.4)

(15.8)

(1o.o)

(21.3)

(5.7)

(19.2)

(7.3)

(14.6)

(21.3)

(1.5)

58 53 52 52

(17.6) (18.1) (15.8) (15.8)

26 21 20 11

(7.9) (6.4) (6.0) (3.3)

70 70 70 70

(21.3) (21.3) (21.3) (21.3)

13 12

(3.9) (3.6) NA NA

67 62 57 52

(20.4) (18.8) (17.3) (15.8)

40 33 26 20

(12.1 ) (10.0) (7.9) (6.0)

54 53 52 52

(16.4) (16.1) (15.8) (15.8)

70 70 70 70

(21.3) (21.3) (21.3) (21.3)

NA NA NA NA

54 49 48 47

(16.4) (14.9) (14.6) (14.3)

23 18 17 8

(7.0) (5.9) (5.1) (2.4)

70 70 70 70

(21.3) (21.3) (21.3) (21.3)

12 11

(3.6) (3.3) NA NA

62 57 52 47

(18.8) (17.3) (15.8) (14.3)

29 22 15 9

(8.8) (6.7) (4.6) (2.7)

50 49 48 47

(15.2) (14.9) (14.6) (14.3)

70 70 70 70

(21.3) (21.3) (21.3) (21.3)

NA NA NA NA

50 45 44 43

(15.2) (13.7) (13.4) (13.1)

21 16 15 6

(6.4) (4.8) (4.6) (1.8)

68 67 66 64

(20.7) (20.4) (20.1) (19.5)

10 9

(3.0) (2.7) NA NA

58 53 48 43

(17.6) (16.1) (14.6) (13.1)

18 11

(5.4) (3.3) NA NA

47 45 44 43

(14.3) (13.7) (13.4) (13.1)

70 70 67 62

(21.3) (21.3) (20.4) (18.8)

NA NA NA

Table 13--Maximum Allowable Pipe Length - Ft. (M) (Continued)

NON-DIRE

ALTITUDE UNIT SIZE ONLY

DIRECT VENT (2-PIPE) NUMBER OF 90 ° ELBOWS

FT (i) (BTUR)

TERMINATIO

N TYPE 1

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 2-in. 45

Concentric

2 Pipe or 2-in.

(51 ram)

Concentric

7001 to

8000

(2134 to

2438),

8001 to

9000

(2438 to

2743)*

9001 to

60,000

80,000

100,000

120,000

60,000

80,000

100,000

120,000

60,000 (51 mm) (13.7)

80,000

10,000

(2743 to

3048)*

*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.

tWide radius elbow. SVent 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. Wide 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 (2 M) for all applications.

6. Use 3-in. (76 mm) diameter vent termination kit for installations requiring 4-in. (102 mm) diameter pipe.

100,000

120,000

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

PIPE DIA

(IN.)*

1- 1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)f no disk

4t no disk

1- 1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)f no disk

4t no disk

2 (51)

2-1/2 (64)

3 (76)

4t no disk

CT VENT

(1 -PIPE)

ONLY

PIPE DIA

(IN.)*

1- 1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)t

4t no disk

1- 1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)t

4t no disk

2 (51)

2-1/2 (64)

3 (76)

3 (76)t

4t no disk

2 3 4 5 6

12 7

(3.6) (2.1) NA NA NA NA

53 48 46 41 40 38

(16.1) (14.6) (14.0) (12.4) (12.1) (11.5)

36 31 19 14 12

(10.9) (9.4) (5.7) (4.2) (3.6) NA

66 65 63 62 60 59

(20.1) (19.8) (19.2) (18.8) (18.2) (17.9)

25 17 8 7

(7.6) (5.1) (2.4) (2.1) NA NA

63 58 53 48 43 38

(19.2) (17.6) (16.1) (14.6) (13.1) (11.5)

20 13 7

(6.0) (3.9) (2.1) NA NA NA

46 44 43 41 40 38

(14.0) (13.4) (13.1) (12.4) (12.1) (11.5)

61 56 51 46 41 36

(18.5) (17.0) (15.5) (14.0) (12.4) (10.9)

11 6

(3.3) (1.8) NA NA NA NA

49 44 42 37 35 34

(14.9) (13.4) (12.8) (11.2) (10.6) (10.3)

33 28 17 12 10

(10.0) (8.5) (5.1) (3.6) (3.0) NA

62 60 58 56 55 53

(18.8) (18.2) (17.6) (17.0) (16.7) (16.1)

23 15 7 5

(7.0) (4.6) (2.1) (1.5) NA NA

59 54 49 44 39 34

(17.9) (16.4) (14.9) (13.4) (11.8) (10.3)

(3.0) NA NA NA NA NA

43 41 39 37 35 34

(13.1) (12.4) (11.8) (11.2) (10.6) (10.3)

35 30 25 20 15 10

(10.6) (9.1) (7.6) (6.1) (4.6) (3.0)

40 38 33 31 29

(12.1) (11.5) (10.0) (9.4) (8.8)

30 25 14 9 7

(g.1) (7.6) (4.2) (2.7) (2.1) NA

57 55 53 51 49 47

(17.3) (16.7) (16.1) (15.5) (14.9) (14.3)

21 13 5

(6.4) (3.9) (1.5) NA NA NA

54 49 44 39 34 29

(16.4) (14.9) (13.4) (11.8) (10.3) (8.8)

39 37 35 33 31 29

(11.8) (11.2) (10.6) (10.0) (9.4) (8.8)

10 5

(3.0) (1.5) NA NA NA NA

5. Be certain that mating surfaces of inducer housing connection elastomeric (rubber) coupling, and 2-in. (51

mm) 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. (51 mm) diameter vent pipe through the elastomeric (rubber) coupling and fully into inducer housing connection until it

touches a stop inside the inducer housing outlet. Tighten the screws on both clamps to 15-in-lb. of torque, pipe to

inducer housing. Tighten the clamp screws to 15 in.-lb, of torque.

NOTE: Starting at furnace, slope vent pipe a minimum of 1/4-in. (6 mm) per linear ft with no sags between hangers.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component damage.

Inducer housing outlet cap must be installed and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage.

6. Install casing hole filler cap (factory-supplied in loose parts bag) in unused vent pipe casing hole.

Attachment of Vent Extension Pipe Furnaces with 100,000 Btuh and larger input are supplied with a

PVC vent extension pipe (2-in. (51 mm) diameter by 12-in. (305 mm) 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. 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.

Installation Guidelines for Combustion Air Pipe and Vent

Pipe

It is recommended that all pipes be cut, prepared, and pre-assembled before permanently cementing any joint.

1. Attach combustion air pipe and vent pipe per instructions in sections "Combustion Air Pipe" and "Vent Pipe."

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

3. Deburr inside and outside of pipe.

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

5. Clean and dry all surfaces to be joined.

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

7. 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.

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

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

made joint.

10. Handle pipe joints carefully until cement sets.

11. Horizontal portions of the venting system shall be supportive to prevent sagging support. Support

combustion air piping (if applicable) and vent piping a minimum of every 5 ft (2 M) (3 ft or .9 M for SDR-21 or

-26 PVC) using perforated metal hanging strap.

12. Slope combustion air piping (if applicable) and vent piping downward towards furnace a minimum of 1/4 in. (6 mm) per linear ft with no sags between hangers.

13. Horizontal portions of the venting system shall be installed so as to prevent the accumulation of condensate.

14. Use appropriate methods to seal openings where combustion air pipe (if applicable) and vent pipe pass

through roof or sidewall.

COMBUSTION-AIR PIPE GROMMET

UNUSED 1-3/4 -IN. (44 mm) DIAMETER GAS

HOLE

NOTE: PIPE GROMMETS AND ENTRY HOLE FILLER

PLUGS ARE INCLUDED IN FACTORY-SUPPLIED LOOSE PARTS BAG

illi0 _-- GASL,NEENTRY

HOLE FILLER PLUG

A05057

Fig. 40 - Typical Gas Pipe Arrangement

FURNACE

(

NOT IN HORIZONTAL SECTION

TRANSITION iN

VERTICAL SECTION

Fig. 41 - Combustion-Air and Vent Pipe Diameter

Transition Location and Elbow Configuration

COMBUSTION AIR

3/8 ID TUBE --

D I1,

TRAPJt

TO OPEN --

DRAIN

Fig. 42 - Air Intake Housing Plug Fitting Drain

TAKE HOUSING BURNER

--_ j_.-_ VENT/2 PIPE)

7 -- b_€

BOX

['1, COMBUSTION-AIR I _PIPE (DIRECT

COMBUSTION-AIR PIPE (NON-DIRECT

VENT/I-PIPE)

A93034

A05093

EXAMPLE: An 080-12 size furnace located in Indianapolis, elevation

650 fl (198 M) above sea level, could be installed as either a direct vent/2-pipe system that requires 3 elbows and 32 fl (10

M) of vent pipe, along with 5 elbows and 34 fl (10 M) of combustion-air pipe OR a non-direct vent/I-pipe system that requires 3 elbows and 32 fl (10 M) vent pipe.

For a direct vent/2-pipe system, Table 13 indicates this application would allow a 2-in. (51 mm) diameter vent pipe,

but require a 2-1/2 in. (64 mm) diameter combustion air pipe. According to Table 13, 2-in. (51 mm) diameter pipe is good for 35 fi (11 M) with 3 elbows, but only 30 ft (9 M) with 5 elbows. Therefore, 2-1/2 in. (64 mm) diameter pipe must be

used for both vent and combustion-air pipes since larger required diameter must always be used for both pipes.

For a non-direct vent/I-pipe system, Table 13 indicates that this application would allow a 2-in. (51 mm) diameter vent pipe.

If same installations were in Albuquerque, elevation 5250 ft (1600 M) above sea level:

For a direct vent/2-pipe system, Table 13 indicates that 2-1/2 in. (64 mm) diameter vent pipe and combustion-air pipe are required.

For a non-direct vent/I-pipe system, Table 13 indicates that 2-1/2-in. (64 mm) diameter vent pipe is required.

If same applications are to be installed at 5001 to 6000 fi (1524 to 1829 M)elevation:

For a direct vent/2-pipe system, 2-in. (51 mm) pipe is only good for 23 ft (7 M) (with 3 elbows) and 17 fl (5 M)(with 5

elbows). Therefore, 2-1/2 in. (64 mm) diameter combustion air and vent pipe must be used.

For a non-direct vent/I-pipe system, a 2-in. (51 mm) diameter pipe is only good for 23 fl (7 M) with 3 elbows. A 2-1/2-in. (64 mm) diameter vent pipe must be used.

--12MN 1

-,_l--_ 12" MI N------B_ I

VENT PIPE

0 L

HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL

COMBUSTION-AIR PIPE

COMBUSTION-AIR

VERTICAL TO ROOF VERTICAL TO SIDEWALL

NOTE: A 12-in. (304.8mm) minimum offset pipe section is recommended

with short (5 to 8 ft / 1.5 to 2.5M) vent systems. This recommendation is to reduce excessive condensate droplets.

Fig. 43 - Short Vent (5 to 8 ft (1.5 to 2.4 M)) System

F VENT PIPE

(305mm) _

-- COMBUSTION-AIR PIPE

VENT PIPE

A96230

VENT TERMINATION

General Combustion-air (direct vent/2-pipe system only) and vent pipe

must terminate outside structure, either through sidewall or roof. For vent termination clearance, refer to Table 8 for Direct

Vent/2-Pipe system and Table 9 for Non-direct Vent/I-Pipe system. For exterior piping arrangements, refer to

Fig. 44 for Direct Vent/2-Pipe system and Fig. 45 for Non-Direct/I-Pipe system.

Roof termination is preferred since it is less susceptible to damage or contamination, and it has less visible vent vapors.

Sidewall termination require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive

combustion products of vent system. NOTE: (Direct Vent/2-Pipe system ONLY). A factory accessory

termination kit MUST be used. See section "Vent Termination Kit (Direct Vent/2-Pipe System Only)" in this instruction.

When determining appropriate location for termination, consider the following guidelines:

1. Comply with all clearance requirements stated in Table 8 or Table 9 per application.

2. Termination or termination kit should be positioned where vent vapors will not damage plants/shrubs or air

conditioning equipment.

3. Termination or termination kit should be positioned so that it will not be affected by wind eddy, such as inside

building corners, nor by recirculation of flue gases,

airborne leaves, or light snow.

4. Termination or termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones, balls, etc.

5. Termination or termination kit should be positioned where

vent vapors are not objectionable.

Extended Exposed Sidewall Pipes

Sidewall combustion air pipe termination (direct vent/2-pipe

system only) and vent pipe termination may be extended beyond

area shown in Fig. 44 or in Fig. 45 per application in outside ambient by insulating pipe as indicated in Table 10.

1. Determine combustion air pipe diameter (direct vent/2-pipe system only) and vent pipe diameter, 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 length(s).

NOTE: Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 13.

Vent Termination Kit (Direct Vent/2-Pipe System Only) NOTE: Always refer to the instructions in termination kit for the

latest version.

Table14 - Vent Termination Kit for Direct Vent/2-Pipe System

DIRECT VENT (2-PIPE) TERMINATION KIT TERMINATION SYSTEM PIPES - IN (mm)

2-in. (51 mm) Concentric Vent Kit Single Penetration of Wall or Roof 1, 1 - 1/2, 2, or 2-1/2 (25, 38, 51,64 mm)

3-in. (76 ram)Concentric Vent Kit Single Penetration of Wall or Roof 2-1/2, 3 or 4 (64, 76, 102 mm)

2-in. (51 ram)Termination Bracket Kit 2-Pipe Termination System 1, 1-1/2 or 2 (25, 38, 51mm)

3-in. (76 ram) Termination Bracket Kit 2-Pipe Termination System 2-1/2, 3 or 4 (64, 76, 102 mm)

Rool _ rmlnatlon (Preferred)

At Feast 36 in

(914mm)

Vertical separation between combustion

air and vent

"-,.

Maintain 12 in (3O5mm)min clearance above

......... _ _go_ % vaen................ i .............

DIAM, OF COMBUSTION AIR AND VENT

Con c_mtric V#nt and Combustion Air

Roo f f_rruination (preferred) ..................

Maintain 12 in (3O5mm) min clearance above

highest anticipatod snow level maximum of

24 i{I above roof

A05090

Fig. 44 - Combustion Air and Vent Pipe Termination for Direct Vent (2-pipe) System

Roof Termination (Preferred)

Maintain 12 in 3O5mm " """

above highest anticipated

snow [evel maximum of

24 _n (610ram) abov_ roof _.

"\\

Side wall termination

\\\\\\\\\

w_th 2 elbows (preferred)

.... I--..

Abandoned masonry used as raceway (per code)

overhang or roof whichever _s greater

w_th Sha[ght P_pe (preferred)

Maintain 12 in 3O5mm m[n[mu m c earance

above highest anticipated s_qow level or grade

"_Mchever _s greater

A05091

Fig. 45 - Vent Pipe Termination for Non-Direct Vent (1-pipe) System

Combustion air and vent pipes MUST terminate outside structure. A factory accessory termination kit must be installed as shown in

Table 14. There are four options of vent/combustion air termination kits available as shown in Table 14.

NOTE: Combustion air pipe must have the same diameter as vent pipe.

Concentric Vent/Combustion Air Termination Kit (Direct Vent/2-Pipe System Only)

Determine an appropriate location for termination kit using the guidelines provided in section "Vent Termination: General" in

this instruction.

1. Cut one 4-in. (102 mm) diameter hole for 2-in. (51 mm) kit, or one 5-in. (127 mm) diameter hole for 3-in. (76 mm)

kit.

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

3. Slide assembled kit with rainshield 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. 44.

Sidewall terminations Locate assembly through sidewall with rain shield positioned no more than 1-in. (25

mm) from wall as shown in Fig. 44.

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

5. Check required dimensions as shown in Fig. 44.

Two-Pipe Termination Kit (Direct Vent/2-Pipe System Only) Determine an appropriate location for termination kit using the

guidelines provided in section "Vent Termination: General" in this instruction.

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

2. 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. 44.

For applications using combustion-air pipe option, indicated by dashed lines in Fig. 44, install 90 ° street

elbow into 90 ° elbow, making a U-fitting. A 180 ° U-fitting may be used.

Sidewall terminations - Install bracket as shown in Fig.

44. For applications using vent pipe option indicated by dashed lines in Fig. 44, rotate vent elbow 90 ° from

position shown in Fig. 44.

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

4. Check required dimensions as shown in Fig. 44.

Multi-venting and Vent Terminations When 2 or more 58MTB Furnaces are vented near each other,

each furnace must be individually vented. NEVER common vent or breach vent 58MTB furnaces.

(Direct Vent/2-Pipe System ONLY) - When 2 or more 58MTB furnaces are vented near each other, 2 vent terminations may be

installed as shown in Fig. 44, but next vent termination must be at least 36 in. (914 mm) away from first 2 terminations. It is important that vent terminations be made as shown in Fig. 44 to

avoid recirculation of flue gases. Step 11 - Condensate Drain

UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent

unit operation. 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 (0°C) and below unless drain trap

and drain line have adequate freeze protection. See Service and Maintenance Instructions for winterizing procedure.

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. (13 mm) CPVC, 1/2-in. (13 mm)

PVC, or 5/8-in. (16 mm) ID tube connection. Drain pipe and fittings must conform to ANSI standards and

ASTM D1785, D2466 or D2846. CPVC or PVC cement must conform to ASTM D2564 or F493. Primer must conform to

ASTM F656. In Canada, use CSA or ULC listed 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.

APPLICATION The furnace, A/C, and humidifier drains may be combined and

drained together. The A/C drain must have an external, field-supplied 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. 46 for example of possible field drain attachment using 1/2-in. (13 mm) CPVC or PVC tee for vent and A/C or humidifier

drain connection.

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.

__/ \__

PIPEFOR

A/COR

HUMIDIFIER

OPENSTAND/

DRAIN

A94054

Fig. 46 - Example of Field Drain Attachment

PERSONAL INJURY HAZARD

Caution should be taken to prevent draining where slippery

conditions may cause personal injuries. Excessive condensate draining may cause saturated soil

conditions which could result in damage to plants.

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 120-v and 40°F (4°C) 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. 47.)

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

47.)

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.

START-UP ADJUSTMENT AND

SAFETY CHECK

CONDENSATE

WIRE TIE

HEAT

(3 WRAPS MINIMUM)

A93036

Fig. 47 - Condensate Trap Heat Tape

Step 1 - General

The furnace must have a 115-v power supply properly connected

and grounded.

NOTE: Proper polarity and proper grounding must be

maintained for 115-v wiring. If polarity is incorrect, control status indicator light will flash rapidly and the furnace will not operate.

Natural gas service pressure must not exceed 0.5 psig (14-in. wc),

and be no less than 0.16 psig (4.5-in. wc).

Thermostat wire connections at R and W/W1 are the minimum required for gas heating operation. W2 must be connected for 2-stage heating thermostats. COM, Y/Y2, and G are required for

cooling, heat pumps, and some clock thermostats. These must be made at the 24-v terminal block on the control. (See Fig. 37.)

This furnace can be installed with either a single-stage heating or

a 2-stage heating thermostat.

For single-stage thermostats, connect thermostat W to W/W1 at furnace control terminal block. (See Fig. 31 and 50H.) For

single-stage thermostats, the control will determine, based on length of previous heating on and off cycles, when to operate in

low- and high-gas heat for optimum comfort. Setup switch-1 (SW-1) must be in the factory-shipped OFF position. See Fig. 36

and Table 11 and 12 for setup switch information.

FURNACE MAY NOT OPERATE

Failure to follow this caution may result in furnace operation stopping and water pipes freezing during cold weather.

Furnace control must be grounded for proper operation, or control will lockout. Control is grounded through green/yellow wire connected to gas valve C-terminal and burner box screw.

FIRE HAZARD

Failure to follow this caution may result in intermittent unit operation or performance satisfaction.

This furnace is equipped with a manual reset limit switch in the burner box area. The switch will open and shut off power

to the gas valve if a flame rollout or overheating condition occurs in the burner enclosure area. DO NOT bypass the

switch. Correct inadequate combustion-air supply, component failure, or restricted flue gas passageway before resetting

the switch.

Step 2 - Prime Condensate Trap With Water

A99118

Fig. 48 - Inducer Housing Drain Tube Cap

If a 2-stage heating thermostat is to be used, move SW-1 to ON position at end of furnace installation. This overrides built-in

control process for selecting high and low fire and allows the 2-stage thermostat to select gas heating modes. The W2 from

thermostat must be connected to W2 on control terminal block. (See Fig. 32 and 50-57.) Before operating furnace, check each flame rollout manual reset

switch for continuity. If necessary, press and release button to reset switch. The blower compartment door must be in place to

complete the l15-v circuit to the furnace.

UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit

operation or performance satisfaction. Condensate trap must be PRIMED or proper draining may not

occur. The condensate trap has 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. 48.)

2. Connect field-supplied 1/2-in. (13 mm) 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. 49.)

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

Step

3 - Purge Gas Lines

After

all connections have been made, purge the gas lines and

check

for leaks.

FIRE AND EXPLOSION HAZARD

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

never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of

leaks to check all connections, as specified in "Gas Piping"

and "Start-up Adjustment, and Safety Check" sections of

these instructions.

Fig. 49 - Filling Condensate Trap

A99119

Step 4 - Sequence of Operation

Using schematic diagram in Fig. 36, follow the sequence of operation through the different modes. Read and follow diagram

very carefully.

NOTE: If power interruption occurs during "call for heat" (W/W1 or W/W1 and W2), the control will run the blower for the selected blower off delay period after power is restored, if the thermostat is still calling for gas heating. The amber LED will flash code 12 during this period, after which the LED will be ON continuous as long as no faults are detected. After this period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through blower door interlock switch ILK to furnace control

CPU,transformer TRAN, inducer motor IDM, blower motor

BLWM, hot surface igniter HSI, and gas valve GV. TWO-STAGE HEATING WITH SINGLE-STAGE

THERMOSTAT (ADAPTIVE MODE) (See Fig. 31 for thermostat connections.)

NOTE: Low-heat-only switch, SW-1, selects either the low-heat-only operation mode when ON, or adaptive heating mode when OFF, in response to a call for heat. (See Fig. 37.)

This furnace can operate as a 2-stage furnace with a single-stage thermostat because furnace control CPU includes a programmed

adaptive sequence of controlled operation, which selects low-gas- heat or high-gas-heat operation. This selection is based upon the

stored history of the length of previous gas heating on/off periods of the single-stage thermostat.

The furnace will start up in either low-or high-gas heat. If the furnace starts up in low-gas heat, the control CPU determines the

low-gas heat on time (from 0 to 16 minutes) which is permitted before switching to high-heat.

If power is interrupted, the stored history is erased. When this happens, the control CPU will initially select low-heat for up to

16 minutes and then switch to high-heat, as long as the thermostat continues to "call for heat." Subsequent selection is based on stored history of thermostat cycle times.

When wall thermostat "calls for heat", R-W/W1 circuit closes. The furnace control performs a self check, verifies the low-heat and high-heat pressure switch contacts LPS and HPS are open,

and starts inducer motor IDM in high speed.

1. Inducer Prepurge Period - If the furnace control CPU selects low-heat operation the inducer motor IDM comes

up to speed, the low-heat pressure switch LPS closes, and the furnace control CPU begins a 15-second prepurge

period. After the low-heat pressure switch re-closes the furnace control CPU will begin a 15-second prepurge

period, and continue to run the inducer motor IDM at high-speed.

If the furnace control CPU selects high-heat operation, the inducer motor IDM remains running at high-speed, and the

high-heat pressure switch relay HPSR is de-energized to close the NC contact. When sufficient pressure is available

the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is energized. The furnace control CPU begins a 15-second prepurge period

after the low-heat pressure switch LPS closes. If the high-heat pressure switch HPS fails to close and the

low-heat pressure switch LPS closes, the furnace will operate at low-heat gas flow rate until the high-heat

pressure switch closes for a maximum of 2 minutes after ignition.

2. IgniterWarm-Up - At end of the inducer prepurge period, the Hot Surface Igniter HSI is energized for a 17-sec

igniter warm-up period.

3. Trial-For-Ignition Sequence - When the igniter warm-up period is completed the main gas valve relay contacts

GVR close to energize the gas valve GV, the gas valve opens. The gas valve GV permits gas flow to the burners

where it is ignited by the Hot Surface Igniter HSI. Five seconds after the GVR closes, a 2-second flame period

begins. The HIS igniter will remain energized until the flame is sensed or until the 2-second flame proving

period begins.

4. Flame-Proving - When burner flame is proved at the flame-proving sensor electrode FSE, the inducer motor IDM switches to low-speed unless running at high-speed,

and the furnace control CPU begins the blower-ON delay period and continues to hold the gas valve GV-M open. If

the burner flame is not proved within two seconds, the control CPU will close the gas valve GV-M, and the

control CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to

Ignition-Lockout. Lockout will be reset automatically after three hours, by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at

SEC1 or SEC2 to the furnace control CPU (not at W/Wl, G, R, etc.). If flame is proved when flame should not be

present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM on

high speed until flame is no longer proved.

5. Blower-On Delay - If burner flame is proven the blower motor BLWM is energized 66 sec after gas valve GV-M is

opened. Low-heat - The blower motor BLWM is energized at LO

HEAT speed. Hi-heat - The BLWM is energized at HI HEAT speed.

Simultaneously, the electronic air cleaner terminal EAC-1 is energized and remains energized as long as the blower

motor BLWM is energized.

6. Switching From Low- To High-Heat - If the furnace control CPU switches from low-heat to high-heat, the

furnace control CPU will switch the inducer motor IDM speed from low to high. The high-heat pressure switch

relay HPSR is de-energized to close the NC contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid

GV-HI is energized. The blower motor BLWM will switch to HI HEAT speed five seconds after the furnace control

CPU switches from low-heat to high-heat.

7. Switching From High- To Low-Heat - The control CPU

will not switch from high-heat to low-heat while the

thermostat R-to-W circuit is closed when a single-stage thermostat is used.

8. Blower-Off delay - When the thermostat is satisfied, the R to W circuit is opened, de-energizing the gas valve GV-M, stopping gas flow to the burners, and de-energizing

the humidifier terminal HUM. The inducer motor IDM

will remain energized for a 15-second post-purge period.

The blower motor BLWM and air cleaner terminal EAC-1

will remain energized for 90, 120, 150, or 180 seconds

(depending on selection at blower-OFF delay switches). The furnace control CPU is factory-set for a 120-second

blower-OFF delay.

TWO-STAGE HEATING WITH TWO-STAGE THERMOSTAT (NON-ADAPTIVE HEATING MODE)

(See Fig. 32 and 50-56 for thermostat connections). NOTE: In this mode, the low-heat only switch must be ON to

select the low-heat only operation mode in response to closing the thermostat R-to-W1 circuit. Closing the thermostat R-to-W1

and-W2 circuits always causes high-heat operation, regardless of

the setting of the low-heat-only switch. The wall thermostat "calls for heat", closing the R to W1 circuit

for low-heat or closing the R to W1 and-W2 circuits for high-heat. The furnace control performs a self-check, verifies the

low-heat and high-heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high-speed.

The start-up and shutdown functions and delays described in item 1 above apply to 2-stage heating mode as well, except for

switching from low-to high-heat and vice versa.

1. Switching From Low- To High-Heat - If the thermostat

R to W1 circuit is closed and the R to W2 circuit closes, the furnace control CPU will switch the inducer motor

IDM speed from low to high. The high-heat pressure switch relay HPSR is de-energized to close the NC

contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high-heat gas valve solenoid GV-HI is energized. The blower motor BLWM

willswitchtoHIHEATspeedfivesecondsaftertheRto W2circuitcloses.

2.Switching From High-To Low-Heat - If the thermostat R

to W2 circuit opens, and the R to Wl circuit remains closed, the furnace control CPU will switch the inducer

motor IDM speed from high to low. The high-heat pressure switch relay HPSR is energized to open the NC

contact and de-energize the high-heat gas valve solenoid GV-HI. When the inducer motor IDM reduces pressure

sufficiently, the high-heat pressure switch HPS will open. The gas valve solenoid GV-M will remain energized as

long as the low-heat pressure switch LPS remains closed. The blower motor BLWM will switch to LO HEAT speed

five seconds after the R to W2 circuit opens.

COOLING MODE

The thermostat "calls for cooling".

1. Single-Speed Cooling (See Fig. 31 or 32 and 50, 52, or 54 for thermostat connec-

tions.) The thermostat closes R-to-G-and-Y circuits. The R- to-Y circuit starts the outdoor unit, and R-to-G-and-Y/Y2 circuits start the furnace blower motor BLWM on COOL

speed. The electronic air cleaner terminal EAC-1 is ener- gized with 115-v when blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y circuits are opened. The outdoor unit will stop, and furnace blower motor BLWM will continue operating on COOL speed for an additional 90 sec. Jumper Y/Y2 to DHUM to reduce the cool- ing off-delay to 5 seconds. (See Fig. 37.)

2. Two-Speed Cooling and Single-Stage Thermostat (Adaptive Mode)

(See Fig. 31 and 50-57 for thermostat connections.) This furnace can operate a two-speed cooling unit with a

single-stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low-cooling or high-cooling operation. This selection is based upon the stored history of the length of previous cooling period of the single-stage

thermostat.

NOTE: The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to

a call for cooling. (See Fig. 32.) When in place the furnace control CPU can turn on the air conditioning relay ACR to

energize the Y/Y2 terminal and switch the outdoor unit to high-cooling.

The furnace control CPU can start up the cooling unit in either low-or high-cooling. If starting up in low-cooling,

the furnace control CPU determines the low-cooling on-time (from 0 to 20 minutes) which is permitted before

switching to high-cooling. If the power is interrupted, the stored history is erased and

the furnace control CPU will select low-cooling for up to 20 minutes and then energize the air conditioning relay

ACR to energize the Y/Y2 terminal and switch the outdoor unit to high-cooling, as long as the thermostat continues to

call for cooling. Subsequent selection is based on stored history of the thermostat cycle times.

The wall thermostat "calls for cooling", closing the R to G-and-Y circuits. The R to YI circuit starts the outdoor

unit on low-cooling speed, and the R to G-and-Yl circuits starts the furnace blower motor BLWM at low-cool speed

(same speed as LO HEAT). If the furnace control CPU switches from low-cooling to

high-cooling, the furnace control CPU will energize the air conditioning relay ACR. When the air conditioning relay

ACR is energized the R to Yl-and-Y2 circuits switch the outdoor unit to high-cooling speed, and the R to

G-and-Yl-and-Y/Y2 circuits switch the furnace blower motor BLWM to COOL speed.

NOTE: When transitioning from low-cooling to high-cooling the outdoor unit compressor will shutdown for 1 minute while the

BLWM continues to run at low-cool speed (same speed as LO-HEAT) until the outdoor unit compressor comes back on at

high speed.

The electronic air cleaner terminal EAC-1 is energized

with 115 vac whenever the blower motor BLWM is

operating. When the thermostat is satisfied, the R to G-and-Y circuit are opened. The outdoor unit stops, and

the furnace blower BLWM and electronic air cleaner terminal EAC-1 will remain energized for an additional 90

seconds. Jumper YI to DHUM to reduce the cooling off-delay to 5 seconds. (See Fig. 37.)

3. Two-Speed Cooling and Two-Stage Thermostat (See Fig. 32 and Fig. 50-56 for thermostat connections)

NOTE: The ACRDJ must be disconnected to allow thermostat control of the outdoor unit staging. (See Fig. 37.)

The thermostat closes the R to G-and-Yl circuits for low- cooling or closes the R to G-and-Yl-and-Y2 circuits for

high-cooling. The R to YI circuit starts the outdoor unit on low-cooling speed, and the R to G-and-Yl circuit starts the

furnace blower motor BLWM on low-cool speed (same speed as LO-HEAT).

The R-to-Yl-and-Y2 circuits start the outdoor unit on high-cooling speed, and the R to G-and-Y/Y2 circuits start the

furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC-1 is energized with

115 vac whenever the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Yl or R-to

G-and-Yl-and-Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal

EAC-1 will remain energized for an additional 90 seconds. Jumper YI to DHUM to reduce the cooling off-delay to 5

seconds. (See Fig. 37.) THERMIDISTAT MODE

(See Fig. 50-53 for Thermidistat connections.) The dehumidification output, DHUM on the Thermidistat should

be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM input is

activated, which means 24 vac signal is removed from the

DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. Once 24 vac is detected by the furnace control on

the DHUM input, the furnace control operates in Thermidistat mode. If the DHUM input is low or OFF for more than 48 hours,

the furnace control reverts back to non-Thermidistat mode. The cooling operation described above also applies to operation

with a Thermidistat. The exceptions are listed below:

a. When the R to G-and-Yl circuit is closed and there is

a demand for dehumidification, the furnace blower motor BLWM will continue running at low-cool speed (same speed as LO HEAT).

THERMIDISTAT TWO-STAGE SINGLE-SPEED FURNACE HEAT PUMP

FURNACE AIR CONDITIONER

THERMIDISTAT TWO-STAGE SINGLE-SPEED

HEAT STAGE 2 I_-

N/A I_

HEAT STAGE 1 I_-_

COOL STAGE 1 __

FAN _l F_

24 VAC HOT __

DEHUMIDIFY I_0__

24 VAC COMM __

HUMIDIFY [_0__ _

N/A I_

Os%_OO__-l_q -

CONNECT,ONLl_q-

NOTE 11 _1_ 1

F_q

-l_q

-l_--

........___

-l_q

-p_

1 HUM

........ z_ HUMIDIFIER(24VAC) I_L---i

........ _ OUTDOORsENSOR

See notes 2, 5, 7, 10, and 11

........ I

Fig. 50 - Two-Stage Furnace with Single-Speed

Air Conditioner

THERMIDISTAT TWO-STAGE TWO-SPEED

FURNACE AIR CONDITIONER

RVS COOLING_

HEATSTAGE3_

(FURNACEHI)

HEAT STAGE 2 [_

(FURNACE LO)

HEAT/COOL STAGE 1

(COMPRESSOR)

FAN 1_

24 VAC HOT 1_

DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY

N/A [_

i i

NOTE 11

I_ HUM

'_ { HUMIDIFIER ] _ i

(24 VAC)

_{ OUTDOOR _,

SENSOR

CONNECT,ON[_

See notes 1, 2, 4, 6, 7, 9, 10, 11, and 15

A00275

Fig. 52 - Two-Stage Furnace with Single-Speed

Heat Pump (Dual Fuel)

THERMIDISTAT TWO-STAGE TWO-SPEED

FURNACE HEAT PUMP

A00277

HEAT STAGE 2 I_-.

COOL STAGE 1 _.

HEAT STAGE 1 IW_-.

COOL STAGE 2 I_.

FAN I_F.

24 VAC HOT I_F.

DEHUMIDIFY I_0_.

24 VAC COMM I_F.

HUMIDIFY I_MI _.

N/A I_

NOTE 11

NOTE 12

........ HUMIDIFIER ____

-F_q

-I_ ---

-I_F --

FI HUM

OUTDOOR

Os_T_OO__-r_h •

CONNECT,ONLl_h

See notes 2, 5, 8, 10, 11, and 12

Fig. 51 - Two-Stage Furnace with Two-Speed

Air Conditioner

(24 VAC)

SENSOR

RVS COOLING

HEAT/COOL STAGE 1 _.

(COMPRESSOR LO)

HEAT STAGE 3 _.

(FURNACE)

HEAT/COOL STAGE 2 _.

(COMPRESSOR HI)

FAN [_.

24 VAC HOT [_.

DEHUMIDIFY [_

24 VAC COMM I_

HUMIDIFY[_ ............... _!_ HUMIDIFIER(24VAC) k _q! --_i

N/A [_

_ NOTE 12

[_ HUM

CON.EOT,ONL_

See notes1, 2, 3, 4, 6, & 9,10,12,13, and15

A00276

Fig. 53 - Two-Stage Furnace with Two-Speed

Heat Pump (Dual Fuel)

A00278

DUAL FUEL TWO-STAGE SINGLE-SPEED TWO-STAGE TWO-STAGE TWO-SPEED

THERMOSTAT FURNACE HEAT PUMP

THERMOSTAT FURNACE AIR CONDITIONER

RVS COOLING

HEAT STAGE 3

(FURNACE HI)

HEAT STAGE 2

(FURNACE LO)

HEAT/COOL STAGE 1

(COMPRESSOR)

FAN

24 VAC HOT [_

24 VAC COMM

N/A

RVS SENSING [_

°s_T#°°__E?!_

CONNECT,ONLE2_

NOTE 11

C_ E2_

I HUM

OUTDOOR _

SENSOR

See notes 1, 2, 4, 1 t, 14, 15, and t 6

A00279

Fig. 54 - Dual Fuel Thermostat with Two-Stage Furnace and

Single-Speed Heat Pump

DUAL FUEL TWO-STAGE TWO-SPEED

THERMOSTAT FURNACE HEAT PUMP

[_-

NOTE 11

-F q

I q- I q-

NOTE 12

I q- I q-

-i q

-F_ ---

-I q

I q-

I HUM

See notes 2, 11, and 12

A00281

Fig. 56 - Two-Stage Thermostat with Two-Stage Furnace

and Two-Speed Air Conditioner

SINGLE-STAGE TWO-STAGE TWO-SPEED

THERMOSTAT FURNACE AIR CONDITIONER

RVS COOLING

E2_

HEAT/COOL STAGE 1

(COMPRESSOR LO)

HEAT STAGE 3

(FURNACE)

HEAT/COOL STAGE 2

(COMPRESSOR HI)

FAN

24 VAC HOT [_

24 MAC COMM

N/A [_

RVS SENSING [_

NOTE 12

C_ E2_

I HUM

OUTDOOR _jZ_,

SENSOR

IW31

CONNECT'ONi_

See notes I, 2, 3, 4, I2, 13, 14, 15, and I7

A00280

Fig. 55 - Dual Fuel Thermostat with Two-Stage Furnace and

Two-Speed Heat Pump

-I q

I HUM

See note 2

A00262

Fig. 57 - Single-Stage Thermostat with Two-Stage Furnace

and Two-Speed Air Conditioner

NOTES FOR FIG. 50-57:

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

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

3. Select the "ZONE" position on the two-speed heat pump control.

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

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

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

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

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

9. Configuration Option No. 10 "Dual Fuel Selection" must be turned ON in all dual fuel applications.

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

11. Optional connection. If wire is connected, dip switch No. 1 on furnace control should be set in ON position to allow Thermidistat/ Thermostat to control furnace staging.

12. Optional connection. If wire is connected, ACRDJ jumper on furnace control should be removed to allow Thermidistat/Thermostat to control outdoor unit staging.

13. Furnace must control its own high-stage heating operation via furnace control algorithm. This is factory default.

14. The RVS Sensing terminal "L" should not be connected. This is internally used to sense defrost operation.

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

16. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single-speed compressor operation. This is factory default.

17. Dip switch D on Dual Fuel Thermostat should be set in ON position for two-speed compressor operation.

b.WhentheRtoG-andY/Y2circuitisclosedandthere

isademandfordehumidification,thefurnaceblower motorBLWMwilldroptheblowerspeedfromCOOL

toHIHEATforamaximumof10minutesbefore revertingbacktoCOOLspeed.If thereisstilla

demandfordehumidificationafter20minutes,the furnacecontrolCPUwilldroptheblowerspeedback toHIHEATspeed.Thisalternating10-minutecycle

willcontinueaslongasthereisacallforcooling.

c.Whenthe:'callforcooling"issatisfiedandthereisa

demandfordehumidification,thecoolingblower-off delayisdecreasedfrom90secondsto5seconds.

CONTINUOUS BLOWER MODE

When the R to G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous-blower speed (can be

set to LO HEAT, HI HEAT, or COOL speed). Factory default is LO HEAT speed. Terminal EAC-1 is energized as long as the blower motor BLWM is energized.

During a call for heat, the blower BLWM will stop during igniter warm-up (17 seconds), ignition (7 seconds), and blower-ON

delay (66 seconds), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at LO HEAT or HI HEAT speed respectively.

In high-heat, the furnace control CPU will hold the blower motor BLWM at HI HEAT speed during the selected blower-OFF delay

period before reverting to continuous-blower speed. When the thermostat :'calls for low-cooling", the blower motor

BLWM will switch to operate at low-cool speed (same speed as LO HEAT). When the thermostat is satisfied, the blower motor

BLWM will operate an additional 90 seconds on low-cool speed before reverting back to continuous-blower speed.

When the thermostat :'calls for high-cooling", the blower motor BLWM will operate at COOL speed. When the thermostat is

satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous-blower speed.

When the R to G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other

function requires blower motor BLWM operation. Continuous Blower Speed Selection from Thermostat - To

select different continuous-blower speeds from the room thermostat, momentarily turn off the FAN switch or push-button

on the room thermostat for 1 - 3 seconds after the blower motor BLWM is operating. The furnace control CPU will shift the

continuous- blower speed from the factory setting of LO HEAT to HI HEAT speed. Momentarily turning off the FAN switch again

at the thermostat will shift the continuous-blower speed from HI HEAT to COOL. Repeating the procedure will shift the continuous-blower speed from COOL to LO HEAT speed. The

selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption.

HEAT PUMP (See Fig. 50 C-F for thermostat connections)

When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower

off times during demand defrost cycles. When the R to W/Wl-and-Y1 or R to W/Wl-and-Yl-and-G circuits are

energized, the furnace control CPU will switch to or turn on the blower motor BLWM at low cool speed (same speed as LO HEAT), and begin a low-heat cycle. The blower motor BLWM

will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at LO HEAT speed. When the

W/W1 input signal disappears, the furnace control begins a normal inducer post-purge period and the blower remains running at LO HEAT speed. If the R-to-W/Wl-and-Yl-and-G signals

disappear at the same time, the blower motor BLWM will remain

on for the selected blower-OFF delay period. If the R-to W/Wl-and-Y1 signals disappear, leaving the G signal, the blower

motor BLWM will remain on for the selected blower-OFF delay period then switch to continuous-blower speed. When the R-to W/WI-and-Y/Y2, R-to-W/Wl-and-

Y/Y2-and-G, R-to W/Wl-and-Yl-and-Y/Y2, or R-to-W/W1-

and-Yl-and- Y/Y2-and-G circuits are energized the furnace

control CPU will switch to or turn on the blower motor BLWM

at COOL speed, and begin a high-heat cycle. The blower motor

BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HI HEAT

speed. When the W/W1 input signal disappears, the furnace control begins a normal inducer post-purge period and the

blower switches to COOL speed after a 3 second delay. If the R-to-W/Wl-and-Y/Y2-and-G or R-to W/Wl-and-Yl-and-

Y/Y2-and-G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower-OFF

delay period. If the R-to W/WI-and-Y/Y2 or R-to-W/Wl-and-Yl-and-Y/Y2 signals disappear, leaving the G

signal, the blower motor BLWM will remain on for the selected blower- OFF delay period then switch to continuous- blower speed.

COMPONENT SELF-TEST

NOTE: The furnace control component test allows all components to run for a short time; except the gas valve and humidifier terminal HUM are not energized for safety reasons. The EAC-1 terminal is energized when blower is energized. This feature helps diagnose a system problem in case of a component failure. The component test feature will not operate if any thermostat signal is present at control and not until all time delays

are completed.

To Begin Component Self-Test:

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in electrical shock,

personal injury, or death. Blower access panel door switch opens 115-v power to control

board. No component operation can occur. Caution must be taken when manually closing this switch for service purposes.

1. Remove blower access door.

2. Disconnect thermostat R lead from furnace control.

3. Manually close blower door switch.

4. For approximately 2 sec, short (jumper) the COM-24V terminal on control to the TEST/TWIN 3/16-in. (5 mm)

quick- connect terminal on control until LED turns off. Remove jumper from terminals. (See Fig. 37.)

NOTE: If TEST/TWIN and COM-24V terminals are jumpered longer than 2 sec, LED will flash rapidly and ignore component test request.

Component test sequence for 2-stage furnace is as follows:

a. LED will display previous status code 4 times.

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

run until Step g of component test sequence.

c. Hot surface igniter is energized for 15 sec, then off. d. Blower motor operates on LO-HEAT speed for 10 sec.

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

f. Blower motor operates on COOL speed for 10 sec.

g. Inducer motor goes to low-speed for 10 sec, then stops.

5. Reconnect R lead to furnace control, remove tape from

blower door switch, and re-install blower door.

6.Operatefurnaceperinstructiononouterdoor.

7.Verifyfurnaceshutdownbyloweringthermostatsetting belowroomtemperature.

8.Verifythatfurnacerestartsbyraisingthermostatsetting aboveroomtemperature.

OPERATE FURNACE

Follow procedures on operating instructions label attached to furnace.

FURNACE RESTART

With furnace operating, set thermostat below room temperature and observe that furnace goes off. Set thermostat above room temperature and observe that furnace restarts.

Step 5 - Adjustments SET GAS INPUT RATE

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M).

In the U.S.A., the input ratings for altitudes above 2000 fl (610 M) must be reduced by 2 percent for each 1000 ft. (305 M) above

sea level. In Canada, the input ratings must be derated by 5 percent for

altitudes of 2001 fi to 4500 fl (610 to 1372 M)above sea level. Adjust manifold pressure to obtain input rate.

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 gas heat value (at installed altitude)

from local gas supplier.

b. Obtain average gas specific gravity from local gas

supplier.

c. Verify furnace model and size. Table 15 can only be

used for model 58MTB furnaces with heating inputs of 20,000/13,000 (High/Low) Btuh per burner.

d. Find installation altitude in Table 15.

NOTE: For Canada altitudes of 2001 to 4500 ft. (610 to 1372 M), use U.S.A. altitudes of 2001 to 3000 ft (610 to 914 M) in

Table 15.

e. Find closest natural gas heat value and specific gravity

on Table 15.

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 (0-610 M) altitude using Table 15)

Heating value = 1050 Btu/cu fi

Specific gravity = 0.62

Therefore: Orifice No. 45 Manifold pressure 3.6-in. wc for high heat

1.5-in. wc for low heat * 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.

g. Check and verify burner orifice size in furnace.

NEVER ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY.

2. Adjust Manifold Pressure To Obtain Input Rate.

a. Remove burner enclosure front.

NOTE: Manifold pressure MUST always be measured with burner enclosure front REMOVED.

b. Remove regulator seal caps that conceal adjustment

screws for low-and high-heat gas valve pressure regulators. (See Fig. 58.)

c. Move setup switch SW-1 on control center to ON

position. This keeps furnace locked in low-heat operation.

d. Jumper R and W/WI thermostat connections on

control to start furnace.

e. Turn low-heat adjusting screw (3/32 hex Allen wrench)

counterclockwise (out) to decrease input rate or clock-wise (in) to increase input rate.

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

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

UNIT DAMAGE HAZARD

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

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.

f. Move setup switch SW-1 to OFF position after

completing low-heat adjustment.

g. Jumper R and W1 and W2 thermostat connections on

control. (See Fig. 37.) This keeps furnace locked in high-heat operation.

h. Turn high-heat adjusting screw (3/32 hex Allen

wrench) counterclockwise (out) to decrease input rate or clockwise (in) to increase rate.

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

3.2-in. wc or more than 3.8-in. wc for natural gas. If manifold pressure is outside this range, change main burner orifices to obtain pressure in this range.

i. When correct input is obtained, replace caps that

conceal gas valve regulator adjustment screws. Main burner flame should be clear blue, almost transparent.

(See Fig. 59.)

j. Remove jumper R-to-W1 and W2.

UNIT DAMAGE HAZARD Failure to follow this caution may result in component damage

due to flame impingement of burners and heat exchangers. DO NOT redrill orifices. Improper drilling (burrs,

out-of-round holes, etc.) can cause excessive burner noise and misdirection of burner flames. (See Fig. 60.)

Table15 - Model 58MTB Orifice Size and High/Low-Heat Manifold Pressures for Correct Inputs

for Use with 060 Through 120 Size Furnaces Only

(Tabulated Data Based on 20,000/13,000 Btuh per Burner,

Derated 2 Percent for Each 1000 ft (305 M)Above Sea Level)*

ALTITUDE

RANGE

FT (a)

0 to

2000

(0 to

61O)

derate

ALTITUDE

RANGE

FT (a)

U,S,

Altitudes

2001

to 3000

(610 to

914)

Canada

Altitudes

2001 to

4500

(610 to

1371) 5%

derate

ALTITUDE

RANGE

FT (a)

_>, 3001 to

4000

• (914 to

,_. 1219)

::5 derate

Orifice numbers shown in shading are factory installed.

NOTE: Percents of derate are based on midpoints of U=S=altitude ranges.

AVG GAS

HEAT VALUE (BTU/CU FT)

850 875

900 925

950 975

1000 1025

1050 1075

1100

AVG GAS

HEAT VALUE (BTU/CU FT)

775 800

825 850

875 900

925 950

975

1000 1025

AVG GAS

HEAT VALUE (BTU/CU FT)

750 775

800 825

850 875

900 925

950 975

1000

0.58 0.60 0.62 0.64 0.66

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

no. Pressure no. Pressure no. Pressure no. Pressure no. Pressure

43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/12.6 42 3.2/1.4

44 3.7/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 44 3.5/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5

44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

45 3.7/1.6 45 3.8/1.6 44 3.2/1.4 44 3.4/1.4 44 3.5/1.5 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4

45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5

47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.4/1.4 45 3.5/1.5

0.58 0.60

Orifice Manifold Orifice Manifold Orifice

no. Pressure no. Pressure no.

43 3.8/1.6 42 3.2/1.4 42 43 3.5/1.5 43 3.7/1.5 43

44 3.8/1.6 43 3.4/1.5 43 44 3.6/1.5 44 3.7/1.6 44

44 3.4/1.4 44 3.5/1.5 44 44 3.2/1.4 44 3.3/1.4 44

45 3.7/1.5 45 3.8/1.6 44 45 3.5/1.5 45 3.6/1.5 45

45 3.3/1.4 45 3.4/1.4 45 47 3.7/1.6 45 3.2/1.4 45

47 3.6/1.5 47 3.7/1.6 45

0.58

Orifice Manifold Orifice

no. Pressure no.

43 3.7/1.6 43 43 3.5/1.5 43

44 3.7/1.6 43 44 3.5/1.5 44

44 3.3/1.4 44 45 3.8/1.6 44

45 3.6/1.5 45 45 3.4/1.4 45

45 3.2/1.4 45 47 3.6/1.5 45

47 3.5/1.5 47

SPECIFIC GRAVITY OF NATURAL GAS

0.62 0.64 Manifold Orifice Manifold Orifice

Pressure no. Pressure no.

3.3/1.4 42 3.4/1.4 42

3.8/1.6 42 3.2/1.4 42

3.6/1.5 43 3.7/1.5 43

3.8/1.6 43 3.5/1.5 43

3.6/1.5 44 3.7/1.6 43

3.4/1.4 44 3.5/1.5 44

3.2/1.4 44 3.3/1.4 44

3.7/1.6 45 3.8/1.6 44

3.5/1.5 45 3.6/1.5 45

3.4/1.4 45 3.5/1.5 45

3.2/1.3 45 3.3/1.4 45

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64 Manifold Orifice Manifold Orifice Manifold Orifice

Pressure no. Pressure no. Pressure no.

3.8/1.6 42 3.3/1.4 42 3.4/1.4 42

3.6/1.5 43 3.7/1.6 43 3.8/1.6 42

3.4/1.4 43 3.5/1.5 43 3.6/1.5 43

3.6/1.5 44 3.8/1.6 43 3.4/1.4 43

3.4/1.4 44 3.5/1.5 44 3.7/1.5 44

3.2/1.4 44 3.3/1.4 44 3.5/1.5 44

3.7/1.6 45 3.8/1.6 44 3.3/1.4 44

3.5/1.5 45 3.6/1.5 45 3.7/1.6 44

3.3/1.4 45 3.4/1.5 45 3.5/1.5 45

3.2/1.3 45 3.3/1.4 45 3.4/1.4 45

3.6/1.5 45 3.7/1.6 45 3.2/1.4 45

0.66

Manifold Pressure

3.5/1.5

3.3/1.4

3.8/1.6

3.6/1.5

3.4/1.4

3.6/1.5

3.4/1.5

3.3/1.4

3.8/1.6

3.6/1.5

3.4/1.4

0.66

Manifold

Pressure

3.5/1.5

3.2/1.4

3.7/1.6

3.5/1.5

3.8/1.6

3.6/1.5

3.4/1.4

3.2/1.3

3.7/1.5

3.5/1.5

3.3/1.4

Table 15 - Model 58MTB Orifice Size and High/Low-Heat Manifold Pressures for Correct Inputs (Continued)

for Use With 060 Through 120 Size Furnaces Only

(Tabulated Data Based on 20,000/13,000 Btuh per Burner;

Derated 2 Percent for Each 1000 ft (305 M) Above Sea Level)*

AVG GAS

HEAT

VALUE

(BTU/CU FT)

725 75O

775 8OO 825

85O 875

9OO 925

95O

AVG GAS

HEAT

VALUE

(BTU/CU FT)

7OO

725

75O

775 8OO

825 85O

875 9OO

925 95O

975

1000

AVG GAS

HEAT

VALUE

(BTU/CU FT)

65O 675

7OO

725

75O

775 8OO

825 85O 875

0.58

Orifice Manifold

no. Pressure

43 3.7/1.5 44 3.4/1.4

44 3.7/1.6 44 3.51.5

44 3.2/1.4 45 3.5/1.5

45 3.3/1.4 45 3.3/1.4

47 3.7/1.6 47 3.5/1.5

0.58

Orifice Manifold

no. Pressure

43 3.6/1.5 43 3.4/1.4

44 3.6/1.5 44 3.4/1.4

44 3.2/1.3 45 3.6/1.5

45 3.4/1.4 45 3.2/1.4

47 3.6/1.5 47 3.4/1.4

48 3.7/1.6 48 3.5/1.5

48 3.3/1.4

0.58

Orifice Manifold

no. Pressure

42 3.2/1.3 43 3.6/1.5

44 3.8/1.6 44 3.6/1.5

44 3.3/1.4 45 3.8/1.6

45 3.5/1.5 45 3.3/1.4

47 3.7/1.6 47 3.5/1.5

0.60

Orifice Manifold

no. Pressure 43 3.8/1.6

43 3.5/1.5 44 3.8/1.6

44 3.6/1.5 44 3.4/1.4 45 3.8/1.6

45 3.6/1.5 45 3.4/1.4

45 3.2/1.4 47 3.6/1.5

0.60

Orifice

no.

43 43

44 44

44 45

45 45 47

47 48

48 48

0.60

Orifice

no.

42 43 43

44 44

44 45

45 45 47

ALTITUDE

RANGE

FT (a)

4001

>, to

5000

(1219

4 to

_,, 1524)

"_ 9%

derate

ALTITUDE

RANGE

FT (a)

5001

>, to

"_ 6000 0 (1524

_J 1829) :5 11%

derate

ALTITUDE

RANGE

FT (a)

6001

7000

• (1829

_. to

_. 2134)

13%

derate

Orifice numbers shown in shading are factory installed.

NOTE: Percents of derate are based on midpoints of U.S. altitude ranges.

SPECIFIC GRAVITY OF NATURAL GAS

0.62

Orifice Manifold

no. Pressure

42 3.2/1.4 43 3.7/1.5

43 3.4/1.4 44 3.7/1.6

44 3.5/1.5 44 3.3/1.4

45 3.7/1.6 45 3.5/1.5

45 3.3/1.4 45 3.2/1.3

Orifice Manifold Orifice Manifold

no. Pressure no. Pressure 42 3.3/1.4 42 3.4/1.4

43 3.8/1.6 42 3.2/1.4 43 3.5/1.5 43 3.7/1.5

44 3.8/1.6 43 3.4/1.4 44 3.6/1.5 44 3.7/1.6 44 3.4/1.4 44 3.5/1.5

44 3.2/1.3 44 3.3/1.4 45 3.6/1.5 45 3.8/1.6

45 3.4/1.5 45 3.6/1.5 45 3.3/1.4 45 3.4/1.4

SPECIFIC GRAVITY OF NATURAL

0.62

Manifold Orifice

Pressure no.

3.7/1.6 42

3.5/1.5 43

3.7/1.6 43

3.5/1.5 44

3.3/1.5 44

3.7/1.6 44

3.5/1.5 45

3.3/1.4 45

3.7/1.6 45

3.5/1.5 47

3.8/1.6 47

3.6/1.5 48

3.5/1.5 48

Manifold Orifice

Pressure no.

3.2/1.3 42

3.6/1.5 43

3.4/1.4 43

3.6/1.5 44

3.4/1.4 44

3.2/1.4 44

3.6/1.5 45

3.4/1.5 45

3.3/1.4 45

3.7/1.5 45

3.5/1.5 47

3.8/1.6 47

3.6/1.5 48

SPECIFIC GRAVITY OF NATURAL

0.62

Manifold Orifice

Pressure no.

3.3/1.4 42

3.7/1.6 43

3.4/1.5 43

3.7/1.6 44

3.4/1.5 44

3.2/1.4 44

3.7/1.5 45

3.4/1.5 45

3.2/1.4 45

3.6/1.5 45

Manifold Orifice

Pressure no.

3.4/1.4 42

3.8/1.6 42

3.6/1.5 43

3.8/1.6 43

3.6/1.5 44

3.3/1.4 44

3.8/1.6 44

3.6/1.5 45

3.4/1.4 45

3.2/1.3 45

0.64 0.66

GAS

0.64 Manifold

Pressure

3.3/1.4

3.7/1.6

3.5/1.5

3.7/1.6

3.5/1.5

3.3/1.4

3.8/1.6

3.6/1.5

3.4/1.4

3.2/1.3

3.6/1.5

3.4/1.4

3.7/1.6

Or_ce

no.

42 43

43 43

44 44

44 45 45

45 47

47 48

GAS

0.64 Manifold

Pressure

3.5/1.5

3.2/1.4

3.7/1.6

3.4/1.4

3.7/1.6

3.4/1.5

3.2/1.4

3.7/1.6

3.5/1.5

3.3/1.4

Or_ce

no.

42 42 43

43 44

44 44

45 45 45

0.66

Manifold Pressure

3.4/1.4

3.8/1.6

3.6/1.5

3.4/1.4

3.6/1.5

3.4/1.4

3.2/1.4

3.7/1.5

3.5/1.5

3.3/1.4

3.7/1.6

3.5/1.5

3.8/1.6

0.66

Manifold Pressure

3.6/1.6

3.3/1.4

3.8/1.6

3.5/1.5

3.8/1.6

3.5/1.5

3.3/1.4

3.8/1.6

3.6/1.5

3.4/1.4

Table 15 - Model 58MTB Orifice Size and High/Low-Heat Manifold Pressures for Correct Inputs (Continued)

for Use With 060 Through 120 Size Furnaces Only

(Tabulated Data Based on 20,000/13,000 Btuh per Burner;

Derated 2 Percent for Each 1000 ft (305 M) Above Sea Level)*

AVG GAS

HEAT

VALUE

(BTU/CUFT)

625 65O 675

7OO

725

75O

775

8OO 825 85O

AVG GAS

HEAT

VALUE

(BTU/CUFT)

6OO 625 65O

675

7OO

725

75O

775

8OO

AVG GAS

HEAT

VALUE

(BTU/CUFT)

575 6OO

625 65O

675

7OO

725

75O

775

0.58 0.60 0.62 0.64 0.66

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

no. Pressure no. Pressure no. Pressure no. Pressure no. Pressure

43 3.8/1.6 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5 42 3.6/1.5 43 3.5/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

44 3.8/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 44 3.5/1.5 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5

44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5

45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6

47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 47 3.4/1.4 47 3.5/1.5 47 3.7/1.5 45 3.2/1.3 45 3.3/1.4

0.58 0.60 0.62 0.64 0.66

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

no. Pressure no. Pressure no. Pressure no. Pressure no. Pressure

43 3.8/1.6 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5 42 3.6/1.5 43 3.5/1.5 43 3.6/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

44 3.7/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.5

44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.6/1.5 44 3.7/1.6 45 3.6/1.5 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4

45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.8/1.6 44 3.2/1.4 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5

47 3.6/1.5 47 3.7/1.6 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4

0.58 0.60 0.62 0.64 0.66

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

no. Pressure no. Pressure no. Pressure no. Pressure no. Pressure

43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.3/1.5 42 3.6/1.5 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 42 3.2/1.3 42 3.3/1.4

44 3.7/1.6 44 3.8/1.6 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 44 3.4/1.4 44 3.5/1.5 44 3.7/1.5 44 3.8/1.6 43 3.4/1.4 44 3.8/1.6 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6

47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.5/1.5 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4

ALTITUDE

RANGE FT (a)

7001

8000

(2134 to

2438)

:5 15%

derate

ALTITUDE

RANGE FT (a)

Altitudes

8001

to 9000 (2438 to

2743)

:5 17%

derate

ALTITUDE

RANGE FT (a)

9001

_>, to

10000

• (2743

<. to cn 3048) :5 19%

derate

*Orifice numbers shown in shading are factory installed. NOTE: Percents of derate are based on midpoints of U.S. altitude ranges.

SPECIFIC GRAVITY OF NATURAL GAS

SPECIFICGRAVITYOF NATURALGAS

)FF

SWITCH

" INLET

PRESSURE

MANIFOLD

PRESSURE

TAP

Fig. 58 - Redundant Automatic Gas Control Valve

BURNER FLAME "-_

f_," V BURNER

LOW-FIRE ADJUSTMENT ALLEN SCREW

(UNDER CAP)

HIGH-FIRE ADJUSTMENT ALLEN SCREW

(UNDER CAP)

:;i:"7

MAN IFOLD J

Fig. 59 - Burner Flame

A97358

A89020

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 2 percent derate for each 1000 ft above sea level. See Example and Table 16 for derate

multiplier factor.

EXAMPLE:

Furnace Input Rate X Derate = Furnace Input Rate

NOTE: Clocking gas input rate MUST always be performed with the burner box cover INSTALLED.

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

adjustment of gas heating value.

100,000 Btuh input furnace installed at 4300 ft.

at Sea Level Multiplier at Installation

Factor Altitude

100,000 X 0.91 = 91,000

CANADA

At installation altitudes from 2001 to 4500 ft, this furnace must be derated 5 percent by an authorized Gas

Conversion Station or Dealer. To determine correct

input rate for altitude, see example above and use 0.95

as derate multiplier factor.

b. Reinstall burner box cover.

c. Check that gas valve adjustment caps are in place for

proper input to be clocked.

d. Obtain yearly heat value average for local gas supply.

e. Check and verify orifice size in furnace. NEVER

ASSUME THE ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

f. Turn off all other gas appliances and pilots.

g. Move setup switch SW-1 to ON position. This keeps

furnace locked in low-heat operation.

h. Jumper R-to-W/W1.

i. Let furnace run for 3 minutes in low-heat operation.

j. Measure time (in sec) for gas meter to complete 1

revolution. Note reading.

k. Refer to Table 17 for cubic ft of gas per hr.

1. Multiply gas rate cu ft/hr by heating value (Btu/cu ft).

In. Move setup switch SW-1 to OFF position and jumper

R and W1 and W2 thermostat connections. This keeps furnace locked in high-heat operation. Repeat items 'i'

through '1' for high-heat operation.

ORIFICE

_ BURNER

Fig. 60 - Burner Orifice

3. Verify Natural Gas Input Rate By Clocking Gas Meter.

A93059

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 17) Btu heating input = 103 X 975 = 100,425 Btuh. In this example, the orifice size and manifold pressure adjustment

is within ---2percent of the furnace input rate.

NOTE: Measured gas inputs (high-heat and low-heat) must be within ---2 percent of that stated on furnace rating plate when

installed at sea level or derated per that stated above when installed at higher altitudes.

n. Remove jumper across R, W/W1, and W2 thermostat

connections to terminate call for heat.

Table 16- Altitude Derate Multiplier for USA.

ALTITUDE

FT (i)

0-2000

(0-610)

2001-3000

(610-914) 3001-4000 (914-1219)

4001-5000

(1219-1524)

5001-6000

1524-1829)

6001-7000

(1829-2134)

7001-8000

(2134-2438)

8001-9000

(2438-2743) 9001-10,000

(2743-3048)

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

SECONDS

FOR1 FOR 1

REVOLUTION 1 2 5 REVOLUTION 1 2 5

10 360 720 1800 50 72 144 360 11 327 555 1536 51 71 141 355

12 300 600 1500 52 69 138 346

13 277 555 1385 53 68 136 340

14 257 514 1286 54 67 133 333

15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321

17 212 424 1059 57 63 126 316

18 200 400 1000 58 62 124 310

19 189 379 947 59 61 122 305

20 180 360 900 60 60 120 300

21 171 343 857 62 58 116 290

22 164 327 818 64 56 112 281

23 157 313 783 66 54 109 273

24 150 300 750 68 53 106 265

25 144 286 720 70 51 103 257

26 138 277 692 72 50 100 250

27 133 267 667 74 48 97 243

28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231

30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220

32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209

34 106 212 529 88 41 82 205

35 103 206 514 90 40 80 200

36 100 200 500 92 39 78 196

37 97 195 486 94 38 76 192

38 95 189 474 96 38 75 188

39 92 185 462 98 37 74 184

40 90 180 450 100 36 72 180

41 88 176 439 102 35 71 178 42 88 172 429 104 35 69 173

43 84 167 419 106 34 68 170

44 82 164 409 108 33 67 167

45 80 160 400 110 33 65 164

46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155

48 75 150 375 120 30 80 150

49 73 147 367 124 29 58 145

PERCENT OF

DERATE

4-8

8-8

8-10

10-12

12-14

14-16

16-18

18-20

DERATE MULTIPLIER

FACTOR*

1.00

0.95

0.93

0.91

0.89

0.87

0.85

0.83

0.81

Table 17 - Gas Rate (CU FT/HR)

SIZE OFTEST SIZE OF TEST

DIAL SECONDS DIAL

Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft

SET TEMPERATURE RISE

UNIT DAMAGE HAZARD Failure to follow this caution may result in overheating the

heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate.

Temperature rise must be within limits specified on furnace rating plate. Recommended operation is at midpoint of rise

range or slightly above.

Place SW-1 in ON position. Jumper R to W/W1 and W2 to check high-gas-heat temperature rise. To check low-gas-heat temperature rise, remove jumper to W2. Determine air

temperature rise for both high and low gas heat. Do not exceed temperature rise ranges specified on unit rating plate for high and

low gas heat. This furnace must operate within the temperature rise ranges

specified on the furnace rating plate. Determine the air temperature as follows:

a. Place duct thermometers in return and supply ducts as

close to furnace as possible. Be sure thermometers do not "see" heat exchangers so that radiant heat does not

affect thermometer readings. This is particularly

important with straight run ducts.

b. When thermometer readings stabilize, subtract

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

If the temperature rise is outside this range, check the following:

a. Gas input for low-and high gas heat operation. b. Derate for altitude if applicable. c. Return and supply ducts for excessive restrictions

causing static pressures greater than 0.50-in. wc.

d. Adjust temperature rise by adjusting blower speed.

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

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury

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

For high-heat, the following connections can be made at HI HEAT on control:

a. Med-high (Yellow) b. Med (Orange) - Available only on 5-speed motors.

Factory setting for these motors.

c. Med-Low(Blue) - Do NOT use for HI GAS-HEAT

on 80K & 120K Btuh input models. Factory setting for 4-speed motors.

UNITDAMAGE HAZARD

Failure to follow this caution may result in damage to the heat exchangers due to over temperature or condensate corrosion.

1. NEVER connect Low Speed (Red) wire to "HI HEAT".

2. Do NOT connect Medium Low Speed (Blue) wire to

"HI-HEAT" on 80,000 Btuh and 120,000 Btuh input model sizes.

Table 18 - Speed Selection

LEAD COLOR SPEED AS SHIPPED

White Common COM

Black High Cool

Yellow Med - High SPARE

Orangef Med High-Gas Heat

Blue Med- Low Spare/High-Gas Heat

Red Low* Low-Gas Heat

* Continuous blower speed

1-Available on 5-speed blowers only

For low-heat, the following connections can be made at LO- HEAT on control:

a. Med (Orange) - Available only on 5-speed motors

b. Med-Low (Blue)

c. Low (RED) - Factory setting.

To change blower motor speed selections for heating mode, remove blower motor lead from control HI-HEAT terminal. (See Fig. 37.) Select desired blower motor speed lead from one of the

other motor leads and relocate it to HI-HEAT terminal. See Table 18 for lead color identification. Reconnect original lead on

SPARE terminal. Follow this same procedure for proper selection of LO-HEAT and COOL speed selection.

Set Blower Off Delay

a. Remove Blower Access Door if installed.

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

blower off delay. See Table 11 and 12 or Fig. 36 and 37.

ADJUST BLOWER OFF DELAY (HEAT MODE) If desired, the main blower off time delay period may be

lengthened or shortened when operating in the heating mode to provide greater comfort. See Table 11 for position of switches

and Fig. 36 or 37 for location of switches on control center. SET THERMOSTAT HEAT ANTICIPATOR

When using a nonelectronic thermostat, the thermostat heat-anticipator must be set to match the amp draw of the electrical components in R-W/W1 circuit. Accurate amp

draw readings can be obtained at thermostat subbase terminals R and W.

Fig. 61 illustrates an easy method of obtaining actual amp draw. The amp reading should be taken after blower motor has started

and furnace is operating in low heat. To operate furnace in low-heat, first move SW-1 to ON position, then connect ammeter wires as shown in Fig. 61. The thermostat anticipator should

NOT be in the circuit while measuring current. If thermostat has no subbase, the thermostat must be disconnected from R and

W/W1 wires during current measurement Return SW-1 to final desired location after completing the reading.

See thermostat manufacturer's instructions for adjusting heat anticipator and for varying heating cycle length.

When using an electronic thermostat, set cycle rate for 3 cycles per hour.

Step 6 - Check Safety Controls

This section covers the safety controls that must be checked before the installation is complete. The flame sensor, gas valve,

and pressure switch were all checked in the Start-up procedure

section as part of normal operation.

1. Check Primary Limit Control This control shuts off gas 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.

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED

HOOK-AROUND

VO LT/AM METER

10TURNS

FROM UNIT 24-VOLT

TERMINAL BLOCK

EXAMPLE:

5.0 AMPS ON AMMETER - 0.5 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS

Fig. 61 - Amp Draw Check with Ammeter

Check Pressure Switch This control proves operation of draft inducer. Check switch

operation as follows:

a. Turn off 115-v power to furnace.

b. Remove outer furnace door and disconnect inducer

motor lead wires from wire harness.

c. Turn on 115-v power to furnace. d. Set thermostat to "call for heat" and wait 1 minute.

When pressure switch is functioning properly, hot surface igniter should not glow, and status code LED

flashes a Status Code 32. 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.

e. Turn off 115-v power to furnace.

f. Reconnect inducer motor leads, reinstall main furnace

door, and turn on 115-v power supply.

A80201

CHECKLIST

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

2. Check SW-1 through SW-3 after completing installation to ensure desired settings for thermostat type (SW-1) and

blower-OFF delay (SW-2 and SW-3).

3. Verify flame rollout manual reset switch has continuity.

4. Verify that blower and outer doors are properly installed.

5. Cycle test furnace with room thermostat.

6. Check operation of accessories per instructions.

7. Review User's Guide with owner.

8. Leave literature packet near furnace.

CHECKLISTmDIRECT VENT (2-PIPE) INSTALLATION

LOAD CALCULATION Condensate Drain

manufacturer's

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

COMBUSTION AIR 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

Unit Level or Pitched Forward

Internal Tubing Connections Free of Kinks and Traps

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

CHECKLIST - NON DIRECT VENT (1-PIPE) INSTALLATION

LOAD CALCULATION

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

VENT PIPING

Termination Location

Roof or Sidewall

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

Condensate Drain

Unit Level or Pitched Forward

Internal Tubing Connections Free of Kinks and Traps

External Drain Connection Leak Tight 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

and

Primary Limit Pressure Switch

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

Catalog No: 58MTB-2SI

Replaces: 58MTB- 1St

Carrier 58MTB100F10116, 58MTB100F10120, 58MTB120F10120, 58MTB060F10112, 58MTB080F10112 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual