Carrier 58MVB120F10120, 58MVB060F10114, 58MVB100F10120, 58MVB080F10120, 58MVB080F10116 Installation Guide

Installation Instruction

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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,

®

to the Expertg

iso 9001:2000

Special Venting Requirements for Installations in Canada

Installation in Canada nmst 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) '_, 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

L'installation faite au Canada doit se conformer aux exigences du
code CSA B149. Ce syst_me de ventillation dolt 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 g_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) '_, 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.

L'op_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 L'acceptation du standard Canadien CSA B419 est

directement reli_ _ 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, "GAS 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 - GAS 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.

TABLEOFCONTENTS......................... PAGE

IMPORTANT ..................................... 2

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

CODES AND STANDARDS ......................... 6

INTRODUCTION .................................. 7

APPLICATIONS ................................... 7

LOCATION ...................................... 15

INSTALLATION .................................. 20

START-UR ADJUSTMENTS AND SAFETY CHECK ... 43

4_ _ HOR/Z?NTA I HORIIZGOHNTAL_ 0

AIRFLOW AIRFLOW

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AIRFLOW

Fig. 1 - Multipoise Orientations

A93041

FURNACE RELIABILITY HAZARD

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.

Improper 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-BI49.1 and .2 Natural Gas and Propane

Installation Codes, and Canadian Electrical Code CSA C22A

Recognize safety information. This is the safety-alert symbol Z_
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.

g

SAFETY CONSIDERATIONS

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous
operation, serious iniury, 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 iniury 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.

ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental

polution.
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.

2 IN (51 mm) COMBUSTION

!_lN(13mm)

GAS CONN

2IN
VENTOONN

]_INDIA(13mm)

1

(576 mm)

(684 ram)

664 ram)

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AIRFLOW

A_ (14 ram)

TYP

(829 mm)

(21 ram)

TRAP LOCATION
(DOWNFLOW &

HORIZONTAL LEFT)

;a IN DIA (22ram)

_- POWER CONN

ACCESSORY
POWER ENTRY

LOCATION
(ALTERNATE

UPFLOW)

DRAIN TRAP ]

8_6' 17 _16"

TYP (439

(240 ram)

DRAIN LOCATION 11'!6"_ _ 1'16"
(UPFLOW) (17 ram) (17 ram)

OUTLET

[]_] HORIZONTAL RIGHT) "_

INLET

_E_

28 i_, (724 mm)

_26 s,i6" (684 mm)

2614" (667 ram)

22 _' (567 mm)_

'l:',r,, T

CONDENSATE DRAIN

(DOWNFLOW &

OR ALTERNATE

!_z IN D]A GAS CONN

1

30 %" _+_ 2 N _f/T,r,l_5 39 7S"

(......... ) f_ _'_"- _ENT_ONN (......... )

1

l'T' ,' ,,,,,.......1

DRAIN LOCATION / _ 22 1i' TYP _1 _g_6" (11 mm)

(UPFLOW) (o65 ram)

............... J _.__TTu#_1_47___lI...... ,,( ........ )

FOR NORIZONTAL

HANGING (614 ram)

_19"(483 ram) _ _!_1d' (21 ram)

I / COMBUSTION AIR CONN b6"|

GAS CONN

......../

,Z......

T_4 ER MOSTAT_TRY |

SIDE INLET ,

b <!

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

see flex duct manufacturerb recommendations for equivalent diameters.

2. Minimum return-air opening at furnace:
a. For 800 OFM 16-in. (408mm) round or !41A (388 mm)x 12-in. (305 mm) rectangle

b. For !200 CFM 20-in. (508mm) round or 141# (368mm)x 197Mn. (495mm).rectangle
c. For !600 CFM 22-in. (558mm) round or 141# (368mm)x 231#-in.(591mm) [ectangle
d. 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 1 side and the bottom, or the bottom only will ensure adequate

return air openings for airflow requirements above 1800 CFM.

Dimensions - In. (mm)

UNIT SIZE A D E
040-14 / 042040 24-1/2 (622)* 22- 7/6 (581)* 23 (584)*
060-14 / 042060 17-1/2 (445) 15- 7/8 (403) 16 (406)

080-14 / 042080 21 (533) 19- 3/6 (492) 19-1/2 (495)
080-20 / 060080 21 (533) 19-3/6 (492) 19-1/2 (495)

100-20 / 060100 21 (533) 19- 3/6 (492) 19-1/2 (495)
120-20 / 060120 24-1/2 (622) 22- 7/6 (581) 23 (584)

*These dimensions reflect the wider casing for the Trophy (96.6% AFUE) furnace.

Fig. 2 - Dimensional Drawing

The 58MVB Multipoise Condensing Gas-Fired Furnaces are 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.
The 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.

Maintain a 1-in. (25 ram) clearance from combustible materials to
supply air ductwork for a distance of 36 inches (914.4 ram)
horizontally from the furnace. See NFPA 90B or local code for
further requirements.

These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring. In

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

Special base is not required when this furnace is installed on
Manufacturer's Coil Assembly or when Manufacturer's Coil Box

is used. These furnaces are suitable for installation in a structure
built on site or a manufactured building completed at final site. The

design of this furnace line is NOT CSA design-certified for
installation in recreation vehicles, manufactured (mobile) homes or

outdoors.
This furnace is designed for continuous return-air minimum

temperature of 60°F (16°C) db or intermittent operation down to

A05124

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.)
These furnaces are shipped with the drain and pressure tubes

connected for UPFLOW applications. Minor modifications are
required when used in DOWNFLOW, HORIZONTAL RIGHT, or
HORIZONTAL LEFT (supply-air discharge direction)

applications as shown in Fig. 1. See details in Applications section.

Install this furnace only in a location and position as specified in
LOCATION and INSTALLATION sections of these instructions.

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 detection of leaks to

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

Always install the 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.

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 -2,135m).

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

• This famace is for indoor installation in a building constructed on site. This furnace may be instated 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 fabdcant, pour passer au gaz propane ou pour certaines installations au gaz natureL
e Cette foumaise & air pulse est pour installation a I'intedeur 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 fabrleant.

• 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 iiste 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 ventil6e 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 _,. MINI 14" (6.35mm) TO
horizonfal application, the furnace must be pitched minimum 1/4" (6.35mm) to maximum of 1/Z' (12.7mm) forward for 1/2" (12.7mm) MAXj ¢_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 application hodzontale, lafOumaise dOlt &'Ire inclle_-_eenli'e minimum UPFLOW OR F_0RONT_)
1/4" (6.35mm) et maximum 1/2" (12.7ram) du niveau pour le drainage 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 ou_et ends.

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

DEGAGEMENT IVIINII_UIVIEN POUCESAVECI_LCMENTSDECONSTRUCTION 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 combustible 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 dearance to

combustibles 0".

g

Fig. 3 - Clearances to Combustibles

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 ducts 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 and Fig. 5.
The furnace may be used for construction heat provided that the

furnace installation and operation complies with the first
CAUTION in the LOCATION section of these instructions.

This gas furnace 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

A08435

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

constructionprocessmustbeeitherchangedorthoroughly

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. If this

furnace is installed with a direct-vent (combustion air and flue)
system, a factory accessory termination kit nmst be installed. In a

direct-vent system, all air for combustion is taken directly from
the outside atmosphere. See furnace and factory accessory
termination kit instructions for proper installation.

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

Installer Packet Includes:

Installation, Start-up, and Operating Instructions
Service and Maintenance Instructions

User's Information Manual

Warranty Certificate

Loose Parts Bag includes: Quantity

Pressure tube extension 1
Collector Box or condensate trap extension tube 1

Inducer Housing drain tube 1

1/2-in. (13 mm) CPVC street elbow 2

Drain tube coupling 1

Drain tube coupling grommet 1
Gas line grommet 1

Vent pipe grommet 1

Combustion-air pipe grommet 2

Gas line entry hole filler plug 1
Power entry hole filler plug 2

Condensate trap hole filler plug 3

Vent and combustion-air intake hole filler plug 2

Combustion-air pipe perforated disk assembly 1

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

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

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 Canada.

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

Step 1 -- Safety

• US: National Fuel Gas 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) CAN/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

• CANADA: NSCNGPIC. For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard,

Step 3 -- Combustion and Ventilation Air

• NFPA 54-2006/ANSI Z223.1-2006, Air for Combustion and
Ventilation

• CANADA: Part 8 of the NSCNGPIC 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 American
Society of Heating, Refrigeration, and Air Conditioning

Engineers (ASHRAE) 2005 Fundamentals Handbook Chapter

35.

Step 5 -- Acoustical Lining and Fibrous Glass

Duct

• US and CANADA: current edition of SMACNA, NFPA 90B as

tested by UL Standard 181 for Class I Rigid Air Ducts

Step 6 -- Gas Piping and Gas Pipe Pressure

Testing

• US: NFGC; chapters 5, 6, 7, and 8 and national plumbing codes

• CANADA: NSCNGPIC Parts 4, 5, 6 and 9. 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 inches.

! MAX80°F/270

FRONT

:_ MIN60°F / 16 C

A06745

Fig. 4 - Return-Air Temperature

18-1N. (457.2 mm)

MINIMUM TO BURNERS

Fig. 5 - Installation in a Garage

• When lever type gas shutoffs are used they shall be T-handle
type.

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

Step 7 -- Electrical Connections

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

• CANADA: Canadian Electrical Code CSA C22.1

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

A93044

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

control from damage. If the control is to be installed in a
furnace, follow items 1 through 5 before bringing the

control or yourself into contact with the furnace. Put all
used AND new controls into containers before touching

ungrounded objects.

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

INTRODUCTION

The model 58MVB 4-way multipoise, Gas-Fired, Category IV,
direct vent and non-direct vent condensing furnace is available in

model sizes ranging in input capacities of 40,000 to 120,000 Btuh.

APPLICATIONS

Step 1 -- General
Some assembly and modifications are required for furnaces /

installed in any of the 4 applications shown in Fig. 1. All drain and
pressure tubes are connected as shown in Fig. 7. See appropriate

application instructions for these procedures.

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.

1

ii

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unit
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 a clean, unpainted, metal surface of the
furnace chassis which is close to the control. Tools held in a

person's hand during grounding will be satisfactorily
discharged.

3. After touching the chassis, you may proceed to service the
control or connecting wires as long as you do nothing that

recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch

ungrounded objects, etc.)

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

touching control or wires.

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

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

Step 2 -- Upflow Applications

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

air is discharged upwards.

Condensate Trap Tubing (Factory-Shipped Orienta-

tion)_

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. 70

NOTE: See Fig. 7 or tube routing label on main furnace door to
confirm location of these tubes,

1. Collector Box Drain, Inducer Housing Drain, Relief Port,
and Pressure Switch Tubes These tubes should be factory

attached to condensate trap and pressure switch ready for
use in UPFLOW applications. These tubes can be identified

by their connection location and also by a color label on

each tube. These tubes are identified as follows: collector

box drain tube (blue label), inducer housing drain tube

(violet label or molded), relief port tube (green label), and
pressure switch tube (pink label).

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

field attachment by doing the following:

a. Determine location of field drain connection. (See Fig. 2

or 7.)

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.

b. Remove and discard casing drain hole plug button from

desired side.

c. Install drain tube coupling grommet (factory-supplied

in loose parts bag) in selected casing hole.

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

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

e. Cement 2 factory-supplied l/2-in. (13 mm)street CPVC

elbows to rigid drain tube connection on condensate
trap. (See Fig. 7.) These elbows must be cemented

together and cemented to condensate trap drain
connection.

NOTE: Failure to use CPVC elbows may allow drain to kink,
preventing draining.

f. Connect larger diameter drain tube and clamp

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

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

Condensate Trap Tubing (Alternate Upflow

Orientation)

An alternate location for the condensate trap is the left-hand side of

casing. (See Fig. 2 and 8.)
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.

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).

BLOWERSHELF '_ FURNACE

CONDENSATE '_

TRAP (INSIDE)

TUBE LOCATION

--ALTERNATE DRAIN
CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

DOOR r'-" CONDENSATE

X

FURNACE

\

FIELD 26 /4 11/2

DRAIN (667mm) (38ram)

CONN

SIDE VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

SLOTFORSCREW --7

HORIZONTAL/

APPLICATION

(OPTIONAL) /

11/2 (88ram) /

__/4 (44ram)! ,_,1 _

E 3mm)7/8--I ,--"

GUIDES " -_1 21/4
(WHEN USED) (57ram)

FRONT VIEW SIDE VIEW

/

f

RNACE

DOOR

4

(102mm)

261/4

DRAIN

CONN

1/4" (6mm)
COLLECTOR BOX TO
TRAP RELIEF PORT

1/2 (13ram)
INDUCER HOUSING

DRAIN CONNECTION
5/8 (16ram)

COLLECTOR BOX
DRAIN CONNECTION

SCREW HOLE FOR
UPFLOW OR DOWN-

FLOW APPLICATIONS
(OPTIONAL)

1/2 IN. (13ram) PVC OR CPV

(667mm)

END VIEW

HORIZONTAL

APPLICATIONS

i FURNACE

IDE

_4 (146mm)

3/4

(19ram)

FRONT VIEW

Fig. 6 - Condensate Trap

A07459

PLUG--

oAP >.. o HH

D AO L O O 'tOX--,Lr'h ',/All

TUBE (PINK) _ 2 I I- F

PLUG _',

CAP --'-

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX j

TUBE (GREEN) _ C j_'_" ........ _*,,.-\-''-'--,L2 lib

J £O0 E ISATEII

/ ?tlr

FA F_E;;::iiiiiii )/ _/_ "

FIELD-INSTALLED J FIELD-INSTALLED -_

FACTORY-SUPPLIED FACTORY-SUPPLIED

102 -IN. CPVC STREET DRAIN TUBE

ELBOWS (2) FOR COUPLING (RIGHT

LEFT DRAIN OPTION DRAIN OPTION)

A94213

Fig. 7 - Factory-Shipped Upflow Tube Configuration

(Shown with Blower Access Panel Removed)

Condensate Trap Tubing (alternate Upflow Orienta-
tion)_

NOTE: See Fig. 8 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 ram) wide furnaces ONLY, cut tube
between corrugated sections to prevent kinks.

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

condensate trap.

c. Determine appropriate length, then cut and connect

tube.

d. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

a. Connect relief port tube (green label) to condensate trap.

b. Extend this tube (if required) by splicing to small

diameter tube (factory-supplied in loose parts bag).

Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and
procedures.

COLLECTOR BOX --

DRAIN TUBE (GREEN)

CONDENSATE "'''_l _

TRAP EL

INDUCER --J

HOUSING

DRAIN TUBE

(VIOLET)

A94214

Fig. 8 - Alternate Upllow Tube Configuration and Trap

Location

Pressure Switch Tubing

The LOWER collector box pressure tube (pink label) is factory
connected to the pressure switch and should not require any

modification.
NOTE: See Fig. 7 or 8 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. 7 or 8 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. 7 or 8 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

A downflow furnace application is where furnace blower is located

above combustion and controls section of furnace, and conditioned
air is discharged downwards.

B

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAPII I

PLUG

c II

TUBE (PINK)

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX --_

EXTENSION TUBE

CONDEN_

TRAP

INDUCER HOUSING

DRAIN TUBE(VIOLET)

Fig. 9 - Downflow Tube Configuration

(Left-Hand Trap Installation)

©

A94215

DRAINTUBE

COUPLING

TUBE (GREEN)

PLUG

O O

DRAIN TUBE (BLUE)

TUBE (PINK)

DRAIN TUBE (BLUE
& WHITE STRIPED)

EXTENSION TUBE

DRAIN TUBE
_IOLET)

©

EXTENSION
DRAIN TUBE

Fig. 10 - Downflow Tube Configuration

(Right-Hand Trap Installation)

;TOR BOX

BOX

BOX

BOX

CTOR BOX

JCERHOUSING

TRAP

A94216

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, 9, 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 in-
ward and rotating trap.

3. Remove casing hole filler cap from casing hole. (See Fig. 2
and 10.)

4. 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 iniury
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 left-hand side casing hole by
inserting tube connection stubs through casing hole and

rotating until tabs snap into locking position.

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

Condensate Trap Tubing

NOTE: See Fig. 9 or 10 or tube routing label on main furnace

door to check for proper connections.

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

box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector

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

c. Connect LOWER collector box drain connection to

condensate trap.

• 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.

• 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 (factorysupplied in loose

parts bag) to drain tube coupling, extending collector box
drain tube for connection to condensate tr@.

c. Route extended collector box drain tube between gas valve

and inlet housing as shown in Fig. 10.

d. Determine @propriate 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 c@ and clamp from LOWER

inducer housing drain connection.

10

PLUG

AUXILIARY "J" BOX

COLLECTOR BOX

DRAIN TUBE
(BLUE AND WHITE STRIPED)

O
O

CONDENSATE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

TRAP

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR

BOX EXTENSION

DRAIN TUBE

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

060, AND 080 HEATING INPUT FURNACES

Fig. 11 - Horizontal Left Tube Configuration

COLLECTOR BOX

TUBE (GREEN)

JCER HOUSING

DRAIN TUBE (VIOLET)

DRAIN TUBE (BLUE)

A02288

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

factorysupplied 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,

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 pro-

cedure,

Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and
procedures.

Pressure Switch Tubing
One collector box pressure tube (pink label) is factory connected to

the pressure switch for use when furnace is installed in UPFLOW
or HORIZONTAL LEFT applications. This tube MUST be

disconnected and used for the condensate trap relief port tube. The
other collector box pressure tube (green label) which was factory

connected to the condensate trap relief port connection MUST be
connected to the pressure switch in DOWNFLOW or

HORIZONTAL RIGHT applications.
NOTE: See Fig. 9 or 10 or tube routing label on main furnace

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

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

2. Extend collector box pressure tube (green label) which was
previously connected to condensate trap relief port
connection by splicing to small diameter tube

(factory-supplied in loose parts bag).

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

4. Extend collector box pressure tube (pink label) which was
previously connected to pressure switch by splicing to

remaining small diameter tube (factory-supplied in loose
parts bag).

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

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

7. Clamp tube to relief port connection.

11

il

MAN1

SHUTOFF

GAS VALVE

SEDIMENT
TRAP

COMBUSTION -

INTAKE

(146mm)

CONDENSATE

TRAP

30" (762 mm)MIN

)RK AREA

DRAIN

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

(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. 12 - Attic Location and Working Platform for Direct Vent (2-Pipe) Application - All Sizes

Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations
and procedures.

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

A horizontal left furnace application is where furnace blower is

located to the right of combustion and controls section of furnace,
and conditioned air is discharged to the left.

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

Condensate Trap Location
The condensate trap nmst be removed from the factory-installed

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

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

1. Remove 3 tubes connected to condensate trap.

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

A93031

3. Remove casing hole filler cap from casing hole. (See Fig. 2
or 11.)

4. 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.

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

rotating until tabs snap into locking position.

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

Condensate Trap Tubing

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

1. Collector Box Drain Tube

a. 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

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

12

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

IS REQUIRED.

S VENT

COMBUSTION

INTAKE

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

SHORT (5 TO 8 FT / 1.5 TO 2.4M) VENT
SYSTEMS TO REDUCE EXCESSIVE

CONDENSATE DROPLETS FROM
EXITING THE VENT PIPE.

30-IN. (762mm) MIN

IN. (146mm)

MANt

SHUTOFF

GAS VALVE

SEDIMENT
TRAP

CONDENSATE

TRAP

DRAIN

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. 13 - Attic Location and Working Platform for Non-Direct Vent (1-Pipe) Applications - Sizes 040 through 120 Only

A96184

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
condensate trap.

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

d. Clamp tube to prevent any condensate leakage.

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

previously connected to 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 condensate trap.

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

d. Clamp tube to prevent any condensate leakage.

Condensate Trap Field Drain Attachment
Refer to Condensate Drain section for recommendations and

procedures.

Pressure Switch Tubing
The LOWER collector box pressure tube (pink label) is factory

connected to the 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. 11 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. Deternfine 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 platforn_ where all required furnace clearances
are met. (See Fig. 3 and 12 or 13.)

13

PLUG

CAP

BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX TUBE (PINK)

BOX RELOCATED HERE

o
0

g

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 14 - Horizontal Right Tube Configuration

[]NIT MAY NOT OPERATE

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

The condensate trap MUST be installed below furnace. See
Fig. 6 for dimensions. The drain connection to condensate trap
must also be properly sloped to an open drain.

NOTE: A 12-in. (305 mm) minimum offset pipe section is
recommended with short (5 to 8 ft./ 1.5 - 2.4 M) vent systems.

This recommendation is to reduce excessive condensate droplets
from exiting the vent pipe. (See Fig. 12, 13 or 42.)

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

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

and conditioned air is discharged to the right.

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 attic

application or over a finished ceiling.

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

CONDENSATE
TRAP

A02289

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 14.

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 iniury
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. 14 or tube routing label on main furnace door to
check for proper connections.

14

1.CollectorBox Drain Tube

a. Remove factory-installed plug from LOWER collector

box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector

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

c. Connect LOWER collector box drain tube (blue and

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

d. Clamp tube to prevent any condensate leakage.

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

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to
condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

d. Use inducer housing drain extension tube (violet label

and factory-supplied in loose parts bag) to connect
LOWER inducer housing drain connection to

condensate trap.

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

condensate trap.

f. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection procedure.

Condensate Trap Field Drain Attachment

Refer to Condensate Drain
procedures.

LEVEL 0" l

TO MIN 1/4"

V2" MAX TO

(0 to 13mm) 1/2" MAX

UPFLOW OR DOWNFLOW HORIZONTAL

Fig. 15 - Proper Condensate Drainage

Pressure Switch Tubing
One collector box pressure tube (pink label) is factory connected to

the pressure switch for use when furnace is installed in UPFLOW

or HORIZONTAL LEFT applications. This tube MUST be
disconnected and used for the condensate trap relief port tube. The
other collector box pressure tube (green label) which was factory

connected to the condensate trap relief port connection MUST be
connected to the pressure switch in DOWNFLOW or
HORIZONTAL RIGHT applications.

NOTE: See Fig. 14 or tube routing label on main furnace door to
check for proper connections.

Relocate tubes as described below.

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

to pressure switch.

2. Extend collector box pressure tube (green label) which was

previously connected to condensate trap relief port
connection by splicing to small diameter tube
(factory-supplied in loose parts bag).

3. Connect collector box pressure tube (green label) to

pressure switch connection labeled COLLECTOR BOX.

section for recommendations and

(6 to 13 mm)

A02146

4. Use remaining small diameter tube (factory-supplied in
loose parts bag) to extend collector box pressure tube (pink

label) which was previously connected to pressure switch.

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

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

7. Clamp tube to relief port connection.

Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations

and procedures.

Construct a Working Platform

Construct working platform where all required furnace clearances
are met. (See Fig. 3 and 12 or 13.)

[]NIT MAY NOT OPERATE

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

The condensate trap MUST be installed below furnace. See
Fig. 6 for dimensions. The drain connection to condensate trap
must also be properly sloped to an open drain.

NOTE: A 12-in. (305 mm) minimum offset pipe section is
recommended with short (5 to 8 ft./ 1.5 - 2.4 M) vent systems.

This recommendation is to reduce excessive condensate droplets
from exiting the vent pipe. (See Fig. 12, 13 or 42.)

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 11.

• 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. (See Fig. 3.)

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

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. 15.)

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 ducts sealed to furnace casing.

The ducts terminate outside the space containing the furnace to
ensure there will not be a negative pressure condition within

equipment room or space.

g

15

g

FIRE, INJURY OR DEATH HAZARD
Failure to follow this warning could result in fire, property

damage, personal iniury, or death.
Do NOT install furnace on its back. (See Fig. 16.) Safety

control operation will be adversely affected. Never connect
return-air ducts to back of furnace.

[]NIT DAMAGE HAZARD

This gas furnace 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.

[]NIT DAMAGE HAZARD
Failure to follow this caution may result in minor property or

unit damage.
If these furnaces are installed in an unconditioned space where

ambient temperatures may be 32°F (0°C) or lower, freeze
protection measures must be taken. (See Fig. 17.)

BACK

A93043

Fig. 16 - Prohibit Installation on Back

32° F/0 ° C MINIMUM INSTALLED

AMBIENT OR FREEZE

PROTECTION REQUIRED

/

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 is in the closed position.

A07911

Fig. 17 - Freeze Protection

Step 2 -- Low-Heat Only Installation

This 58MVB furnace can be installed to operate in the low-heat
only heating mode when sized using the low-heat heating capacity.
This is accomplished by placing setup switch SWI-2 in the ON

position to provide only low-heat operation. See Fig. 37 and Table

13. With this setup, high-heat operation will not occur.

16

[]NITDAMAGEHAZARD

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

The furnace can operate in the high-heat mode when certain
fault conditions occur. The following precautions should be

taken:

1. Size gas piping based on the high-heat input

2. Check the high-heat input and adjust it per the main

literature instruction.

Step 3 -- 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
damper is in full-heat or full-cool position.

Step 4 -- Hazardous Locations

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 9.3 of the NFGC, Air for Combustion

and Ventilation and applicable provisions of the local building
codes.

• Canadian Installations: Part 8 of the NFPA54/ANSI
Z223.1-2006 CAN/CSA-B149.1-05, Venting Systems and Air

Supply for Appliances and all authorities having jurisdiction.

g

FIRE, EXPLOSION, INJURY OR DEATH HAZARD
Improper location or inadequate protection could result in fire

or explosion.
When furnace is installed in a residential garage, it must be

installed so that burners and ignition sources are located a
minimum of 18 in. (457 mm) above floor. The furnace must

be located or protected to avoid physical damage by vehicles.
When furnace is installed in a public garage, airplane hangar,
or other building having a hazardous atmosphere, unit must be
installed in accordance with requirements of National Fire

Protection Association, Inc. (See Fig. 18.)

Step 5 -- Furnace Location and Application
DIRECT VENT (2-PIPE) APPLICATION

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

18-1N. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 18 - Installation in a Garage

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

17

pressure in the equipment room or space. A positive seal nmst be
made between the furnace cabinet and the return-air duct to

prevent pulling air from the burner area.

Indoor combustion air is permitted for combustion, ventilation,

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

Method is used,

il

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

1. 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.

2. 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" (300 ram)

of the ceiling and the second opening MUST commence
within 12" (300 ram) of the floor.

b. Size openings and ducts per Fig. 19 and Table 1.

c. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btuh (1,100 mm /kW) _f combined
input for all gas appliances in the space per Fig. 19 and

Table 1.

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. 19 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 Fig. 19.

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

in the space. The opening shall commence within 12"
(300 ram) of the ceiling. Appliances in the space shall

have clearances of at least 1" (25 ram) from the sides
and back and 6" (150 ram) from the front. The opening

shall directly conmmnicate with the outdoors or shall
communicate through avertical or horizontal duct to the
outdoors or spaces (crawl or attic) that freely

communicate with the outdoors.

Indoor Combustion Air© NFPA & AGA
Standard and Known-Air-Infiltration Rate Methods

2

CARBON MONOXIDE POISONING HAZARD

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

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.

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 n_ininmm
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:

1. For other than fan-assisted appliances, such as a draft
hood-equipped water heater:

Volume - 21ft3 _ I °ther

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

Other ACH 000 Btu/hr

A04002

Volume

Fan

If Iother = combined input of all other than fan-assisted appliances
in Btu/hr

Ifan -- 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.

ACH 000 Btu/hr

A04003

18

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

FURNACE

iNPUT

(BTUH) (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

40,000 20 6 13.4 5 10 4
80,000 30 7 20 6 15 5

80,000 40 8 26.7 6 20 6
100,000 50 8 33.4 7 25 8
120,000 80 9 40 8 30 7

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

Free Area of Opening Round Duct (in. Free Area of Opening Round Duct (in. Free Area of Opening Round Duct (in.

and Duct (Sq. In.) Dia) and Duct (sq In.) Dia) and Duct (Sq In.) Dia)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

100,000 + 40,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

80,000 + 40,000 = (100,000 divided by 3,000) = 33.4 Sq. In. for a Single Duct or Opening
80,000 + 30,000 = (110,000 divided by 2,000) = 55.0 Sq. In. for each of two Horizontal Ducts

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

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

ACH

0.80 1,050 1,400 1,750 1,000 1,500 2,000 2,500 3,000

0.50 1,260 1,680 2,1 O0 1,200 1,800 2,400 3,000 3,600

0.40 1,575 2,1 O0 2,625 1,500 2,250 3,000 3,750 4,500

0.30 2,1 O0 2,800 3,500 2,000 3,000 4,000 5,000 6,000

0.20 3,150 4,200 5,250 3,000 4,500 6,000 7,500 9,000

0.10 6,300 8,400 10,500 6,000 9,000 12,000 15,000 18,000

0.00 NP NP NP NP NP NP NP NP

(1,000'S BTUH GAS INPUT RATE) (1000'S BTUH GAS INPUT RATE)

30 40 50 40 80 80 100 120

Space Volume (ft3)

/

U

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in.2/l,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" (300 ram) of the

ceiling and the second opening shall commence within
12" (300 ram) of the floor. The n_ininmm dimension of

air openings shall be at least 3 in. (80 ram). (See Fig.

20.)

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
conmmnicates 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 nmst 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,
must not be smaller than 1/4-in. (6 ram) mesh. Louvers and grilles

nmst be constructed so they cannot be closed.

19

VENT THROUGH ROOF

(305mm)

(305mm)

OUTDOORS BTUH*

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

A&BC&DD&EF&G

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

Outdoors

PER 4000

A03174

When combustion air ducts are used, they nmst be of the same
cross sectional area as the free area of the openings to which they

connect. The n_ininmm dimension of ducts must not be less than 3
in. (76 ram).

Combination of Indoor and Outdoor Air

1. Indoor openings shall compy with the Indoor Combustion
Air Method below and,

2. Outdoor openings shall be located as required in the
Outdoor Combustion Air Method mentioned previously
and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air
Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above
multiplied by reduction Factor in b. above. The

minimum dimension of air openings shall be not less
than 3 in. (76 mm).

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. 21.) Install field-supplied,
corrosion-resistant 5/16-in. (8 ram) machine bolts and nuts.

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

1. Position furnace on its back. Locate and drill a 5/16-in. (8
ram) diameter hole in each bottom corner of furnace. (See

Fig. 21.) Holes in bottom closure panel may be used as
guide locations,

(305mm)

1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL

INTERIOR

HEATED

SPACE

UNCONFINED
SPACE

6" MIN (152mm)

(FRONT)0

1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL

L 12" MAX(805ram)

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. with minimum dimensions of 3 in. (76 mm)

t Minimum of 3 in. (76 mm) when type-B1 vent is used.

A03175

Fig. 20 - Air for Combustion, Ventilation, and Dilution from

Indoors

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.)

5/16',

(8rnm)

1

(44mm)

1 3/4"

(44mm)

(8rnm)

5/16"

(44ram) 1 3/4"

(44ram) 1

A89014

Fig. 21 - Leveling Legs

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

NOTE: Bottom closure nmst be used when leveling legs are used.

See Bottom Closure Panel section.

Step 2 -- Installation in Upflow or Downflow

Applications
NOTE: This furnace is approved for use on combustible flooring.

Special base is not required when this furnace is installed on

2O

Manufacturer's Coil Assembly or when Manufacturer's Coil Box is

used.

1. Determine application being installed from Table 3.

2. Construct hole in floor per dimensions specified in Table 3

and Fig. 22.

3. Construct plenum to dimensions specified in Table 3 and

Fig. 22.

4. If downflow subbase is used, install as shown in Fig. 23.

5. If coil assembly is used, install as shown in Fig. 24.

NOTE: Remove furnace perforated discharge duct flanges when
they interfere with mating flanges on coil on downflow subbase.

To remove furnace perforated discharge duct flange, use hand
seamers, wide duct pliers or duct flange tool to bend flange back

and forth until it breaks off. Be careful of sharp edges. (See Fig.

25.)

[]NIT 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. 25. 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. 25.

Step 3 -- Installation in Horizontal Applications

These furnaces can be installed in either horizontal left or right
discharge position. In a crawlspace, furnace can either be hung

from floor joist or installed on suitable blocks or pad. Furnace can
be suspended from each corner by hanger bolts and angle iron

supports. (See Fig. 26.) Cut hanger bolts (4 each 3/8-in. (10 mm)
all-thread rod) to desired length. Use 1 X 3/8-in. (10 mm) fiat

washers, 3/8-in. (10 mm) lock washers, and 3/8-in. (10 mm) nuts
on hanger rods as shown in Fig. 26. Dimples are provided for hole

locations. (See Fig. 2.)

[]NIT 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.
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.

Flexible connections should be used between ductwork and
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. (914 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

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

internal acoustical lining. As an alternative, fibrous ductwork may
be used if constructed and installed in accordance with the latest

edition of SMACNA construction standard on fibrous glass ducts.
Both acoustical lining and fibrous ductwork shall comply with

NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air
ducts.

SUPPLY AIR CONNECTIONS

Upflow Furnaces

Connect supply-air duct to 3/4-in. (19.1 mm) flange on furnace

supply-air outlet. The supply-air duct attachment must ONLY be
connected to furnace supply-/outlet-air duct flanges or air
conditioning coil casing (when used). DO NOT cut main furnace

casing to attach supply side air duct, humidifier, or other

accessories. All accessories MUST be connected external to

furnace main casing.

Downflow Furnaces

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

supply-air duct attachment must ONLY be connected to furnace
supply/outlet or air conditioning coil casing (when used), when

installed on non-combustible material. When installed on
combustible material, supply-air duct attachment must ONLY be

connected to an accessory subbase or factory approved air
conditioning coil casing. DO NOT cut main furnace casing to

attach supply side air duct, humidifier, or other accessories. All
accessories MUST be connected external to furnace main casing.

Supply air opening duct flanges must be modified per Fig. 25.

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.

g

21

FURNACE

FACTORY SUPPLIED

CASED COIL OR COIL BOX

COMBUSTIBLE

FLOORING

/

SHEET METAL

PLENUM

FLOOR _

OPENING

Fig. 22 - Floor and Plenum Opening Dimensions

FURNACE

(OR OTHER MANUFACTURER'S

COIL CASING WHEN USED)

/_ COMBUSTIBLE

FLOORING

_/

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

Fig. 23 - Furnace, Plenum, and Subbase Installed

on a Combustible Floor

A96283

A07585

A07586

Fig. 24 - Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

DISCHARGE DUCT
FLANGE

210 DEG.

Fig. 25 - Duct Flanges

MIN

A93029

NO

YES

YES

22

Table 3- Opening Dimensions - In. (mm)

FURNACE

CASING

WIDTH

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

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

(446) base Furnace with or without CAP, CAR, CNPV, CNRV Coil Assem-

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

Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or

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

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

(533) base Furnace with or without CAP, CAR, CNPV, CNRV Coil Assem-

Downflow Applications on Combustible Flooring NOT Using KGASB

Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or 20 20

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

24-1/2 Downflow Applications on Combustible Flooring Using KGASB Sub- 28-8/4 20-3/8

(622) base Furnace with or without CAP, CAR, CNPV, CNRV Coil Assem-

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

Subbase Furnace with CAP, CAR, CNPV, CNRV Coil Assembly or

APPLICATION

A B

16 24-1/8

Upflow Applications (422) (629)

(406) (613)

15-7/8 19

(403) (483)

15-1/8 19

bly or KCAKC Coil Box (425) (518)

(384) (483)

15-1/2 19

KCAKC Coil Box (419) (508)

(394) (483)

19-1/2 24-1/8

Upflow Applications (511) (629)

(495) (613)

19-3/8 19

(492) (483)

18-5/8 19

bly or KCAKC Coil Box (514) (518)

(473) (483)

19 19

KCAKC Coil Box (508) (508)

(483) (483)

23 24-1/8

Upflow Applications (600) (629)

(584) (613)

22-7/8 19

(581) (483)

22-1/8 19

bly or KCAKC Coil Box (603) (518)

(562) (483)

22-1/2 19

KCAKC Coil Box (597) (508)

(572) (483)

FLOOR OPENINGPLENUM OPENING

C D

16-5/8 24-3/4

16-1/2 19-5/8

20-1/8 24-8/4

20 19-5/8

23-5/8 24-3/4

23-1/2 19-5/8

......... _ APPLICATION)

........ 2.

_ COMBUSTION-AIR INTAKE IS REQUIRED-_

_ (NON-DIRECT VENT/I-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

(B) ALTERNATE SUPPORT

NOTES: 1. A 1 In. (25mm) clearance minimum between

top of furnace and combustible material.

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

3. For non-direct vent/I-pipe application,
bottom side combustion-air entry cannot be

used when furnace is installed with hangers
as shown.

3/16-1N. (21mm) MAX

LOCATION FROM BACK

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

ALTE RNATE SUPPORT
LOCATION 4-IN. (102mm) MIN

-IN. (203mm) MAX

A93304

Fig. 26 - Crawlspace Horizontal Application for Direct Vent / 2-Pipe Installation (Sizes 040 through 140) and for Non-Direct Vent

/ 1-Pipe Installation (Sizes 040 through 120 Only)

23

RETURN AIR CONNECTIONS

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

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

upflow applications only.

CUT HAZARD
Failure to follow this caution may result in personal injury.

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

and appropriate protective clothing.

g

Upflow Furnaces
The return-air duct nmst be connected to bottom, sides (left or

right), or a combination of bottom and side(s) of main furnace
casing. Bypass hunfidifier 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 hunfidifier connections should
be made at ductwork or coil casing sides exterior to furnace.

Step 5 -- Filter Arrangement

FIRE, CARBON MONOXIDE AND POISONING
HAZARD

Failure to follow this warning could result in 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. Factory supplied washable filters are shipped in the
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 the factory-supplied washable filter or a factory-specified
high-efficiency disposable filter (see cabinet instructions). If

installing the filter in the furnace blower compartment, deternfine
location for filter and relocate filter retaining wire, if necessary. See

Table 4 to deternfine correct filter size for desired filter location.
Table 4 indicates filter size, location, and quantity shipped with this

furnace. See Fig. 2 for location and size of bottom and side
return-air openings.

[]NIT MAY NOT OPERATE

Failure to follow this caution may result in internfittent 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. 27.

For bottom return-air applications, filter may need to be cut to fit
some furnace widths. Install filter as shown in Fig. 28.

Table 4 - Filter Information

AIR FILTER LOCATED iN BLOWER COMPARTMENT

Furnace

Casing

Width

In. (ram)

17-1/2

(445)

2!

(533)

24-1/2 (1or2) 18X25 (1) 24 X 25 X 3/4

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

* Factory-provided with the furnace. Filters may be field modified by cut-

ting filter material and support rods (3) in filters. 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*1- Bottom Return*

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

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

X 3/4

Filter Type

Framed

Washable

Washable

Washable

24

WASHABLE

FILTER

FILTER
RETAINER

A93045

Fig. 27 - Filter Installed for Side Inlet

171/2-1N.(444mm) WIDE CASINGS ONLY:
CASINGS ONLY: SUPPORT RODS (3)

INSTALL FIELD-SUPPLIED EXTEND 1/4" (6ram) ON
FILTER FILLER STRIP EACH SIDE OF FILTER AND

UNDER FILTER. REST ON CASING FLANGE

\

SUPPORT

Fig. 28 - Bottom Filter Arrangement

NOTE: Remove and discard bottom closure panel when bottom

inlet is used.

21-IN. (533mm) WIDE

_HABLE

FILTER

FILTER
RETAINER

A00290

Step 6 -- Bottom Closure Panel

These furnaces are 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 following:

1. Tilt or raise furnace and remove 2 screws holding front filler
panel. (See Fig. 29.)

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

3. Remove bottom closure panel.

4. Reinstall front filler panel and screws.

Step 7 -- Gas Piping

Gas piping nmst be installed in accordance with national and local

codes. Refer to NFGC NFPA54/ANSI Z2223.1-2006 in the U.S.

Canadian installations must be made in accordance with
CAN/CSA-BI49A-05 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

n_ininmm of 1 hanger every 6 ft. (1.8 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, explosion,
personal iniury 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 naininmm of 2 in. (51 ram) 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. 30.)

An accessible manual shutoff valve MUST be installed external to
furnace casing and within 6 ft. (1.8 M) of furnace. A l/8-in. (3

ram) 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.

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. 31.)

NOTE: The gas valve inlet pressure tap connection is suitable to
use as test gauge connection providing test pressure DOES NOT

exceed n_axinmm 0.5 psig (14-in. wc) stated on gas valve. (See
Fig. 59.)

25

g

Table 5 - Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE SIZE

IN. (MM)

1/2(13)

3/4 (19)

1(25)

1-1/4 (32)

1-1/2(38)

* Cubic ft. of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less and
a pressure drop of 0.5-in wc (based on a 0.60 specific gravity gas). Ref:
Table 9.2 NFGC.

Piping should be pressure and leak tested in accordance with
NFGC in the United States or NSCNGPIC in Canada, local, and

national plumbing and gas codes before the furnace has been
connected. If pressure exceeds 0.5 psig (14-in. wc), gas supply

pipe must be disconnected from furnace and capped before
pressure test.

If test )ressure is equal to or less than 0.5 psig (14-in. wc), turn off
electric shutoff switch located on gas valve before test. It is
recommended that ground joint union be loosened before pressure

testing. After all connections have been made, purge lines and
check for leakage at furnace prior to placing it into service.

The gas supply pressure shall be within the maximum (13.6-in.
wc) and and nfininmm (4.5-in. wc) inlet supply pressures marked

on the rating plate with the furnace burners ON at HI-HEAT and
OFF.

INTERNAL LENGTH OF PIPE - FT. (M)

DIA. 10 20 30 40 50

IN. (MM) (3.0) (6.0) (9.1) (12.1) (15.2)

0.622

(158)

0.824 (21) 360 250 200 170 151

1.049 (27) 680 465 375 320 285

1.380 (35) 1400 950 770 660 580

1.610 (41) 2100 1460 1180 990 900

175 120 97 82 73

SUPPLY

MANUAL _/ II
SHUTOFF ._. _

VALVE

SEDIMENT /
TRAP !

Fig. 30 - Typical Gas Pipe Arrangement

UNION -J

A93324

Step 8 -- Electrical Connections

See Fig. 32 for field wiring diagram showing typical field l15-v
and 24-v wiring. Check all factory and field electrical connections

for tightness.

ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal iniury

or death.
Blower access door switch opens 115-v power to furnace

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

BOTTOM
CLOSURE
PANEL

Fig. 29 - Removing Bottom Closure Panel

[]NIT MAY NOT OPERATE

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

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

screw.

A93047

115-V WIRING Before proceeding with electrical connections,

make certain that voltage, frequency, and phase correspond to that
specified on furnace rating plate. Also, check to be sure that service
provided

26

_ OMBUSTION

-AIRPIPE

IGAS

COMBUSTION-AIR PIPE GROMMET

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

CONN. HOLE

_VENT PIPE

GAS LINE GROMMET

VENT PIPE GROMMET

NOTE: PIPE GROMMETS AND ENTRY HOLE FILLER

PLUGS ARE INCLUDED IN FACTORY-SUPPLIED
LOOSE PARTS BAG

Fig. 31 - Casing Pipe Grommets

[THERMOSTAT

L_J ITERMINALS FIELD-SUPPLIED

I I DISCONNECT

[ I

[[[[__ GAS LINE ENTRY

.... FIELD 24-V WIRING

.... FIELD 115-, 208/280-, 460-V WIRING

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

HOLE FILLER PLUG

A05057

SINGLE

115-V f

PHASE

115-V AUXILIARY

FIELD-SUPPLIED J-BOX

DISCONNECT

SWITCH

FURNACE

CONTROL

CENTER

Connect Y or Y/Y2 terminal as shown for proper cooling operation.
Proper polarity must be maintained for 115-v wiring.
Use W2 with 2-stage thermostat when zoning.
If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.

8.

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

Fig. 32 - Heating and Cooling Application Wiring Diagram

27

208/230- OR

460-V

PHASE

208/230-V

SINGLE

PHASE

A98325

Table 6 - Electrical Data

UNIT SIZE

040-14 / 042040 14 61 (9) 15
060-14 / 042060 14 61 (9) 15

080-14 / 042080 14 30 (9) 15
080-20 / 060080 12 61 (9) 20

100-20 / 060100 12 61 (9) 20
120-20 / 060120 12 61 (9) 20

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

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

VOLTS-

HERTZ-

PHASE

115-60-1
115-60-1

115-60-1
115-60-1

115-60-1
115-60-1

OPERATING VOLTAGE

RANGE

Maximum*

127
127

127
127

127
127

Minimum*

104
104

104
104

104
104

MAXIMUM

UNIT

AMPS

8.90

8.90

8.90

14.00

14.00

14.00

MINIMUM

WIRE SIZE

MAXIMUM

WIRE LENGTH

FT. (M)_

MAXIMUM FUSE

OR CKT BKR

AMPS**

by power supply is sufficient to handle load imposed by this
equipment. Refer to rating plate or Table 6 for equipment electrical

specifications.
Make all electrical connections in accordance with National

Electrical Code (NEC) ANSI/NFPA 70-2008 and any local codes

ELECTRIC

DISCONNECT

SWITCH

or ordinances that might apply. For Canadian installations, all
electrical connections must be made in accordance with Canadian

Electrical Code CSA C22.1 or authorities having jurisdiction.
Field-supplied wiring shall conform with the limitations of 63°F

(33 ° C) rise.
The furnace must be electrically grounded in accordance with local

codes; or in the absence of local codes, with the National Electric
Code ANSI/NFPA 70 and/or the Canadian Electric Code, CSA

Fig. 33 - Disconnect Switch and Furnace

A93033

C22.1, Part I, if an external electrical source is utilized.
Use a separate 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 must be maintained for 115-v wiring. If

polarity is incorrect, furnace control status code indicator light will
flash rapidly and furnace will NOT operate.

Factory Installed J-Box Location
Install power 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 power entry hole filler plugs (factory-supplied loose
parts bag) in unused power entry holes. (See Fig. 35.)

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.)

FIRE OR ELECTRICAL SHOCK 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.

ELECTRICAL AND FIRE HAZARD
Failure to follow this warning could result in electrical shock,

fire or death.
The cabinet 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 iniury 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.

CONTINUOUS FAN (CF) SETUP SWITCHES

The CF setup switches are used to select desired airflow when
thermostat is in continuous fan mode or to select low-cooling

airflow for two-speed cooling units. This setup feature allows

continuous fan airflow or low-cooling airflow to be adjusted. To
set desired continuous fan airflow or low-cooling airflow:

1. Remove main furnace door and blower access panel.

2. Locate CF setup switches on furnace control. (See Fig. 37.)

3. Determine desired continuous fan airflow or low-cooling
airflow.

4. Use Fig. 47 or wiring schematic to determine proper setup
position of CF switches. (See Fig. 36.)

5. Replace main furnace door and blower access panel.

28

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

UNUSED 7/SqN. (22
DIAMETER POWER

ENTRY HOLES

INSTALLED
LOCATION

f ACTORY

2. Humidifier (HUM)
Connect an accessory 24 VAC, 0.5 amp maximum

humidifier (if used) to the 1/4-in. (6 mm) male
quick-connect HUM terminal and COM-24V screw
terminal on the control board thermostat strip. The HUM

terminal is energized when blower is energized in heating.
(See Fig. 37.)

A05113

Fig. 34 - Factory Installed J-Box Location

SETUP SWITCHES (SW1)

The furnace control has 8 setup switches that may be set to meet
the application requirements. Position these setup switches for the

appropriate requirement.

1. Remove main furnace door and blower access panel.

2. Locate setup switches on furnace control. (See Fig. 37.)

3. See Table 13 for setup switch description.

4. Replace main furnace door and blower access panel.

NOTE: If a bypass humidifier is used, setup switch SWI-3 (Low
HEAT Rise Adjust) should be in ON position. This compensates

for the increased temperature in return air resulting from bypass.
NOTE: If modulating dampers are used, blower motor

automatically compensates for modulating dampers. 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.

24-V Wirin_

Make field 24-v thermostat connections at 24-v terminal block on
furnace control. Y wire from thermostat MUST be connected to

Y/Y2 terminal on control, as shown in Fig. 32, for proper cooling
operation. The 24-v terminal block is marked for easy connection

of field wiring. (See Fig. 37.) The 24-v circuit contains a 3-amp,
automotive-type fuse located on furnace control. (See Fig. 370

Any electrical shorts of 24-v wiring during installation, service, or
maintenance may cause fuse to blow. If fuse replacement is

required, use only a fuse of identical size (3 amp) and type. The
furnace control will flash status code 24 when fuse needs

replacement.
NOTE: Use 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.
NOTE: For additional thermostat connection diagrams, reference

Fig. 51-58.

ACCESSORIES

1.

Electronic Air Cleaner (EAC)
The furnace control EAC terminals are energized with 115v

(1.0-amp maximum) during blower operation.
Connect an accessory Electronic Air Cleaner (if used) using

l/4-in. (6 mm) female quick connect terminals to the two
male 1/4-in. (6 mm) quick-connect terminals on the control

board marked EAC-I and EAC-2. The terminals are rated
for II5VAC, 1.0 amps maximum and are energized during

blower motor operation. (See Fig. 37.)

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 Thermidistat '_ , Zone Controller or

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

connection.

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

For additional venting information, contact www.Carrier.com.
Vent system or vent connectors may need to be resized. For any

other appliances when resizing vent systems or vent connectors,
system or connector must be sized to approach minimum size as

determined using appropriate table found in the NFGC
NFPA54/ANSI Z223.1-2006 or CAN/CSA-BI49.1-05.

The 58MVB can be vented as either a direct vent or as a non-direct
vent 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 (I-pipe) applications, refer to the non-direct vent
(l-pipe) procedures in the same section.

Common venting prohibited.

DIRECT VENT/2-PIPE SYSTEM (ALL SIZES)

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 (SIZES
I)40 THROUGH 121) ONLY)

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.

29

ALTERNATE

FIELD

LOCATION

I l
: I

J

J

POWER ENTRY HOLE -----¢p_@¢_"_IU.-
FILLER PLUG (FACTORY-

SUPPLIED LOOSE PARTS BAG)

/

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

Fig. 35 - Relocating J-Box

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 Z223.1- 2006/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.

iNSTALLED
LOCATION

FACTORY

POWER ENTRY HOLE

iiiiii_0 _ --FILLER PLUG (FACTORY-

SUPPLIED LOOSE PARTS BAG)

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

A05058

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.

FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in fire, property

damage, personal iniury 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
ABSDWV 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 (I-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 iniury, or death.

All combustion-air and vent pipes must be airtight and
watertight. Pipes must also terminate exactly as shown in Fig.

43 for direct vent (2-pipe) system and Fig. 44 for non-direct
vent (l-pipe) system.

30

Table 7 - Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials

ASTM SPECiFICATiON

(MARKED ON

MATERIAL)

D1527
D1785
D2235
D2241
D2466

D2468
D2564
D2661
D2665

F438
F441

F442
F493

F628

F656
F891

MATERIAL PiPE FITTINGS

ABS Pipe --

PVC Pipe --

For ABS -- --

PVC Pipe --
PVC -- Fittings

ABS -- Fittings

For PVC -- --

ABS Pipe Fittings

PVC Pipe Fittings
CPVC -- Fittings
CPVC Pipe --
CPVC Pipe --

For CPVC -- --

ABS Pipe

For PVC

PVC Pipe

An abandoned masonry chinmey 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. 43 for Direct Vent (2-Pipe) system and Fig. 44 for
Non-Direct Vent (l-Pipe) system.

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

Other gas appliances with their own venting system may also use
the abandoned chinmey 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.

SOLVENT CEMENT AND

PRIMERS

DESCRIPTION

Schedule--40
Schedule--40

Solvent Cement

For ABS

SDR--21 & SDR--26

Schedule--40
Schedule--40

Solvent Cement

For PVC

DWV at Schedule--40 IPS sizes

DWV

Schedule--40
Schedule--40

SDR

Solvent Cement

For CPVC

Cellular Core DWV at Schedule-40

IPS sizes

Primer

For PVC

Cellular Core Schedule-40 & DWV

UNIT CORROSION HAZARD

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

Combustion air nmst 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, pipe.

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
chinmey is used as a raceway, pipe nmst be insulated as shown
in Table 10 with Armaflex-type insulation.

Furnace combustion air and vent pipe connections are sized for
2-in. (51 ram) 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. See Fig. 40.

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 (I-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 (See Fig. 38.)
Maintain a 3-in minimum clearance between the opening of the

combustion-air inlet pipe and any object.

NOTE: All pipe joints nmst 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/l-Pipe System ONLY)

1. Permanently install perforated disk assembly (factory sup-
plied 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 ram) diameter PVC pipe to
length as determined per Fig. 39.

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 11, individually determine the smallest

combustion air and vent pipe diameters permitted for each
pipe. Pick the larger of these two pipe diameters and use this

for both combustion-air and vent pipes.

NOTE: Do not count elbows or pipe sections in terminations or
within furnace (All elbows shown in Fig. 43 are not to be counted).

31

C _ce _oa perm_ closed _r_

/

/

/,

/

/

2_24_=2

_ = _,00_ B_uh(30 kW), 36 _ 50,000 _uh (_5_v_, 12 _r_ (_)for a_r_ >
(91 c_) _ _es > 100,_ _t_ (30 kW) 5o_oe__tuh (_5_w)

J _r_n_e _o n_-me_ar_lcal air s_pi'y _nlet to l_J_idit_ or 12 inches (30 cm) for applieances >10,000 Btuh(3 kW)

the _,_t _nl_ I0 _t ap_ and <_ 100,000 Btuh(30kW), 36 inches (91cm) for

appliances > 100,000 Btuh(30kW)

9 inch_ (23 _) _, app_ > 10._ 8tuh (3kW) and

50i000 Btuh (i5k_V), 12 tr_ (_s(30_)_or _

> 50,000 _h (_SkW)

A08600

Table 8 - Direct Vent Termination Clearance

32

/

/

//

/

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. 1 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

F 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(t .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 kW0) 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 12 inches(30 cm) +

M

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.) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
(2.) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

# 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.t, 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. Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nusiance or hazard or property damage; or
c. Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

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 (9t cm) for

appliances > 100,000 Btuh (30 kW)

and -< 100,000 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

33

II

I

u

I
i

Fig. 36 - Wiring Diagram

34

A07902

MODEL PLUG
CONNECTOR

SW1 SETUP

SWITCHES AND

BLOWER OFF-

DELAY

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

24-V THERMOSTAT

TERMINALS

STATUS AND COMM

LED LIGHTS

3-AMP FUSE

USER INTERFACE CONTINUOUS FAN SW4 SETUP

OR ADVANCED (CF) AIRFLOW OAT SWITCHES

BETUPBW,TCHEBCONNECTOR

\p= /OA,

•_ _4.11/ d

/

HU==M__------'---

ACRDJ

m_ COMM

FUSE 3-AMP

!i0- o

SEC-2 SEC-1

HUMIDIFIER

TERMINAL(24-VAC

O.BAMPMAX.

ACRDJ -AIR

CONDITIONING

RELAY DISABLE

JUMPER

CONNECTOR

(FACTORY

ONLY)

g

TRANSFORMER 24-VAC

CONNECTIONS

11S-VAC (L2) NEUTRAL

CONNECTIONS

PL1 - LOW VOLTAGE MAIN

HARNESS CONNECTOR

SOFTWARE PART DATE

VERSION NUMBER CODE

NUMBER

Fig. 37 - Control Center

@OWNS ;i@

3(.)_,IBIIIYIIO 8

A_

aORI O_TA£ IF t GH/_,£OE

_I Isertlqll@dl Io_ [)i141 Ve_ 8Or,16#F @I'_)I_ t# Otd_l/_S k3

ORe_ I'_ faces s _ewa_

1¸¸_ _n_ake _

H©_ ZOt'_l_A_ ,R;$ "r D SC: ARO

_R

V_

Fig. 38 - Combustion-Air and Vent Pipe Connections

EAC-1 TERMINAL

(115 WAC 1.0 AMP MAX.)

EXAMPLE:

A07898

EAC-1

PL2

VS HSI HI LO_,_

i

\ \

11SWAC (L1) LINE

VOLTAGE CONNECTIONS

[]NIT 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 ram) diameter pipe must be used within
furnace casing. Make all pipe diameter transitions outside furnace

casing per Fig. 40.

2. Unless noted in Table 11, 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.

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.

PL2 - HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

A07422

35

Table 10 - Maximum Allowable Exposed Vent Pipe Length (Ft / M) with Insulation in

Winter Design Temperature Ambient*

WINTER DESIGN

UNIT SIZE

TEMPERATURE

F(C)

20°F (-6.7 °)

040

060

080

100

120

Pipe length (ft./m) specified for maximum pipe lengths located in unconditioned

pipe length as specified in Table 11.

1qnsulation thickness based on R value of 3.5 per in. (25 mm)

0OF (-17.8 °)

-2OOF (-28.9 o)
2O°F (-6.7 °)

0OF (-17.8 °)

-2OOF (-28.9 o)
2O°F (-6.7 °)
0OF (-17.8 °)

-2OOF (-28.9 o)
2O°F (-6.7 °)
0OF (-17.8 °)

-2OOF (-28.9 o)
2O°F (-6.7 °)

0OF (-17.8 °)

-2OOF (-28.9 o)

MAXIMUM PiPE

DIAMETER

IN. (ram)

2 (51)
2 (51)

2 (51)
2 (51)

2 (51)
2 (51)
2 (51)
2 (51)

2 (51)
2-1/2 (64)
2-1/2 (64)

2-1/2 (64)

3 (76)

3 (76)

3 (76)

INSULATION THICKNESS - IN. (ram)l

o (o) a/8" (1o)

21 (6) 37(11)
10 (3) 22 (7)

5 (2) 14 (4)

30 (9) 55 (17)

16 (5) 33 (10)

9 (3) 23 (7)

37 (11 ) 65 (20)

20 (6) 39 (12)
11 (3) 27 (8)

41 (13) 70 (21)

21 (6) 42 (13)

1/2" (13) 3/4" (19)

42 (13) 50 (15)

25 (8) 30 (9)
17 (5) 21 (6)

61 (19) 70 (21)
38 (12) 46 (14)

26 (8) 33 (10)
70 (21) 70 (21)
45 (14) 55 (17)

31 (9) 39 (12)
70 (21) 70 (21)

48 (15) 59 (18)

11 (3) 28 (8) 33 (10) 41

49 (15) 70 (21) 70 (21) 70

26 (8) 51 (16) 58 (18) 70
15 (5) 35 (11 ) 40 (12) 50

spaces. Pipes located in unconditioned space cannot

1" (25)

57 (17)

35 (11)

25 (8)

70 (21)

53 (16)

38 (12)
70 (21)

63 (19)
45 (14)

70 (21)
68 (21)

(13)

(21)
(21)

(15)

exceed total allowable

49 (15)

70 (21)
70 (21)

59 (18)

FIELD-SUPPLIED
2-IN. (51 mm) DIA._ FIELD-SUPPLIED
PVC90ELBOW J 2-IN. (51 mm) DIA.

J PVC PIPE

--E 1

i -_ A _

COMBUSTION-AIR DISC LOCATION-NON DIRECT
VENT/I-PIPE SYSTEM (FACTORY-SUPPLIED IN
LOOSE PARTS BAG)

A05122

CASING WIDTH A

8-1/2 +/- 1/2

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

10-1/2 +/- 1/2

21 (533) (267 +/- 13)

12+/- 1/2

24-1/2 (622) (605 +/- 16)

Fig. 39 - Combustion-Air Inlet Pipe Assembly - In, (ram)

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

5. Drill a 1/8-in. hole in 2-in, 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 remove
pipe for service of igniter or flame sensor.

Attachment of Combustion Air Intake Housing Plug

Fittin_
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 ram) 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 tbund in combustion air intake pipe and
combustion box. If use of this drain connection is desired, drill out

fitting's tap plug with 3/16-in. drill and connect a field-supplied
3/8-in. tube. This tube should be routed to open condensate drain

for furnace and A/C (if used), and should be trapped, as shown in
Fig. 41.

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. 43 so that it will not be susceptible to area where

light snow or others sources of moisture could be pulled in.

VENT PIPE

General

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

CARBON MONOXIDE POISONING AND PROPERTY

DAMAGE HAZARD

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

Vent pipes must be airtight. NOTE: A 2-in. (51 ram) diameter
pipe must be used within the furnace casing. Make all pipe

diameter transitions outside furnace casing per Fig. 40.

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

casing per Fig. 40.

36

ALTITUDE UNIT SIZE

F_ (M) (BTUH)

0 to 2000 80,000

(0to610)

ALTITUDE

2001 to 3000 80,000

(610 to 914)

ALTITUDE

3001 to 4000 80,000

(914 to 1219)

ALTITUDE

4001to 50005

(1219 to 1524) 80,000

ALTITUDE

5001to 60005

(1524 to 1829) 80,000

*See notes on next page.

40,000

60,000

100,000

120,000

UNIT SIZE

(BTUH)

40,000

60,000

100,000

120,000

UNIT SIZE

(BTUH)

40,000

60,000

100,000

120,000

UNIT SIZE

(BTUH)

40,000

60,000

100,000

120,000

UNIT SIZE

(BTUH)

40,000

60,000

100,000

120,000

Table11- MaximumAllowablePipe Length (Ft. / M)

VARIABLE SPEED VENT SIZING TABLE

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(76) Concentric

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(76) Concentric

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(76) Concentric

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(76) Concentric

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(76) Concentric

Direct & Non-

Direct Pipe

Dia.

In. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)
2 (51)

2 - 1/2 (64)
2 - 1/2 (64)

3 (76)

3 (76)l-

Direct & Non-

Direct Pipe

Dia. in. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)
2 (51)

2 - 1/2 (64)

3 (76)

3 (76)l-

Direct & Non-

Direct Pipe

Dia. in. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)
2 (51)

2 - 1/2 (64)

3 (76)

3 (76)l-

Direct & Non-

Direct Pipe

Dia. in. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)
2 (51)

2 - 1/2 (64)

3 (76)1-

Direct & Non-

Direct Pipe

Dia. in. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)
2 (51)

2 - 1/2 (64)

3 (76)1-

1 2

5O(15) 45(14)

70 (21) 70 (21)
5O (15) 45 (14)

70 (21) 70 (21)

30 (9) 25 (8)

70 (21) 70 (21)
45 (14) 40 (13)

70 (21) 70 (21)

10 (3) NA
35 (11) 30 (9)
70 (21) 70 (21)

1 2

45 (14) 40 (13)
70 (21) 70 (21)

45 (14) 40 (13)
70 (21) 70 (21)

26 (8) 21 (6)
70 (21) 70 (21)
40 (12) 35 (11)

70 (21) 70 (21)

31 (9) 26 (8)
63 (19) 62 (19)

1 2

42 (13) 37 (11)
70 (21) 70 (21)

42 (13) 37 (11)
70 (21) 70 (21)

25 (8) 20 (6)
70 (21) 70 (21)
38 (12) 33 (10)

70 (21) 70 (21)

29 (9) 24 (7)
59 (18) 59 (18)

1 2

40 (12) 35 (11)
70 (21) 70 (21)

40 (12) 35 (11)
70 (21) 70 (21)

23 (7) 18 (6)
70 (21) 70 (21)

36(11) 31 (9)
70 (21) 70 (21)

56 (17) 55 (17)

1 2

37 (11) 32 (10)
70 (21) 70 (21)

37 (11) 32 (10)
70 (21) 70 (21)

22 (7) 17 (5)
70 (21) 70 (21)

33 (10) 28 (9)
70 (21) 70 (21)

53 (16) 52 (16)

NUMBER OF 90 ° ELBOWS

3 4

40(13) 35 (11)
70 (21) 70 (21)

40(13) 35 (11)
70 (21) 70 (21)

20 (6) 15 (5)

70 (21) 70 (21)
35 (11) 30 (9)

70 (21) 70 (21)

NA NA

15 (5) NA

70 (21) 70 (21)

NUMBER OF 90 ° ELBOWS

3 4

35 (11) 30 (9)
70 (21) 70 (21)

35 (11) 30 (9)
70 (21) 70 (21)

16 (5) 11 (3)

70 (21) 70 (21)

30 (9) 25 (8)

70 (21) 70 (21)

12 (4) NA

62 (19) 61 (19)

NUMBER OF 90 ° ELBOWS

3 4

32 (10) 27 (8)
70 (21) 70 (21)

32 (10) 27 (8)
70 (21) 70 (21)

15 (5) 10 (3)

70 (21) 70 (21)

28 (9) 23 (7)

70 (21) 70 (21)

10 (3) NA

58 (18) 57 (17)

NUMBER OF 90 ° ELBOWS

3 4

30 (9) 25 (8)

70 (21) 70 (21)

30 (9) 25 (8)

70 (21) 70 (21)

13 (4) 8 (2)

70 (21) 70 (21)

26 (8) 21 (6)

70 (21) 70 (21)

54 (17) 53 (16)

NUMBER OF 90 ° ELBOWS

3 4

27 (8) 22 (7)

70 (21) 70 (21)

27 (8) 22 (7)

70 (21) 70 (21)

12 (4) 7 (2)

70 (21) 70 (21)

23 (7) 18 (6)

70 (21) 70 (21)
50 (15) 49 (15)

30 (9)

70 (21)

30 (9)

70 (21)

10 (3)

70 (21)

25 (8)

70 (21)

NA
NA

70 (21)

5

25 (8)

70 (21)

25 (8)

70 (21)

6 (2)

70 (21)

20 (6)

70 (21)

NA

61 (19)

5

22 (7)

70 (21)

22 (7)

70 (21)

5 (2)

70 (21)

18 (6)

70 (21)

NA

57 (17)

5

20 (6)

70 (21)

20 (6)

70 (21)

NA

70 (21)

16 (5)

70 (21)
52 (16)

5

17 (5)

70 (21)

17 (5)

70 (21)

NA

68 (21)

13 (4)

70 (21)
48 (15)

25 (8)

70 (21)

25 (8)

70 (21)

5 (2)

70 (21)

20 (6)

70 (21)

NA
NA

70 (21)

6

20 (6)

70 (21)

20 (6)

70 (21)

NA

70 (21)

15 (5)

70 (21)

NA

61 (19)

6

17 (5)

70 (21)

17 (5)

70 (21)

NA

70 (21)

13 (4)

70 (21)

NA

56 (17)

6

15 (10)

70 (21)

15 (10)

70 (21)

NA

68 (21)

11 (3)

70 (21)
52 (16)

6

12 (4)

70 (21)

12 (4)

70 (21)

NA

63 (19)

8(2)

70 (21)

47 (14)

37

B

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, determine the smallest diameter allowed by the table for each pipe, then use the larger diameter for both pipes.

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

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

5. The minimum pipe length is 5 ft. (1.5 M) for all applications.

Table 11 -- Maximum Allowable Pipe Length (Ft. / M) (Continued)

Variable Speed Vent Sizing Table

ALTITUDE

FT. (M)

6001 to 70001:

(1829 to 2134)

ALTITUDE

7001 to 80005

(2134 to 2438)

ALTITUDE

8001 to 9000

Ft.$

(2438 to 2743)

ALTITUDE

9001 to 10000 1:

(2743 to 3048)

Disk usage-Unles. _
Wide radius elbow.

UNIT SIZE

(BTUH)

40,000

80,000

80,000

100,000

120,000

UNIT SIZE

(BTUH)

40,000

80,000

80,000

100,000

120,000

UNIT SIZE

(BTUH)

40,000

80,000

80,000

100,000

120,000

UNIT SIZE

(BTUH)

40,000

80,000

80,000

100,000

120,000

otherwise statec

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(78) Concentric

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(78) Concentric

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(78) Concentric

Termination

Type

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 2-In.
(51) Concentric

2 Pipe or 3-In.
(78) Concentric

I, use perforated disk

Direct & Non- NUMBER OF 90 °

Direct Pipe

Dia. in. (ram)* 1 2 3

1-1/2 (38) 35 (11) 30 (9) 25 (8)

2 (51) 70 (21) 70 (21) 88 (21)

1-1/2 (38) 35 (11) 30 (9) 25 (8)

2 (51) 70 (21) 70 (21) 88 (21)

1-1/2 (38) 20 (8) 15 (5) 10 (3)

2 (51) 70 (21) 70 (21) 88 (21)
2 (51) 31 (9) 26 (8) 21 (8)

2-1/2 (64) 70 (21) 70 (21) 88 (21)

3 (78)1- 49 (15) 48 (15) 47 (14)

Direct & Non-

Direct Pipe

Dia. in. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)
2 (51)

2 - 1/2 (64)

3 (76)1-

Direct & Non-

Direct Pipe

Dia. in. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)
2 (51)

2 - 1/2 (64)

3 (76)1-

Direct & Non-

Direct Pipe

Dia. in. (ram)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)
2 (51)

2 - 1/2 (64)

3 (76)1-

ssembly (factory-

1

32 (10)
86 (20)

32 (10)
86 (20)

18 (8)
86 (20)

29 (9)
86 (20)

48 (14)

1

30 (9)
82 (19)

30 (9)
82 (19)

17 (5)
82 (19)

27 (8)
82 (19)

43 (13)

1

27 (8)
57 (17)

27 (8)
57 (17)

15 (5)
57 (17)

24 (7)
57 (17)

39 (12)

supplied in k

85 (20)

85 (20)

85 (20)

85 (20)

44 (13)

80 (18)

80 (18)

80 (18)

80 (18)

41 (13)

55 (17)

55 (17)

55 (17)

55 (17)

37 (11)

ose parts ba!

NUMBER OF 90 ° ELBOWS

2

27 (8)

22 (7) 17 (5)

83 (19) 82 (19)

27 (8)

22 (7) 17 (5)

83 (19) 82 (19)

13 (4)

8 (2) NA

83 (19) 82 (19)

24 (7)

19 (8) 14 (4)

83 (19) 82 (19)
43 (13) 41 (13)

NUMBER OF 90 ° ELBOWS

2

25 (8)

20 (8) 15 (5)

58 (18) 56 (17)

25 (8)

20 (8) 15 (5)

58 (18) 56 (17)

12 (3)

7 (2) NA

58 (18) 56 (17)

22 (7)

17 (5) 12 (4)

58 (18) 56 (17)
39(12) 37(11)

NUMBER OF 90 ° ELBOWS

2

22 (7)

17 (5) 12 (4)

53 (18) 51 (18)

22 (7)

17 (5) 12 (4)

53 (18) 51 (18)

10 (3)

5 (2) NA

53 (18) 51 (18)

19 (8)

14 (4) 9 (3)

53 (16) 51 (16)
35 (11) 33 (10)

I).

3 4

3 4

3 4

Vent sizing for Canadian installations over 4500 ft. (1372 M) above sea level are subject to acceptance by the local authorities having jurisdiction.

ELBOWS

4

20 (8)

87 (20)

20 (8)

87 (20)

5 (2)

87 (20)

18 (5)

87 (20)

45 (14)

5

15 (5)

86 (20)

15 (5)

86 (20)

NA

82 (19)

11 (3)

86 (20)
44 (13)

5

12 (4)

80 (18)

12 (4)

80 (18)

NA

57 (17)

9 (3)

eo (18)

40 (12)

5

10 (3)

55 (17)

10 (3)

55 (17)

NA

51 (16)

7 (2)

55 (17)
35 (11)

5

7 (2)

49 (15)

7 (2)

49 (15)

NA

48 (14)

NA

49 (15)
31 (10)

8

10 (3)

84 (20)

10 (3)

84 (20)

NA

57 (17)

8 (2)

84 (20)
43 (13)

8

7 (2)

59 (18)

7 (2)

59 (18)

NA

52 (16)

NA

59 (18)
38 (12)

8

5 (2)

53 (18)

5 (2)

53 (18)

NA

48 (14)

NA

53 (16)
34 (10)

6

NA

47 (14)

NA

47 (14)

NA

41 (13)

NA

47 (14)

29 (9)

38

NOTIN
HORIZONTAL
SECTION

FURNACE

[]NIT 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.

TRANSITION IN

VERTICAL SECTION

A93034

Fig. 40 - Combustion-Air and Vent Pipe Diameter Transition

Location and Elbow Configuration

COMBUSTION AIR

3/8" (10 mm) ID TUBE --

KE HOUSING BURNER

TRA ?

AOO ST'ON

TO OPEN --

DRAIN

A93035

Fig. 41 - Intake Housing Plug Fitting Drain

The n_ininmm vent pipe length for these furnaces is 5 ft. (1.5 M)
Short pipe lengths (5-8 ft. / 1.5 - 8 M) may discharge condensate
droplets. These condensate droplets may be undesirable. A 12-in.

(304.8 ram) n_ininmm offset pipe section is recommended to
reduce excessive condensate droplets from exiting vent pipe outlet.

(See Fig. 42.)
Attachment of Vent Pipe
Determine combustion-air and vent pipe diameter.

1. Using Table 11, individually determine the smallest
combustion-air and vent pipe diameters permitted for eahc
pipe. Pick the larger of these two pipe diameters and use

this diameter for both combustion-air and vent pipes.

NOTE: (Direct Vent/2-Pipe ONLY) vent pipe system has the
same diameter and same length as combustion air pipe as
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. 43 and Fig. 44 are not be
counted).

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

3. Reposition elastomeric (rubber) inducer housing outlet cap
and clamp to appropriate unused inducer housing

connection. Tighten clamp.

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

(See Fig. 31.)

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 ram)

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 ram) per linear ft. with no sags between hangers.

[]NIT DAMAGE HAZARD

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

Vent pipe must be installed and fully seated against inducer
housing internal stop. 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.

Installation Guidelines for Combustion Air Pipe and

Vent Pipe

It is recommended that all pipes be cut, prepared, and preassembled
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.

39

g

il

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. (1.5 M)(3 ft. (.91 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 nfininmm of 1/4 in. (6 ram)

per linear ft. with no sags between hangers.

13. Horizontal portions of the venting system shall be installed
so as to prevent the accunmlation of condensate.

14. Use appropriate methods to seal openings where
combustion air pipe (if applicable) and vent pipe pass

through roof or sidewall.

EXAMPLE
An 100-14 size furnace located in Indianapolis, elevation 650

ft. (198 M) above sea level, could be installed as either a direct
vent/2-pipe system that requires 3 elbows and 28 ft. (8.5 M)
of vent pipe, along with 5 elbows and 34 ft. (10.3 M) of
combustion-air pipe OR a non-direct vent/I-pipe system that
requires 3 elbows and 28 ft. (8.5 M) vent pipe.
For a direct vent/2-pipe system, Table 11 indicates this

application would allow a 2-in. (51 ram) diameter vent pipe,
but require a 2-1/2 in. (64 ram) diameter combustion air pipe.
According to Table 11, 2-in. (51 ram) diameter pipe is good
for 30 ft. (9.1 M) with 3 elbows, but only 20 ft. (6.1 M) with 5
elbows. Therefore, 2-1/2 in. (64 ram) diameter pipe nmst 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/l-pipe system, Table 11 indicates that
this application would allow a 2-in. (51 ram) 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 11 indicates that 2-1/2
in. (64 ram) diameter vent pipe and combustion-air pipe are

required.
For a non-direct vent/l-pipe system, Table 11 indicates that

2-1/2-in. (64 ram) diameter vent pipe is required. If same

applications are to be installed at 5001- to 6000 ft. (1524 -

1829 M) elevation:
For a direct vent/2-pipe system, 2-in. (51 ram) pipe is only
good for 23 ft. (7.0 M) (with 3 elbows) and 13 ft. (3.9 M)
(with 5 elbows). Therefore, 2-1/2 in. (64 ram) diameter

combustion air and vent pipe must be used.
For a non-direct vent/l-pipe system, a 2-in. (51 ram)

diameter pipe is only good for 23 ft. (7.0 M) with 3 elbows. A
2-1/2-in. (64 ram) diameter vent pipe must be used.

VENT TERMINATION

General
Combustion-air (direct vent/2-pipe system only) and vent pipe

must ternfinate outside structure, either through sidewall or roof.
For vent ternfination 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. 43 for
Direct Vent/2-Pipe system and Fig. 44 for Non-Direct/I-Pipe

system.
Roof ternfination is preferred since it is less susceptible to damage

or contanfination, and it has less visible vent vapors. Sidewall
ternfination 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
ternfination kit MUST be used. See section "Vent Ternfination Kit

(Direct Vent/2-Pipe System Only)" in this instruction.
When deternfining appropriate location for ternfination, consider

the following guidelines:

1. Comply with all clearance requirements stated in Table 8 or
Table 9 per application.

2. Ternfination or ternfination kit should be positioned where
vent vapors will not damage plants/shrubs or air

conditioning equipment.

3. Ternfination or ternfination 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. Ternfination or ternfination kit should be positioned where it
will not be damaged by or subjected to foreign objects such

as stones, balls, etc.

5. Ternfination or ternfination 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. 43 or in Fig. 44 per @plication 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 @propriate temperature for your @plication and

furnace model.

3. Deternfine required insulation thickness for exposed pipe
length(s).

NOTE: Pipe length (ft. / M) specified for naaxinmm pipe lengths
located in unconditioned spaces cannot exceed total allowable pipe
length as specified in Table 11.

Vent Termination Kit (Direct Vent/2-Pipe System

NOTE: Always refer to the instructions in termination kit for the
latest version.

Combustion air and vent pipes MUST terminate outside structure.

A factory accessory termination kit must be installed as shown in
Table 12. There are four options of vent/combustion air

ternfination kits available as shown in Table 12.
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 @propriate location for termination kit using the
guidelines provided in section "Vent Termination: General" in this

instruction.

1. Cut one 4-in. (102 ram) diameter hole for 2-in. (51 ram)
kit, or one 5-in. (125 ram) diameter hole for 3-in. (76 ram)

kit.

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

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

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

Roof terminations-Locate assembly through roof to @propriate
height as shown in Fig. 43.

Sidewall terminations-Locate assembly through sidewall with

rain shield positioned no more than 1-in. (25 ram) from wall as
shown in Fig. 43.

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

5. Check required dimensions as shown in Fig. 43.

40

I

VENTP'PE---".II VENTP'PE--'-.,I]

!! !!i"--C° UST'°N-A'RP'PE!! !!,--'-C°MBUST'°N-A'RP'PE

HORIZONTALTO ROOF HORIZONTAL TO SIDEWALL

COMBUSTION-AIR PIPE "_

COMBUSTION-AIRPIPE --,_ f VENT PIPE

I]J

:_-----_ 12" MIN

(304.8mm)

VERTICALTO 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. 42 - Short Vent (5 to 8 Ft. or 1.5M - 2.4M) System

[i 12,_MIN _ /

(304.1mm)

VENT PIPE

A96230

Two-Pipe Termination Kit (Direct Vent/2-Pipe System

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 prop-
erly cut vent pipe. Coupling must be positioned so bracket

will mount as shown in Fig. 43.
For applications using combustion-air pipe option, indic-

ated by dashed lines in Fig. 43, 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. 43.

For applications using vent pipe option indicated by dashed
lines in Fig. 43, rotate vent elbow 90 ° from position shown

in Fig. 43.

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

4. Check required dimensions as shown in Fig. 43.

Multiventing and Vent Terminations

When 2 or more 58MVB Furnaces are vented near each other, each
furnace must be individually vented. NEVER common vent or

breach vent 58MVB furnaces.

(Direct Vent/2-Pipe System ONLY)-When 2 or more 58MVB
furnaces are vented near each other, 2 vent terminations may be
installed as shown in Fig. 43, but next vent termination must be at

least 36 in. (914 ram) away from first 2 terminations. It is
important that vent terminations be made as shown in Fig. 43 to

avoid recirculation of flue gases.

Step 11 -- Condensate Drain
General

Condensate trap is shipped installed in the blower shelf and factory

connected for UPFLOW applications. Condensate trap nmst 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 ram) CPVC, l/2-in. PVC (13 ram), or

5/8-in. (16 ram) ID tube connection.
Drain pipe and fittings must conform to ANSI standards and

ASTM D1785, D2466, or D2846. CPVC or PVC cement nmst
conform to ASTM D2564 or F493. Primer nmst conform to

ASTM F656. In Canada, use CSA or ULC certified schedule 40

CPVC or PVC drain pipe, fittings, and cement.

When a condensate pump is required, select a pump which is

approved for condensing furnace applications. To avoid

condensate spillage, select a pump with an overflow switch.

41

g

Rool Te rmlnat[on (Preferred)

Con c_mt ric Vont and Combustion Air

_4_rtica[ separation
belween combustion

air and vent

Maintain 12 in (305ram)rain
clear an_ above

\\\\\\

Note: "A" denotes 0 to < 2 in. (51ram)

Between the first 2 vents

Third vent must be > 36 in. away (914mm)

i

Abandoned masonry
used asraceway

(percode)

snowlevelorgrade
wh4cheveris greater(typ}

Roo f Tot ruination (preferred} ...........................

Fig. 43 - Combustion Air and Vent Pipe Termination for Direct Vent (2-pipe) System

12 in(3O5mm)mm4mumfrom
overhangorroof

A05090

Roof Termination (Preferred)

Maintainminimum12ciearancein(3OSmm) ........... ":]above highest anticipated

snow level maximum of ' ,

24 _n (610ram) above roof ........ J"-....

"',L ............

Abandoned masonry
used as raceway
(per code)

12 in rain (305 mm)fi

6 in 152mm) minimum clearance

betweenwa andendo vent pipe

10 _n (254mm) maximum p_pe le_h

w_th Straight P_pe (preferred)

Maintain 12 in (3O5mm)
m[n[mu m clearance

above Mghest anticipated
s_qow level or grade

Side wall termination

\\\\\\\\ w_th 2 elbows (preferred)

iMchever _s greater

Fig. 44 - Vent Pipe Termination for Ventilated Combustion Air System

S_dewa[I Termination

Maintain 12 in 3O5mm
m[n[mu m c earance
above Mghest anticipated

snow [evel or grade
wMchever _s gleater

A05091

42

Table 12 - Vent Termination Kit for Direct Vent / 2-Pipe System

DIRECT VENT (2 PIPE) TERMINATION KIT TERMINATION SYSTEM

2-in. (51 mm) Concentric Vent Kit Single Penetration of Wall or Roof 1, 1-1/2, 2, or 2-1/2

3-in. (76 mm) Concentric Vent Kit Single Penetration of Wall or Roof 2-1/2, 3 or 4 (64, 76, or 102)

2-in. (51 mm)Termination Bracket Kit 2Pipe Termination System 1, 1-1/2 or 2 (25, 38, or 51)

3-in. (76 mm) Termination Bracket Kit 2Pipe Termination System 2-1/2, 3 or 4 (64, 76, or 102)

DIAMETER OF COMBUSTION AIR AND

VENT PIPES - IN. (MM)

(25, 38, 51, or 64)

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,

fieldsupplied trap prior to the furnace drain connection. All drain
connections (furnace, A/C, or humidifier) nmst 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. 45 for example of possible field drain attachment using
l/2-in. (13 ram) 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.

PERSONAL INJURY HAZARD
Failure to follow this warning could result in property damage

and personal iniury or death.

Caution should be taken to prevent draining causing slippery
conditions Excessive condensate draining may cause
saturated soil conditions which may result in damage to plants,

NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control status indicator light flashes rapidly

and furnace does not operate.

2. Thermostat wire connections at terminals R, W/WI, G, and
Y/Y2 must be made at 24-v terminal block on furnace

control.

3. Natural gas service pressure nmst not exceed 0.5 psig

(14-in. wc), but nmst be no less than 0.16 psig (4.5-in. wc).

4. Blower access panel nmst be in place to complete l15-v

electrical circuit to furnace.

f \

PIPE FOR

A/C OR

HUMIDIFIER

OPEN STANDy

DRAIN

TEE Uh_

CONDENSATE DRAIN PROTECTION

Freezing condensate left in condensate trap and drain line may
cause cracks, and possible water damage may occur. If freeze

protection is required, use condensate freeze protection accessory
or equivalent 3 to 6 watt per ft. at 120v and 40°F (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. 46.)

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

46.)

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, ADJUSTMENTS AND SAFETY

CHECK

Step 1 -- General

1. Furnace must have a 115-v power supply properly
connected and grounded.

A94054

Fig. 45 - Example of Field Drain Attachment

CONDENSATE TRAP-_

WiRE TiE

HEAT TAPE_.

(8WRAPS MINIMUM)_

A93036

Fig. 46 - Condensate Trap Heat Tape

43

AIR CONDITIONING

TONS (12,000 BTU/HR)

1-1/2

2

2-1/2

3

3-1/2

4
5
6

X Indicates an allowable selection.
* Airflow shown in parentheses is airflow unit that the

AIRFLOW* (CFM) 040,060 & 080-14

525 (600) X
700 (800) X X X

875 (1000) X X X

1050 (1200) X X X
1225 (1400) X X X
1400 (1600) X X
1750 (2000) X X

2100 (2100) X

MODEL 080-20 & 100 MODEL 120 MODEL

unit will deliver when setup switch SW1-5 is ON (selects 400 CFM/ton)

AIRCONDITIONING (A/C) ORCONTINUOUS-FAN (CF)

BASED ON 350 CFMMON (SETUP SWITCH SWl-5 OFF)

I

MODEL m'_ r-_

SIZE

g I SETUP SWITCH SW2 & SW3 POSITIONS

o, 060, 3.5q

040,060,3.5T080
5T080, 100 DEF. 7002 875 1050 1225 1400 1750_ 1750

I

120 DEF. 700 8752 1050 1225 1400 17501 2100

BASEDON 400 CFM/TON (SETUPSWITCHSW1-5 ON)

MODEL

AIRFLOW SELECTIONCHART

0 _ _ _ _ _ _

m_c, m_co mr--m c_

DEF. 5252 700 875 1050, I 1225 1225 1225

SETUP SWITCH SW2 & SW3 POSITIONS

S,ZE o Z,

m_c, m_co m_c, m_c_ ml:_mco ml:_mo: _l:_mco ml:_mo.

040,060,3.5T080 DEF. 6002 800 1000 1200,I 1400 1400 1400

5T080, 100 DEF. 8002 1000 1200 1400 1600 2000_ 2000

120 DEF. 800 10002 1200 1400 1600 2000_ 2100

1.DEFAULT A/C AIRFLOW WHEN A/C SWITCHESARE IN OFF POSITION

2. DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION

3. SWITCH POSITIONS AREALSO SHOWN ON FURNACE WIRING DIAGRAM

Fig. 47 - A/C or CF Airflow Selection Chart Based on 350

and 400 CFM/Ton

[]NIT MAY NOT OPERATE
Failure to follow this caution may result in internfittent unit

operation or performance satisfaction.
These furnaces are equipped with a manual reset linfit switch

in burner box. This switch opens and shuts off power to the
gas valve if an overheat condition (flame rollout) occurs in

burner enclosure. Correct inadequate combustion-air supply
or improper venting condition before resetting switch. DO
NOT jumper this switch.

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

Step 2 -- Sdeet Setup Switch Positions
AIR CONDITIONING (A/C) SETUP SWITCHES

The air conditioning setup switches are used to match furnace
airflow to cooling unit used.

To set the desired cooling airflow:

1. Remove main furnace door and blower access panel.

A07899

A07907

Fig. 48 - Example of Setup Switch in Off Position

2. Locate A/C setup switches on furnace control. (See Fig. 37.)

3. Deternfine air conditioning tonnage used,

4. Use Fig. 47 or wiring schematic to deternfine proper setup
position of A/C switches. (See Fig. 36 and 48.)

NOTE: Excessive airflow caused by improper A/C switch setup
may cause condensate blowoff in cooling mode.

5. Replace main furnace door and blower access panel.

NOTE: EAC-1 ternfinal is energized whenever blower operates.
HUM ternfinal is only energized when blower is energized in
heating.

CONTINUOUS FAN (CF) SETUP SWITCHES

The CF setup switches are used to select desired airflow when
thermostat is in continuous fan mode or to select low-cooling

airflow for two-speed cooling units. This setup feature allows

continuous fan airflow or low-cooling airflow to be adjusted, To
set desired continuous fan airflow or low-cooling airflow:

1. Remove main furnace door and blower access panel.

2. Locate CF setup switches on furnace control. (See Fig. 37.)

3. Deternfine desired continuous fan airflow or low-cooling
airflow,

4. Use Fig. 47 or wiring schematic to deternfine proper setup
position of CF switches. (See Fig. 36 and 48.)

5. Replace main furnace door and blower access panel.

44

Table13- Furnace Setup Switch Description

SETUP SWITCH NORMAL

NO. POSiTiON

SW1- 1 StatusCode Recovery OFF

SW1-2 Adaptive Heat Mode OFF

SW1-3 Low Heat RiseAdjust OFF pensatesfor increased return airtemperature caused with bypass

SW1-4 Comfort/EfficiencyAdjustment ON airflow 8 percent for maximumcomfort. On 040 unitwill decrease

SW1-5 CFM perton adjust OFF TurnON for 400 CFM per ton. Turn OFFfor 350 CFMper ton.

SW1-6 Component Self-Test OFF sistancewhen Rthermostat lead is disconnected. Turn OFFwhen

SW1-7 BlowerOFF delay ONor OFF SeeTable 14.
SW1-8 BlowerOFF delay ONor OFF

SWITCH NAME DESCRIPTION OF USE

TurnON to retrieveup to 7 stored status codesfor troubleshooting
assistancewhen R thermostat lead is disconnected.

Allows 2-stage operation with a single stage thermostat. Turn ON
when using 2 stagethermostat to allow Low Heat operation when

Rto W/W1 closes and High Heatoperation when R to W/W1 and

W2 close.
TurnON to increase LowHeat airflow by 18 percent.This com-

humidifier.

TurnON to decrease Low Heatairflow by 7 percent and High Heat

Low- HeatAirflow 11 percent and High- HeatAirflow 10percent.

TurnON to initiate Component Self-Test fortroubleshooting as- 1

Self-Test is completed.
Control blower Off Delaytime. Usedin conjunction with SW1-8.

Control blower Off Delaytime. Usedin conjunction with SW1-7.
SeeTable 14.

SETUP SWITCHES (SW1)

The furnace control has 8 setup switches that may be set to meet
the application requirements. Position these setup switches for the

appropriate requirement.

1. Remove main furnace door and blower access panel.

2. Locate setup switches on furnace control. (See Fig. 37.)

3. See Table 13 for setup switch description. (See Fig. 36 and

48.)

4. Replace main furnace door and blower access panel.

NOTE: If a bypass humidifier is used, setup switch SWl-3 (Low
HEAT Rise Adjust) should be in ON position. This compensates

for the increased temperature in return air resulting from bypass.
NOTE: If modulating dampers are used, blower motor

automatically compensates for modulating dampers.

FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal iniury,

death or property damage.
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.

Step 5 -- Sequence of Operation

Step 3 -- Prime Condensate Trap With Water

[]NIT MAY NOT OPERATE

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

[]NIT 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 2 internal chambers which can
ONLY be primed by pouring water into the inducer drain side

of condensate trap.

1. Remove upper inducer housing drain connection cap. (See
Fig. 49.)

2. Connect field-supplied 1/2-in. (13 mm) ID tube to upper
inducer housing drain connection.

3. Insert field-supplied flmnel 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. 50.)

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

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

[]sing schematic diagram, follow sequence of operation through
different modes. (See Fig. 36.) Read and follow wiring diagram

carefully.
NOTE: If a power interruption occurs during a call for heat

(W/W1 or W/Wl-and-W2), the control will start a 90-second
blower-only ON period two seconds after power is restored, if the
thermostat is still calling for gas heating. The amber LED light will
flash code 12 during the 90-second period, after which the LED
will be ON continuous, as long as no faults are detected. After the

90-second period, the furnace will respond to the thermostat

normally.
The blower door must be installed for power to be conducted

through the blower door interlock switch ILK to the furnace
control CPU, transformer TRAN, inducer motor IDM, blower

motor BLWM, hot-surface igniter HSI, and gas valve GV.

Step 4 -- Purge Gas Lines

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

U

45

©

Agg118

Fig. 49 - Inducer Housing Drain Tube

SINGLE-STAGE THERMOSTAT AND TWO-
STAGE HEATING (ADAPTIVE MODE)

See Fig. 32 or 58 for thermostat connections

NOTE: Low-heat-only switch, SWI-2, selects either the
low-heat- only operation mode when ON, (see item 2. below) or

adaptive heating mode when OFF, in response to a call for heat.

(See Fig. 37.) When the W2 thermostat terminal is energized, it
will always cause high-heat operation when the R to W circuit is

closed, regardless of the setting of the low-heat only switch.

DESIRED
HEATING

MODE

BLOWER OFF

DELAY (SEe)

9O

120
15O
18O

This furnace can operate as a two-stage furnace with a single-stage
thermostat because furnace control CPU includes a programmed

adaptive sequence of controlled operation, which selects low-heat
or high-heat operation. This selection is based upon the stored
history of the length of previous gas heating periods of the

single-stage thermostat.
The furnace will start up in either low- or high-heat. If the furnace

starts up in low-heat, the furnace control CPU determines the
low-heat on time (from 0 to 16 minutes) which is permitted before

switching to high-heat.

SETUP SWITCH (SW1-7 AND SW1-8)

POSITION

SW1-7 SW1-8

OFF OFF

ON OFF

OFF ON

ON ON

Aggllg

Fig. 50 - Filling Condensate Trap

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.

The wall thermostat "calls for heat", closing the R to W circuit. The
furnace control CPU performs a self-check, verifies the low-heat

and high-heat pressure switch contacts LPS and HPS are open.

1. Inducer Prepurge Period - The furnace control CPU turns

on inducer motor IDM and slowly increases the inducer
motor speed. When the low-heat pressure switch LPS

closes, inducer motor RPM is noted by the furnace control
CPU, and a 25-sec. prepurge period begins. The RPM is

used to evaluate vent system resistance. This evaluation is
then used to determine the required RPM necessary to
operate the inducer motor during the low-heat prepurge

period and low-heat mode.
NOTE: The heat cycle can start in either high-or low-heat. If a
high-heat cycle is initiated, the furnace control CPU will

deenergize the high-heat pressure switch relay HPSR to close the
NC contact and continues to increase the inducer motor speed after
the low-heat pressure switch LPS closes. When the high-heat
pressure switch closes, inducer motor RPM is noted by the furnace
control CPU before the 25-sec prepurge period begins. The RPM
is used to evaluate vent system resistance. This evaluation is then
used to determine the required RPM necessary to operate the
inducer motor in high-heat mode.

2. Igniter Warm-Up - At end of the 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

46

ignited by the Hot Surface Igniter HSI. Five seconds after
the GVR closes, a 2-second flame period begins. The HSI

igniter will remain energized until the flame is sensed or
until the 2-second flame proving period begins.

If the furnace control CPU selects high-heat operation, the
high-heat gas valve solenoid GV-HI is also energized.

4. Flame-Proving - When burner flame is proved at the

flameproving sensor electrode FSE, 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 furnace control CPU will repeat
the ignition sequence for up to three more Trials-For-Igni-

tion before going to Ignition-Lockout. Lockout will be re-
set automatically after three hours, by momentarily inter-

rupting 115 vac power to the furnace, or by interrupting 24
vac power at SEC1 or SEC2 to the furnace control CPU

(not at W/W1, 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. Inducer Speed Change - If the cycle starts in low-heat,

the furnace control CPU reduces the inducer speed slightly
after flame sense. If cycle starts in high-heat, the furnace

control CPU increases the inducer speed 15 seconds after
flame sense. The reduction in speed in low-heat is to optim-

ize combustion for maximum efficiency.

6. Blower-On delay - If the burner flame is proven, the
blower-ON delay for low-heat and high-heat are as fol-

lows:
Low-heat-60 seconds after the gas valve GV-M is opened,

the BLWM is turned ON at low-heat airflow.
High-heat-35 seconds after gas valve GV-M is opened,

the BLWM is turned ON at high-heat airflow. Simultan-
eously, the humidifier terminal HUM and electronic air

cleaner terminal EAC-1 are energized and remain energized
throughout the heating cycle.

7. Switching From Low- To High- Heat - If the furnace
control CPU switches from low-heat to high-heat, the fur-

nace control CPU will de-energize the the high-heat pres-
sure switch relay HPSR to close the NC contact and slowly

increase the inducer motor speed until the high-heat pres-
sure switch HPS closes. When the high-heat pressure

switch HPS closes, the high-heat gas valve solenoid GV-
HI is energized and the inducer motor RPM is noted by the

furnace control CPU. The RPM is used to evaluate vent sys-
tem resistance. This evaluation is then used to determine the

required RPM necessary to operate the inducer motor in
high-heat mode. The blower motor BLWM will transition

to high-heat airflow five seconds after the furnace control
CPU switches from low-heat to high-heat.

8. Switching From High- To Low- Heat - The furnace con-
trol CPU will not switch from high-heat to low-heat while

the thermostat R-to-W circuit is closed when using a
single-stage thermostat.

9. 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 hu-
midifier terminal HUM. The inducer motor IDM will re-

main energized for a 15-second post-purge period. The
blower motor BLWM and air cleaner terminal EAC-1 will

remain energized at low-heat airflow or transition to low-
heat airflow for 90, 120, 150, or 180 seconds (depending on

selection at blower-OFF delay switches). The furnace con-
trol CPU is factory-set for a 120-second blower-OFF
delay.

TWO-STAGE THERMOSTAT AND TWO-

STAGE HEATING

See Fig. 57 for thermostat connections.

NOTE: In this mode, the low-heat only switch SWl-2 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-Wl-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 Wl circuit for
low-heat or closing the R to Wl-and-W2 circuits for high-heat.

The furnace control performs a self-check and verifies the
low-heat and high-heat pressure switch contacts LPS and HPS are

open.
The start-up and shutdown flmctions 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 Wl circuit is closed and the R toW2 circuit closes, the

furnace control CPU will de-energize the high-heat
pressure switch relay HPSR to close the NC contact and

slowly increase the inducer motor speed until the high-heat
pressure switch HPS closes. When the high-heat pressure

switch closes, the highheat gas valve solenoid GV-HI is
energized and the inducer motor RPM is noted by the

furnace control CPU. The RPM is used to evaluate vent
system resistance. This evaluation is then used to determine

the required RPM necessary to operate the inducer motor in
high-heat mode. The blower motor BLWM will transition

to high-heat airflow five seconds after the R to W2 circuit
closes.

2. Switching From High- To Low- Heat- If the thermostat

R to W2 circuit opens, and the R to WI circuit remains
closed, the furnace control CPU will energize the high-heat

pressure switch relay HPSR to open the NC contact and
slowly decrease the inducer motor speed to the required

low-heat RPM. When the high-heat pressure switch HPS
opens, the high-heat gas valve solenoid GV-HI is

de-energized. 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 transition to

low-heat airflow five seconds after the R to W2 circuit

opens.

COOLING MODE

The thermostat "calls for cooling".

1. Single-Speed Cooling (See Fig. 32 and Fig. 51 for
thermostat connections.)

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 cooling
airflow. Cooling airflow is based on the A/C selection
shown in Fig. 47.

The electronic air cleaner terminal EAC-1 is energized 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 at cooling

airflow for an additional 90 sec. Jumper Y/Y2 to DHUM to
reduce the cooling off-delay to 5 seconds. (See Fig. 37.)

2. Single-Stage Thermostat and Two-Speed Cooling

(Adaptive Mode)
(See Fig. 58 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

47

operation,whichselectslow-coolingor high-cooling
operation.Thisselectionisbaseduponthestoredhistoryof

thelengthofpreviouscoolingperiodofthesingle-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. 37.) 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-cooling airflow which is the true on-board

CF selection as shown in Fig. 47.
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
transition the furnace blower motor BLWM to highcooling airflow.

High-cooling airflow is based on the A/C selection shown in Fig.

47.
NOTE: When transitioning from low-cooling to high-cooling the

outdoor unit compressor will shut down for 1 minute while the
furnace blower motor BLWM transitions to run at high-cooling

airflow.
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 Y1 to DHUM to reduce the
cooling off-delay to 5 seconds. (See Fig. 37.)

3. Two-Stage Thermostat and Two-Speed Cooling

(See Fig. 57 for thermostat connections)

NOTE: The air conditioning relay disable jumper 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-cooling airflow which is the true on-board CF

selection as shown in Fig. 47. 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 at high-cooling
airflow. High-cooling airflow is based on the A/C selection shown

in Fig. 47.
The electronic air cleaner terminal EAC-I 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-I will remain energized for an additional 90 seconds. Jumper
YI to DHUM to reduce the cooling off-delay to 5 seconds. (See

Fig. 370

THERMIDISTAT MODE

See Fig. 51-54 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 for more than 48 hours, the furnace control

reverts back to non-Thermidistat mode.
The cooling operation described in item 3. above applies to

operation with a Thermidistat. The exceptions are listed below:

a. Low cooling-When the R to G-and-Yl circuit is closed

and there is a demand for dehumidification, the furnace

blower motor BLWM will drop the blower airflow to 86%

of low-cooling airflow which is the true on-board CF
selection as shown in Fig. 47.

b. High cooling-When the R to G-and Y/Y2 circuit is closed

and there is a demand for dehumidification, the furnace

blower motor BLWM will drop the blower airflow to 86%

of high-cooling airflow. High-cooling airflow is based on
the A/C selection shown in Fig. 47.

c. Cooling off-delay-When the "call for cooling" is satisfied

and there is a demand for dehumidification, the cooling

blower-off delay is decreased from 90 seconds to 5

seconds.

SUPER-DEHUMIDIFY MODE

Super-Dehumidify mode can only be entered if the furnace control

is in Thermidistat mode and there is a demand for
dehumidification. The cooling operation described in Item 3.

above also applies to operation with a Thermidistat. The exceptions
are listed below:

a. Low cooling-When the R to YI circuit is closed, R to

G circuit is open, and there is a demand for

dehumidification, the furnace blower motor BLWM will
drop the blower airflow to 65% of low-cooling airflow
for a maximum of 10 minutes each cooling cycle or

until the R to G circuit closes or the demand for
dehumidification is satisfied. Low-cooling airflow is the
true on-board CF selection as shown in Fig. 47.

b. High cooling-When the R to Y/Y2 cicuit is closed, R

to G circuit is open, and there is a demand for
dehumidifiation, the furnace blower motor BLWM will

drop the blower to 65% of high-cooling airflow for a
maximum of 10 minutes each cooling cycle or until the

R to G circuit closes or the demand for dehumidification
is satisfied. High-cooling airflow is based on the A/C

selection shown in Fig. 47.

c. Cooling off-delay-When the "call for cooling" is

satisfied and there is a demand for dehumidification, the
cooling blower-off delay is decreased from 90 seconds

to 5 seconds.

CONTINUOUS BLOWER MODE

When the R to G circuit is closed by the thermostat, the blower
motor BLWM will operate at continuous-blower airflow.

Continuous blower airflow selection is initially based on the CF

selection shown in Fig. 4% Factory default is shown in Fig. 4%
Terminal EAC-I is energized as long as the blower motor BLWM

is energized.
During a call for heat, the blower BLWM will transition the blower

motor BLWM to continuous blower airflow, low-heat airflow, or
the mid-range airflow, whichever is lowest. The blower motor

OFF and remain OFF for the blower-ON delay (60 seconds in

low-heat and 35 seconds in high-heat) allowing the furnace heat

48

exchangersto heat more quickly, then restarts at the end of the

blower-ON delay period at low-heat or high-heat airflow
respectively.

The blower motor BLWM will revert to continuous-blower
airflow after the heating cycle is completed. In high-heat, the
furnace control CPU will drop the blower motor BLWM to

low-heat airflow during the selected blower-OFF delay period
before transitioning to continuous-blower airflow.

When the thermostat "calls for high-cooling", the blower motor
BLWM will operate at high-cooling airflow. When the thermostat

is satisfied, the blower motor BLWM will operate an additional 90
seconds at high-cooling airflow before transitioning back to

continuous-blower airflow.
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 pushbutton on

the room thermostat for 1-3 seconds after the blower motor
BLWM is operating. The furnace control CPU will shift the

continuous-blower airflow from the factory setting to the next
highest CF selection airflow as shown in Fig. 47. Momentarily

turning off the FAN switch again at the thermostat will shift the
continuous-blower airflow up one more increment. If you repeat

this procedure enough, you will eventually shift the
continuous-blower airflow to the lowest CF selection as shown in

Fig. 47. The selection can be changed as many times as desired and
is stored in the memory to be automatically used following a power

interruption.
This feature is disabled when blower off delay is set for 180 sec.

HEAT PUMP

See Fig. 53-56 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. Whenever W/W1 is energized along with

Y1 or Y/Y2, the furnace control CPU will transition to or bring on
the blower motor BLWM at cooling airflow, low-heat airflow, or

the mid-range airflow, whichever is the lowest. The blower motor
BLWM will remain on until the main burners ignite, then shut OFF

and remain OFF for 25 seconds before coming back on at heating
airflow. When the W/W1 input signal disappears, the furnace

control begins a normal inducer post-purge period while changing
the blower airflow. If Y/Y2 input is still energized, the furnace

control CPU will transition the blower motor BLWM airflow to
cooling airflow. If Y/Y2 input signal disappears and the Y1 input is

still energized, the furnace control CPU will transition the blower
motor BLWM to low-cooling airflow. If both the Y1 and Y/Y2

signals disappear at the same time, the blower motor BLWM will
remain on at low-heat airflow for the selected blower-OFF delay

period. At the end of the blower-OFF delay, the blower motor
BLWM will shut OFF unless G is still energized, in which case the

blower motor BLWM will operate at continuous blower airflow.

COMPONENT TEST

The furnace features a component test system to help diagnose a
system problem in the case of a component failure. To initiate the

component test procedure, ensure that there are no thermostat
inputs to the control and all time delays have expired. Turn on
setup switch SWl-6 (See Fig. 37.)

NOTE: The component test feature will not operate if the control
is receiving any thermostat signals or until all time delays have
expired.

The component test sequence is as follows:

a. The furnace control CPU turns the inducer motor IDM

ON at medium speed and keeps it ON through step c.

b. After waiting 15 seconds, the furnace control CPU turns

the hot surface igniter ON for 15 seconds, then OFF.

c. The furnace control CPU then turns the blower motor

BLWM ON at mid-range airflow for 15 seconds, then

OFF.

d. After shutting the blower motor BLWM OFF, the

furnace control CPU shuts the inducer motor IDM OFF.

NOTE: The EAC terminals are energized when the blower is
operating.

After the component test is completed, 1 or more status codes (11,
25, 41, or 42) will flash. See Service Label on blower access panel
or Service/Status Code Instructions for explanation of status codes.

NOTE: To repeat component test, turn setup switch SWI-6 to

OFF and then back ON.

Step 6 -- 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 rating for altitudes above 2000 ft. (610 M)
must be reduced by 2 percent for each 1000 ft. (305 M) above sea

level.
In Canada, the input rating must be derated by 5 percent for

altitudes of 2000 ft. to 4500 ft. (610 to 1372 M) above sea level.

Adjust manifold pressure to obtain input rate.
Furnace input rate must be within +/-2 percent of input rate on

furnace rating plate.

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

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

local gas supplier.

b. Obtain average specific gravity from local gas supplier.

c. Verify furnace model. Table 14 can only be used for

model 58MVB Furnaces.

d. Find installation altitude in Table 14.

NOTE: For Canadian altitudes of 2000 to 4500 ft. (610 to 1372
M), use U.S.A. altitudes of 2001 to 3000 ft. (610 to 914 M) in

Table 14.

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

Table 14.

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

intersection to find orifice size and low- and high-heat
manifold pressure settings for proper operation.

EXAMPLE: 0-2000 ft. altitude (0-610 M)
Heating value = 1050 Btu/cu ft.
Specific gravity = 0.62

Therefore: Orifice No. 45
Manifold pressure:

3.8-in. wc for high heat

1.6-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 proper input rate.

g. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE; ALWAYS CHECK AND
VERIFY.

49

THERMIDISTAT TWO-STAGE SINGLE-SPEED FURNACE HEAT PUMP

FURNACE AIR CONDITIONER

THERMIDISTAT TWO-STAGE SINGLE-SPEED

HEAT STAGE 2 IO_._

N/A

HEAT STAGE 1 I___

COOL STAGE 1 __

FAN I_--

24 VAC HOT __

DEHUMIDIFY I_Mt_ _

24 VAC COMM __

HUMIDIFY [_0__ _

N/A [_

%T%OR_-I_q-

CONNECT,ONLl_q-

NOTE 11 __

C_

-i_q

-i_q--

........_--IB

-i_q

-i_q

-i_

I HUM

........ _ HUMIDIFIER(24VAC) t-Z_L---

........ _ OUTDOORsENSOR t--Z_;

See notes 2, 5, 7, 10, and 11

........ I

Fig. 51 - Two-Stage Furnace with Single-Speed

Air Conditioner

THERMIDISTAT TWO-STAGE TWO-SPEED

FURNACE AIR CONDITIONER

RVSCOOLING_

HEATSTAGE3_

(FURNACEHI)

HEATSTAGE2_

(FURNACELO)

HEAT/COOLSTAGEI_

(COMPRESSOR)

FAN

24 VAC HOT

DEHUMIDIFY

24 VAC COMM [_

HUMIDIFY

N/A

I
I

NOTE 11

C_

I HUM "'-.

_)x_ HUMIDIFIER _ i

(24 VAC)

z_[ OUTDOOR _

SENSOR

CONNECTIONL_

See notes 1, 2, 4, 6, 7, 9, 10, 11, and 15

A00275

Fig. 53 - Two-Stage Furnace with Single-Speed

Heat Pump (Dual Fuel)

THERMIDISTAT TWO-STAGE TWO-SPEED

FURNACE HEAT PUMP

A00277

HEAT STAGE 2 _-.

COOL STAGE 1 [_.

HEAT STAGE 1 _-.

COOL STAGE 2 __.

FAN [__.

24 VAC HOT __.

DEHUMIDIFY [_.

24 VAC COMM [_-.

HUMIDIFY [_.

N/A _]

Os_oo__-I_ •

CONNECTION k[_- .

NOTE 11

-I_q

NOTE 12

-I_q

I HUM

........ HUMIDIFIER ___lI

........ _ OUTDOORsENSOR

See notes 2, 5, 8, 10, 11, and 12

Fig. 52 - Two-Stage Furnace with Two-Speed

Air Conditioner

(24 VAC)

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

HUMIDIFY

N/A

i
i

OUTDOOR [_" _ OsUTND_)OR ]_/_

................. [_ .......

I HUM ""_ .... ,

{"=°'F'=,24we,

J _Ol

coS SO,¢q...............................

Seenotes l, 2, 3, 4, 6, 8, 9,10,12,13, and15

A00276

Fig. 54 - Two-Stage Furnace with Two-Speed

Heat Pump (Dual Fuel)

A00278

50

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 [_

OONNEOTIONL_

NOTE 11

C_

] HUM

OUTDOOR _

SENSOR

See notes 1, 2, 4, 11, 14,15, and 16

A00279

Fig. 55 - Dual Fuel Thermostat with Two-Stage Furnace and

Single-Speed Heat Pump

DUAL FUEL TWO-STAGE TWO-SPEED

THERMOSTAT FURNACE HEAT PUMP

NOTE 11

I q-
I q-

I q-

NOTE 12

I q-
I q-

[_-

HUM

See notes 2, 11, and 12

A00281

Fig. 57 - Two-Stage Thermostat with Two-Stage Furnace

and Two-Speed Air Conditioner

SINGLE-STAGE TWO-STAGE TWO-SPEED

THERMOSTAT FURNACE AIR CONDITIONER

RVS COOLING

HEAT/COOL STAGE 1

(COMPRESSOR LO)

HEAT STAGE 3

(FURNACE)

HEAT/COOL STAGE 2

(COMPRESSOR HI)

FAN [_

24 VAC HOT [_

24 VAC COMM [_

N/A [_

RVS SENSING [_

Os_2#oo_/ _

NOTE 12

E2_
E2_

] HUM

OUTDOOR ] z_

SENSOR

IW31

CONNEOT'ON[12_

See notes 1, 2, 3, 4, 12, 13, 14,15, and 17

A00280

Fig. 56 - Dual Fuel Thermostat with Two-Stage Furnace and

Two-Speed Heat Pump

HUM

See note 2

A02348

Fig. 58 - Single-Stage Thermostat with Two-Stage Furnace

and Two-Speed Air Conditioner

51

Notes for Fig. 51-58:

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.l 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 SWI-2 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.

52

ALTITUDE

RANGE

ft (m)

¢;

"0

t-

r-

2001 (611)

"o

C

(3

3000 (914)

t-

t_

Canada

2001 (611)

450011372/

r'-

o

t=

0

C

0

C

o

Table 14 - Orifice Size* and Manifold Pressures for Gas Input Rate

(Tabulated Data Based on 20,000 Btuh High-Heat/13,000 Btuh Low-Heat Per Burner,

Derated 2%/1,000 Ft. (305 M) Above Sea Level)

0

(o)

to

2000
(610)

U.S.A.

to

to

3001
(915)

to

4000

(1219)

4001

(1220)

to

5000

(1524)

5001

(1525)

to

6000

(1829)

6001

(1830)

to

7000

(2133)

AVG. GAS

HEAT VALUE

AT ALTITUDE

IBtu/cu _1

900
925
950

975
1000
1025
1050
1075
1100

800

825

850

875

900

925

950

975
1000

775

800

825

850

875

900

925

950

750

775

800

825

850

875

900

925

725

750

775

800

825

850

875

900

675

700

725

750

775

800

825

850

0.58 0.60 0.62

Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press

No. Hi_hlLow No. Hi_hlLow No. Hi_h/Low

43 3.5 / 1.5 43 3.6 / 1.5 43 3.8 / 1.6
44 3.8 / 1.6 43 3.5 / 1.5 43 3.6 / 1.5
44 3.6 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4
44 3.4 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6
44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5
45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4
45 3.6 / 1.5 45 3.7 / 1.6 45 3.8 / 1.6
45 3.4 / 1.4 45 3.5 / 1.5 45 3.7 / 1.5
45 3.3 / 1.4 45 3.4 / 1.4 45 3.5 / 1.5
43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4
43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6
43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5
44 3.7 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4
44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6
44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5
45 3.7 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4
45 3.6 / 1.5 45 3.7 / 1.6 45 3.8 / 1.6
45 3.4 / 1.4 45 3.5 / 1.5 45 3.6 / 1.5
43 3.7 / 1.6 42 3.2 / 1.3 42 3.3 / 1.4
43 3.5 / 1.5 43 3.6 / 1.5 43 3.8 / 1.6
44 3.8 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5
44 3.6 / 1.5 44 3.7 / 1.6 44 3.8 / 1.6
44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5
44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4

45 3.7 / 1.5 45 3.8 / 1.6 44 3.2 / 1.4
45 3.5 / 1.5 45 3.6 / 1.5 45 3.7 / 1.6

43 3.7 / 1.6 43 3.8 / 1.6 42 3.2 / 1.4
43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6
44 3.7 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5
44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6
44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5
45 3.8 / 1.6 44 3.2 / 1.4 44 3.3 / 1.4
45 3.6 / 1.5 45 3.7 / 1.6 45 3.8 / 1.6
45 3.4 / 1.4 45 3.5 / 1.5 45 3.6 / 1.5
43 3.6 / 1.5 43 3.8 / 1.6 42 3.2 / 1.4
43 3.4 / 1.4 43 3.5 / 1.5 43 3.6 / 1.5
44 3.7 / 1.5 44 3.8 / 1.6 43 3.4 / 1.4
44 3.4 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6
44 3.2 / 1.4 44 3.3 / 1.4 44 3.4 / 1.5

45 3.7 / 1.6 45 3.8 / 1.6 44 3.2 / 1.4
45 3.5 / 1.5 45 3.6 / 1.5 45 3.7 / 1.6
45 3.3 / 1.4 45 3.4 / 1.4 45 3.5 / 1.5

42 3.2 / 1.3 42 3.3 / 1.4 42 3.4 / 1.4
43 3.6 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6
44 3.8 / 1.6 43 3.5 / 1.5 43 3.6 / 1.5
44 3.6 / 1.5 44 3.7 / 1.6 44 3.8 / 1.6
44 3.4 / 1.4 44 3.5 / 1.5 44 3.6 / 1.5
45 3.8 / 1.6 44 3.3 / 1.4 44 3.4 / 1.4
45 3.6 / 1.5 45 3.7 / 1.6 45 3.8 / 1.6
45 3.4 / 1.4 45 3.5 / 1.5 45 3.6 / 1.5

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

42
43
43
44
44
44
44

45

45
42
42
43
43
44
44
44
44

45
42
42
43
43
44
44
44

45
42
43
43
43
44
44
44

45
42
43
43
44
44
44

45

45
42
42
43
43
44
44
44

45

0.64

MnfldPress

Hi_h/Low

3.2/1.3

3.7/1.6

3.5/1.5

3.8/1.6

3.6/1.5

3.4/1.5

3.3/1.4

3.8/1.6

3.6/1.5

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

3.2/1.4

3.7/1.6

3.4/1.4

3.2/1.3

3.7/1.5

3.4/1.5

3.7/1.6

3.5/1.5

3.3/1.4

3.8/1.6

3.3/1.4

3.8/1.6

3.6/1.5

3.4/1.4

3.6/1.5

3.4/1.5

3.2/1.4

3.7/1.6

3.3/1.4

3.8/1.6

3.5/1.5

3.8/1.6

3.6/1.5

3.4/1.4

3.8/1.6

3.6/1.5

3.5/1.5

3.3/1.4

3.7/1.6

3.5/1.5

3.7/1.6

3.5/1.5

3.3/1.4

3.7/1.6

A08376A

53

B

Table 14 -- Orifice Size* and Manifold Pressures for Gas Input Rate

(Tabulated Data Based on 20,000 Btuh High-Heat/13,000 Btuh Low-Heat Per Burner,

Derated 2%/1,000 Ft. (305 M) Above Sea Level) (Cont)

ALTITUDE

RANGE

ft (m)

7001

--_ (2134)

C

O

to

8000

(2438)

8001

" (2439)

O

to

9000

!27431

9001

--_ (2744)

C

O

<." to

10000

!30481

* Orifice numbers shown inBOLD are factory-installed.

AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS

HEAT VALUE 0.58 0.60 0.62

AT ALTITUDE Orifice MnfldPress Orifice MnfldPress Orifice MnfldPress

!Stu/cu ft ! No. Hi_h/Low No. Hi_h/Low No. Hi_h/Low

650 43 3.8 / 1.6 42 3.2 / 1.4 42 3.4 / 1.4
675 43 3.5 / 1.5 43 3.7 / 1.6 43 3.8 / 1.6
700 44 3.8 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5
725 44 3.5 / 1.5 44 3.6 / 1.5 44 3.8 / 1.6
750 44 3.3 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5
775 45 3.7 / 1.6 44 3.2 / 1.3 44 3.3 / 1.4

800 45 3.5 / 1.5 45 3.6 / 1.5 45 3.7 / 1.6
825 45 3.3 / 1.4 45 3.4 / 1.4 45 3.5 / 1.5
625 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4
650 43 3.5 / 1.5 43 3.6 / 1.5 43 3.8 / 1.6
675 44 3.7 / 1.6 43 3.4 / 1.4 43 3.5 / 1.5
700 44 3.5 / 1.5 44 3.6 / 1.5 44 3.7 / 1.6
725 44 3.2 / 1.4 44 3.4 / 1.4 44 3.5 / 1.5
750 45 3.7 / 1.5 45 3.8 / 1.6 44 3.2 / 1.4
775 45 3.4 / 1.5 45 3.6 / 1.5 45 3.7 / 1.6
600 43 3.8 / 1.6 42 3.2 / 1.4 42 3.3 / 1.4
625 43 3.5 / 1.5 43 3.6 / 1.5 43 3.7 / 1.6
650 44 3.7 / 1.6 44 3.8 / 1.6 43 3.4 / 1.5
675 44 3.4 / 1.4 44 3.5 / 1.5 44 3.7 / 1.5
700 44 3.2 / 1.3 44 3.3 / 1.4 44 3.4 / 1.4
725 45 3.6 / 1.5 45 3.7 / 1.6 45 3.8 / 1.6

Orifice

No.

42
42
43
43
44
44
44

45
42
42
43
44
44
44

45
42
43
43
44
44
44

0.64

Mnfld Press

Hi,h/Low

3.5/1.5

3.2/1.4

3.6/1.5

3.4/1.4

3.6/1.5

3.4/1.4

3.2/1.4

3.6/1.5

3.4/1.5

3.2/1.3

3.6/1.5

3.8/1.6

3.6/1.5

3.3/1.4

3.8/1.6

3.4/1.4

3.8/1.6

3.6/1.5

3.8/1.6

3.5/1.5

3.3/1.4

A08376B

54

2. Adjust manifold pressure to obtain input rate.
a. Remove burner enclosure front.

NOTE: Manifold pressure MUST always be measured with the
burner box cover REMOVED.

b. Remove regulator seal caps that conceal adjustment

screws for low- and high-heat gas valve regulators.
(See Fig. 59.)

c. Move setup switch SWI-2 on control center to ON

position. (See Fig. 37.) 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
clockwise (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 manifold

)ressure in this range.

[]NIT DAMAGE HAZARD
Failure to follow this caution may result in reduced furnace

life or property damage.
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.

ON/OFF SWITCH

1/2 NPT INLET

INLET

PRESSURE TAP

/2 NPT OUTLET J

_ -REGULATOR COVER SCREW

....... PLASTIC ADJUST SCREW

i ADJUSTMENT
;

Fig. 59 - Redundant Automatic Gas Valve

A04167

g

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 SWI-2 to OFF position after

completing low-heat adjustment.

g. Jumper R and W/W1 and W2 thermostat connections

on furnace 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
manifold pressures 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. 61.)

j. Remove jumpers R to W/W1 and R to W2.

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

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

A93059

Fig. 60 - Burner Orifice

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

UNITED STATES
At altitudes above 2000 ft. (610 M), this furnace has

been approved for a 2 percent derate for each 1000 ft.
(305 M) above sea level. See Table 15 for derate

multiplier factor and example.

55

BURNER FLAME

/X F BURNER

..!:_.:-.

MANIFOLD J

Fig. 61 - Burner Flame

Table 15 - Altitude Derate Multiplier for USA.

ALTITUDE PERCENT OF DERATE MULTIPLIER

FT (M) DERATE FACTOR*

0-2000

(0-810) 0 1.00

2001-3000

(610-914) 4-6 0.95

3001-4000
(914-1219) 6-8 0.93

4001-5000

(1219-1524) 8-10 0.91

5001-8000

1524-1829) 10-12 0.89

8001-7000

(1829 -2134) 12-14 0.87

7001-8000

(2134-2438) 14-16 0.85

8001-9000

(2438-2743) 16-18 0.83
9001-10,000 18- 20 0.81

(2743-3048)

Derate multiplier factors are based on midpoint altitude for altitude range.

EXAMPLE: 100,000 BTUH HIGH-HEAT INPUT
FURNACE INSTALLED AT 4,300 FT. (1311 M)

A89020

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 SW1-2 to ON position. (See Fig.

37.) 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 16 for cubicfl, of gas per hr.

1. Multiply gas rate cu fl./hr by heating value (Btu/cu ft.).

m. Move setup switch SW1-2 to OFF position and jumper

R and W/W1 and W2 thermostat connections. (See Fig.

37.) This keeps furnace locked in high-heat operation.
Repeat items i through 1 for high-heat operation.

EXAMPLE: (High-heat operation at 0-2000ft. (0-610 M)
altitude)

Furnace input from rating plate is 100,000 Btuh
Btu heating input = Btu/cuft. 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 16)
Btu heating input = 103 X 975 = 100,425 Btuh In this
example, the orifice size and manifold pressure adjustment

is within +/-2 percent of the furnace input rate.

NOTE: Measured gas inputs (high heat and low heat) nmst 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/WI, and W2 thermostat

connections to ternfinate call for heat.

Furnace Input Rate at Sea Level X Derate Multiplier Factor
= Furnace Input Rate at Installation Altitude

100,000 X 0.91 = 91,000

CANADA

At installation altitudes from 2000 to 4500 fl, (610 to 1372 M) this
furnace nmst be derated 5 percent by an authorized Gas

Conversion Station or Dealer. To deternfine correct input rate for
altitude, see example above and use 0.95 as derate multiplier factor.

b. Reinstall burner box cover.

NOTE: Clocking gas input rate MUST always be performed with
the burner box cover INSTALLED.

c. Check that gas valve adjustment caps are in place for

proper input to be clocked.

d. Obtain average heat value (at altitude) from local gas

supplier.

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.

56

Table16- Gas Rate Cu Ft./Hr

SECONDS SIZE OF TEST DIAL SECONDS

FOR 1 1 2 5 FOR 1

REVOLUTION REVOLUTION

10 360 720 1800 50
11 327 655 1636 51
12 300 600 1500 52
13 277 555 1385 53
14 257 514 1286 54
15 240 480 1200 55

16 225 450 1125 56
17 212 424 1059 57
18 200 400 1000 58
19 189 379 947 59
20 180 360 900 60
21 171 343 857 62

22 164 327 818 64
23 157 313 783 66
24 150 300 750 68
25 144 288 720 70
26 138 277 692 72
27 133 267 667 74

28 129 257 643 76
29 124 248 621 78
30 120 240 600 80
31 116 232 581 82
32 113 225 563 84
33 109 218 545 86
34 106 212 529 88

35 103 206 514 90
36 100 200 500 92
37 97 195 486 94
38 95 189 474 96
39 92 185 462 98
40 90 180 450 100

41 88 176 439 102
42 86 172 429 104
43 84 167 419 106
44 82 164 409 108
45 80 160 400 110
46 78 157 391 112

47 76 153 383 116
48 75 150 375 120

49 73 147 367

cuff. cuff. cuff.

SIZE OF TEST DIAL

1 2 5

cuff. cuff. cuff.

72 144 360
71 141 355
69 138 346
68 136 340
67 133 333
65 131 327

64 129 321
63 126 316
62 124 310
61 122 305
60 120 300
58 116 290

56 112 281
54 109 273 1

53 106 265
51 103 257
50 100 250
48 97 243

47 95 237
46 92 231
45 90 225
44 88 220
43 86 214
42 84 209
41 82 205

40 80 200
39 78 196
38 76 192
38 75 188
37 74 184
36 72 180

35 71 178
35 69 173
34 68 170
33 67 167
33 65 164
32 64 161

31 62 155
30 60 150

U

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 unit rating
plate. Operation is within a few degrees of midpoint of rise
range when setup switch SWl-4 is OFF.

Furnace must operate within ranges of temperature rise specified
on the furnace rating plate. Determine air temperature rise as

follows:

1. Place thermometers in return and supply ducts as near
furnace as possible. Be sure thermometers do not see heat

exchanger so that radiant heat does not affect readings. This
practice is particularly important with straight-run ducts.

2. When thermometer readings stabilize, subtract return-air
temperature from supply-air temperature to determine air

temperature rise.

NOTE: Temperature rise can be determined for low-heat
operation by placing setup switch SWI-2 on furnace control in

ON position. For high-heat operation, place setup switch SWI-2
in OFF position and jumper R-W2 on furnace control. DO NOT
forget to return setup switch to OFF position and remove R-W2
jumper upon completion of testing. (See Fig. 37 for switch and
terminal location.)

3. This furnace is capable of automatically providing proper
airflow to maintain the temperature rise within the range
specified on furnace rating plate. If temperature rise is

outside this range, proceed as follows:

a. Check gas input for low- and high-heat operation.

b. Check derate for altitude if applicable.

c. Check all return and supply ducts for excessive

restrictions causing static pressure greater than 0.5-in.
wc.

d. Ensure Low Heat Rise Adjust switch SWl-3 on furnace

control is in ON position when a bypass humidifier is
used. (See Fig. 37 for switch location.)

e. Check Troubleshooting Guide for Variable-Speed

2-Stage Electronic Condensing Furnaces Series 170 and
later.

57

il

SET THERMOSTAT HEAT ANTICIPATOR

When using a non-electronic thermostat, the thermostat heat
anticipator nmst be set to match the amp draw of components in
the R-W/WI circuit. Accurate amp draw measurements can be

obtained only at the thermostat subbase terminals R and W.
The thermostat and 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.
Fig. 62 illustrates an easy method of obtaining thermostat amp

draw measurements. The amp reading should be taken after blower
motor has started and furnace is operating in low-heat.

1. To operate furnace in low-heat, turn setup switch SWI-2 to
ON position (See Fig. 37) and connect ammeter leads across

thermostat subbase R-W.

2. See thermostat manufacturer's instructions for adjusting the
heat anticipator and for varying heating cycle length.

NOTE: When using an electronic thermostat, set cycle rate for 3
cycles per hr.

TERMINALS WITH
THERMOSTAT REMOVED

(ANITICIPATOR, CLOCK, ETC.,
MUST BE OUT OF CIRCUIT.)

10 TURNS

FROM UNIT 24-V

CONTROL TERMINALS

EXAMPLE: 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT

10 TURNS AROUND JAWS ANTICIPATOR SETTING

Fig. 62 - Amp Draw with Ammeter

3. Return setup switch SW1-2 to OFF position and replace
thermostat on subbase.

SUBBASE

AMMETER

A96316

Step 7 -- 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 switches were all checked in the Start-up procedure
section as part of normal operation.

CHECK PRIMARY LIMIT CONTROL

This control shuts off the gas control system and energizes the

air-circulating blower motor if furnace overheats.

1. The recommended method of checking this linfit control is
to gradually block off return air after furnace has been
operating for a period of at least 5 nfinutes.

2. As soon as limit control has shut off burners, a status code
33 will appear on furnace control.

3. The return-air opening should be unblocked to pernfit
normal air circulation.

By using this method to check the linfit control, it can be
established that the linfit is functioning properly and the furnace

will operate safely if there is a restricted return-air duct or motor
failure. If the linfit control does not function during this test, the
cause nmst be determined and corrected.

CHECK PRESSURE SWITCHES

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

1. Turn off 115-v power to furnace.

2. Remove control access door and disconnect inducer motor
12-pin wire harness at inducer motor.

3. Turn on 115-v power to furnace.

4. Set thermostat to "call for heat." When pressure switches are
functioning properly, status code 42 will flash on furnace

control approximately 20 sec after thermostat switch is
closed. If either a status code 31 or 32 is flashed when

inducer motor is disconnected, the furnace will shut itself
down immediately. Deternfine the reason pressure switches

did not function properly and correct the condition.

5. Turn off 115-v power to furnace.

6. Reconnect inducer motor wire harness. Reinstall furnace
access door.

7. Turn on l15-v power to furnace.

8. Reset thermostat to desired temperature.

CHECKLIST

1. Put away tools and instruments. Clean up debris.

2. Verify flame rollout manual reset switch has continuity.

3. Verify that blower and main access doors are properly

installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer's

instructions.

6. Review User's Manual with owner.

7. Leave literature packet near furnace.

58

CHECKLIST-- DIRECT VENT (2-PIPE) INSTALLATION

LOAD CALCULATION

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

COMBUSTION AND VENT PIPING

Termination Location

Roof or Sidewall

Termination Kit - 2 Pipe or Con-
centric

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

Condensate Drain

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

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 Switches

59

CHECKLIST -- 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 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 Switches

Copyright 2008 Carrier Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 12/08

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

60

Catalog No: 58MVB-4SI

Replaces: 58MVB-3SI