Carrier 58MVP080, 58MVP060, 58MVP100, 58MVP040, 58MVP120 Installation, Start-up, And Operating Instructions Manual

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Page 1

4-Way Multipoise Direct-Vent

Variable-Capacity Condensing Gas Furnace

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Installation, Start-Up, and Operating Instructions

For Sizes 040—120, Series 140 and 150

NOTE: Read the entire instruction

manual before starting the installation.

ama

A93040

58MVP

CERTIFIED

This symbol → indicates a change since the last issue. Index Page

DIMENSIONAL DRAWING........................................................3

SAFETY CONSIDERATIONS.....................................................2

Clearances to Combustibles......................................................4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........2

INTRODUCTION.......................................................................2-4

APPLICATIONS ......................................................................5-11

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

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

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

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

Horizontal Right (Supply-Air Discharge) Applications...10-11

LOCATION ............................................................................11-13

General...............................................................................11-12

Low-Fire Only Installation.....................................................13

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

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

INSTALLATION....................................................................13-14

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

Installation In Upflow or Downflow Applications ..........14-15

Installation In Horizontal Applications..................................14

AIR DUCTS............................................................................14-18

General Requirements.............................................................14

Ductwork Acoustical Treatment.............................................14

Supply-Air Connections..........................................................14

Return-Air Connections..........................................................14

Filter Arrangement ............................................................16-17

Bottom Closure Panel.............................................................17

Gas Piping..........................................................................17-18

ELECTRICAL CONNECTIONS...........................................18-22

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

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

Accessories ........................................................................21-22

DIRECT VENTING ...............................................................22-31

Removal of Existing Furnaces from

Common Vent Systems.....................................................23

Combustion-Air and Vent Piping...........................................23

Concentric Vent and Combustion-Air Termination

Kit Installation..............................................................28-31

Multiventing and Vent Terminations.....................................31

CONDENSATE DRAIN........................................................31-33

General...............................................................................31-32

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

AIRFLOW

REGISTERED QUALITY SYSTEM

AIRFLOW

UPFLOW

HORIZONTAL

LEFT

DOWNFLOW

AIRFLOW

HORIZONTAL

RIGHT

Fig. 1—Multipoise Orientations

AIRFLOW

A93041

Application..............................................................................31

Condensate Drain Protection..................................................31

SEQUENCE OF OPERATION..............................................33-36

Self-Test Mode........................................................................33

Heating Mode..........................................................................33

Heating Mode—Two Stage....................................................34

Emergency Heat Mode...........................................................34

Cooling Mode .........................................................................34

Heat Pump Mode...............................................................34-35

Continuous Fan Mode.......................................................35-36

Component Test......................................................................36

Bypass Humidifier Mode........................................................36

Dehumidification Mode..........................................................36

Zone Mode..............................................................................36

START-UP PROCEDURES ..................................................36-45

General....................................................................................36

Select Setup Switch Positions................................................37

Prime Condensate Trap With Water......................................37

Purge Gas Lines......................................................................38

Adjustments .......................................................................38-45

Set Gas Input Rate ............................................................38-44

Set Temperature Rise..............................................................44

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

Book 1 4 Tab 6a 8a

PC 101 Catalog No. 535-80021 Printed in U.S.A. Form 58MVP-11SI Pg 1 2-01 Replaces: 58MVP-10SI

Page 2

Set Thermostat Heat Anticipator............................................45

CHECK SAFETY CONTROLS..................................................45

Check Primary Limit Control.................................................45

Check Pressure Switch ...........................................................45

CHECKLIST................................................................................45

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply.

Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No. 54-1999/ANSI Z223.1-1999 and the Installation Standards, Warm Air Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B. In Canada, refer to the current edition of the CAN/CGA-B149.1- and .2-M95 National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls.

Recognize safety information. This is the safety-alert symbol When you see this symbol on unit or in instructions and manuals, be alert to potential for personal injury.

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with 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 would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

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

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

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

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

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

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

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

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

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

INTRODUCTION

The 58MVP Multipoise Condensing Gas-Fired Furnaces are CSA (A.G.A. and C.G.A.) certified for natural and propane gases and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A manufacturer’s accessory gas conversion kit is required to convert furnace for use with propane gas.

These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, a manufacturers accessory floor base MUST be used when installed on combustible materials and wood

flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used. The design of this furnace line is not CSA (A.G.A. and C.G.A.) certified for installation in mobile homes, recreation vehicles, or outdoors. These furnaces are suitable for installation in a residence built on site or a manufactured residence completed at final site.

These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGHT, or HORIZONTAL LEFT (supply-air discharge direction) applications as shown in Fig. 1. See details in Applications section.

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

Installer Packet includes:

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

Loose Parts Bag includes: Quantity

Pressure tube extension 1 Collector box or condensate trap extension tube 1 Inducer housing drain tube 1 1/2-in. CPVC street elbow 2 Drain tube coupling 1 Drain tube coupling grommet 1 Vent and combustion-air pipe support 2 Combustion-air pipe perforated disk assembly 1 Condensate trap hole filler plug 3 Vent and combustion-air intake hole filler plug 2

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

Before installing the furnace in the United States, refer to the current edition of the NFGC and the NFPA 90B. For copies of the NFGC and NFPA 90B, contact the National Fire Protetion

Page 3

Fig. 2—Dimensional Drawing

Dimensions (In.)

UNIT SIZE A D E

040-14* 24-1/2* 22-7/8* 23*

060-14 17-1/2 15-7/8 16 080-14 21 19-3/8 19-1/2 080-20 21 19-3/8 19-1/2 100-20 21 19-3/8 19-1/2 120-20 24-1/2 22-7/8 23

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

A99111

17 5⁄16"

⁄2"

⁄16"

TYP

⁄8"

⁄16"

TYP

⁄16"

⁄8"

TYP

⁄4"

TYP

CONDENSATE DRAIN TRAP LOCATION (ALTERNATE UPFLOW)

⁄8-IN. DIA

ACCESSORY POWER ENTRY

⁄8-IN. DIA

POWER CONN

CONDENSATE DRAIN TRAP LOCATION (DOWNFLOW & HORIZONTAL LEFT)

26 15⁄16"

24 1⁄2"

⁄16"

-IN. COMBUSTION-

AIR CONN

⁄2-IN. DIA

GAS CONN

-IN. VENT CONN

⁄2-IN. DIA THERMOSTAT

ENTRY

22 11⁄16"

SIDE INLET

23 1⁄4" TYP

SIDE INLET

11⁄4"

1" E

INLET

⁄16"

OUTLET

AIRFLOW

OUTLET

26 15⁄16"

⁄2"

⁄16"

19"

⁄16"

⁄8"

⁄16"

⁄8"

22 1⁄4" TYP

⁄16"

24 3⁄16"

BOTTOM INLET

18 1⁄4"

22 11⁄16"

CONDENSATE DRAIN

TRAP LOCATION

(DOWNFLOW &

HORIZONTAL RIGHT)

OR ALTERNATE

⁄2-IN. DIA GAS CONN

2-IN. COMBUSTIONAIR CONN

⁄2-IN. DIA

GAS CONN

⁄8-IN. DIA

POWER CONN

⁄2-IN. DIA

THERMOSTAT ENTRY

2-IN. VENT CONN

DIMPLE LOCATORS

FOR HORIZONTAL

HANGING

14 1⁄2"

TYP

SIDE INLET

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

see flex duct manufacturer’s recommendations for equivalent diameters.

2. Minimum return-air opening at furnace: a. For 800 CFM–16-in. round or 141/2

x 12-in. rectangle.

b. For 1200 CFM–20-in. round or 141/2

x 191/2

-in. rectangle.

c. For 1600 CFM–22-in. round or 141/2

x 231/4

-in. rectangle.

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.

9 7⁄16"

TYP

26 15⁄16" TYP

CONDENSATE DRAIN LOCATION (UPFLOW)

30 1⁄2"

⁄16"

TYP

CONDENSATE

DRAIN LOCATION

(UPFLOW)

26 1⁄4"

Page 4

Association Inc., Batterymarch Park, Quincy, MA 02269; or American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209.

Before installing the furnace in Canada, refer to the current edition of the NSCNGPIC. Contact Standard Sales CSA International, 178 Rexdale Boulevard, Etobicoke, (Toronto) Ontario, Canada M9W 1R3.

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

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

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

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

For accessory installation details, refer to applicable installation literature.

INSTALLATION

This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m). An accessory kit, supplied b y the manufacturer, shall be used to convert to propane gas use or may be required for some natural

gas applications.

This furnace is for indoor installation in a building constructed on site . This furnace may be installed in a manufactured (mobile)

home when stated on rating plate and using factory authorized kit.

This furnace ma y be installed on com bustible flooring in alcove or closet at minimum clearance from combustible material.

This appliance requires a special venting system . Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC, PVC-DWV, or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).

Furnac e m ust be installed le ve l, or pitched forward within 1/2 inch of level for proper drainage. Failure will result in equipment or property dam age. See Installation Man ual for IMPOR TANT unit support details on horizontal applications.

UPFLOW OR DOWNFLOW

MINIMUM INCHES CLEARANCE TO

COMBUSTIBLE CONSTRUCTION

ALL POSITIONS:

Mimimum front cle arance for service 30 inches

(762mm).

DOWNFLOW POSITIONS:

For installation on co m b ustible floors only when

†

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

HORIZO NTAL POSITIONS:

Clearance shown is for air in let and air outlet en d.

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

120 size Furnace require 1 inch bottom clearance to

combustible materials.

LEVEL (0")

1/2" MAX

FRONT

This furnace is approved for UPFLOW, DOWN F LO W and HORIZONTAL installations.

Clearance arrows do not change with furnace orientation.

LEVEL (0")

1/2" MAX

FRONT

HORIZONTAL

TOP/PLENUM

MIN

325400-201 REV. A

(LIT. TOP )

Clearance in inches.

Fig. 3—Clearances to Combustibles

BOTTOM

†

Vent clearance to

combustibles 0".

A99103

Page 5

BLOWER SHELF

CONDENSATE TRAP (INSIDE)

ALTERNATE DRAIN TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

FURNACE DOOR

FIELD

DRAIN

CONN

EXTERNAL UPFLOW APPLICATIONS

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

WIRE TIE GUIDES (WHEN USED)

CONDENSATE TRAP

FURNACE

SIDE

FURNACE DOOR

FIELD

DRAIN

CONN

FURNACE SIDE

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

⁄4 OD

COLLECTOR BOX TO TRAP RELIEF PORT

⁄2 OD

INDUCER HOUSING DRAIN CONNECTION

⁄8 OD

COLLECTOR BOX DRAIN CONNECTION

SCREW HOLE FOR UPFLOW OR DOWNFLOW APPLICATIONS (OPTIONAL)

⁄2-IN. PVC OR CPVC

HORIZONTAL

APPLICATIONS

FRONT VIEW SIDE VIEW

Fig. 4—Condensate Trap

APPLICATIONS

Step 1—General

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

Step 2—Upflow Applications

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

CONDENSATE TRAP LOCATION (FACTORY-SHIPPED ORIENTATION)

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

CONDENSATE TRAP TUBING (FACTORY-SHIPPED ORIENTATION)

NOTE: See Fig. 5 or tube routing label on main furnace door to confirm location of these tubes.

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

A93026

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

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

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

5.)

NOTE: If internal filter or side filter/media cabinet is used, drain tube should be located to opposite side of casing of return duct attachment to assist in filter removal.

b. Remove and discard casing drain hole plug button from

desired side.

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

loose parts bag) in selected casing hole.

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

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

Page 6

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (GREEN)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄2 -IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE TRAP

DRAIN TUBE

DRAIN OPTION)

A94213

Fig. 5—Factory-Shipped Upflow Tube Configuration

(Shown With Blower Access Panel Removed)

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

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

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

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

supplied in loose parts bag) to condensate trap and clamp

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

CONDENSATE TRAP LOCATION (ALTERNATE UPFLOW ORIENTATION)

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

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

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

1. Remove 3 tubes connected to condensate trap.

COLLECTOR BOX

DRAIN TUBE (GREEN)

CONDENSATE

TRAP

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

A94214

Fig. 6—Alternate Upflow Tube Configuration and

Trap Location

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.

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

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

CONDENSATE TRAP TUBING (ALTERNATE UPFLOW ORIENTATION)

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

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

trap.

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

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

drain tube which was previously connected to condensate trap.

Page 7

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE

TRAP

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX TUBE (GREEN)

PLUG CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (PINK)

COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED)

COLLECTOR BOX EXTENSION TUBE

INDUCER HOUSING DRAIN TUBE (VIOLET)

CONDENSATE TRAP

COLLECTOR BOX EXTENSION DRAIN TUBE

DRAIN TUBE COUPLING

A94215

Fig. 7—Downflow Tube Configuration

(Left-Hand Trap Installation)

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, cut, and connect tube. d. Clamp tube to prevent any condensate leakage.

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

tube (factory-supplied in loose parts bag).

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

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

procedures. PRESSURE SWITCH TUBING

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

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

UPPER COLLECTOR BOX AND INDUCER HOUSING (UNUSED) DRAIN CONNECTIONS

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

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

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

A94216

Fig. 8—Downflow Tube Configuration

(Right-Hand Trap Installation)

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

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

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

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

tions and procedures.

Step 3—Downflow Applications

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

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

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

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

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.

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

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

Page 8

CONDENSATE TRAP TUBING NOTE: See Fig. 7 or 8 or tube routing label on main furnace door

to check for proper connections.

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

drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector box

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

c. Connect LOWER collector box drain connection to con-

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

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

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

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

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

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

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

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

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

(c.) Route extended collector box drain tube between

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

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

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

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

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

e. Connect inducer housing drain connection to condensate

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

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

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

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

directly from collector box drain 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

procedure.

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

procedures. PRESSURE SWITCH TUBING One collector box pressure tube (pink label) is factory connected to

the pressure switch for use when furnace is installed in UPFLOW 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. 7 or 8 or tube routing label on main furnace door to check for proper connections.

Relocate tubes as described below.

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

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

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

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

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

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

7. Clamp tube to relief port connection.

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

tions and procedures.

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

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

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

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

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

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

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

1. Remove 3 tubes connected to condensate trap.

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

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

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

Page 9

PLUG

AUXILIARY "J" BOX

CAP

COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040, 060, AND 080 HEATING INPUT FURNACES

Fig. 9—Horizontal Left Tube Configuration

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

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

check for proper connections.

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

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

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

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

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

to appropriate length.

d. Clamp tube to prevent any condensate leakage.

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

drain tube which was previously connected to condensate trap.

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

factory-supplied in loose parts bag) to connect LOWER

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

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

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

COLLECTOR BOX TUBE (GREEN)

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOX DRAIN TUBE (BLUE)

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

A00215

b. Route extended collector box pressure tube to relief port

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

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

procedures. PRESSURE SWITCH TUBING

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

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

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

tions and procedures. CONSTRUCT A WORKING PLATFORM

Construct working platform where all required furnace clearances are met. (See Fig. 3 and 10.)

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

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

Page 10

MANUAL

SHUTOFF

GAS VALVE

COMBUSTION – AIR

SEDIMENT TRAP

INTAKE

⁄4″

CONDENSATE TRAP

VENT

30″ MIN WORK AREA

DRAIN

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

ACCESS OPENING FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

Fig. 10—Attic Location and Working Platform

NOTE: A 12-in. minimum offset pipe section is recommended

with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 10 or 32.)

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

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

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

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

NOTE: The auxiliary junction box (J-box) MUST be relocated to opposite side of furnace casing. (See Fig. 11.) 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 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. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed.

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

5. Fill unused condenstate trap casing holes with placstic 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. 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.

Page 11

CAP

PLUG

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 11—Horizontal Right Tube Configuration

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

AUXILARY “J” BOX RELOCATED HERE

CONDENSATE TRAP

A00214

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

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

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

condensate trap.

f. Clamp tube to prevent any condensate leakage.

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

procedure.

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

procedures. PRESSURE SWITCH TUBING One collector box pressure tube (pink label) is factory connected to

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

Relocate tubes as described below.

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

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

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

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 recommenda-

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

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

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

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

NOTE: A 12-in. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 10 or 29.)

LOCATION

Step 1—General

When a furnace is installed so that supply ducts carry air to areas outside the space containing the furnace, return air must also be handled by ducts sealed to furnace casing. The ducts terminate outside the space containing the furnace to ensure there will not be a negative pressure condition within equipment room or space.

Page 12

Furnace may be located in a confined space without special provisions for dilution or ventilation air. This furnace must be installed so electrical components are protected from water.

LEVEL (0″)

⁄2″ MAX

UPFLOW OR DOWNFLOW HORIZONTAL

FRONT

LEVEL (0″)

⁄2″ MAX

FRONT

A93025

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

If these furnaces are used during construction when adhesives, sealers, and/or new carpets are being installed, make sure all combustion and circulating air requirements are followed. If operation of furnace is required during construction, use clean outside air for combustion and ventilation. Compounds of chlorine and fluorine, when burned with combustion air, form acids which will cause corrosion of heat exchangers. Some of these compounds are found in paneling, dry wall adhesives, paints, thinners, masonry cleaning materials, and many other solvents commonly used in the construction process. Excessive exposure to contaminated combustion air will result in safety and performance related problems.

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

FRONT

A93042

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

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

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

B A C K

BACK

FRONT

A93043

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

Page 13

32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED

A93058

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

Step 2—Low-Fire Only Installation

This 58MVP furnace can be installed to operate in the low-fire only heating mode when sized using the low-fire heating capacity. This is accomplished by placing setup switch SW-2 in the ON position to provide only low-fire-heat operation. See Fig. 25 and Table 10. With this setup, high-fire operation will not occur.

When the model no. on the furnace rating plate is followed by an asterisk (*), the furnace has an alternate low-fire only efficiency rating as listed in the GAMA and CEC directories. This alternate rating will be listed as the furnace model number followed by an (-L) suffix.

18-IN. MINIMUM

TO BURNERS

A93044

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

⁄16″

1 3⁄4″

⁄4″

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

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

2. Check the high-fire input and adjust it per the main literature instructions.

NEVER assume the high-fire input rate is not important for low-fire-only installation.

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 must prevent chilled air from entering furnace. If dampers are manually operated, they must be equipped with a means to prevent operation of either unit unless damper is in full-heat or full-cool position.

Step 4—Hazardous Locations

INSTALLATION

Step 1—Leveling Legs (If Desired)

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

⁄16″

1 3⁄4″

Fig. 12—Leveling Legs

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

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

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

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

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

A89014

Page 14

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

Step 2—Installation in Upflow or Downflow Applications

NOTE: This furnace is approved for use on combustible flooring

when manufacturer’s accessory floor base, Part No. KGASB0201ALL, is used. Manufacturers accessory floor base in not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC is used.

1. Determine application being installed from Table 1.

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

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

13.

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

If coil assembly CD5 or CK5 or Coil Box KCAKC is used, install as shown in Fig. 15.

NOTE: Remove furnace perforated, discharge duct flanges when they interfere with mating flanges on coil on downflow subbase. To remove furnace perforated, discharge duct flange, use wide duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 16.)

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

Step 3—Installation in Horizontal Applications

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

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.

AIR DUCTS

Step 1—General Requirements

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

When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace, the return air must also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

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

Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

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

Step 2—Ductwork Acoustical Treatment

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

Step 3—Supply Air Connections

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

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

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

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

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

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

Step 4—Return Air Connections

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

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

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

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

Page 15

PLENUM

OPENING

FLOOR

OPENING

A96283

Fig. 13—Floor and Plenum Opening Dimensions

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 14—Furnace, Plenum, and Subbase

Installed on a Combustible Floor

Table 1—Opening Dimensions (In.)

FURNACE

CASING

WIDTH

17-1/2

24-1/2

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

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

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

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

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

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

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

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

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

APPLICATION

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

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

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

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96284

Fig. 15—Furnace, Plenum, and Coil

Assembly or Coil Box Installed

on a Combustible Floor

PLENUM OPENING FLOOR OPENING

ABCD

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

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

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

19 19 20 20

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

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

Page 16

PERFORATED DISCHARGE DUCT FLANGE

Fig. 16—Duct Flanges

210°

MIN

YES

A93029

Step 5—Filter Arrangement

Never operate unit without a filter or with filter access door removed. Failure to follow this warning can cause fire, personal injury, or death.

The air filter arrangement will vary due to application 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, determine location for filter and relocate filter retaining wire if necessary. See Table 2 to determine correct filter size for desired filter location. Table 2 indicates filter size, location, and quantity shipped with this furnace. See Fig. 2 for location and size of bottom and side return-air openings.

ANGLE IRON OR EQUIVALENT

(B)

(A) ROD LOCATION

USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS)

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

⁄

″

(B)

(A)

DRAIN

(A)

(B)

/8-IN. HEX NUT

& WASHER (4)

REQD PER ROD

NOTES:

(A)

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

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

(B)

/16-IN. MAX ALTERNATE SUPPORT LOCATION FROM BACK

Fig. 17—Crawlspace Horizontal Application

⁄8-IN. ROD

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

A93304

Page 17

Table 2—Filter Information

FURNACE

CASING

WIDTH (IN.)

17-1/2 (1)16X25X1† (1)16X25X1† Cleanable

21 (1)16X25X1 (1)20X25X1† Cleanable

24-1/2 (1or2)16X25X1 (1)24X25X1† Cleanable

* Filters may be field modified by cutting filter material and support rods (3) in

filters. Alternate sizes can be ordered from your distributor or dealer.

† Factory-provided with furnace.

Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves, and appropiate protective clothing. Failure to follow this caution could result in personal injury.

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.

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

For bottom return-air applications, filter may need to be cut to fit some furnace widths. Install filter as shown in Fig. 19.

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

Step 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. 20.)

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 must be installed in accordance with national and local codes. Refer to current edition of NFGC. Canadian installations must be made in accordance with NSCNGPIC and all authorities

FILTER SIZE (IN.)*

Side Return Bottom Return

FILTER TYPE

FRAMED

171⁄2-IN. WIDE CASINGS ONLY:

INSTALL FIELD-SUPPLIED FILTER FILLER STRIP UNDER FILTER.

3″

/2″

1″

FILTER SUPPORT

21-IN. WIDE CASINGS ONLY:

SUPPORT RODS (3) EXTEND 1/4" ON EACH SIDE OF FILTER AND REST ON CASING FLANGE

FILTER RETAINER

Fig. 19—Bottom Filter Arrangement

WASHABLE FILTER

A00290

WASHABLE

FILTER

Fig. 18—Filter Installed for Side Inlet

FILTER RETAINER

A93045

BOTTOM CLOSURE PANEL

FRONT FILLER PANEL

Fig. 20—Removing Bottom Closure Panel

having jurisdiction. Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 3 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate

A93047

Page 18

straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.

Table 3—Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE SIZE

(IN.)

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

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

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

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

INTERNAL

DIAMETER

(IN.)

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

LENGTH OF PIPE (FT)

10 20 30 40 50

GAS SUPPLY

MANUAL SHUTOFF VALVE (REQUIRED)

SEDIMENT TRAP

UNION

A93324

Fig. 21—Typical Gas Pipe Arrangement

from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14-in. wc), turn off electric shutoff switch located on gas valve before test. It is recommended that ground joint union be loosened before pressure testing. After all connections have been made, purge lines and check for leakage.

ELECTRICAL CONNECTIONS

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

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

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

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

An accessible manual shutoff valve MUST be installed upstream of furnace gas controls and within 6 ft of furnace. A 1/8-in. NPT plugged tapping, accessible for test gage connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve. NOTE: The gas valve inlet press tap connection is suitable to use as test gage connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. wc) stated on gas valve. (See Fig. 50.) Piping should be pressure tested in accordance with local and national plumbing and gas codes before furnace has been attached. In Canada, refer to current edition of NSCNGPIC. If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected

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

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

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

Step 1—115-v Wiring

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

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

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

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

Page 19

115-V

SINGLE

PHASE

115-V

FIELD-SUPPLIED

DISCONNECT

SWITCH

FURNACE CONTROL

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

FIVE

WIRE

THREE-WIRE

NOTE 5

WCR GY

THERMOSTAT TERMINALS

FIELD-SUPPLIED

HEATING

ONLY

AUXILIARY J-BOX

W/W1

Y/Y2

24-V

NOTE

NOTE 1

TWO WIRE

GND

CONDENSING

UNIT

TERMINAL

CENTER

BLOCK

NOTES:

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.

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

Fig. 22—Heating and Cooling Application Wiring Diagram

DISCONNECT

208/230- OR

460-V

THREE PHASE

GND

208/230-V

SINGLE

PHASE

GND

A98325

ELECTRIC

DISCONNECT

SWITCH

COPPER

WIRE ONLY

ALUMINUM

WIRE

A93033

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

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

J-Box Relocation

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

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

ALTERNATE

FIELD

LOCATION

FACTORY INSTALLED LOCATION

A00212

Fig. 23—Relocating J-Box

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

Step 2—24-v Wiring

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

Page 20

→Fig. 24—Unit Wiring Diagram

A00350

FRS LS

ALS

FSE

NOTE #3

PL1

PL7

12104 6

ORN

BRN

YEL

GRN

YEL

PL9

HSI

1.5 AMP

EAC1

EAC2

2 1

PL4

YEL

ORN

BRN

GRN

BLU

BRN

RED

1011

RED 9

PL3

5BLU

4YEL

3VIO

2ORN

1RED

RED

ORN

VIO

YEL

WHT

BLK

RED

ORN

VIO

YEL

9876 4321

PL10

PL11

IND.

NOTE

PL11

PL12

12543

RED ORN

VIO

YEL

GRN/YEL

YEL BLU

MTR2

PL13

POS.

A/C AND CF

SELECT. CHART

SWITCH

POS.

A/C AND CF

A/C CF

DEFAULTDEFAULT

1-1/2 TON

TON 2-1/2

TON

1000 CFM

800 CFM

TON

1200

CFM 3-1/2 TON

1400

CFM

TON

1600

CFM

TON

2000

CFM

PCB

PL6

FU1

LEDS

(1-4)

(1-8)

FUSE

24VAC-3A

234

CF A/C

123

12345

FLT

LOW HEAT

BPH

EMER. HEATMZCOMP. TEST

BLOWER

OFF-DELAY

PL5

321 654

BLOWER

OFF-DELAY

SELECTION CHART

SEC.

135

SEC.

180

SEC.

225

SEC.

OFF

NOTE

OFF

SEC-2

SEC-1

DEHUM

HUM

Y/Y2

W/W1

12 34

PL2

YEL

LPS

TRAN

HPS

ILK

BLK WHT

FU2

FUSED DISCONNECT SWITCH

(WHEN REQ’D)

NOTE #2

MTR1

A/C AIR CON DITIONIN G (ADJUSTABLE T ONNAGE) ALS AUXILIARY LIMIT SWTICH OVERTEMP - MANUAL RESET SPST-(N.C) CF CONTINUOUS FAN (ADJUSTABLE CFM) CPU1 MAIN MICROPROCESSOR & CIRCUITRY CPU2 IGNITION MICROPROCESSOR & CIRCUITRY DE DEHU MIDIFY ENABLE - IF DE CONNECTION PROV IDED REMO VE

JUMPER TO ENABLE DEHUM INPUT DEHUM DEHU MIDIFICATION CONNECTION (24VAC .02 AMPS) EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.) EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON) FRS FLAME ROLLOUT SWITCH - MANUAL RESET, SPST-(N.C.) FSE FLAME PROVING SENSOR ELECTRODE FU1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED FU2 FUSE OR CIRCUIT BREAKER CURREN T INTERRUPT DEVICE

(FIELD INSTALLED & SUPPLIED) GND EQUIPMENT GROUND GV GAS VALVE GVR GAS VALVE RELAY, DPST-(N.O.) HI GAS VALVE HIGH STAGE OPERATOR HPS HIGH HEAT PRESSURE SWITCH, SPST- (N.O.) HSI HOT SURFACE IGNITOR (115 VAC) HSIR HOT SURFACE IGNITOR RELAY , SPST-(N.O.) HUM 24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.) HUMR HUMIDIFIER RELAY, SPST-(N.O.) ILK BLOW ER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.) IND INDUCTOR (NOTE #7) JB JUNCTION BOX LEDS LIGH T EM ITTING DIOES FOR STATUS CODES LGPS LOW GAS PRESSURE SWITCH, SPST (N.O.) LPS LOW HEAT PRESSSURE SWITCH, SPST-(N.O.) LS LIMIT SW ITCH, AUTO RESET, (N.C.) MTR1 MOTOR (ICM) INDUCER MTR2 MOTOR (ICM) BLOWER PCB PRINTED C IRCUIT BOARD PL1 11-CIRCUIT CONNECTOR PL2 4-CIRCUIT PRESSURE SWITCH CONNECTOR PL3 5-CIRCUIT BLOWER MTR CONNECTOR PL4 2-CIRCUIT HSI CONNECTOR PL5 6-CIRCUIT MODEL PLUG

PL6 3-CIRCUIT COMM. CONNECTOR PL7 12-CIRCUIT INDUCER MTR CONNECTOR PL9 2-CIRCUIT HSI CONNECTOR PL10 9-CIRCUIT BLOWER ADAPTER CONNECTOR PL11 1-CIRCUIT INDUCTOR SPLICE CONNECTOR PL12 5-CIRCUIT BLOWER POWER CONNECTOR PL13 16-CIRCUIT B LOWER CTRL. CONNECTOR SW1 MANUAL SWITCH, FAULT DISPLAY, SPST-(N.O.) SW2 MANUAL SWITCH, LOW HEAT, SPST-(N.O.) SW3 MANUAL SWITCH, BYPASS HUMIDIFIER, SPST-(N.O.) SW4 MANUAL SWITCH, EMERGENCY HEAT, SPST-(N.O.) SW5 MANUAL SWITCH, MULTIPLE ZONE, SPST-(N.O.) SW6 COMPONENT TEST, SPST-(N.O.) SW7-8 MANUAL SWITCH, BLOW ER OFF-DELAY, SPST-(N.O.) TRAN TRANSFORMER - 115VAC/24VAC

JUNCTION UNMARKED TERMINAL PCB TERMINAL (FAC TORY CONNECTED) FACTORY WIRING (115 VAC) FACTORY WIRING (24 VAC) FIELD WIRING (115 VAC) CONDUCTOR ON PCB FIELD WIRING SCREW TERMINAL TERMINA L BLO CK - M AR KE D TER M INA L FIELD EARTH GROUND EQUIPMENT GROUND FIELD SPLICE PCB TERMINAL (FIELD CON NECTION) PLUG RECEPTACLE

NOTE #2

EQUIPMENT GROUND

PL1

654

PL7

MTR1

12 6 4

D.C. POWER SUPPLY

PCB

NOTE #5

SW - 4

EMER. HEAT

SCHEMATIC DIAGRAM

(NATURAL GAS & PROPANE )

PL13

CPU1

CPU2

PL3

12345

B1 7

PL11

PL10

IND

NOTE #7

PL11

PL12

5 4

3 2 1

MTR2

HSIR

EAC

FRS

ALS

PL1-9

EAC-1 EAC-2

PL4

PL9

HSI

NOTE #6

FU1

SEC-1

24VAC

SEC-2

TRAN

115VA C

PL1-11

PCB NOTE #5

HUMR

D.C . POWER

SUPPLY

DEHUM

HUM

R G

Y/Y2

W2 W/W1 C

PL1-1

PL2-1

PL2-2

PL2-4

PL1-10

PL1-2

EAC

GVR

NOTE #3

HPS

PL1-7

FSE

LPS

CPU2

CPU1

NOTES:

HUMR

HSIR

GVR

T 2

T 1

T 2

T 1

213

OFF

213

OFF

213

OFF

213

OFF

213

OFF

213

OFF

213

OFF

213

OFF

2 1

TO 115 VAC FIELD DISCONNECT

ILK

MODEL

JUMPERS

1-4 2-5 3-6

X XX

042040 042060 042080 060100

SIZE

060080 060120

ORN

BRN

LGPS

(WHEN USED)

ORN

NOTE #11

LGPS

NOTE #11

(WHEN USED)

NOTE #11

BLK

WHT

RED

BLU

BLK

WHT

SELECT. CHART

CFM

600

WHT

(WHEN USED)

BLK

WHT

BLK

WHT

BLK

BLU

RED

WHT

BLK

RED

BLK

WHT

YEL

ORN

BRN

SWITCH

WHT

BLK

RED

GRN / YEL

GRN/YEL

BRN

BLU

LEGEND

1. If any of the original equi pment wire is replaced use wire rated for 105°C.

2. Use only copper wire between the disconnect switch and the furnace junction box (JB).

3. This wire must be connected to furnace sheet metal for control to prove flame.

4. Symbols are electrical representation only.

5. Solid lines, inside circuit board PCB are printed circuit board traces and are no t dep icted as s ho wn in the legend.

6. Replace only with a 3 AMP fuse.

7. Inductor used on all 060 or -20 airflow units.

8. Blower-on delay, gas heating 60 seconds low heat, 35 seconds high heat, cooling or heat pump 2 seconds..

9. Blower-off delay, gas heating 90, 135, 180 or 225 seconds, cooling or heat pump 90 seconds.

10. Ignition -loc k out will occur after four consecutive unsuc cess ful trials-for-ignition. Control will auto-reset after three hours.

11. Factory connected when LGPS not used.

322296-101 REV. E

YEL

GND

BLU

Page 21

Table 4—Electrical Data

UNIT

SIZE

040-14 115—60—1 127 104 8.9 12.0 14 31 15 060-14 115—60—1 127 104 8.9 12.0 14 31 15 080-14 115—60—1 127 104 8.9 12.0 14 31 15 080-20 115—60—1 127 104 13.8 17.9 12 32 20 100-20 115—60—1 127 104 13.8 18.1 12 32 20 120-20 115—60—1 127 104 11.6 15.3 12 37 20

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

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

VOLTS— HERTZ—

PHASE

OPERATING

VOLTAGE RANGE

Maximum* Minimum*

MAXIMUM

UNIT

AMPS

UNIT

AMPACITY†

MINIMUM

WIRE

SIZE

MAXIMUM WIRE

LENGTH (FT)‡

MAXIMUM FUSE OR

CKT BKR AMPS**

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

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

NOTE: For 2-speed applications, refer to Sequence of Operation section.

Step 3—Accessories

1. Electronic Air Cleaner (EAC) The control center EAC terminals are energized with 115v

(1.5-amp maximum) during blower operation. a. Two extension leads are connected to the control center

EAC terminals to assist field installation of an EAC. (See Fig. 25.) To use these leads, proceed with the following:

(1.) Strip EAC power lead insulation approximately 1/4 in. (2.) Insert stripped end into factory-supplied black lead’s

butt connector and crimp to secure.

EAC-ELECTRONIC AIR CLEANER TERMINALS

(115-VAC 1 AMP MAX)

MAIN BLOWER

CONTROL WIRE

CONNECTOR

TRANSFORMER

24-V CONNECTORS

(3.) Strip EAC neutral lead insulation approximately 1/4

in.

(4.) Insert stripped end into factory-supplied white leads’s

butt connector and crimp to secure.

NOTE: If desired, cut butt connectors off factory leads and strip insulation approximately 1/4 in and use field-supplied wire nuts to connect.

b. An alternate method to attach EAC lead to control center is

the following procedure: (1.) Remove 2 screws securing the control box to furnace

blower shelf.

(2.) Remove and discard 2 factory-supplied leads from

control center EAC terminals.

(3.) Strip EAC power leads insulation approximately 1/8

in.

HOT SURFACE IGNITOR CONNECTOR

HUM

W/W1 Y/Y2

COM

115-V CONNECTORS

PRESSURE SWITCH CONNECTOR

HUM-HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX)

24-V THERMOST AT TERMINALS

24V

DEHUMIDIFY ENABLE (DE)

DEHUMIDIFIER (DEHUM) CONNECTOR 3-AMP FUSE

STATUS AND DIAGNOSTIC LED LIGHTS

CONTINUOUS

FAN (CF) SETUP

SWITCHES

AIR CONDITIONING (A/C) SETUP SWITCH SETUP SWITCHES (SW) AND BLOWER OFF DELAY SETUP SWITCHES

MODEL PLUG

COMMUNICATION

CONNECTOR

A99097

Fig. 25—Control Center

Page 22

EAC1

EAC2

A93053

Fig. 26—EAC Terminals on Control Center

NOTE: The control center EAC terminals are sized for 12 gage

maximum, solid or stranded wire.

(4.) Route EAC leads through right-hand wire grommet. (5.) Insert EAC stripped leads into control center EAC

terminals by depressing terminal’s arm with a screwdriver or finger. (See Fig. 26.)

(6.) Reinstall control box to furnace blower shelf using 2

screws removed earlier.

2. Humidifier (HUM) Screw terminals (HUM and C

humidifier connection. (See Fig. 24.) HUM terminal is energized with 24v (0.5-amp maximum) after inducer motor prepurge period.

OM) are provided for 24-v

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

3. Dehumidification (DEHUM) A dehumidification input is provided via a 1/4-in. male

quick-connect labeled DEHUM located next to the transformer secondary connections. When there is a dehumidify demand, the DEHUM input is activated, which means 24 vac signal is removed from the DEHUM input terminal. In other words, the DEHUM input logic is reversed. the DEHUM input is turned ON when no dehumidify demand exists and is turned OFF when demand exists. This logic reversal has come about from historical use of a standard humidistat to do dehumidification since the contacts open on high humidity, thus removing the 24-v signal to initiate dehumidification.

The DEHUM output on the thermidistat control or the humidistat output is connected directly to the DEHUM terminal on the furnace control. In addition, the DE jumper located next to the DEHUM terminal must be removed to enable the DEHUM input. (See Fig. 27 and 28.) When a dehumidify demand exists, the furnace control reduces the blower airflow by 21 percent to 315 CFM per ton during continuous fan or cooling operation.

DIRECT VENTING

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

W/W1 Y/Y2 HUMRG

24V

W2 Com

SEC-2

SEC-1

DE CONNECTION

LOCATION

DEHUM

DE CONNECTION

Fig. 27—58MVP Variable Speed Furnace Control

A99098

Page 23

VARIABLE-SPEED

THERMIDISTAT

24 VA C HOT

DEHUMIDIFY

24 VA C COMM

DHUM

NOTE 1 - Remove DE Connection To Enable DEHUM Input

CONDENSING

FURNACE

DEHUM

NOTE 1

Com

A98295

Fig. 28—Thermidistat Connection

Step 1—Removal of Existing Furnaces from Common Vent Systems

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

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code, NFPA 541999/ANSI Z223.1-1999 or the CAN/CGA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition.

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

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

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

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

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

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

Step 2—Combustion-Air and Vent Piping

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

National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards D1785 (schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and SDR-26 PVC), D2661 (ABS-DWV), F628 (schedule-40 ABS), F891 (PVC-DWV cellular core) or F441 (schedule-40 CPVC pipe) and F438 (schedule -40 CPVC fittings). Pipe cement and primer must conform to ASTM standards D2564 or F493 (PVC or CPVC) D2235 (ABS). See Table 6 for maximum pipe lengths and Fig. 34, 35, 36, 37, and 38 for exterior piping arrangements.

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

NOTE: Furnace combustion-air and vent pipe connections are sized for 2-in. pipe. Any pipe size change should be made outside furnace casing in vertical pipe. (See Fig. 29.) This allows proper drainage of vent condensate.

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

Table 5—Combustion-Air and Vent Pipe

Termination Clearances

LOCATION

Above grade level or above anticipated snow depth

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

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

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

Above grade when adjacent to public walkway

* Horizontal distance.

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

NOTES:

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

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

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

Furnace combustion-air and vent pipe connections must be attached as shown in Fig. 31. Combustion-air intake plug fitting and inducer housing alternate vent cap may need to be relocated in some applications.

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

CLEARANCE (FT)

U.S.A. Canada

11†

4* 6‡

Note 3 Note 3

Page 24

NOT IN HORIZONTAL SECTION

FURNACE

PIPE DIAMETER

TRANSITION IN

VERTICAL SECTION

Combustion air must not be taken from inside structure because that air is frequently contaminated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, adhesives, paint, and other household products. Locate combustion-air inlet as far as possible from swimming pool and swimming pool pump house. Excessive exposure to contaminated combustion air will result in safety and performance related problems.

A93034

Fig. 29—Combustion-Air and Vent Pipe Diameter

Transition Location and Elbow Configuration

NOTE: Select 1 vent pipe connection and

Select 1 vent pipe connection and 1 combustion-air pipe connection.

AIR

COMBUSTION-

AIR

VENT

COMBUSTION-

AIR

FLOW

HORIZONTAL-LEFT DISCHARGE HORIZONTAL-RIGHT DISCHARGE

FLOW

COMBUSTION-

AIR

UPFLOW DOWNFLOW

AIR

VENT

NOTE:

1 combustion-air pipe connection.

VENT

COMBUSTION-

AIR

FLOW

COMBUSTION-

VENT

COMBUSTION-

AIR

FLOW

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

All combustion-air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 33, 34, 35, 36, or 37. Failure to follow this warning could result in property damage, personal injury, or death.

NOTE: The minimum combustion-air and vent pipe length (each) for these furnaces is 5 ft. Short pipe lengths (5-8 ft) may discharge water droplets. These droplets may be undesirable, and a 12-in. minimum offset pipe section is recommended, as shown in Fig. 31, to reduce excessive droplets from exiting vent pipe outlet.

COMBUSTION-AIR AND VENT PIPE DIAMETER Determine combustion-air and vent pipe diameter.

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

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

NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 34, 35, 36, 37, and 38.

Fig. 30—Combustion-Air and Vent Pipe Connec-

tions

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

When vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, pipe must be insulated as shown in Table 7 with Armaflex-type insulation.

A96187

Page 25

12″ MIN

VENT PIPE

HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL

COMBUSTION-AIR PIPE

12″ MIN

VENT PIPE

COMBUSTION-AIR PIPE COMBUSTION-AIR PIPE

COMBUSTION-AIR PIPE

VENT PIPE

12″ MIN

VENT PIPE

VERTICAL TO SIDEWALLVERTICAL TO ROOF

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

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

Fig. 31—Short Vent (5 to 8 Ft) System

EXAMPLE: An 080-14 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed in an application requiring 3 elbows and 17 ft of vent pipe, along with 5 elbows and 16 ft of combustion-air pipe. Table 6 indicates this application would allow a 1-1/2-in. diameter vent pipe, but require a 2-in. diameter combustion air pipe (1-1/2-in. pipe is good for 20 ft with 3 elbows, but only 10 ft with 5 elbows). Therefore, 2-in. diameter pipe must be used for both vent and combustion-air pipes since larger required diameter must always be used for both pipes. If same installation were in Albuquerque, elevation 5250 ft above sea level, installation would require 2-in. vent pipe and combustion-air pipe. At 5001- to 6000-ft elevation, 1-1/2in. pipe is not allowed with 5 elbows, but 2-in. pipe is good for 68 ft with 5 elbows.

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

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

1. Attach combustion-air pipe as follows:

A96230

a. Determine location of combustion-air intake pipe connec-

tion to combustion-air intake housing as shown in Fig. 30 for application.

b. Reposition combustion-air intake housing plug fitting in

appropriate unused intake housing connection.

c. Insert perforated disk assembly (factory supplied) in intake

housing where combustion-air intake pipe will be connected.

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

into selected furnace casing combustion-air pipe hole. Pipe

support should be positioned to bottom of casing hole. e. Insert 2-in. diameter pipe into intake housing. f. Install casing hole filler cap (factory-supplied in loose parts

bag) in unused combustion-air pipe casing hole.

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

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

in intake housing as a guide. h. Install a field-supplied No. 6 or No. 8 sheet metal screw

into combustion-air pipe.

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

Page 26

ALTITUDE

0 to 2000

ALTITUDE

2001 to 3000

ALTITUDE

3001 to 4000

ALTITUDE

4001 to 5000‡

ALTITUDE

5001 to 6000‡

See notes on next page.

UNIT SIZE

040-14

060-14 080-14

080-20 100-20

120-20

UNIT SIZE

040-14

060-14 080-14

080-20 100-20

120-20

UNIT SIZE

040-14

060-14 080-14

080-20 100-20

120-20

UNIT

SIZE

040-14

060-14 080-14

080-20 100-20

120-20

UNIT

SIZE

040-14

060-14 080-14

080-20 100-20

120-20

Table 6—Maximum Allowable Pipe Length (Ft)

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIAMETER

(IN.)*

1-1/2 50 45 40 35 30 25

2 707070707070

1-1/2 50 45 40 35 30 25

2 707070707070

1-1/2 30 25 20 15 10 5

2 707070707070

2 454035302520 2-1/2 70 70 70 70 70 70 2-1/2 10 NA NA NA NA NA

3 353015NANANA

3† 70 70 70 70 70 70

PIPE DIAMETER

(IN.)*

1-1/2 45 40 35 30 25 20

2 70707070 70 70

1-1/2 45 40 35 30 25 20

2 70707070 70 70

1-1/2 26 21 16 11 6 NA

2 70707070 70 70 2 40353025 20 15

2-1/2 70 70 70 70 70 70

3 312612NANANA

3† 63 62 62 61 61 61

PIPE DIAMETER

(IN.)*

1-1/2 42 37 32 27 22 17

2 70707070 70 70

1-1/2 42 37 32 27 22 17

2 70707070 70 70

1-1/2 25 20 15 10 5 NA

2 70707070 70 70 2 38332823 18 13

2-1/2 70 70 70 70 70 70

3 292410NANANA

3† 59 59 58 57 57 56

PIPE DIAMETER

(IN.)*

1-1/2 40 35 30 25 20 15

2 7070707070 70

1-1/2 40 35 30 25 20 15

2 7070707070 70

1-1/2 23 18 13 8 NA NA

2 7070707070 68 2 3631262116 11

2-1/2 70 70 70 70 70 70

3† 56 55 54 53 52 52

PIPE DIAMETER

(IN.)*

1-1/2 37 32 27 22 17 12

2 7070707070 70

1-1/2 37 32 27 22 17 12

2 7070707070 70

1-1/2 22 17 12 7 NA NA

2 7070707068 63 2 3328231813 8

2-1/2 70 70 70 70 70 70

3† 53 52 50 49 48 47

123456

1234 5 6

12345 6

NUMBER OF 90° ELBOWS

Page 27

Table 6—Maximum Allowable Pipe Length (Ft) Continued

ALTITUDE

UNIT SIZE

040-14

060-14

6001 to 7000‡

080-14 080-20

100-20

120-20

ALTITUDE

UNIT SIZE

040-14

060-14

7001 to 8000‡

080-14 080-20

100-20

120-20

ALTITUDE

UNIT SIZE

040-14

060-14

8001 to 9000‡

080-14 080-20

100-20

120-20

ALTITUDE

UNIT SIZE

040-14

060-14

9001 to 10000‡

080-14 080-20

100-20

120-20

* Disk usage—Unless otherwise stated, use perforated disk assembly (factory-supplied in loose parts bag).

† Wide radius elbow. ‡ Vent sizing for Canadian installations over 4500 ft (1370m) above sea level are subject to acceptance by the local authorities having jurisdiction. NA—Not Allowed; pressure switch will not make.

NOTES:

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

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

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

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

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

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

TERMINATION

TYPE

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

PIPE DIAMETER

(IN.)*

12345 6

1-1/2 35 30 25 20 15 10

2 7070686766 64

1-1/2 35 30 25 20 15 10

2 7070686766 64

1-1/2 20 15 10 5 NA NA

2 7070686762 57 2 3126211611 6

2-1/2 70 70 68 67 66 64

3† 49 48 47 45 44 43

PIPE DIAMETER

(IN.)*

1234 5 6

1-1/2 32 27 22 17 12 7

2 66656362 60 59

1-1/2 32 27 22 17 12 7

2 66656362 60 59

1-1/2 18 13 8 NA NA NA

2 66656362 57 52 2 29241914 9 NA

2-1/2 66 65 63 62 60 59

3† 46 44 43 41 40 38

PIPE DIAMETER

(IN.)*

1234 5 6

1-1/2 30 25 20 15 10 5

2 62605856 55 53

1-1/2 30 25 20 15 10 5

2 62605856 55 53

1-1/2 17 12 7 NA NA NA

2 62605856 51 46 2 27221712 7 NA

2-1/2 62 60 58 56 55 53

3† 43 41 39 37 35 34

PIPE DIAMETER

(IN.)*

1234 5 6

1-1/2 27 22 17 12 7 NA

2 57555351 49 47

1-1/2 27 22 17 12 7 NA

2 57555351 49 47

1-1/2 15 10 5 NA NA NA

2 57555351 46 41 2 241914 9 NANA

2-1/2 57 55 53 51 49 47

3† 39 37 35 33 31 29

NUMBER OF 90° ELBOWS

Page 28

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

COMBUSTION-AIR INTAKE HOUSING PLUG FITTING

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

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

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

NOTE: Moisture in combustion-air intake may be result of improper termination. Ensure combustion-air intake pipe is similar to that shown in Fig. 33, 34, 35, 36, or 37 so it will not be susceptible to areas where light snow or other sources of moisture could be pulled in.

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

32.)

COMBUSTION – AIR

3/8" ID TUBE

3/16"

DRILL

4″

TRAP

TO OPEN

MIN

DRAIN

Fig. 32—Intake Housing Plug Fitting Drain

INTAKE HOUSING

BURNER BOX

COMBUSTION – AIR PIPE

A93035

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

housing as shown in Fig. 30 for application.

b. Reposition elastomeric (rubber) inducer housing outlet cap

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

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

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

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

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

tion, elastomeric coupling, and 2-in. diameter vent pipe are clean and dry. Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps) onto inducer housing connection. Insert the 2-in. diameter vent pipe through the

elastomeric (rubber) coupling and fully into inducer housing connection until it bottoms on the internal stop. Tighten both clamps to secure the pipe to inducer housing. Tighten the clamp screws to 15 in.-lb. of torque.

e. Install casing hole filler cap (factory-supplied in loose parts

bag) in unused combustion-air pipe casing hole.

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

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

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

4. Deburr inside and outside of pipe.

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

6. Clean and dry all surfaces to be joined.

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

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

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

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

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

11. Handle pipe joints carefully until cement sets.

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

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

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

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

NOTE: If these instructions differ from those packaged with

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

factory accessory termination kit must be installed in 1 of the installations shown in Fig. 33, 34, 35, 36, or 37. Four termination kits are available.

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

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

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

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

Page 29

VERTICAL SEPARATION

BETWEEN COMBUSTION

MAXIMUM OF 24 IN. ABOVE ROOF.

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

MAINTAIN 12 IN. MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL.

COUPLING

VENT

ROOF

18″ MAXIMUM

BRACKET

COMBUSTION AIR

Fig. 33—Roof Termination (Preferred)

VENT

COMBUSTION AIR

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

A93054

Fig. 34—Concentric Vent and Combustion-Air Roof

Termination (Preferred)

OVERHANG OR ROOF

A87224

OVERHANG OR ROOF

12″ MINIMUM

1″ MAXIMUM

COMBUSTION-AIR

VENT

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

A93055

Fig. 35—Concentric Vent and Combustion-Air Side

Termination

OVERHANG OR ROOF

12″ MINIMUM

VENT

BRACKET

90°

COMBUSTION-AIR

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

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

Fig. 36—Sidewall Termination of 12 in. or More

A87225

12″ MINIMUM

VENT

BRACKET

COUPLING

90°

COMBUSTION-AIR (ELBOW PARALLEL TO WALL)

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

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

Fig. 37—Sidewall Termination of Less than 12 in.

A87226

Page 30

Table 7—Maximum Allowable Exposed Vent Pipe Length (Ft) With Insulation in Winter Design

Temperature Ambient*

UNIT SIZE

040-14

060-14

080-14 080-20

100-20

120-20

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

as specified in Table 6.

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

WINTER DESIGN

TEMPERATURE

(°F)

20 2 2137425057

0 2 10 22 25 30 35

-20 2 5 14 17 21 25 20 2 3055617070

0 2 16 33 38 46 53

-20 2 9 23 26 33 38 20 2 3765707070

0 2 20 39 45 55 63

-20 2 1127313945 20 2-1/2 41 70 70 70 70

0 2-1/2 21 42 48 59 68

-20 2-1/2 11 28 33 41 49 20 3 4970707070

0 3 26 51 58 70 70

-20 3 1535405059

MAXIMUM PIPE

DIAMETER

(IN.)

INSULATION THICKNESS (IN.)†

0 3/8 1/2 3/4 1

NOTE: Shaded parts in Fig. 33, 34, 35, 36, and 37 are considered

to be terminations. These components should NOT be counted when determining pipe diameter. Roof termination is preferred since it is less susceptible to damage, has reduced chances to intake contaminants, and has less visible vent vapors. (See Fig. 33 or 34.) Sidewall termination may require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system.

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

extended beyond area shown in Fig. 36 or 37 in outside ambient by insulating pipes as indicated in Table 7.

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

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

3. Determine required insulation thickness for exposed pipe lengths.

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

TWO-PIPE TERMINATION KIT

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

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

b. Termination kit should be positioned where vent vapors

will not damage plants/shrubs or air conditioning equipment.

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

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

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

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

e. Termination kit should be positioned where vent vapors are

not objectionable.

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

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

Roof terminations—Loosely install pipe coupling on prop- erly cut vent pipe. Coupling must be positioned so bracket will mount as shown in Fig. 33.

For applications using combustion-air pipe option indicated by dashed lines in Fig. 33, install 90° street elbow into 90° elbow, making U-fitting. A 180° U-fitting may be used.

Sidewall terminations—Install bracket as shown in Fig. 36 or

37. For applications using vent pipe option indicated by dashed

lines in Fig. 36, rotate vent elbow 90° from position shown in Fig. 36.

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

5. Check required dimensions as shown in Fig. 33, 36, or 37.

CONCENTRIC VENT/AIR TERMINATION KIT

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

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

b. Termination kit should be positioned where vent vapors

will not damage plants/shrubs or air conditioning equipment.

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

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

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

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

e. Termination kit should be positioned where vent vapors are

not objectionable.

Page 31

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

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

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

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

Roof terminations—Locate assembly through roof to appro- priate height as shown in Fig. 34.

Sidewall terminations—Locate assembly through sidewall with rain shield positioned no more than 1-in. from wall as shown in Fig. 34 .

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

6. Check required dimensions as shown in Fig. 34 or 35.

Step 4—Multiventing and Vent Terminations

When 2 or more 58MVP Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent 58MVP furnaces. When 2 or more 58MVP furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 38, 39, 40, 41, or 42, but next vent termination must be at least 36 in. away from first 2 terminations. It is important that vent terminations be made as shown to avoid recirculation of flue gases. Dimension "A" in Fig. 38, 39, 40, 41, and 42 represents distance between pipes or rain shields, as touching or 2-in. maximum separation.

32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED

A93058

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

CONDENSATE DRAIN

Step 1—General

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

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

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

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

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

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

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

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

Step 2—Application

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

See Fig. 43 for example of possible field drain attachment using 1/2-in. 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.

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

Step 3—Condensate Drain Protection

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

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

2. Locate heat tape between sides of condensate trap back. (See Fig. 44.)

3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig. 44.)

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.

Page 32

A96128

Fig. 38—Rooftop Termination (Dimension "A" is Touching or 2-In. Maximum Separation)

VENT

COMBUSTION AIR

A93056

Fig. 39—Concentric Vent and Combustion-Air Roof

Termination (Dimension "A" is Touching or

2-In. Maximum Separation)

VENT

1″ MAXIMUM (TYP)

COMBUSTION AIR

VENT

A93057

Fig. 40—Concentric Vent and Combustion-Air Side

Termination (Dimension "A" is Touching or

2-In. Maximum Separation)

VENT

COMBUSTION AIR

Fig. 41—Sidewall Termination of 12 in. or Less

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

Maximum Separation)

A96129

COMBUSTION AIR

Fig. 42—Sidewall Termination of More Than 12 in.

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

Maximum Separation)

A96130

Page 33

OPEN STAND

PIPE FOR

A/C OR

HUMIDIFIER

DRAIN

TEE

TO OPEN DRAIN

A94054

Fig. 43—Example of Field Drain Attachment

CONDENSATE TRAP

WIRE TIE(S)

(3 WRAPS MINIMUM)

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

Using schematic diagram (see Fig. 24), follow sequence of operation through different modes. This furnace has a new control system. Read and follow wiring diagram carefully.

NOTE: If 115-v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates at low-heat speed for 60 sec when power is restored before heating cycle is resumed.

Step 1—Self-Test Mode

The control center goes through a brief self-test whenever 115-v or 24-v power is interrupted. The self-test takes approximately 2 sec to complete. After power is restored, red (microprocessor) LED

HEAT TAPE

Fig. 44—Condensate Trap Heat Tape

SEQUENCE OF OPERATION

A93036

briefly comes on. Then green LED comes on for 1 sec, followed by 1 sec where both yellow and green LEDs are on. During this time, the microprocessor is checking itself.

Step 2—Heating Mode

When thermostat calls for heat, R-W/W1 circuit closes.

1. Prepurge period—The inducer motor is turned on and slowly comes up to speed. When low-pressure switch closes, inducer motor RPM is noted by microprocessor, and a 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine required RPM necessary to operate inducer in low-heat mode.

NOTE: The heat cycle can start in either high or low heat. If a high-heat cycle is initiated, the inducer continues increasing its speed after low-pressure switch closes. When high-pressure switch closes, inducer motor RPM is noted by microprocessor before the 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is then used to determine required RPM necessary to operate inducer in high-heat mode.

2. Humidifier (HUM)—The HUM terminal is energized after the inducer prepurge period is completed.

3. Ignitor warm up—At end of prepurge period, the hot surface ignitor (HSI) is energized for a 17-sec HSI warm-up period.

4. Ignition sequence—After HSI ignitor warm-up period is completed, the gas valve opens, permitting gas flow to burners where it is ignited. After 5 sec, the HSI is de-energized, and a 2-sec flame-sensing period begins.

NOTE: The initial heat mode after 115-v or 24-v power interruption will be LOW HEAT. Low heat remains energized for 16 minutes before high heat is initiated, providing thermostat is still calling for heat.

After initial cycle, the microprocessor evaluates the length of lowand high-heat operating times and calculates optimum length of low and high heat for next heat cycle. This accommodates the heat load requirement seen as a result of thermostat operating time.

5. Flame sensing—When burner flame is sensed, the control center holds gas valve open and begins blower on delay period.

NOTE: Ignition sequence repeats 3 additional times before a lockout occurs. Lockout automatically resets after 3 hr, or can be manually reset by turning 115-v or 24-v power off (not at thermostat) for 3 sec minimum, then turning on again.

6. Inducer speed operation—If cycle starts in low heat, inducer speed reduces slightly after flame sense. If cycle starts in high heat, inducer speed increases 15 sec after flame sense. The reduction in speed in low heat is to optimize combustion for maximum efficiency.

7. Blower on delay—The blower starts 60 sec after flame sense if cycle started in low heat or 35 sec after flame sense if cycle started in high heat.

NOTE: The blower starts at approximately 400-500 RPM. After 20 sec, the motor is turned off for 1/10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide proper airflow for heating mode.

8. Electronic Air Cleaner—The EAC-1 terminal is energized whenever the blower operates.

9. Blower off delay—When thermostat is satisfied, the R-W/W1 signal is terminated, de-energizing gas valve (stopping gas flow to burners), and HUM terminal is de-energized.

Page 34

The blower reduces its speed to low-heat RPM. The blower and EAC remain operating 90, 135, 180, or 225 sec (depending on blower off time selection). The furnace is factory set for a 90-sec blower off delay.

10. Post purge—The inducer continues operating for 15 sec after

gas valve is de-energized.

Step 3—Heating Mode—Two Stage

The control center provides 2-stage heating using a single-stage thermostat. The control center maximizes comfort while optimizing efficiency to meet the demands of conditioned area when a thermostat R-W/W1 signal is received.

If thermostat control over furnace staging is desired, a 2-stage thermostat can be used. When control center receives a thermostat R-W/W1 and R-W2 signal, high heat is energized and when a R-W/W1 signal alone is received, low heat is energized. This method overrides microprocessor control of high or low heat.

NOTE: When using 2-stage thermostat operation with R-W/W1 and R-W2 signals, setup switch SW-2 MUST be in ON position.

The heat cycle operates as stated in Heating Mode section. To allow for greater comfort, 2-stage thermostat control is recom-

mended when zone systems are used.

Step 4—Emergency Heat Mode NOTE: The furnace should not be operated in emergency heat

mode for extended periods of time. Operation is only recommended to provide heat until replacement components can be obtained or fault resolved.

In this mode, the microprocessor is bypassed and motors operate at full speed with high-heat operation. The heat exchangers, motors, and electronics can be overstressed and may reduce the life of components if operated for an extended period.

NOTE: No safeties are bypassed when using emergency heat mode.

Emergency heat mode can be selected using setup switch SW-4. SW-4 should be used when a fault condition exists or difficult to resolve problems occur. This allows heating until fault can be corrected.

In emergency heat mode, the normal heat mode outlined in Heating Mode section is not followed. The following sequence will occur:

When thermostat calls for heat, the R-W/W-1 circuits close.

1. Prepurge period—The inducer motor is turned on IMMEDI-

ATELY operating at maximum speed, closing low- and high-pressure switches. Prepurge begins 25 sec after highpressure switch closes.

2. Blower on—The blower motor is turned on IMMEDIATELY

and slowly increases to maximum speed as soon as a call for heat is received. No blower calibration occurs.

3. Electronic Air Cleaner—The EAC-1 terminal does not

operate in emergency heat mode.

4. Humidifier—The HUM terminal is energized IMMEDI-

ATELY.

5. Ignitor warm up—The HSI is energized for a 17 sec

warm-up period after prepurge period is completed.

6. Ignition sequence—After HSI warm-up period has com-

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

NOTE: Emergency heat mode only operates in high heat.

7. Flame sensing—When burner flame is sensed, control center

holds gas valve open. If burner flame is not sensed, control

center de-energizes gas valve and ignition sequence is repeated.

NOTE: Ignition sequence repeats 3 additional times before lockout occurs. Lockout automatically resets after 3 hr, or can be manually reset by turning 115-v or 24-v power off (not at thermostat) for 3 sec minimum, then turning on again. Fault codes will not flash in emergency heat mode.

8. Blower off delay—When thermostat is satisfied, the R-W/W1

signal is terminated, de-energizing gas valve (stopping gas flow to burners), and HUM terminal is de-energized. The blower stops immediately.

9. Post purge—Post purge does NOT occur. The inducer stops

immediately.

Step 5—Cooling Mode

SINGLE-SPEED APPLICATIONS When thermostat calls for cooling, the R-G and R-Y/Y2 circuits

close.

1. Cooling unit—The cooling unit starts when thermostat R-Y

signal is received.

2. Blower on—The control center starts blower immediately

when it receives an R-Y/Y2 and R-G signal. The blower starts at approximately 400-500 RPM. After 20 sec, the blower is turned off for 1/10 of a sec where a coast down calibration is done to evaluate resistance of the conditioned air duct system. The microprocessor then determines blower RPM required to provide selected cooling airflow.

NOTE: In cooling mode, the microprocessor adjusts blower RPM to operate at 400 CFM per ton as selected on A/C setup switches. Airflow will be reduced to 315 CFM per ton when a dehumidification demand exists. See Air Conditioning Setup Switches section. There is also a chart on wiring diagram. (See Fig. 24.)

NOTE: If Y/Y2 thermostat lead is not connected to furnace control center, blower motor operates in continuous fan speed and indoor coil freeze-up may occur.

3. Electronic Air Cleaner—The EAC-1 terminal is energized

whenever blower operates.

4. Cooling unit—The cooling unit stops when thermostat R-Y

signal is terminated.

5. Blower off delay—When thermostat is satisfied, the R-Y/Y2

and R-G signals are terminated, and blower remains operating for 90 sec. The blower airflow will drop by 21 percent during the off-delay period when the DE jumper is connected. The DE jumper is only removed to enable the DEHUM input for use with a thermidistat or humidistat for dehumidification

purposes. TWO-SPEED APPLICATIONS For details on 2-speed cooling applications, refer to Fig. 45.

Step 6—Heat Pump Mode

SINGLE-SPEED APPLICATIONS When furnace is operating in heat pump heating mode, R-Y/Y2

and R-G circuits are closed energizing heat pump, and blower operates at cooling speed. When heat pump defrost is required, R-W/W1 circuits close starting gas heat cycle, and blower adjusts to low-heat speed.

1. Prepurge period—The inducer motor is turned on and slowly

comes up to speed. When low-pressure switch closes, inducer

motor RPM is noted by microprocessor, and a 25 sec prepurge

period begins. The RPM is used to evaluate vent system

resistance. This evaluation is then used to determine required

RPM necessary to operate inducer in low-heat mode.

Page 35

2-SPEED

THERMOSTAT

R R

C C

Y2 Y2

L L

Y1 Y1

VARIABLE

SPEED

THERMOSTAT

W/W1

Y/Y2

2-SPEED AIR

CONDITIONER

10. Call for heat terminated—When the call for heat is satisfied,

the R-W/W1 signal is terminated, de-energizing gas valve (stopping gas flow to burners), and HUM terminal is deenergized.

a. R-W/W1 signal terminated with R-Y/Y2 and R-G still

present—The blower changes its speed to cooling RPM.

b. R-W/W1 with R-Y/Y2 and R-G signals terminated—

The blower continues to operate completing a normal heating blower off delay.

11. Post purge—The inducer continues operating for 15 sec after

gas valve is de-energized. TWO-SPEED APPLICATIONS For details on 2-speed heat pump applications, refer to Fig. 46.

2-SPEED

THERMOSTAT

R R

C C

VARIABLE

SPEED

THERMOSTAT

2-SPEED

HEAT PUMP

A94302

Fig. 45—Wiring Schematic for 2-Speed

Cooling Applications

NOTE: The heat cycle can start in either high or low heat. If a

high-heat cycle is initiated, inducer continues increasing its speed after low-pressure switch closes. When high-pressure switch closes, inducer motor RPM is noted by microprocessor before the 25 sec prepurge period begins. The RPM is used to evaluate vent system resistance. This evaluation is used to determine required RPM necessary to operate inducer in high-heat mode.

2. Humidifier—The HUM terminal is energized after inducer

prepurge period is completed.

3. Ignitor warm up—After prepurge period, HSI is energized

for 17 sec.

4. Ignition sequence—After HSI warm-up period is completed,

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

5. Flame sensing—When burner flame is sensed, control center

holds gas valve open. If burner flame is not sensed, control center de-energizes gas

valve, and ignition sequence is repeated.

6. Blower off period—Ten sec after gas valve is energized, the

blower stops for 25 sec to allow heat exchangers to warm up.

7. Blower on delay—After blower off period, blower starts.

8. Electronic Air Cleaner—The EAC-1 terminal is energized

whenever blower operates.

9. Inducer speed operation—If cycle starts in low heat, inducer

speed reduces slightly after the flame sense. If cycle starts in high heat, inducer speed increases 15 sec after flame sense. The reduction in speed in low heat is to optimize combustion for maximum efficiency.

Y2 Y2

L L

O O

Y1 Y1

W/W1

Y/Y2

A94303

Fig. 46—Wiring Schematic for 2-Speed

Heat Pump Applications

Step 7—Continuous Fan Mode

1. Operating with continuous fan only— a. Call for continuous fan—The thermostat closes R-G

circuit.

b. Blower on—The blower starts immediately.

NOTE: The continuous fan speed is the same as low-heat speed unless it is field adjusted to another desired airflow. See Continuous Fan Setup Switches section. There is also a chart on wiring diagram. (See Fig. 24.)

c. Electronic Air Cleaner—The EAC-1 terminal is ener-

gized whenever blower operates, regardless of operating mode.

2. Operating with continuous fan (R-G) and call for heat (R-W/W1) is received—Same as heat pump mode except blower on delay is 10 sec less than heat mode. After call for

Page 36

heat (R-W/W1) is terminated, the blower remains operating at low-heat speed for selected blower off delay before resuming continuous fan speed.

3. Operating with continuous fan (R-G) and call for cooling (R-Y/Y2) is received—See Cooling Mode section. After call for cooling (R-Y/Y2) is terminated, the blower remains operating at cooling speed for 90 sec before resuming continuous fan speed.

Step 8—Component Test

All components are functionally operated except gas valve with component test feature.

This feature helps diagnose a system problem in case of a component failure.

NOTE: Setup switch SW-1 MUST be in OFF position or Fault Code 22 (setup error) will occur.

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

To initiate component test feature, proceed with the following:

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

2. Remove main furnace door.

3. Remove blower access panel.

4. Move setup switch SW-6 to ON position.

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

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

When items 1-5 have been completed, the following will occur:

1. The control center goes through a brief self-test. This self-test takes approximately 2 sec to complete. After door switch is closed, red (microprocessor) LED briefly comes on. Then green LED comes on for 1 sec, followed by 1 sec where both green and yellow LEDs are on. During this time, the microprocessor is checking itself.

2. Inducer motor operates for 20 sec at low speed, operates for 20 sec at high speed, then turns off.

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

4. Main blower motor operates for 20 sec at low speed, operates for 20 sec at high speed, then turns off.

5. After component operation test is completed, 1 or more fault codes (11, 22, 41, or 42) will flash. See service label on back of main furnace door for explanation of fault codes.

NOTE: To repeat component test, turn setup switch SW-6 to OFF and then back to ON.

After component test, perform the following:

1. Release blower panel access door switch and turn setup switch SW-6 to OFF position.

2. If applicable, replace blower access panel and check LED status by removing plug in blower access panel.

3. Reinstall main furnace door if all LEDs are off, indicating furnace is ready to operate when a signal from thermostat is received.

Step 9—Bypass Humidifier Mode

When setup switch SW-3 BPH is in ON position, RPM calculated for low heat is multiplied by 1.15 for all furnace model sizes. This compensates for increased return-air temperature caused by bypassed air supply.

Step 10—Dehumidification Mode

A dehumidification input is provided via a 1/4 in. male quickconnect terminal labeled DEHUM located next to the transformer secondary connections. When there is a dehumidify demand, the DEHUM input is activated, which means 24 vac signal is removed from the DEHUM input terminal. In other words, the DEHUM input logic is reversed. the DEHUM input is turned ON when no dehumidify demand exists and is turned OFF when demand exists. This logic reversal has come about from historical use of a standard humidistat to do dehumidification since the contacts open on high humidity, thus removing the 24-v signal to initiate dehumidification.

The DEHUM output on the thermidistat control or the humidistat output, is connected directly to the DEHUM terminal on the furnace control. In addition, the DE jumper located next to the DEHUM terminal must be removed to enable the DEHUM input (See Fig. 27 and 28). When a dehumidify demand exists, the furnace control reduces the blower airflow by 21 percent to 315 CFM per ton during continuous fan or cooling operation.

This blower speed reduction compensates for high humidity conditions during cooling operation on all furnace model sizes. Reference Thermidistat™ Control Installation, Start-Up, and Operating Instructions for further details.

Step 11—Zone Mode

When setup switch SW-5 MZ is in ON position, blower motor control is the same as above except with the following exceptions:

1. While blower is operating in either low heat or continuous fan, the coast down calibration is performed once a minute to update blower RPM for zone damper position changes during a given cycle unless the blower pulse width to blower motor is greater than 60 percent. This prevents nuisance faults from occurring when a high continuous fan CFM has been selected.

2. While blower is operating in either high heat or cooling, blower pulse width to blower motor is frozen when blower RPM is within 10 percent of calculated blower RPM for 5 sec.

START-UP PROCEDURES

Step 1—General

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

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control center fault indicator light flashes rapidly and furnace does not operate.

2. Thermostat wire connections at terminals R, W/W1, G, and Y/Y2 must be made at 24-v terminal block on control center.

3. Natural gas service pressure must not exceed 0.5 psig (14-in. wc), but must be no less than 0.16 psig (4.5-in. wc).

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

Page 37

Table 8—Air Conditioning (A/C) Airflow Setup Switch Position

AIR

CONDITIONER

(TONS) Default

1-1/2 600 ON OFF OFF X X X ———

2 800OFFONOFFXXXXXX

2-1/2 1000 ON ON OFF XXXXXX

3 1200 OFF OFF ON XXXXXX

3-1/2 1400 ON OFF ON XXXXXX

4 1600 OFF ON ON ———XXX 5 2000 ON ON ON ———XXX

X—Indicates allowable selection.

CFM AIRFLOW

1200 or

2000

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

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

Step 2—Select Setup Switch Positions

AIR CONDITIONING (A/C) SETUP SWITCHES The air conditioning setup switches are used to match furnace

airflow to cooling unit used. This furnace will provide 400 CFM per selected air conditioning tonnage.

To set the desired cooling airflow:

1. Remove main furnace door and blower access panel.

2. Locate A/C setup switches on control center. (See Fig. 25.)

3. Determine air conditioning tonnage used.

4. Use Table 8 or wiring schematic to determine proper setup position of A/C switches. (See Fig. 24 and 47.)

A/C SETUP

SWITCH POSITION

A/C-1 A/C-2 A/C-3 040-14 060-14 080-14 080-20 100-20 120-20

OFF OFF OFF

3 Tons

1200 CFM

ALLOWABLE FURNACE MODEL SETUP

3 Tons

1200 CFM

3 Tons

1200 CFM

5 Tons

2000 CFM

5 Tons

2000 CFM

5 Tons

2000 CFM

1. Remove main furnace door and blower access panel.

2. Locate CF setup switches on control center. (See Fig. 25.)

3. Determine desired continuous fan airflow.

4. Use Table 9 or wiring schematic to determine proper setup position of CF switches. (See Fig. 24 and 48.)

NOTE: The CF switches are factory set to provide continuous fan airflow equal to low-heat mode.

5. Replace main furnace door and blower access panel.

SETUP SWITCHES (SW) The control center 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 control center. (See Fig. 25.)

3. See Table 10 for setup switch description. (See Fig. 24 and

48.)

4. Replace main furnace door and blower access panel.

NOTE: If a bypass humidifier is used, setup switch SW-3 (BPH) should be in ON position. This prevents nuisance limit trips caused by the increased temperature in return air resulting from bypass.

NOTE: If modulating dampers are used, setup switch SW-5 (MZ) should be in ON position. This allows furnace control center to compensate for modulating dampers. The control re-calibrates for new system static conditions once every minute while operating in low-heat or continuous fan modes.

OFF

Fig. 47—Example of Setup Switch in OFF Position

NOTE: Excessive airflow caused by improper A/C switch setup

may cause condensate blow off in cooling mode.

5. Replace main furnace door and blower access panel.

NOTE: EAC-1 terminal is energized whenever blower operates. HUM terminal is only energized when gas valve is energized.

CONTINUOUS FAN (CF) SETUP SWITCHES The CF setup switches are used to select desired airflow when

thermostat is in continuous fan mode. This setup feature allows continuous fan airflow to be adjusted. To set desired continuous fan airflow:

A95198

Step 3—Prime Condensate Trap With Water

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

1. Remove upper inducer housing drain connection cap. (See Fig. 48.)

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

3. Insert field-supplied funnel into tube.

4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 49.)

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

Page 38

Table 9—Continuous Fan (CF) Airflow Setup Switch Position

CONTINUOUS

FAN (CFM)

Default OFF OFF OFF 565* 515* 690* 690* 860* 1035*

600 ON OFF OFF X X X ———

800 OFFONOFFXXXXXX 1000 ONONOFFXXXXXX 1200 OFFOFFONXXXXXX 1400 ONOFFONXXXXXX 1600 OFF ON ON ———XXX 2000 ON ON ON ———XXX

* Add 15% additional CFM when Bypass Humidifier switch SW-3 on control board is used. X—Indicates allowable selection.

CF-1 CF-2 CF-3 040-14 060-14 080-14 080-20 100-20 120-20

CF SETUP

SWITCH POSITION

ALLOWABLE FURNACE MODEL SETUP

Table 10—Setup Switch Description

SETUP

SWITCH NO.

SW-1 (FLT)

SW-2

(LOW)

SW-3

(BPH)

SW-4

(EMER HEAT)

SW-5

(MZ)

SW-6

(COMP TEST)

SW-7 and -8

(Blower Off Delay)

NORMAL

POSITION

OFF

See Table 11

DESCRIPTION OF USE

Turn switch to ON for fault history display. No thermostat signal can be present for fault history display.

Turn switch to ON to lock furnace in low-heat mode only or when using a 2-stage thermostat with R-W/W1 and R-W2 signals.

Turn switch to ON when a bypass humidifier is used. This compensates for higher return-air temperature and provides 15 percent more airflow in low-heat mode only.

Turn switch to ON to bypass microprocessor control. Furnace will operate at high heat only with main blower and inducer motor operating at maximum RPM. NO safeties are bypassed.

Turn switch to ON when modulating dampers are used. In this mode, main blower speed is recalculated once every minute while furnace is in low-heat or continuous fan mode.

Turn switch to ON to initiate component test. Furnace will operate inducer motor for 20 sec at low speed, operate inducer motor for 20 sec at high speed, energize HSI for 15 sec, operate blower for 20 sec at low speed, and operate blower for 20 sec at high speed. SW-1 must be in OFF position. No thermostat signal can be present for component test to be initiated.

Adjust switches to provide desired heating mode blower off delay time, 90, 135, 180, or 225 sec.

Table 11—Blower Off Delay Setup Switch

Position

DESIRED HEATING

MODE BLOWER

OFF DELAY (SEC)

90 OFF OFF 135 ON OFF 180 OFF ON 225 ON ON

Step 4—Purge Gas Lines

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

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

Step 5—Adjustments

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

up to 2000 ft.

SETUP SWITCH (SW-7 AND -8) POSITION

SW-7 SW-8

In the U.S.A., the input rating for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level.

In Canada, the input rating must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level.

Furnace input rate must be within ±2 percent of input on furnace rating plate.

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

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

local gas supplier.

b. Obtain yearly specific gravity average from local gas

supplier.

c. Verify furnace model. Table 12 can only be used for model

58MVP Furnaces.

d. Find installation altitude in Table 12.

NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 12.

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

Table 12.

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.

Page 39

Fig. 48—Inducer Housing Drain Tube

A99118

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

Manifold pressure: 3.6-in. wc for high heat

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

g. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY.

2. Adjust manifold pressure to obtain input rate. a. Remove burner enclosure front.

NOTE: Manifold pressure MUST always be measured with the burner box cover REMOVED.

b. Remove caps that conceal adjustment screws for low- and

high-heat gas valve regulators. (See Fig. 50.)

c. Move setup switch SW-2 on control center to ON position.

(See Fig. 25.) This keeps furnace locked in low-heat operation.

d. Jumper R and W/W1 thermostat connections on control

center to start furnace.

e. Turn low-heat adjusting screw (5/64 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.

Fig. 49—Filling Condensate Trap

A99119

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

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

f. Move setup switch SW-2 to OFF position after completing

low-heat adjustment.

g. Jumper R and W2 thermostat connections on control

center. (See Fig. 25.) This keeps furnace locked in highheat operation.

h. Turn high-heat adjusting screw (5/64 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.

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. 51.)

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.

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

Page 40

Table 12—Model 58MVP Orifice Size and Manifold Pressure for Correct Input

(Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner

Derated 2% for each 1000 ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

0 925 44 3.5/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5

to 975 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

2000 1025 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4

U.S.A. and Canada

ALTITUDE

RANGE

(FT)

U.S.A. 775 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5

Altitudes 800 43 3.5/1.5 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

2001 825 44 3.8/1.6 43 3.4/1.5 43 3.6/1.5 43 3.7/1.5 43 3.8/1.6

to 850 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 43 3.5/1.5 43 3.6/1.5

3000 875 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 43 3.4/1.4

or 900 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

Canada 925 45 3.7/1.5 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5

Altitudes 950 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4

U.S.A. and Canada

2000 975 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.8/1.6

to 1000 47 3.7/1.6 45 3.2/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5

4500 1025 47 3.6/1.5 47 3.7/1.6 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4

ALTITUDE

RANGE

(FT)

3001 825 44 3.5/1.5 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5

to 875 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.5/1.5 44 3.6/1.5

U.S.A. Only

4000 925 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3

* Orifice numbers shown in BOLD are factory installed.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

850 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4 875 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 900 44 3.7/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6

950 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6

1000 45 3.7/1.6 45 3.8/1.6 44 3.2/1.4 44 3.4/1.4 44 3.5/1.5

1050 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 1075 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 1100 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.4/1.4 45 3.5/1.5

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

750 43 3.7/1.6 43 3.8/1.6 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5 775 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 800 44 3.7/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6

850 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.7/1.5 44 3.8/1.6

900 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4

950 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.5/1.5 45 3.7/1.5 975 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5

1000 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Manifold Pressure High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

No.

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

No.

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Manifold Pressure High/Low

Manifold

Pressure

High/Low

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

Manifold

Pressure

High/Low

Manifold Pressure High/Low

Page 41

Table 12—Model 58MVP Orifice Size and Manifold Pressure for Correct Input (Continued)

(Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner

ALTITUDE

RANGE

(FT)

4001 800 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4

to 850 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5

U.S.A. Only

5000 900 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.8/1.6

ALTITUDE

RANGE

(FT)

5001 800 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

to 850 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.8/1.6 44 3.2/1.4

U.S.A. Only

6000 900 47 3.6/1.5 47 3.7/1.6 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5

ALTITUDE

RANGE

(FT)

6001 725 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5

to 775 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5

U.S.A. Only

7000 825 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6

* Orifice numbers in BOLD are factory installed.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4 750 43 3.4/1.4 43 3.5/1.5 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 775 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5 43 3.7/1.5

825 44 3.2/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6

875 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4

925 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 950 47 3.5/1.5 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

700 43 3.6/1.5 43 3.7/1.6 42 3.2/1.3 42 3.3/1.4 42 3.4/1.4 725 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 750 44 3.6/1.5 44 3.7/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 775 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 43 3.4/1.4

825 45 3.6/1.5 45 3.7/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4

875 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.5

925 47 3.4/1.4 47 3.5/1.5 47 3.7/1.5 45 3.2/1.3 45 3.3/1.4 950 48 3.7/1.6 48 3.8/1.6 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 975 48 3.5/1.5 48 3.6/1.5 48 3.8/1.6 47 3.4/1.4 47 3.5/1.5

1000 48 3.3/1.4 48 3.5/1.5 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650 42 3.2/1.3 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5 42 3.6/1.5 675 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 700 44 3.8/1.6 43 3.4/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6

750 44 3.3/1.4 44 3.4/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6

800 45 3.5/1.5 45 3.7/1.5 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4

850 47 3.7/1.6 45 3.2/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 875 47 3.5/1.5 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4

Orifice

No.

Orifice

No.

Orifice

No.

Derated 2% for each 1000 ft Above Sea Level) *

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Page 42

Table 12—Model 58MVP Orifice Size and Manifold Pressure for Correct Input (Continued)

(Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner

Derated 2% for each 1000 ft Above Sea Level) *

ALTITUDE

RANGE

(FT)

7001 700 44 3.5/1.5 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5

to 750 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5

U.S.A. Only

8000 800 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6

ALTITUDE

RANGE

(FT)

8001 650 44 3.7/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6

to 700 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.6/1.5 44 3.7/1.6

U.S.A. Only

9000 750 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.8/1.6 44 3.2/1.4

ALTITUDE

RANGE

(FT)

9001 625 44 3.7/1.6 44 3.8/1.6 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6

to 675 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

U.S.A. Only

10,000 725 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6

* Orifice numbers shown in BOLD are factory installed.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

625 43 3.8/1.6 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5 42 3.6/1.5 650 43 3.5/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 675 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6

725 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6

775 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4

825 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 850 47 3.4/1.4 47 3.5/1.5 47 3.7/1.5 45 3.2/1.3 45 3.3/1.4

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

600 43 3.8/1.6 42 3.3/1.4 42 3.4/1.4 42 3.5/1.5 42 3.6/1.5 625 43 3.5/1.5 43 3.6/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

675 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.5

725 45 3.6/1.5 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4

775 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 800 47 3.6/1.5 47 3.7/1.6 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

575 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.5/1.5 42 3.6/1.5 600 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 42 3.2/1.3 42 3.3/1.4

650 44 3.4/1.4 44 3.5/1.5 44 3.7/1.5 44 3.8/1.6 43 3.4/1.4

700 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4

750 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.5/1.5 775 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure High/Low

0.58 0.60 0.62 0.64 0.66

Manifold Pressure High/Low

0.58 0.60 0.62 0.64 0.66

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Orifice

No.

Manifold Pressure High/Low

Page 43

LOW-FIRE ADJUSTMENT ALLEN SCREW (UNDER CAP)

HIGH-FIRE ADJUSTMENT ALLEN SCREW (UNDER CAP)

INLET PRESSURE TAP

BURNER

ENCLOSURE

REFERENCE

PRESSURE TAP

ON/OFF SWITCH

MANIFOLD

PRESSURE

TAP

Fig. 50—Redundant Automatic Gas Valve

A97386

BURNER FLAME

BURNER

MANIFOLD

A89020

Fig. 51—Burner Flame

Table 13—Altitude Derate Multiplier for U.S.A.

ALTITUDE

(FT)

0—2000 0 1.00 2001—3000 4—6 0.95 3001—4000 6—8 0.93 4001—5000 8—10 0.91 5001—6000 10—12 0.89 6001—7000 12—14 0.87 7001—8000 14—16 0.85 8001—9000 16—18 0.83

9001—10,000 18—20 0.81

* Derate multiplier factor is based on midpoint altitude for altitude range.

%OF

DERATE

DERATE MULTIPLIER FACTOR FOR U.S.A.*

BURNER

ORIFICE

A93059

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

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

for a 2 percent derate for each 1000 ft above sea level. See Table 13 for derate multiplier factor and example.

EXAMPLE: 100,000 BTUH INPUT FURNACE INSTALLED AT

4300 FT.

Furnace Input Rate

at Sea Level

100,000 X 0.91 = 91,000

Derate

Multiplier

Factor

Furnace Input Rate

at Installation

Altitude

CANADA At installation altitudes from 2000 to 4500 ft, this furnace

must be derated 5 percent by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example above and use 0.95 as derate multiplier factor.

b. Reinstall burner box cover.

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 yearly heat value average for local gas supply.

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

e. Check and verify orifice size in furnace. NEVER ASSUME

THE ORIFICE SIZE. ALWAYS CHECK AND VERIFY. f. Turn off all other gas appliances and pilots. g. Move setup switch SW-2 to ON position. (See Fig. 25.)

This keeps furnace locked in low-heat operation.

Page 44

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 revolu-

tion. Note reading. k. Refer to Table 14 for cubic ft of gas per hr. l. Multiply gas rate cu ft/hr by heating value (Btu/cu ft). m. Move setup switch SW-2 to OFF position and jumper R

and W2 thermostat connections. (See Fig. 25.) This keeps furnace locked in high-heat operation. Repeat items h through k for high-heat operation.

EXAMPLE: (High-heat operation at 0—2000 ft altitude) Furnace input from rating plate is 100,000 Btuh Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 975 Btu/cu ft Time for 1 revolution of 2-cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 14) 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) must be within ±2 percent of that stated on furnace rating plate when installed at sea level or derated per that stated above when installed at higher altitudes.

n. Remove jumper across R, W/W1, and W2 thermostat

connections to terminate call for heat.

Table 14—Gas Rate Cu Ft/Hr

SECONDS

FOR 1

REVOLUTION

10 11 12 13 14

15 16 17 18 19

20 21 22 23 24

25 26 27 28 29

30 31 32 33 34

35 36 37 38 39

40 41 42 43 44

45 46 47 48 49

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

360

720 655 600 555 514

480 450 424 400 379

360 343 327 313 300

288 277 267 257 248

240 232 225 218 212

206 200 195 189 185

180 176 172 167 164

160 157 153 150 147

1800 1636 1500 1385 1286

1200 1125 1059 1000

947 900

857 818 783 750

720 692 667 643 621

600 581 563 545 529

514 500 486 474 462

450 439 429 419 409

400 391 383 375 367

327 300 277 257

240 225 212 200 189

180 171 164 157 150

144 138 133 129 124

120 116 113 109 106

103 100

97 95 92

90 88 86 84 82

80 78 76 75 73

SECONDS

FOR 1

REVOLUTION

50 51 52 53 54

55 56 57 58 59

60 62 64 66 68

70 72 74 76 78

80 82 84 86 88

90 92 94 96 98

100 102 104 106 108

110 112 116 120

SIZE OF TEST DIAL

cu ft2cu ft5cu ft

144 141 138 136 133

131 129 126 124 122

120 116 112 109 106

103 100

97 95 92

90 88 86 84 82

80 78 76 75 74

72 71 69 68 67

65 64 62 60

360 355 346 340 333

327 321 316 310 305

300 290 281 273 265

257 250 243 237 231

225 220 214 209 205

200 196 192 188 184

180 178 173 170 167

164 161 155 150

71 69 68 67

65 64 63 62 61

60 58 56 54 53

51 50 48 47 46

45 44 43 42 41

40 39 38 38 37

36 35 35 34 33

33 32 31 30

SET TEMPERATURE RISE

Temperature rise must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise or above. Failure to follow this caution may result in condensing or overheating the heat exchangers.

Furnace must operate within range of temperature rise specified on the unit 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-fire operation by placing setup switch SW-2 on control center in ON position. For high-heat operation, place setup switch SW-2 in OFF position and jumper R-W2 on control center. DO NOT forget to return setup switch to OFF position and remove R-W2 jumper upon completion of testing. (See Fig. 25 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 unit 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 bypass humidifier switch (BPH) setup switch SW-3

on control center is in ON position when a bypass humidifier is used. (See Fig. 25 for switch location.)

e. Check Troubleshooting Guide for Variable-Speed 2-Stage

Electronic Condensing Furnaces.

Page 45

SET THERMOSTAT HEAT ANTICIPATOR The thermostat heat anticipator must be set to match the amp draw

of components in the R-W/W1 circuit. Accurate amp draw measurements can be obtained at the thermostat subbase terminals R and W.

Fig. 52 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 SW-2 to ON position (See Fig. 25) 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.

3. Return setup switch SW-2 to OFF position and replace thermostat on subbase.

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

HOOK-AROUND AMMETER

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

A96316

Fig. 52—Amp Draw Check with Ammeter

CHECK SAFETY CONTROLS

Step 1—Check Primary Limit Control

This control shuts off the combustion control system and energizes the air-circulating blower motor if furnace overheats.

1. The recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 5 minutes.

2. As soon as limit control has shut off burners, a 33 fault code will appear on control center.

3. The return-air opening should be unblocked to permit normal air circulation.

By using this method to check the limit control, it can be established that the limit is functioning properly and the furnace will operate safely if there is a restricted return-air supply or motor failure. If the limit control does not function during this test, the cause must be determined and corrected.

Step 2—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, fault code 42 will flash on control center approximately 10 sec after thermostat switch is closed. If either a fault code 31 or 32 is flashed when ICM inducer motor is disconnected, the furnace will shut itself down immediately. Determine 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 115-v power to furnace.

8. Reset thermostat to desired temperature.

CHECKLIST

1. Put away tools and instruments. Clean up debris.

2. Verify manual reset switch has continuity.

3. Verify that blower and control access doors are properly installed.

4. Cycle test furnace with room thermostat.

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

6. Review User’s Manual with owner.

7. Leave literature packet near furnace.

Page 46

LOAD CALCULATION

____________ Heating Load (Btuh)

____________ Cooling Load (Btuh)

____________ Furnace Model Selection

CHECKLIST—INSTALLATION

________ Unit Level or Pitched Forward

________

Condensate Drain

Internal Tubing Connections Free of Kinks and Traps

COMBUSTION AND VENT PIPING

Termination Location

________ Roof or Sidewall

________ Termination Kit — 2 Pipe or Concentric

________ Combustion-Air Pipe Length

________ Combustion-Air Pipe Elbow Quantity

________ Vent Pipe Length

________ Vent Pipe Elbow Quantity

________ Pipe Diameter Determined from Sizing Table

________ Pipe Sloped To Furnace

Pipe Insulation

________ Over Ceilings

________ Low-Ambient Exposed Pipes

________

________ Condensate Trap Primed before Start-Up

________ Heat Tape Installed if Required

________

________ Temperature Rise Adjusted

________ Anticipator Setting Adjusted or

________ Cycle Rate (3 Cycles per Hr) Selected

________ Primary Limit

________ Pressure Switches

External Drain Connection Leak Tight and Sloped

CHECKLIST—START-UP

Gas Input Rate (Set Within 2 percent of Rating Plate)

Thermostat Anticipator

Safety Controls Check Operation

Page 47

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence

A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book.

Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog.

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A94328

Page 48

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

Book 1 4 Tab 6a 8a

PC 101 Catalog No. 535-80021 Printed in U.S.A. Form 58MVP-11SI Pg 48 2-01 Replaces: 58MVP-10SI