Carrier 58MVP120F15120, 58MVP080F15120 Installation Guide

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Page 1

4-Way Multipoise Direct-Vent

HEATING & COOLING

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Variable-Capacity Condensing Gas Furnace

Installation, Start-Up, and Operating Instructions

For Sizes 040--120, Series 140 and 150

i ama !1

bRfeardestt_ing_r: inist_;lr_t_°nn

A93040

58MVP

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_-

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

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

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

Dowoflow Appiications ......................................................... 7-8

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

Horizontal Right (Supply-Air Discharge) Applications...10÷l 1

LOCATION ............................................................................ 1 l- 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 T_atment ............................................. 14

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

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

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

Boltora Clo_ure 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@ Pa_ner, Carder Coclmca-

don has determined that

thisixed_t m_ tl_ EN.

ERGY STAR® guidelines

for en_g_ efficiency.

AtRFLOW _ AIRFLOW

REGISTERED QUALITY SYSTEM

AIRFLOW

A9_4t

Fig. 1---Multipoise Orientations

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 .........................................................................

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 ............................................................ 3824

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

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

PC 101 Catalog No. 535-80021 Pdnted in U.S.A. Fom_ 58MVP-11SI 1 2-01 Re#aces: 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 person-

nel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as clean-

ing and replacing air filters. All other operations must be per- formed 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-BI49.1- 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 adjustraent procedures and service calls. Recognize safety information. This is the safety-alert symbolz_ x.

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 CAU-

TION. These words are used with safety-alert symbol. DANGER

identifies the most serious hazards which win 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

¥!_['ff:.llii[*l_'l

Electrostatic discharge can affect electronic components, Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will pre- vent 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 coturol, 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 CON- TROL PRIOR TO DISCHARGING YOUR BODY'S ELEC- TROSTATIC 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), FgraJy touch furnace again before touching control or wires.

5. Use this procedme 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 Ga_-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 suit-

able 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) applica- tions 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 lnstnlctions

Service and Maintenance Instructions User's Information Manual

Warranty Cert'fficate

Loose Parts Bag includes: Quantity

Pressure tube extension 1 Collector box or condensate (rapextension tube l

Inducer housing drain tube 1

l/2-in. CPVC street elbow 2

Drain tube coupling 1 Drain tube coupling grommet I

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 _ NFGC and the NFPA 90B. For copies of the

NFGC and NFPA 90B, contact the National Fire Protetion

Page 3

26 _/_ '

26 _

24 I_,,m

2-IN. COMBUSTION- AIR CONN

GAEC NN-- tt

2-IN. VENT CONN _

_-IN. DIA THERMOSTAT -- _.Jv

r7 ................. "q_

14 I/_ SIDE INLET

TYP i

ENTRY

TRAP LOCATION

f ONDENSATE DRAIN

(DOWNFLOW &

HORIZONTAL LEFT)

7_-IN. OIA

/f POWER CONN

7/_-IN. OIA ACCESSORY

POWER ENTRY

i i

DRAIN TRAP 279/. LOCATION TYP

i""-- CONDENSATE lI

(ALTERNATE UPFLOW) 24

--_ -- 17 _'le" 97A6 "

TYP

AIRFLOW

CONDENSATE DRAIN

TRAP LOCATION --'_

(OOWNFLOW &

HORIZONTAL RIGHT)

OR ALTERNATE

1/2-1N, DIA GAS CONN

30t_"

26¼"

19"_ 1_/16"

2-1NCOMBUST,ON-

.,._ _ ½-IN DIA

_ INDIA

GAS CONN

POWER DONN

-IN DIA

THERMOSTAT ENTRY

,I VENT CONN

;._

SIDE INLET

39 %

I ".4=- 23 i/_., TYP

SIDE INLET

26 %16 TYP

3ONDENSATE

DRAIN LOCATION (UPFLOW)

NOTES: 1. Minimum return-air openings at furnace, based on metal duct. ifflex 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 14% x 12-in. rectangle.

1¼e"..im

INLET

.e- _1/16" DRAIN LOCATION

(UPFLOW)

DIMPLE LODATORS

FOR HORIZONTAL

HANGING

b. For 1200 CFM-26-in. round or 14% x 19V_-in.rectangle. c. For 1600 CFM-22-in. round or 14% x 23%-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, orthe bottom only will ensure adequate

return air openings for airflow requirements above 1800 CFM.

A99111

Dimensions (In.)

UNIT SIZE

040-14"

060-14 080-14

080-20 100-20 120-20

• These dimensions reflect the wider casin(

24-1/2"

17-1/2

21 21 21

24-1/2

for the Trophy (96.6 percent AFUE) furnace.

D E

22-7/8" 23*

15-7/8 16 19-3/8 19-1/2

19-3/8 19-1/2

19-3/8 19-1/2 22-7/8 23

Fig. 2--Dimensional Drawing

Page 4

A,_sociation 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

IR3.

Installation must comply with regulations of serving gas supplier and local building, heating, plumbing or other codes in effect in the

_ea 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 instal-

lation and conform to existing national standar&s 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, mainte- nance, or use can cause carbon monoxide poisoning, explo-

sion, 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 distribu- tor 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, ftre,

personal injury, or death.

For accessory installation details, refer to applicable installation literature.

INSTALLATION

Ttis forced ar furnaceisequippedforu=e,_ithnaturalgasat aJtittJdes0 - 10,_ ff (0 *3,_). Anaccessorykit,supplied_ _e manufacturer,shaJlbe usedtoc_t to propanegasuse or may _ r_u_ f_ _ _

flJrnaceis fat indoorinstaJlationina I_ilotng constructed_ site.]_is furnace may be _nstailedin a mandacturecl(mobile)

hc_e v,he_ statedon ratingpl_e andusingfactc_y authcciz_l_t.

furnacemay be ins_lled an c_l:i e ftoo_n9 in _ orcloset_ rrir_murndear_ncefrom o:_bus_iblematerial.

Ttis applmrce reqdres a speaal ve_ng system Refertothe itz_taJ_on _q._rt_ic_ fo¢par_ _stand _ of instaHa_or_Th_ furnaceis fc_ usewithschedule-40PVC, PVC-DWV, or ABS-DWVppe, andmust notbevent_ in _ _ o_ _ _pli_ce_ C_nslruc0on_rough _ch ve,_/air intake pipesmaybe installedis ma_rnum24 inches (600 ram),rrinimurn3'4inches (19 rr_) thid_ss (inclua_ roolingmaterials).

FurreceraJstbeinaalledlevel,or pitchedfo_wadw_hin1/2inchoflevel forproperdrainage.Failure_ill resuttin eq_pmea orpropertydamage.See

Installa_onManualfo_IMPQRTANTunit

suppoddetailsonho_

applications.

1/2" MAX

LEVEL (0") _

UPFLOWOR I I/

DOWNFLOW

MINIMUMINCHESCLEARANCE TO

COMBUSTIBLECONSTRUCTION

ALLP(TolTIONS:

* ICmlimumfrontdearanceforsen,ice30 bches

¢/_mm).

DOWlI,FLOWPOntoONS:

1" ForinstaJlalJ_oncembu_l_leIIoorsonlywhen

inst_ledm specktbaseNo.K_IALL Cdl /_sembly,P_tNO.CO5orCKS,orC_ilC_sing,Part

No.KCAKC

HORIZONTAL POSITIONS:

§ aearanceshownisfor_r inletandairouzelend. Unecottactispem=ssibleortyI:_tweenlines

"l_s lurnaee is _ro_d f_ UFFLCW, DOWNFLOWarrl

HO_ZONTAL inst_ons,

LEVEL (0")

112" M__HORIZONTAL

120 s_zeFurnacerequre1inchbott0md_ to

325400-201RE_.A

(UT.toP)

Fig. 3--Clearances to Combustibles

A99_03

Page 5

BLOWERSHELF FURNACE

CONDENSATE _'- DC'OR -- FURNACE

SIDE FURNACE SIDE

F,E<D 20', ,'/2 F,E

L_ALTERNATE DRAIN CONN CONN

TUBELOCATION

CONDENSATE TRAP"_ SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DRAINTUBE LOCATION

UPFLOW APPLICATIONS EXTERNAL UPFLOW APPLICATIONS APPLICATIONS

DRAIN DRAIN

DOWNFLOW AND ALTERNATE HORIZONTAL

SIDE

LOT: 'i OqaE F 7

GUIDES

(WHEN USED)

FRONT VIEW SIDE VIEW

Fig. 4---Condensate Trap

APPUCATIONS

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--Opflow 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 factury-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

COLLECTOR BOX TO TRAP RELIEF PORT

IizOD

INDUCER HOUSING

DRAINCONNECTION

1/40D

% OO

COLLECTOR BOX

DRAINCONNECTION SCREW HOLE FOR

UPFLOW OR DOWN-

7/8 (OPTIONAL)

__..__, FLOW APPLICATIONS

2114_ _-_ lz2-lN.PVC ORCPVC

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 c_qing 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 robe coupling (factory-supplied in loose parts

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

A93026

Page 6

-i i

DRAIN TUBE (BLUE

& WHITE STRIPED)

TUBE (PINK)

INDUCEI

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

DRAIN TUBE (BLUE)

TUBE (GREEN)

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED /

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

1/2-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

Fig. 5---Factory-Shipped Upflow Tube Configuration

(Shown With Blower Access Panel Removed)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (RIGHT

DRAIN OPTION)

A94213

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK) --_

COLLECTOI

TUBE (GREEN)

DRAIN TUBE (GREEN)

TRAP

HOUSING

DRAIN TUBE

(VIOLET)

Fig. 6_Alternate Upflow Tube Configuration and

Trap Location

A94214

e. Cement 2 factory-supplied l/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 mad relief port tubes must be discon- nected 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:

I. 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 f'dler 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 c_sing holes with placstic filler

caps ffactory-supplied in loose parts bag).

CONDENSATE TRAP TUBING (ALTERNATE UPFLOW ORI- ENTATION)

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 I7-1/2-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

DRAINTUBE (BLUE)

COLLECTOR BOX !

CAPII t

PLUG

COLLECTORBOX --

TUBE (GREEN)

COLLECTORBOX

TUBE(PINK)

DRAIN TUBE (BLUE & WHITE STRIPED)

EXTENSION TUBE

TRAP

INDUCER HOUSINC

DRAIN TUBE (VIOLET)

A94.215

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 par_s 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 CO1,LECTOR BOX AND INDUCER HOUSING (UN- USED) DRAIN CONNECTIONS

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

TUBE(GREEN)

DRAINTUBE(BLUE)

TUBE(PINK)

DRAIN TUBE (BLUE & WRITE STRIPED)

EXTENSION TUBE

DRAIN TUBE (VIOLET)

TRAP

EXTENSION DRAIN TUBE

COUPLING

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 Pig. 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).

R BOX

A94216

Page 8

CONDENSATETRAPTUBING

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

I. 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. (l.I Condensate Trap Located on Left Side of Cmsing

(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.

(2.1 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 previ-

ously plugged.

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

supplied in loose parts bag) to drain tube cou- pling, 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 dis-

connected 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 HORIZON-

TAL 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 remain- ing 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, cuL 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.

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 ms shown in Fig. 2 or 9.

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

i. 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

AL DRAIN TUBE

(BLUE AND WHITE STRIPED)

BOX

CONDENSATE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

TRAP

COLLECTC

BOX EXTENSION

DRAINTUBE

EXTENSIONTUBE

040, 060, AND 080 HEATING INPUT FURNACES

Fig. 9--Horizontal Left Tube Configuration

5. Fill unused condenstate trap casing holes with placstic filler caps (factury-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, extend- ing 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 i,nducer 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

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

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 ATFACHMENT 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.)

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

TUBE(GREEN)

PRBOX

;ER HOUSING

DRAIN TUBE (VIOLET)

[BLUE)

A00215

Page 10

INTAKE

MIN HORIZONTAL PIPE

SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS

TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE.

SHUTOFF

GAS VALVE

SEDIMENT TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

_ONDENSATE

TRAP

Fig. 10_Attic Location and Working Platform

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

(See Fig. l0 or 32.)

Step 5_Horizontal Right (Supply-Air Discharge) Applications

A horizontal fight 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.

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. li.) 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 I I, To relocate condensate trap from the blower shelf to desired

location, perform the following:

I. Remove 3 tubes connected to condensate trap,

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

and rotating trap.

ACCESS OPENING FOR TRAP

DRAIN

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 placsfic 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

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 11--Horizontal Right Tube Configuration

(BLUE)

(GREEN)

COLLECTOR BOX TUBE (PINK)

RELOCATED HERE

TRAP

A0_14

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

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

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

condensate trap.

f. Clamp tube to prevent any condensate leakage.

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

procedure.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and

procedures. PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW or HORIZONTAL LEFT applications. This tube MUST be dis- connected 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 HORIZON-

TAL RIGHT applications.

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

Relocate tubes as described below.

I. 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 labell

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 am 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 mira- mum 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 outaide 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.

UPFLOW OR DOWNFLOW

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.

HORIZONTAL

A93025

MAX 857=

If these furnaces are used during construction when adhe- sives, 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 construc-

tion, 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 mate- rials, and many other solvents commonly used in the con-

struction 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 clear-

ance to combustibles label. (See Fig. 3.) Locate furnace where available electric power and gas supplies meet specifications on

furnace rating plate.

MIN 557=

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 temporature 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.

BACK'

A93043

Page 13

_32°F MINIMUM INSTALLED

%%%%o

/!\

A93058

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.

¥__

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(sL leveling legs may be desired. (See Fig. 12.) Install field-supplied,

corrosion-resistant 5/16-in. machine bolts and nuts.

5/16_

1¾"

A89014

Fig. 12--Leveling Legs

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

1. Position furnace on its back. Locate and drill a 5/16 in. diameter hole in each bottom corner of furnace. (See Fig. 12.)

Holes in bottom closure panel may be used as guide locations.

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

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

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

nut to secure arrangement.

Page 14

NOTE: Bottom closure mttst 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.

KGASB020 IALL, is used. Manufacturers accessory floor base in not required when this furnace is installed on manafacturer's Coil

Assembly Part No. CD5 or CK5, or Coil Box part No. KCAKC is used.

I. Determine application being installed from Table 1.

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

3. Construct plenum to dimensions specified in Table l 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 l 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

8J'ea.

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 (ACCAJ, 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 I-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 fi 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 hning 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-ni. 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 accesso-

ries 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/outiet or air conditioning coil casing (when used), when

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

nected to an accessory subbase or factory approved air condition- ing 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 connec- tions should be made at ductwork or coil casing sides exterior to

furnace.

Page 15

A96283

Fig. 13--Floor and Plenum Opening Dimensions

FURNACE

(OR COIL CASING

WHEN USED)

-- COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL

PLENUM

__FLOOR --

OPENING

A96285

Fig. 14--Furnace, Plenum, and Subbase

Installed on a Combustible Floor

Table l_pening Dimensions (In.)

FURNACE

CASING

WIDTH

17-1/2

24-1/2

Downflow Applications on Non-Combustible Flooring

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

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CE)5 or CK5 Coil Assembly or KCAKC Coit Box

Downflow Applications on Non-Combustible Floodng

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 Floodng

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

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

--COMSUSTIBLE_-_

FLOORING

._.SHEETMETAL

PLENUM

__ FLOOR --

OPENING

A96284

Fig. 15_Furnace, Plenum, and Coil

Assembly or Coil Box Installed

on a Combustible Floor

PLENUM OPENING

A B

16 24-1/8

15-7/8 19 15-1/8 19

15-1/2 19 19-1/2 24-1/8

19-3/8 19

18-5/8 19

19 19

23 24-1/8

22-7/8 19 22-1/8 19

22-1/2 19

FLOOR OPENING

16-5/8 16-1_

16-3/4

16-1/2

20-1/8

20-1/4

23-5/8 23-1/2

23-3/4

23-1F2

24-3/4

19-5/8

20-3/8

24-3/4

19-5/8

20-3/8

24-3/4

19-5/8 20-3/8

Page 16

DISCHARGE DUCT FLANGE

Fig. 16--Duct Flanges

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 flue.

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, deter- mine 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.

IRON OR

(B)

(A) ROD LOCATION

USING DIMPLE LOCATORS

(SEE DIMENSIONAL DWG FOR

LOCATIONS)

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

3/8-1N

& WASHER (4)

REQD PER ROD

NOTES: 1. A 1 In. clearance minimum between top of

fumace and combustible material.

2. The entire length of fumace must be

supported when furnace is used in horizontal position to ensure proper drainage.

13/16-1N.MAX ALTERNATE SUPPORT

LOCATION FROM BACK

Fig. 17--Crawlspace Horizontal Application

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

A93304

Page 17

Table 2--Filter Information

FURNACE FILTER SIZE (IN.)* FILTER TYPE

CASING

WIDTH (IN.) Side Return Bottom Return FRAMED

17-1f2 (f) 16X25X f_ (f) f6X25X 1f Cte_mabte

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

24-1f2 (,lor2) 16X2SX1 (1) 24X25X 11 Gleanable

• Filters may be fieldmodified by cutting filter material and supportrods (3) in filters. Alternate sizes can be ordered from your distributoror dealer.

1"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.

r!_lP?_IJlj_0,VJ

For airflow requirements above 1800 CFM, see Air Delivery

table in Product Data literature for specific use of single side

inlets. The use of both side inlets, a combination of I side and

the bottom, or the bottom only will ensure adequate return air

openings for airflow requirements above 1800 CFM.

NOTE: Side return-air openings can ONLY be used in UPFLOW

configurations. Install filter(s) as shown in Fig. 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

Jnlel JS 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:

ILTilt 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 f'dler 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 instalJatioJas

must be made in accordance with NSCNGPIC and all authorities

171/2-1N.WIDE CASINGS ONLY:

INSTALL FIELD-SUPPLIED FILTER FILLER STRIP UNDER FILTER.

SUPPORT

21-IN.WIDE CASINGS ONLY: SUPPORT RODS (3)

EXTEND 1/4" ON EACH SIDE OF FILTER AND REST ON CASING FLANGI

FILTER

RETA#VER

Fig. 19---Bottom Filter Arrangement

- WASHABLE FILTER

A00290

WASHABLE

j___FILTER

Fig. 18--Filter Installed for Side Inlet

-- FILTER

RETAINER

A93045

BO'Iq-OM CLOSURE

PANEL

_-- FRONTFILLER

PANEL

A93047

Fig, 2_Removing Bottom Closure Panel

having ju15sdicfion. 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

Page 18

straps,hangers,etc.UseaminimumofI hangerevery6ft.Joint compound(pipe dupe) 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

0N-)

1/2 3/4

1-1/4 1-1/2

• Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. we) or less, and a pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Fief; Table 10-2 NFPA .54-f 999.

INTERNAL

DIAMETER

0N.)

0.622

0.824

1.049

1.380

1.610

LENGTH OF PIPE (FT)

10 20 30 40 50

175 120 97 82 73 360 250 200 170 151 680 465 375 320 285

1400 950 770 660 580 2100 1460 1180 990 900

GAS _'_ SUPPLY ._

MANUAL J II

v% oFF

(REOU,,EO f

SREAD/MENTu:IONJ

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 1, 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.

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

Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this wanting 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 conlrols. 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 imtr_diately upstream of g&_ 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. we) 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. wcL gas supply pipe must be disconnected

ELECTRICAL CONNECTIONS

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

for tightness,

Blower access panel door switch opens l15-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 subauthofities 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

--- FIELD 24-V WIRING

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

-- FACTORY 24-V WIRING

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

NOTE5 _ _ _ _ _ THERMOSTAT

FIVE _ I L_ _ L_ L_J L_ ITERMINALS FIELD-SUPPLIED

WIRE _ 'i | ] | ' DISCONNECT

THREE-WIREHEATING -"__ _ H ........_: -_-_ 208/230-

_ _ I I I q [ l-u-_ ---'[_LL_Lr_ _---[THREE PHASE

I..... I _V._ _- , , ,, I_----t---__=-:l---

/-- -- -- i i _ I

T _ Fa_ _ INOTE,, 1 , f....115-V

SINGLE _ -I_---._-:--_ _

PHASEk _ SINGLE

---- -- --------IF--- ; = H ..... 208/230"V

-- -- -- ----_- I i PHASE

l15"V AUXILIARY_1--1- '1 !} !_ _---_---_---_---J

FIELD-SUPPLIED J-BOX (_----_I(hTE_ .... I [_-_

DISCONNECT ,._J_ ..... -- -- II_ CONDENSING

SWITCH _ ...... UNIT

FURNACE TERMINAL CONTROL BLOCK NOTES:

CENTER 1. Connect y or y/Y2 terminal as shown for proper cooling operation.

ONLY "_'<_ ',, I;_; l:_-_L_ _ 480-v

j _ J I i :J

24-V

OW,REJ

2. Proper polarity must be maintained for 115-v widng.

3. UseW2 with 2-stage thermostat when zoning.

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

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

Fig. 22--Heating and Cooling Application Wiring Diagram

F FACTORY

DISCONNECT

ELECTRIC _]C

SWITCH

OPPER

WIRE ONLYI_

ALTERNATE --

FIELD

LOCATION

L__%--,,de'_,--q

, q

A98325

INSTALLED

LOCATION

Ag3033

The cabinet MUST have an uninterrupted or unbroken ground

according to NEC ANSI/NFPA 70-1999 and Canadian Elec- trical Code CSA C22.l 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

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

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

provided.

A00212

Fig. 23--Relocating J-Box

Step 2124-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 shorLs 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

Page 21

Table 4_Electrical Data

UNIT SIZE

040-14

060-14 080-14 080-20 100-20 120-20

• Permissible limits of voltage range at which unit willoperate satisfactorily, t 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.

;t Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

** Time-delay type is recommended.

VOLTS--- HERTZ--

PHASE 115_60_1 115--60--1

115--60--1 115--60--1 115--60--1

115---450--1

OPERATING

VOLTAGE RANGE

Maximum" Minimum*

127 104 127 104 127 104 127 104

127 104

MAXIMUM

UNIT

AMPS

8.9

13.8

11.6

UNIT

AMPACITY t

12.0

17.9

18.1

15.3

MINIMUM

WIRE

SIZE

14 14

14 12

MAXIMUM WIRE

LENGTH (FT):I:

31 31

31 32

32 37

MAXIMUM FUSE OR

CKT BKR AMPS*"

15 15

20 20 20

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

lengths up to 100 ft. For wire lengths over 100 if. 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 ll5v

(l.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 faCtOlT-supplied black lead's

butt connector and crimp to secure.

EAC-ELECTRONI( CLEANER TERMINALS

(115-VAC 1 AMP MAX)

MAIN BLOWER

CONTROL WIRE

CONNECTOR

(3.1 Strip EAC neutral lead insulation approximately 1/4

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

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: (i.) Remove 2 screws securing the control box to furnace

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

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

IGNITOR CONNECTOR

in.

bun connector and crimp to secure.

blower shelf.

control center EAC terminals.

in.

115-V CONNECTORS

PRESSURE SWITCH

) CONNECTOR

_H UM'HUMIDIFIER

TERMINAL (24-VAC 0.5 AMP MAX)

ERMOSTAT

NALS

TRANSFORMER--

24-V CONNECTORS

_ STATUS AND DIAGNOSTIC

UMIDIFY ENABLE (DE)

DEHUMIDIFIER (DEHUM)

CONNECTOR

3-AMP FUSE

ii1%oo - 1"EOL,GHTS

CONTINUOUS-- _ __ _,_/Rc_)_TD/TpIO _ NGCH

FAN (CF) SETUP I[_ _ SETUP SWITCHES

SWrTCHES Ill (swlANUBLOWER

- IILI SWITCHES

COMMUNICATION _ _ Q) [

CONNECTOR '_

Fig. 2,_--Control Center

Ili I_rt[ IIZ,_F,I!II OFFDELAYSETUP

)_ _ MODEL PLUG

A99097

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 screw-

driver 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 CoM) are provided for 24-v

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

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 l/4-in, male

quick-connect labeled DEHUM located next to the trans- former 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 lo_c reversal has come about

from historical use of a standard humidistat to do dehumidi- fication 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 termi- nal 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.

El El

--4.--

I 0:11

0000

9BBIIBB

8BBB BOB

DE CONNECTION

LOCATION

Fig. 27_8MVP Variable Speed Furnace Control

A99098

Page 23

VARIABLE-SPEED

THERMIDISTAT

24 VAC HOT

DEHUMIDIFY

24VAC COMM_-

NOTE 1- RemoveDEConnection

CONDENSING

FURNACE

-_DEHUM

[Z]DE

NOTE1

TOEnable DEHUMInput

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 opera- tion, while any other appliances connected to the venting system are not in operation:

i. 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 54-

1999/ANSI Z223.1-1999 or the CAN/CGA B 149 Installation

Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion, and other deficien-

cies 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 damp-

ers. and any other gas-burning appliance to their previous cot_ditions of u_e.

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 NSC- NGPIC.

Step 2_ombustion-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-DWVI, F628 (scbedule_10 ABS),

F891 (PVC-DWV cellular corel or F441 (schedule-40 CPVC pipel and }:438 (scbedale -40 CPVC fittings). Pipe cement and primer must conform to ASTM standards D2564 or F493 (PVC or CPVCI

D2235 tABS). 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_0 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 CLEARANCE (FT)

Above grade level or above antici- pated snow depth 1 1t

Dryer vent 3 3

From plumbing vent stack 3 3 From any mechanical fresh air intake 1 6 For furnaces with an input capacity

leas than 100,000 BtutP--from any non- mechanical air supply (windows or 1 1 dOors which can be opened) or combustion-eir opening

From service regulator vent, electric 4* 6/; and gas meters, and relief equipment

Above grade when adjacent to public Note 3 Note 3 walkway

* Horizontal distance. t 18 in. above rootsurfacein Canada.

t 36 in. to electricmeterin Canada only, NOTES:

1. If installing 2 adjacent 58MVP Furnaces, refer to Multiventing

and Vent Terminations section for proper vent configurations.

2. When locating combnstion-air and vent terminations, consid- eration 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 at- tached 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.

U.S.A. Canada

Page 24

NOT IN

HORIZONTAL

SECTION

E,3[ff_liiWJ_

Combustion air must not be taken from inside structure

because that air is frequently contaminated by halogens.

which include fluorides, chlorides, bromides, and iodides. Them elements are found in aerosols, detergents, bleaches,

cleaning solvents, salts, air fresheners, adhesives, paint, and other household products. Locate combustion-air inlet az 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.

TRANSITION IN

VERTICALSECTION

A9_34

Fig. 29---Combustion-Air and Vent Pipe Diameter

Transition Location and Elbow Configuration

NOTE: Select 1 vent pipe connection and

1 CornbuSlioll-ait pip_ con_ection.

AIR

COMBUSTION-AIR _ COMBUSTION-AIR

VENT ___J

NOTE: Select 1 vent pipe connection and

I combustion air p_e ¢onnect_n.

VENT , VENT

COMBUSTION- _* COMBUSTION*

COMBUSTION-

AIR

VENT

HORI2 NTAL-LEFT DISCHARGE

AIR AIR AIR

I AIR

HORIZONTAL-RIGHT DISCHARGE

FLOW

DOWNFLOW

COMBUSTION-

VENT

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.

NOTE: The minimum combustion-air and vent pipe length (each)

for these furnaces is 5 ft. Short pipe lengths (5-8 ftl 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 ureas in Fig. 34, 35, 36, 37, and 38.

A96187

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

tions

IV_l_,_

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.

Page 25

-41"_-- 12" MIN A

' IV I

VENT PIPE _ _/__ COMBUSTION.AIR PiPE VENT PIPE "_

_,=_--12" MIN

_ON -AIR PIPE

HORIZONTAL TO ROOF

_,,,,_ VENT PIPE

COMBUSTION-AIR PIPE ---_

_12" MIN i

VERTICAL 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

requiting 3 elbows and 17 ft of vent pipe, along with 5 elbows and 16 fl of combustion-air pipe. Table 6 indicates this application would allow a l-l/2-in, diameter vent pipe, but require a 2-in. diameter combustion air pipe (l-l/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, 1-1/2- in. pipe 5s 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:

HORIZONTAL TO SIDEWALL

COMBUSTION-A

VENT PIPE

VERTICAL TO SIDEWALL

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 con- nected.

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

into selected furnace co.sing 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 l/SAn, 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 5000:1:

ALTITUDE

5001 to6000t

See no_s oo next page.

Table 6---Maximum Allowable Pipe Length (Ft)

UNIT SIZE

040-14

060-14

080-14 080-20

100-20

120-20

UNIT TERMINATION SIZE TYPE

040-14 Concentric

080-14 2 Pipe or 2-In.

080-14 2 Pipe or 2-In. 080-20 Concentric

100-20 2 Pipe or 2-In.

120-20 2 Pipe or 3-In.

UNIT TERMINATION SIZE TYPE

040-14 2 Pipe or 2qn,

060-14 2 Pipe or 2-In.

080-14 2 Pipe or 2-tn. 080-20 Concentric

100-20 2 Pipe or 2-In.

120-20 2 Pipe or 3-In.

UNIT TERMINATION SIZE TYPE

040-14 2 Pipe or 2-In.

060-14 2 Pipe or 2-In.

080-14 2 Pipe or 2-In, 080-20 Concentric

100-20 2 Pipe or 2-In.

120-20 2 Pipe or 3-In.

UNIT TERMINATION SIZE TYPE

040-14 2 Pipe or 2-In.

060-14 2 Pipe or 2-In.

080-14 2 Pipe or 2-In. 080-20 Concentdc

100-20 2 Pipe or 2-In.

120-20 2 Pipe or 3-In.

TERMINATION

TYPE

2 Pipe or 2-In,

Concentdc

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 2-In.

Concentric

2 Pipe or 3-In.

Concentric

2 Pipe or 2-In.

Concentric

PIPE DIAMETER

(IN.)*

1-1/2

2 2

2-1/2 2-1/2

PIPE DIAMETER

(IN.)*

1-1/2

2-I/2

PiPE DIAMETER

(IN.)* 1-1/2

1-1/2

2 2

2-1/2

PIPE DIAMETER

(IN.)*

1-1/2

2 2

2-1/2

PIPE DIAMETER

(IN.)*

1-1/2

2 2

2-1/2

NUMBER OF 90 ° ELBOWS

1 2 3 4 5

50 45 40 35 30 70 70 70 70 70

30 25 20 15 10 70 70 70 70 70 45 40 35 30 25

70 70 70 70 70

10 NA NA NA NA 35 30 15 NA NA

70 70 70 70 70

NUMBER OF 90 ° ELBOWS

1 2 3 4 5

45 40 35 30 25 70 7O 70 70 70

45 40 35 30 25 70 70 70 70 70 26 21 16 11 6 70 70 70 70 70 40 35 30 25 20

70 70 70 70 70 31 26 12 NA NA 63 62 62 61 61

NUMBER OF go° ELBOWS

1 2 3 4 5

42 37 32 27 22

70 70 70 70 70

42 37 32 27 22 70 70 70 70 70 25 20 15 10 5

70 70 7O 7O 70

38 33 28 23 18 70 70 70 70 70

29 24 10 NA NA

59 59 58 57 57

NUMBER OF90 ° ELBOWS

1 2 3 4 5

40 35 30 25 20 70 70 70 70 70

40 35 30 25 20

70 70 70 70 70 23 18 13 8 NA 70 70 70 70 70

36 31 26 21 16 70 70 70 70 70

56 55 54 53 52

NUMBER OF 90 ° ELBOWS

1 2 3 4 I 5 6

37 32 27 22 I 17 12 70 70 70 70 70 70 37 32 27 22 17 12 70 70 70 70 70 70

22 17 12 7 NA NA 70 70 70 70 68 63 33 28 23 18 13 8

70 70 70 70 70 70

53 52 50 49 48 47

25 70

70 NA NA

70 NA

7O NA

6 17 70

7O NA

15 7O

68 11

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

8001to9000_

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 2 Pipe or 3-In.

• Disk usage---Unlessotherwisestated,use perforateddisk assembly(tactory-supptiedin loose partsbag). 1"Wide radiuselbow.

Vent sizing for Canadian installations over 4500 ft (1370m) above sea level are subject to acceptance by the local authorities having judsdicti0n.

NA_ot 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 game sense _ockout 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 tenminagon should not be included in vent length or elbow count.

5. The minimum pipe length is 5 ;1 for all applications.

TERMINATION PIPE DIAMETER

TYPE (IN.)* 1

2 Pipe or 2-In. 1-1/2 35

Concentric 2 70

2 Pipe or 2-In 1-1/2 35

Concentric 2 70

2 Pipe or 2-In. 1-1/2 20

Concentric 2 70

2 Pipe or 2-In. 2 31

Concentric 2-1/2 70

2 Pipe or 3-In 3J- 49

Concentric

TERMINATION PIPE DIAMETER

TYPE (IN,)* 1

2 Pipe or 2-In. 1-1/2 32

Concentric 2 66

2 Pipe or 2-1n. 1-1/2 32

Concentric 2 66

2 Pipe or 2-In. 1-1/2 18

Concentric 2 66

2 Pipe or 2-1n 2 29

Concentric 2-1/2 66

2 Pipe or 3-In 3t 46

Concentric

TERMINATION PIPE DIAMETER

TYPE (IN,)* 1

2 Pipe or 2-in. 1-1/2 30

Concentric 2 62

2 Pipe or 2-In. 1-1/2 30

Concentric 2 62

2 Pipe or 2-In 1-1/2 17

Concentric 2 62

2 Pipe or 2-In. 2 27

Concentric 2-1/2 62

2 Pipe or 3-In. 3t 43

Concentric

TERMINATION PIPE DIAMETER

TYPE (IN.)* 1

2 Pipe or 2-In. 1-1/2 27

Concentric 2 57

2 Pipe or 2-in. 1-1/2 27

Concentric 2 57

2 Pipe or 2-In. 1-1/2 15

Concentric 2 57

2 Pipe or 2-In. 2 24

Concentric 2-1/2 57

Concentric 3t 39

NUMBER OF gO° ELBOWS

2 3 4 5

30 25 20 15

70 68 67 66

30 25 20 15

70 68 67 66

15 10 5 NA 70 68 67 62

26 21 16 11 70 68 67 66

48 47 45 44

NUMBER OF 80° ELBOWS

2 3 4 5 6 27 22 17 12 7 65 63 62 60 59

27 22 17 12 7 65 63 62 60 59 13 8 NA NA NA

65 63 62 57 52 24 19 14 9 NA 65 63 62 60 59

44 43 41 40 38

NUMBER OF 90 ° ELBOWS

2 3 4 5

25 20 15 10

60 58 56 55 25 20 15 10

60 58 56 55

12 7 NA NA

60 58 56 51

22 17 12 7

60 58 56 55 41 39 37 35

NUMBER OFO°ELBOWS

2 3 4 5

22 17 12 7

55 53 51 49 22 17 12 7

55 53 51 49 10 5 NA NA 55 53 51 46

19 14 9 NA 55 53 51 49

37 35 33 31

NA 47

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 flume 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 l/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 combuslion-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_supphed 318-in.

tube. This robe should be routed to open condensate drain for furnace and A]C (if used), and should be tlapped. (See Fig.

32.)

COMBUSTION - AIR

3/8" ID TUBE--

3./16'

INTAKEHOUSING BURNER

P Box

OsrLL

AIR PiPE

TRAP -_

TO OPEN

DRAIN

Fig. 32--Intake Housing Plug Fitting DrainA93°3s

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

housing as shown in Fig. 30 for application.

b. Repositinn elastomeric (rubber) inducer housing outlet cap

and clamp to appropriate unused inducer housing connec- tion. Tighten clamp.

c. Install pipe support (fuctory-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 clampsl onto inducer housing

connection. Insert the 2-in. diameter vent pipe through the

]_ COMBUSTION-

elastomeric (rubber) coupling and fully into inducer hous ing connection until it bottoms on the internal stop. Tighten

both clumps to secure the pipe to inducer housing. Tighten the clump screws to 15 in.-lb, of torque.

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

bag) in unused combustion-air pipe easing hole.

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 ouLside 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 firing socket lover 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 arotmd perimeter of a properly made joint.

1I. 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 mini- mum of 1/4 in. per linear ft with no sags between hangers.

14. Use appropriate methods to seal openings where vent and

combustionoair 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 klL fuUow kit instructions. Combastion-aJr and vent pipes must terminate outside structure. A

factory accessory termination kit must be installed in 1 of the installations shown in Fig. 33, 3,1, 35.36, or 37. Four termination

kits are available.

1. The 2-in. termination bracket kit is for I-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 temrination systems.

3. The 2-in. concentric vent/air termination kit is for l-in., 1-1/2 in., 2-in., and 2-112 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

AIR AND VENT

8 3/4" FOR 3" KIT 6 3/4" FOR 2_ KIT

MAINTAIN 12 IN.

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL.

MAXIMUM OF 24 IN. ABOVE ROOF.

Fig. 33_Roof Termination (Preferred)

MAINTAIN 12 IN. (

MINIMUM CLEARAN ABOVE HIGHEST ANTICIPATED SNOW

LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

A93054

Fig. 34---Concentric Vent and Combustion-Air Roof

Termination (Preferred)

A872.2.4

OVERHANG OR ROOF

12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICfPATEG SNOW

LEVEL OR GRADE,

WHICHEVER IS GREATER.

12 IN.

A9:3055

Fig. 35---Concentric Vent and Combustion-Air Side

Termination

OVERHANG OR ROOF_

BRACKE

SEPARATION

-BETWEEN BO33-OM OF COMBUSTION AIR AND

ABOVE HIGHEST

CLEARANCE ANTICIPATED SNOW

/ COMBUSTION AIR LEVEL OR GRADE,

- WHICHEVER IS

GREATER.

OF VENT

12 IN.

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

AST2_5

(ELBOW PARALLEL

TO WALL)

: COMBUSTION AIR AND

CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW

LEVEL OR GRADE, WHICHEVER IS

GREATER.

OF VENT

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

BOTTOM OF

12 IN.

A87226

Page 30

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

Temperature Ambient*

UNIT TEMPERATURE DIAMETER

WINTER DESIGN MAXIMUM PIPE INSULATION THICKNESS {IN-)t

SIZE (OF) (IN.) 0 3/8 112 3/4 1

20 2 21 37 42 50 57

040-14 0 2 10 22 25 30 35

-20 2 5 14 17 21 25 20 2 30 55 61 70 70

060-14 0 2 16 33 38 46 53

-20 2 9 23 26 33 38 20 2 37 65 70 70 70

080-14 0 2 20 39 45 55 63 080-20

-20 2 11 27 31 39 45 20 2-1/2 41 70 70 70 70

100-20 0 2-1/2 21 42 48 59 68

-20 2-1/2 11 28 33 41 49 20 3 49 70 70 70 70

120-20 0 3 26 51 58 70 70

-20 3 15 35 40 50 59

• P_pe lencjth (ft / specified for maximum pipe lengths tocated in unconditioned spaces. Pipes located in unconditioned space cannot exceed total aitowable pipe tength as specified in Table 6.

t thsuladon thickness based on R value of 3.5 per in.

NOTE: Shadedparts 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 sinceit is less susceptible to damage,hasreduced chancesto intake contaminants, and has less visible ventvapors. (See Fig. 33 or 34.) Sidewalltermination may require sealing or shielding of building

surfaces with a corrosive resistance material due to corrosive

combustion producLsof 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.

I. 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 equip- ment.

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

affected by wind eddy (such as inside building comers) 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 objecL_, 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 1800 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 TERMINAT10N 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 equip- ment.

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

affected by wind eddy (such as inside building cornersl 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. Cat 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 termlnatinns--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 I-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, 4.1. or42, but next vent terrainaoon must be at least 36 in. away from f-Lrst2 terminations. It is important that

vent terminations be made as shown to avoid reeirculation of flue gases. Dimension "A" in Fig. 38, 39, 40, 41, and 42 represents distance between pipes or rain shields, as touching or 2tin.

maximum separation.

CONDENSATE DRAIN

Step 1--General

Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensalg 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 gap or drain robe coupling)

is sized for l/2-in. CPVC, l/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 conden- sate 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 looai authorities to determine if a pH neutralizer is required.

Step 2--Application

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

See Fig. 43 for example of possible field drain attachment using

l/2-in. CPVC or PVC tee for vent and A/C or humidifier drain

connection.

_ziM°F MINIMUM INSTALLED

BLENT OR FREEZE

OTECTION 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.

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.

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 fi at 120v and 40°F self-regaladng, shielded, and waterproof heat tape. See Installation Instructions supplied with accessory or heat tape manufacturer's recommenda-

tions.

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 l wrap per ft.

5. When using field-supplied heat tape, follow heat tape manu-

facturer's instructions for all other installation guidelines.

Page 32

A96128

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

COMBUSTION AIR

VENT

A93056

Fig. 39---Concentric Vent and Combustion-Air Roof

Termination (Dimension "A" is Touching or

2-In. Maximum Separation)

COMBUSTION

A95_29

Fig. 41_idewall Termination of 12 in. or Less

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

Maximum Separation)

A93057

Fig. 40---Concentric Vent and Combustion-Air Side

Termination (Dimension "A" is Touching or

2-In. Maximum Separation)

Ag6130

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

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

Maximum Separation)

Page 33

PIPE FOR

PJCOR

HUMIDIFIER

OPEN STAND

DRAIN

TEE

Ag4054

Fig. 43mExample of Field Drain Attachment

CONDENSATE TRAP--_

WIRE

HEAT TAPE"_

(3 WRAPS MINIMUM)_

Fig. 44---_ondeneate Trap Heat Tape

SEQUENCE OF OPERATION

Using schematic diagram (see Fig. 24), follow sequence of

operation through different modes. Tbis 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 l_elf-Test Mode

The control center goes through a brief self-test whenever I 15-v or 24-v power is interrupted. The self-test takes approximately 2 sec to complete. After power is restored, red (microprocessor) LED

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/W 1 circuit closes.

I. 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. Humidll_er (HUM)_The HUM terminal is energized after

the inducer prepurge period is completed.

3. Ignitor warm ul_-At end of prepurge period, the hot surface

ignitor (HSI) is energized for a 17-see HSI warm-up period.

4. Ignition sequence---After HSI ignitor warm-up period is completed, the gas valve opens, pernfitting 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 interrup- tion 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 low- and 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 sewing--When burner flame is sensed, the control

center holds gas valve open and begins blower on delay period.

NOTE: Ignition sequence repeat._ 3 additional times before a

lockout occurs. Lockout automatically resets after 3 hr, or can be manually reset by turning l15-v or 24-v power off (not at

thermostat) for 3 see 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-I terminal is energized whenever the blower operates.

9. Blower off delay--When thermostat is satisfied, the R-W/W 1 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 (depend-

ing 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 optimiz-

ing efficiency to meet the demands of conditioned area when a

thermostat R-W/W l 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/WI and R-W2 signal, high heat is energized and when a

R-W/Wl 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/W 1

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 recom- mended 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 elecWodics 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_-. 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-I circuits close.

1. Prepurge perlod--The inducer motor is turned on IMMEDI-

ATELY operating at maximum speed, closing low- and

high-pressure switches. Prepurge begins 25 sec after high- pressure 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-I terminal does not

operate in emergency heat mode.

4. Humldifier--The HUM terminal is energized IMMEDI- ATELY.

5. Ignitor warm up---The HS[ is energized for a 17 sec warm-up period after prepurge period is completed.

6. Ignition sequence---After HS1 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 de-

energized, 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 re- peated.

NOTE: Ignition sequence repeals 3 additional times before lock- out occurs. Lockout automatically reseL_ after 3 br. or can be manually reset by turning l15-v or 24-v power off (not at thermostat) for 3 sec minimum, then mrmng on again. Fault codes will not flash in emergency heat mode.

8. Bloweroffdelay--When thermostat is satisfied, the R-W/WI signal is terminated, de-energizing gas valve (stopping gas flow to bumerst, 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 unlt--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-O 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 dehumidifi- cation 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--Wben 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/W 1 circuits close starting gas heat cycle, and blower adjusts

to low-beat speed.

I. Prepurge period_Tbe 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 ttsed to determine required

RPM necessary to operate inducer in low-beat mode.

Page 35

2-SPEED

THERMOSTAT

] .....

] ....

[] - _

] ....

] .......

[] []-

[]-

VARIABLE

SPEED

THERMOSTAT

El-- --

.......... i- ....

...... i .....

2-SPEED AIR

CONDITIONER

10. Call for heat terminated_When the call for heat is satisfied,

the R-W/WI signal is terminated, de-energizing gas valve

)

(stopping gas flow to burners), and HUM terminal is de- energized.

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/WI with R-Y/Y2 and R-G signals terminated--

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

I I. 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

[_--

[_]- -

VARIABLE

SPEED

THERMOSTAT

2-SPEED

HEAT PUMP

A_2_2

Fig. 45--Wiring Schematic for 2-Speed

Cooling Applications

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

high-beat 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. Humldifier--The HUM terminal is energized after inducer prepurge period is completed.

3. Ignitor warm ulr--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.

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-I terminal is energized

whenever blower operates.

9. Inducer speed operation--lf 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.

[_]--

[_-.

[]-

..... I@ .....

[] []-

I 1-

[]-

Fig. 46---Wiring Schematic for 2-Speed

Step 7_ontinuous Fan Mode

I. 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 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 beating mode.

NOTE: The continuous fan speed is the same as low-heat speed unless it is field adjusted to another desired airflow. See Continu-

ous Fan Setup Switches section. There is also a chart on wiring diagram. (See Fig. 24.)

c. Electronic Air Cleaner The EAC-I terminal is ener-

gized whenever blower operates, regardless of operating mode.

2. Operating with continuous fan (R-G) and call for heat

(R-W/WI) is received Same as heat pump mode except blower on delay is 10 sec less than heat mode. After call for

Heat Pump Applications

A94303

Page 36

heat (R-W/W I) 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 con- tinuous 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 fall_.

NOTE: Setup switch SW-I 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 llS-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 t 15-v power to control centgr. No component operation can occur. Caution

must be taken when manually closing this switch for service puqooses. 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 micro- processor 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 hack 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 l. 15 for all furnace model sizes. This

compensates for increased return-air temperature caused by by- passed air supply,

Step lO---Dehumidification Mode

A dehumidification input is provided via a I/4 in. male quick- connect terminal labeled DEHUM located next to the transformer

secondary, connections. When there is a dehumidify demand, the

DEHUM input is activated, which means 24 va¢ 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 TM Control Installation, Start-Up. and Op- crating Instructions for fttrther details.

Step 11--Zone Mode

When setup switch SW-5 MZ is in ON position, blower motor

control is the same a_sabove 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 prevenLs 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 lfl percent of calculated blower RPM for 5 sec.

START-UP PROCEDURES

Step l_eneral

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. WAVI, 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. we), 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 CFM AIRFLOW

(TONS)

1200 or

Default 2000

1-1/2 600

2 800

2-1/2 1000

3 1200

3-1/2 1400

4 1600 5 2000

X-Indicates allowableselection,

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 g 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 NC-2 NC-3 040-14

OFF OFF OFF 1200 CFM

ON OFF OFF X

OFF ON OFF X

ON ON OFF X

OFF OFF ON X

ON OFF ON X

OFF ON ON --

ON ON ON --

3 Tons

ALLOWABLE FURNACE MODEL SETUP

060-14

3 Tons

1200 CFM

X X X

X X

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 bypa._s humidifier is use& setup switch SW-3 (BPH) should be in ON position. This prevents nuisance limit trips caused hy the increased temperature in return air resulling 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.

080-14

3 Tons

1200 CFM

X X X

080-20 5 Tons

2000 CFM

X X

100-20

5 Tons

2000 CFM

X X X

X X

120-20

5 Tons

2000 CFM

X X X

X X

OFF

A95198

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-I terminal is energized whenever blower operates.

HUM termina/is only energized when gas valve is energized. CONTINUOUS FAN (CF) SETUP SWITCHES

The CF setup switches ale used 1o 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:

Step 3--Prime Condensate Trap With Water

¥!_ [q_lljlJL[,]:l

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 l/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

600 800

1000 1200 1400 1600 2000

• Add 15%additionalCFM when Bypass Humidifier switchSW-3 on controlboardis used. X--Indlcates allowable selection.

CF-1 CF-2 CF-3 OFF OFF OFF

ON OFF OFF

OFF ON OFF

ON ON OFF

OFF OFF ON

ON OFF ON

OFF ON ON

ON ON ON

CF SETUP

SWITCH POSITION

040-14

565*

X X X X

ALLOWABLE FURNACE MODEL SETUP

060-14

515"

X X X

080-14

6"90*

080-20

690"

X X

-- ×

X X

Table lO--Setup Switch Description

SETUP NORMAL DESCRIPTION OF USE

SWITCH NO. POSITION

SW-1 OFF Turn switch to ON for fault history display, No thermostat signal can be

(FLT) present for fault history display.

SW-2 OFF Turn switch to ON to lock furnace in low-heat mode only or when using a

(LOW) 2-stage thermostat with R-W/W1 and R-W2 signals.

SW-3 OFF for higher return-air temperature and provides 15 percent more airflow in

(BPH) low-heat mode only,

SW-4 Tum switch to ON to bypass microprocessor control. Furnace will oper-

(EMER HEAT) OFF ate at high heat only with main blower and inducer motor operating at

SW-5 Turn switch to ON when modulating dampers are used. In this mode,

(MZ) low-heat or continuous fan mode.

SW-8 high speed, energize HSI for 15 sac, operate blower for 20 sec at low

(COMP TEST) OFF

SW-7 and -8 Adjust switches to provide desired heating mode blower off delay time,

(Blower Off Delay) See Table 11 90, 135, 180, or 225 sec.

OFF main blower speed is recalculated once every minute while furnace is in

Turn switch to ON when a bypass humidifier is used. This compensates

maximum RPM. NO safeties are bypassed.

Turn switch to ON to initiate component test. Furnace will operate in- ducer motor for 20 sec at low speed, operate inducer motor for 20 seC at

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.

100-20

860 •

X X

120-20

1035"

X X

X X X

Table 11--Blower Off Delay Setup Switch

Position

DESIRED HEATING

MODE BLOWER

OFF DELAY (SEC)

90 135 180 225

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 _is warning could

rasoh in Fu'e, explosion, persona/ injury, or death.

Step _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

OFF OFF

ON OFF

OFF ON

SW-7 I SW-8

ON ON

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 +_2percent 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-beat manifold pressure settings for proper operation.

Page 39

Fig. 48_lnducer 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/Wl thermostat connections on control

center to start furnace.

e, Turn low-heat adjusting screw (5/64 bex 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

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 high- heat 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 va]ve regulator adjustment screws. Main burner flame should be clear blue, almost transparent. (See Fig. 51.)

j. Remove jumpers R to W/Wl 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

(F13

m 0 925

€

o 950

to 975

_ 2O0O 1025

AL_TUDE

RANGE

(FT)

U.S,A.

Altitudes

2001

€1

3000

Canada

Altitudes

20O0

4500

AL_TUDE

RANGE

(F'r)

3001

_. to

4000

* Odfice numbers shown in BOLD are factory installed.

AVG GAS

HEAT VALUE

AT ALTITUDE

DT_CUFT)

850

875

9OO

1000

1050 1075

1100

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

775

800 825

85O

875

900

925

95O

975

1000

1025

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CUFT)

75O 775 800 825

850 875 900 925

950

975

1000

0.58 0.60 0.62 0.64

Orifice Pressure No. No. No.

No. High/Low High/Low High/Low High!Low

43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 43 3.5/1.5 43 3,6/1.5 43 3.7/1.6 43 3.8/1.6 44 3.7/1.6 43 3.4/1.4 43 3,5/1.5 43 3.6/1.5 44 3.5/1.5 44 3.7/1.6 44 3.8/1,6 43 3.4/1.4

44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1,6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5

45 3.7/1.6 45 3.8/1.6 44 3.2/1,4 44 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3

45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.2/1,3 45 3.3/1.4 45 3.4/1,4 45 3,6/1.5 47 3,6/1,5 47 3.7/1,6 45 3,2/1.4 45 3.4/1.4

0.58

Orifice Manifold

No,

43 3.8/1.6

43 3.5/1.5

44 3.8/1,6

44 3.6/1.5 44 3.4/1.4 44 3.2/1.4

45 3.7/1.5 45 3.5/1.5 45 3,3/I ,4

47 3,7/1.6

47 3.6/1.5

0.58

Orifice Manifold

No. Pressure

43 3.7/1.6

43 3,5/1.5

44 3.7/1.6 44 3.5/1.5 44 3.3/1.4

45 3.5/1.6 45 3,6/1.5 45 3,4/1.4

45 3.2/1.4 47 3.6/1.5 47 3.5/1.5

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Orifice Pressure Pressure Pressure

Pressure

High/Low

Odfice Pressure No.

Orifice Pressure

No. High/Low No.

45 3.5/1.6 45

45 3.2/1.3 45 47 3.6/1.5 47

Manifold Orifice Manifold Orifice Manifold

SPECIFIC GRAVITY OF NATURAL GAS

0.60 Manifold Orifice

No, High/Low

42 3,2/1.4 42 43 3.7/1,5 43

43 3,4/1.5 43 44 3.7/1.6 44 44 3,5/1.5 44

44 3.3/1.4 44 45 3,8/I .6 44 45 3.6/1.5 45 45 3.4/I .4 45

45 3,2/1.4 45 47 3,7/1.6 45

SPECIFIC GRAVITY OF NATURAL GAS

O.6O O.62 0.64

Manifold Orifice

43 3.8/1.6 42 43 3.6/1.5 43

43 3.4/1.4 43 44 3.611.5 44 44 3.4/1.4 44

44 3.2/1.4 44 45 3.7/1.6 45

45 3,3/1.4 45

0,62

Manifold

Pressure

High/Low

3.3/1.4

3.8/1.6

3.6/1.5

3.8/1.6 3,6/1.5

3.4/1.4 3,2/I,4

3.7/1.6

3.5/1,5

3.4/1.4

3.2/1.3

Manifold

Pressure

High/Low

3.3/1,4

3,7/1,6

3.5/1.5

3.5/1,6 3,5/1.5 3,3/1.4

3.6/1,6

3.6/1.5

3.4/1.5

3.3/1,4

3.7/1,6

0.64

Orifice I Pressure

No. High/Low

Orifice Pressure Orif_e Pressure

No. High/Low No. High/Low

42 3.4/1.4 42 3.5/1.5

43 3.8/1,6 42 3.2/1.4

43 3.6/1.5 43 3.7/1,6

43 3.4/1.4 43 3.5/1.5 44 3.7/1.5 44 3.8/1.6 44 3.5/1.5 44 3.611.5

44 3.3/1.4 44 3.4/1.4 45 3.7/1.6 44 3,2/1 _3 45 3.5/1.5 45 3.7/1.5 45 3.4/1.4 45 3,5/1.8 45 3.2/1.4 45 3.3/1.4

Manifold

42 3.4/1.4 42 3,2/1.4

43 3.7/1.5 43 3.5/1.5

44 3,7/1.6

44 3.5/1,5

44 3.3/1.4 45 3.8/1.6

45 3.6/1.5 45 3.5/1.5 45 3.3/1.4

Manifold Manifold

0,66

Orifice Manifold

NO. Pressure

High/Low

42 3.4/1.4

42 3.2/1.4 43 3.7/1,6

43 3.5/1,5

44 3.8/1.6 44 3,6/1.5 44 3.5/1.5

44 3.3/1.4 45 3.8/1.6

45 3.6/1.5 45 3.5/1.5

0.66

Orifice Pressure

Manifold

No.

High/Low

42 3.5/1.5 42 3.3/1.4 43 3.6/1.6

43 3.6/1.5

43 3.4/1.4

44 3.6/1,5

44 3,4/1.5

44 3.3/1.4

45 3.6/1.6

45 3.6/1.5

43 3.4/1.4

0.66

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

6_0

ALTITUDE

RANGE

(FT)

5001

6O00

ALTITUDE

RANGE

(FT)

6001

7000

• OffiCe numbers in BOLD are facton

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725 75O

775 80O 825 85O 875

000

925 950

AVG GAS

HEAT VALUE

AT ALTITUDE

(RTU/CU F'r)

7OO 725

750 775 800

825 850

875

90O 925

950

975

1000

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650

675 700 725 750 775

800 025

850 875

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

SPECIFIC GRAVITY OF NATURAL GAS

0.58

Orifice Orifice

No. High/Low No. High/Low !

Odfice Manifold Manifold

No. High/Low No. High/Low

45 3.2/1.4 45 3.3/1,4 46

48 3.7/1.6 48 3.8/1.6 47

48 3.5/1.5 48 3.6/1.5 46

Orifice Manifold

No.

42 3.2/1.3 43 3.6/1,5 44 3.8/1.6 44 3.6/1.5

44 3.3/1.4

45 3.5/1,6 45 3.5/1.5 45 3.3/1.4

47 3,7/1.6 47 3,5/1.5

installed.

Manifold Manifold

Pressure Pressure

43 3.7/1.5 43 3.8/1,6 43 3.4/1.4 43 3.5/1.5 44 3.7/1.6 44 3.8/1,6

44 3.5/1.5 44 3.6/1,5

44 3.2/1.4 44 3.411.4 45 3.7/1.6 45 3.8/1,6 45 3.5/1,5 45 3.5/1.5

45 3.3/1.4 45 3,4/1.4 47 3,7/1.6 45 3.2/1,4 47 3.5/1.5 47 3.6/1,5

0.58 0.60

Pressure Orifice Orifice

43 3.6/1,5 43 3.7/1.6 42

43 3,4/1.4 43 3.5/1,5 43

44 3.6/1.5 44 3.7/1.6 43

44 3.4/1.4 44 3.5/1.5 44 44 3.2/1.3 44 3.3/1.4 44

46 3.6/1.5 45 3.7/1.6 44 45 3.4/1.4 45 3.5/1.5 45

47 3.6/1.5 47 3.7/1.6 46 47 3,4/1,4 47 3,5/1,5 47

48 3.3/1.4 48 3.511.5 48

0.S8

Pressure

High/Low

0.60 0.62 0,54 Orifice

No.

42 43

44 44

44 45

45 45

SPECIFIC GRAVITY OF NATURAL GAS

0.62 0.64

Pressure No.

SPECIFIC GRAVITY OF NATURAL GAS

0.60

Orifice Manifold

No. Pressure

High/Low

42 3.3/1,4 43 3,7/1.6 43 3,4/1.5 44 3.7/1.6

44 3.4/1,5 44 3.2/1.4 45 3.7/1,5

45 3.4/1.5 45 3.2/1,4

47 3,6/1,5

0.62 0.64 0.66

orifice Manifold Orifice Manifold Orifice Manifold

No. High/Low No. High/Low No. High/Low

42 3.4/1.4 42 3.5/1.5 42 3.6/1.5 43 3.8/1.6 42 3,2/1.4 42 3.3/1.4 43 3.6/1.5 43 3.7/1.6 43 3.5/1,6 44 3.8/1.6 43 3.4/1,4 43 3.5/1.5

44 3.6/1.5 44 3.7/f,6 44 3.B]1.6 44 3.311.4 44 3,4/1.5 44 3.5/1.5 45 3.8/1.6 44 3,2/1.4 44 3.3/1.4

46 3.6/1.5 45 3.7/1.6 45 3.8/1.6 45 3.4/1.4 45 3.5/1,5 45 3.6/1,5

45 3.2/1.3 45 3,3/1.4 45 3.4/1.4

0.66

Manifold Orifice Manifold Odfice Manifold

Pressure No. Pressure NO. Pressure

High/Low High/Low High/Low

3.2/1.4 42 3.3/1.4 42 3.4/1.4

3.7/1.5 43 3.8/1.6 42 3.2/1.4 3,4/1.4 43 3.5/1.5 43 3.7/1.5

3.7/1.6 44 3,8/1.6 43 3.4/1.4

3.5/1.5 44 3.6/1.5 44 3.7/1.6

3.3/1.4 44 3.4/1.4 44 3.5/1.5

3.7/1.6 44 3.2/1,3 44 3.3/1.4

3.5/1.5 45 3.6/1.5 45 3.8/1.6 3,3/1.4 45 3,4/1,5 45 3.6/1.5

3.2/1.3 45 3.3/1.4 45 3.4/1.4

0.66

Manifold Orifice Manifold

Pressure No. Pressure

High/Low High/Low

3.2/1,3 42 3,3/1.4

3.6,/1.5 43 3.7/1.6

3.4/1.4 43 3.5/1,5

3.6/1.5 44 3.7/1.6

3.4/1.4 44 3.5/1.5

3.2/1.4 44 3.3/1.4

3.5/1.5 45 3.5/1.6

3.4/1.5 45 3.6/1.5

3.3/1.4 45 3.4/1,4 3,7/1.5 45 3.2/1,3

3.5/1,5 47 3,6/1.5

3.5/1,6 47 3,4/1.4

3.6/1.5 48 3.7/1.6

Pressure Pressure Pressure

Odfice Manifold

NO. PresSUre

High/Low

42 3.4/1.4 43 3.8/1.6

43 3.6/1.5 43 3.4/1.4 44 3,6/1.5

44 3.4/1.4 44 3.2/1.4

45 3.7/1.5 45 3.5/1.5

45 3.3/1.4 47 3.7/1.6

47 3.5/1.5 48 3.8/1.6

Page 42

Table12--Model58MVPOrificeSizeandManifoldPressurefor CorrectInput(Continued)

(TabulatedDataBasedon20,000BtuhHighHeat/13,000BtuhLow HeatperBurner

Derated2%foreach1000ft AboveSeaLevel)*

ALTITUDE

RANGE

(FT)

7001

8000

ALTITUDE

RANGE

(FT)

8001

9000

ALTITUDE

RANGE

(FT)

.._ 9001 O

_ to

10,000

• Onfice numbers shown in BOLD are factory installed.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU IT)

625 65O 675 7OO 725 750

775

8OO 825 850

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

6O0 625 65O 675

700 725 750 775

800

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CUFT)

575

60O 625 650 675

700 725 750 775

0.58

Orifice Pressure

No. High/Low

43 3.8/1.6

43 3.5/1.5 44 3.8/1.6

44 3.5/1,5 44 3.3/1.4

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

47 3.4/1.4

0.58

Odfice

No.

44 44 44

45 45 45

0.58

Orifice Manifold

No. High/Low

43 3,8/1.6

43 3.5/1,5 44 3.7/1,6 44 3.4/1.4

45 3.8/1.6 45 3.6/1.5

45 3.3/1.4 47 3.7/1.6

47 3,5/1.5

Manifold

Pressure

High/Low

3.8/I .6

3.5/1.5

3.7/1.6

3.5/1.5

3.2/1.4

3.5/1.5

3.4/1.4 3,2/1,3

3.5/1,5

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62 0.64

Orifice Pressure

No. High/Low

Orifice

No.

Orifice Manifold

No. High/Low

45 3.7/1.6 45 3.4/1.5 45 3.2/1.4

47 3.6/1,5

Manifold

42 3.3/1.4 43 3.7/1.6

43 3.4/1.4

44 3.6/1.5

44 3.4/1.4 46 3.8/1.6

45 3.6/1.5

45 3.4/1.4

45 3.2/1.3

47 3.5/1.5

SPECIFIC

0.60

Manifold

Pressure High!Low

42 3.3/I .4

43 3.6/1,5 43 3.4/1.4

44 3.6/1.5 44 3.3/1.4

45 3.8/1.6 45 3.5/1.5 45 3,3/I ,4

47 3,7/1,6

SPECIFIC

0.60

Pressure

42 3.2/1.4 43 3.5/1.5 44 3,8/1.6

44 3.5/1.5 44 3.3/1.4

Orifice Orifice

No. High/Low ! No.

GRAVITY OF NATURAL GAS

Orifice

No.

GRAVITY OF

Orifice Pressure

No. High/Low

43 3.7/1.6 43 3.5/1.5

44 3.7/1.5 44 3.4/1.4

45 3.8/I .6 45 3,6/1.5 45 3.3/1,4

47 3,7/1,5

Manifold

Pressure

42 3.4/1.4 42 43 3.8/1.6 42

43 3.5/1.5 43

44 3.8/1.6 43

44 3.5/1.5 44 44 3.3/1.4 44

45 3.7/1.6 45

45 3.5/1.5 45 45 3.3/1.4 45 47 3.7/1.5 45

0.62

Manifold

Pressure

High/Low

42 3.4/1.4

43 3,8/1.6 43 3.5/1,5 44 3.7/1,6 44 3.4/1.5 44 3,2/1.4

45 3.6/1.5

45 3.4/I .4 45 3,2/1.3

NATURAL GAS

0.62

Manifold

42 3.3/1.4

Manifold Manifold

Pressure Orifice Pressure

High/Low No. High!Low

3.8/1.5 42 3.6/1.5

3.2/1.4 42 3.3/1.4

3.6/I .5 43 3.7/1.6

3.4/1.4 43 3.5/1.5

3.6/1.5 44 3.7/1.6

3.4/1,4 44 3.5/1.5

3.8/1.6 44 3.3/1.4

3.5/1.5 45 3.7/1.5 3,4/1.4 45 3.5/1.5

3.2/1.3 45 3.3/1.4

0.64

Orifice Pressure

No. High/Low

O_fice Manifold

No. Pressure

45 3.7/1.6

45 3.2/1.4

Manifold

42 3.511.5 42 3,2/1.4

43 3.6/1.5

44 3,8/1.6 44 3.6/1.5 44 3.3/1.4

45 3,8/1.6

45 3.5/1.5 45 3.3/1.4

0.64

High/Low

42 3,5/1.5 42 3.2/1.3

43 3.6/1.5

44 3.8/1,6 44 3.5/1.5

44 3.3/1.4

45 3,4/1.5

0.66

Orifice

No. Pressure

Orifice Manifold

No. Pressure

44 3,411.4 45 3.8/1.6

45 3.3/1.4

Manifold

High/Low

42 3.6/I .5 42 3.3/1.4

43 3.7/1.6

43 3.4/1.5

44 3.7/1.6 44 3.4/1,4

44 3.2/1.4

45 3.6/I .5 45 3.4/1.4

0.66

High/Low

42 3.6/1.5 42 3,3/1.4 43 3.7/1.6

43 3.4/1.4 44 3.6/1.5

45 3.511.5

Page 43

X'-- INLET \ PRESSURE /,_

ON/OFF

SWITCH

ADJUSTMENT ALLEN SCREW

(UNDER CAP)

ADJUSTMENT ALLEN SCREW

(UNDER CAP)

BURNER FLAME --_

? ;

MANIFOLD J

A89020

Fig. 51--Burner Flame

ENCLOSURE REFERENCE

PRESSURE TAP MANIFOLD

PRESSURE

TAP

A97_6

Fig. 50_Redundant Automatic Gas Valve

ORIFICE

A93059

DO NOT redrill orifices. Improper drilling (burrs, out-of- round 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 It, this furnace has been approved for a 2 percent derate for each 1000 ft above sea level. See Table 13 fur derate multiplier factor and example.

EXAMPLE: 100,000 BTUH INPUT FURNACE INSTALLED AT

4300 FT,

Furnace Input Rate Derate Furnace Input Rate

at Sea Level X Multiplier at Installation

100,000 X 0.91 91,O00

Factor Altitude

Table 13--Altitude Derate Multiplier for U.S.A.

ALTITUDE % OF DERATE MULTIPLIER

(FT) DERATE FACTOR FOR U.S.A.*

0---2000 0 1.00

20014000 4--6 0.95 3001---4000 6--8 0.93 4001--5000 8--10 0.91 50014--6000 10_12 0.89

6001 --7000 12--14 0.87 70014000 14---16 0.85 8001 --9000 16--18 0.83

9001 --10,0O0 18--20 0.81

• Derate multiplier factor is based on midpoint agitude for altitude range.

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 multi-

plier 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-beat operation.

Page 44

h. Jumper R to W/WI. i. Let furnace run for 3 minutes in low-beat operation.

j. Measttre time (in sec) for gas meter to complete 1 revolu

tion. Note reading.

k. Refer to Table 14 for cubic fi of gas per hr.

1. 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, tSee 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 ftha" 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/WI, and W2 thermostat

connections to terminate call for heat.

Table 14---Gas Rate Cu Ft/Hr

SECONDS

FOR 1

REVOLUTION

10 11

15 16 17 18 19

20 21

23 24

25 26 27 28 29

30 31

33 34

36 37 38

3e 40

41 42 43 44

45 46 47 48 4g

S!ZE OF TEST DIAL SECONDS

1 2 5 FOR 1

cuff cuff cuff REVOLUTION

360 720 1800 50

327 655 1636 51 300 600 1500 52 277 555 1385 53 257 514 1286 54

240 480 1200 55 225 450 1125 56 212 424 1059 57 200 400 1000 58

18g 379 g47 59 180 360 900 60

171 343 857 62 164 327 818 64 157 313 783 66

150 300 750 68 144 288 720 70

138 277 692 72

133 267 667 74 129 257 643 76 124 248 621 78

120 240 600 80 116 232 581 82

113 225 563 84

109 218 545 86 106 212 529 88

103 206 514 90

100 200 500 92

97 195 486 94 95 189 474 96

92 185 462 g8 90 180 450 100

88 176 439 102

86 _72 429 104 84 167 419 106

82 164 409 108 80 160 400

78 157 391 110 76 153 383 112 75 150 375 116

73 147 367

120

SIZE OF TEST DIAL

1 2 5

cu _ cu _ cu

72 144 360 71 141 355

69 138 346 68 136 340 67 133 333

65 131 327 64 129 321 63 126 316 62 124 310 61 122 3O5

60 120 300 58 116 290

56 112 281 54 109 273

53 106 265 51 103 257

50 100 250 48 97 243 47 95 237 46 92 231

45 90 225 44 88 220

43 86 214

42 84 209 41 82 205

40 80 200

39 78 196 38 76 192

38 75 188

37 74 184 36 72 180

35 71 178 35 69 173 34 68 170 33 67 167

33 65 32 64 31 62

3O 6O

164 161 155 150

SET TEMPERATURE RISE

Furnace must operate within range of temperature rise specified on the unit rating plate. Determine air temperature rise ,asfollows:

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 tern perature from supply air temperature to determine air tem- perature rise.

NOTE: Temperature rise can be deterntined for low-g'tre opera- tion 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 tern'final

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. h. 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/WI circuit. Accurate amp draw

measurements can be obtained at the thermostat subbase terminals R andW.

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 lov,' heat.

I. To operate furnace in low heat, turn setup switch SW-2 to ON

position (See Fig. 25) and connect ammeter leads acro_ 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 them_ostat on subbase.

TERMINALS WITH THERMOSTAT REMOVED

(ANIT_CIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

FROM UNIT 24-V CONTROL TERMINALS

EXAMPLE" 5.0 AMPS ON AMMETER = 05 AMPS EOR THERMOSTAT

" 10 TURNS AROUND JAWS 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 overheaL_.

I. The recommended method of checking this limit control is to

_adunily block off return air after furnace has been operating for a period of at least 5 minutes.

2. As soon as limit control hax 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:

I. Turn off l15-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 ilS-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 instruc- tions.

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

Condensate Drain

Unit Level or Pitched Forward

Intema_ Tubing Conn_ions Free of Kinks

and Traps

COMBUSTION AND VENT PIPING

Termination Location

Roof or Sidewall

Termination Kit -- 2 Pipe or Concentdc

Combustion-Air Pipe Length

Combustion-Air Pipe Elbow Quantity

Vent Pipe Length

Vent Pipe Elbow Quantity

Pipe Diameter Determined from Sizing Table

Pipe Sloped TO Furnace

Pipe Insulation

Over Ceilings

Low-Ambient Exposed Pipes

External Drain Connection Leak Tight and

Sloped

Condensate Trap Primed before Start-Up

Heat Tape Installed if Required

CHECKLIST--START-UP

Gas Input Rate (Set Within 2 percent of Rating Plate)

Temperature Rise Adjusted

Thermostat Anticipator

Anticipator Setting Adjusted or

Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Check Operation

Primary Limit

Pressure Switches

Page 47

SERVICE TRAINING

Packag_l Service Training programs are an excellent way to increase your knowledge of the equipment discussed inthis manuai, including:

• Unit Familianzation • Maintenance

• Installation Overview • Opera'dng Sequence

A large seleclion of product, theory, and sl_lis programs is available, using popular video-based formats and materials. All include video ancVorslides, plus companion

book.

Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster l_oubleshooling, fewer

callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-962-9212

[ ] Packaged Service Training

[ ] Classroom Service Training

A94328

Page 48

Manufa©turer reserves the right to discontinue, or change at any time, specihcat_ons or designs without notice and withoUt recurring "_ ,-

PC 101 Catalog No. 535-80021 Printed in U,S.A. Form 58MVP-11SI pg 48 2-01 Replaces: 58MVP-10Sl

Carrier 58MVP120F15120, 58MVP080F15120 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual