Carrier 58MXB060-08, 58MXB040-08, 58MXB040-12, 58MXB060-12, 58MXB060-16 Installation, Start-up, And Operating Instructions Manual

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Page 1

Deluxe 4–Way Multipoise

Fixed-Capacity Condensing Gas Furnace

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Installation, Start-Up, and Operating Instructions

Sizes 040-140, Series 100

24–v Wiring.......................................................................26

Accessories ........................................................................26

Removal of Existing Furnaces from Common

Vent Systems ..........................................................................27

Combustion Air and Vent Pipe Systems ...............................27

Condensate Drain....................................................................41

General...............................................................................41

Application.........................................................................42

Condensation Drain Protection .........................................42

A93040

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

NOTE: This furnace can be installed as a

(2-pipe) direct vent

or (1-pipe) non-direct vent condensing gas furnace.

This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

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

CODES AND STANDARDS........................................................4

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........6

INTRODUCTION..........................................................................6

APPLICATIONS............................................................................6

General......................................................................................6

Upflow Applications.................................................................6

Downflow Applications............................................................8

Horizontal Left (Supply-Air Discharge)

Applications ............................................................................10

Horizontal Right (Supply-Air Discharge)

Applications ............................................................................11

LOCATION..................................................................................14

General....................................................................................14

Furnace Location Relative to Cooling Equipment ................15

Hazardous Locations...............................................................15

Furnace Location and Application.........................................15

AIR FOR COMBUSTION AND VENTILATION ....................16

INSTALLATION.........................................................................19

Leveling Legs (If Desired).....................................................19

Installation in Upflow and Downflow

Applications ............................................................................19

Installation in Horizontal Applications..................................19

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

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

Ductwork Acoustical Treatment .......................................21

Supply Air Connections ....................................................21

Return Air Connections.....................................................21

Filter Arrangement..................................................................22

Bottom Closure Panel.............................................................23

Gas Piping...............................................................................23

Electrical Connections ............................................................24

115–v Wiring.....................................................................25

START-UP, ADJUSTMENTS AND SAFETY CHECK...........42

General....................................................................................42

Prime Condensate Trap With Water......................................43

Purge Gas Lines......................................................................43

Sequence of Operation............................................................43

Heating Mode ....................................................................44

Cooling Mode....................................................................44

Thermidistat Mode ............................................................44

Continuous Blower Mode .................................................47

Heat Pump Mode...............................................................47

Component Test.................................................................51

Adjustments.............................................................................51

Set Gas Input Rate ............................................................51

Set Temperature Rise ........................................................55

Adjust Blower Off Delay (Heat Mode)............................55

Set Thermostat Heat Anticipator ......................................55

Check Safety Controls............................................................56

Check Primary Limit Control ...........................................56

Check Pressure Switch......................................................56

Checklist..................................................................................56

58MXB

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

Book 1 4 Tab 6a 8a

PC 101 Printed in U.S.A. Catalog No. 58MXB-1SI Pg 1 8-05 Replaces: 58MXA-18SI

Page 2

AIRFLOW

UPFLOW

HORIZONTAL

RIGHT

AIRFLOW

A93041

AIRFLOW

HORIZONTAL

LEFT

DOWNFLOW

AIRFLOW

Fig. 1—Multipoise Orientations

SAFETY CONSIDERATIONS

UNIT RELIABILITY HAZARD

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

FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

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

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply.

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

Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls.

CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing and gloves when handling parts.

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

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

The 58MXB Multipoise Condensing Gas-Fired Furnaces are CSA (formerly AGA and CGA) design-certified for natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A CSA listed gas conversion kit is required to convert furnace for use with propane gas.

See Fig. 3 for required clearances to combustibles. Maintain a 1-in. clearance from combustible materials to supply air

ductwork for a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code for further requirements.

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

The 58MXB 040 through 120 size units are CSA design-certified

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for use in manufactured (mobile) homes when installed as a 2-pipe (direct vent) furnace and a factory accessory conversion kit is used. The 140 size unit is NOT design-certified for use in manufactured (mobile) homes. These furnaces are suitable for installation in a structure built on site or a manufactured building completed at final site. The design of this furnace line is NOT CSA designcertified for installation in recreation vehicles or outdoors.

This furnace is designed for continuous return-air minimum temperature of 60°F db or intermittent operation down to 55°F db such as when used with a night setback thermometer. Return-air temperature must not exceed 80°F db. Failure to follow these return air limits may affect reliability of heat exchangers, motors and controls. (See Fig. 4.)

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

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

Always provide adequate combustion and ventilation air as speci-

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

Page 3

⁄

A05053

⁄

19"

⁄

AIRFLOW

OUTLET

2-IN. COMBUSTION-

⁄

TYP

TRAP LOCATION

⁄

CONDENSATE DRAIN

OUTLET

⁄

⁄2-IN. DIA

GAS CONN

AIR CONN

(DOWNFLOW &

OR ALTERNATE

-IN. DIA GAS CONN

⁄

HORIZONTAL RIGHT)

⁄8-IN. DIA

POWER CONN

⁄

TYP

⁄2-IN. DIA

THERMOSTAT ENTRY

⁄

TYP

⁄

2-IN. VENT CONN

⁄

TYP

⁄

SIDE INLET

⁄

" TYP

⁄

(UPFLOW)

BOTTOM INLET

HANGING

CONDENSATE

DRAIN LOCATION

FOR HORIZONTAL

DIMPLE LOCATORS

⁄

-in. rectangle.

/ 2

/ 4

INLET

⁄

TYP

⁄

x 12-in. rectangle. / 2

see flex duct manufacturer’s recommendations for equivalent diameters.

a. For 800 CFM–16-in. round or 14

2. Minimum return-air opening at furnace:

x 19

x 23

/ 2

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

c. For 1600 CFM–22-in. round or 14

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

b. For 1200 CFM–20-in. round or 14

Dimensions (in.)

→ Fig. 2—Dimensional Drawing

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

return air openings for airflow requirements above 1800 CFM at 0.5” W.C. ESP.

LOCATION

(ALTERNATE

UPFLOW)

SIDE INLET

⁄

TYP

⁄

TYP

CONDENSATE

DRAIN LOCATION

⁄

(UPFLOW)

" TYP

⁄

SIDE INLET

1" E

⁄8-IN. DIA

POWER CONN

CONDENSATE

CONDENSATE DRAIN

TRAP LOCATION

(DOWNFLOW &

HORIZONTAL LEFT)

⁄

-IN. COMBUSTION2

AIR CONN

-IN. DIA

⁄

GAS CONN

-IN. VENT CONN 2

ENTRY

⁄2-IN. DIA THERMOSTAT

⁄8-IN. DIA

⁄

ACCESSORY

POWER ENTRY

DRAIN TRAP

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

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

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

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

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

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

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

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

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

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

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

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

UNIT SIZE A D E

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

Page 4

Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the Combustion Air and Vent piping sections of these instructions.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for detection of leaks to check all connections as specified in the GAS PIPING section of these instructions.

Always install the furnace to operate within the furnace’s intended rise range with a duct system which has an external static pressure within the allowable range as specified in the SET TEMPERATURE RISE section of these instructions. See furnace rating plate.

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

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

The furnace may be used for construction heat provided that the

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

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

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• The furnace is permanently installed with all electrical wiring, piping, air filters, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

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

• Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

• The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

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

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

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

• After construction is complete, verify furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer’s instructions.

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

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

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Installer Packet includes:

Installation, Startup, and Operating Instructions Service and Maintenance Instructions User’s Information Manual Warranty Certificate

Loose Parts Bag includes: Quantity

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

Vent Pipe Extension 1*

* ONLY supplied with some furnaces.

When this furnace is installed with a direct vent (combustion-air

→

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

For accessory installation details, refer to accessory installation instructions.

CODES AND STANDARDS

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

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

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

Step 1—Safety

• US: National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI Z223.1-2002 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

→

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

Step 2—General Installation

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

• A manufactured (Mobile) home installation must conform with the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or when this standard is not applicable, the Standard for Manufactured Home Installation

(Manufactured Home Sites, Communities, and Set-Ups), ANSI/NCS A225.1, and/or CAN/CSA-Z240, MH Series Mobile Homes

Page 5

This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 ft.

INSTALLATION

(0 - 2,135m). An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications. This furnace is for indoor installation in a building constructed on site. This furnace may be installed in a manufactured (mobile) home when stated on rating plate and using factory authorized kit.. This furnace may be installed on combustible flooring in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below. This furnace requires a special venting system. Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC, PVC-DWV, CPVC, or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).

Cette fournaise à air pulsé est équipée pour utilisation avec gaz naturel et altitudes comprises entre 0 - 3,050m (0 - 10,000 pi),excepté queles fournaises de 140 taille sont pour altitudes comprises entre 0 - 2,135m (0 - 7,000pi). Utiliser une trousse de conversion, fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz naturel. Cette fournaise à air pulsé est pour installation à l´intérieur dans un bâtiment construit sur place. Cette fournaise à air pulse peut être installée dans une maison préfabriquée (maison mobile) si prescrit par la plaque signalétique et si l' on utilise une trousse specifiée par le fabricant. Cette fournaise peut être installée sur un plancher combustible dans un enfoncement ou un placard en observant les Dégagement Minimum En Pouces Avec

Éléments De Construction Combustibles.

Cette fournaise nécessite un système d´évacuation spécial. La méthode d´installation et la liste des pièces nécessaires figurent dans les instructions d´installation. Cette fournaise doit s´utiliser avec la tuyauterie des nomenclatures 40 PVC, PVC-DWV, CPVC, ou ABS-DWV et elle ne peut pas être ventilée conjointment avec d´autres appareils à gaz. Épaisseur de la construction au travers de laquelle il est possible de faire passer les tuyaux d'aération (admission/évacuation): 24 po (600 mm) maximum, 3/4 po (19mm) minimum (y compris la toiture).

For upflow and downflow applications, furnace must be installed level, or pitched within 1/2" of level. For a horizontal application, the furnace must be pitched minimum 1/4" to maximum of 1/2" forward for proper drainage. See Installation Manual for IMPORTANT unit support details on horizontal applications.

Pour des applications de flux ascendant et descendant, la fournaise doit être installée de niveau ou inclinée à pas plus de 1/2" du niveau. Pour une application horizontale, la fournaise doit être inclinée entre minimum 1/4" et maximum 1/2" du niveau pour le drainage approprié. En cas d´installation en position horizontale, consulter les renseignements IMPORTANTS sur le support dans le manuel d´installation.

LEVEL (0") TO

1/2" MAX

UPFLOW OR DOWNFLOW

FRONT

MIN 1/4" TO 1/2" MAX

FRONT

HORIZONTAL

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSITIONS:

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

†

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

DOWNFLOW POSITIONS:I

†

For installation on combustible floors only when installed on special base No. KGASB0201ALL, Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

HORIZONTAL POSITIONS::

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

Clearance shown is for air inlet and air outlet ends. 120 and 140 size furnaces require 1 inch bottom clearance to combustible materials.

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS DE CONSTRUCTION COMBUSTIBLES

POUR TOUS LES POSITIONS:U

Dégagement avant minimum de 610mm (24 po) pour l´entretien.

Pour les fournaises de 140 taille, 1 po (25mm) dégagement des matériaux combustibles est

†

requis au-arriere.

POUR LA POSITION COURANT DESCENDANT:

†

Pour l´installation sur le plancher combustible seulement quand on utilise la base spéciale, pièce nº KGASB0201ALL, l pièce nº KCAKC.

POUR LA POSITION HORIZONTALE:

Le contact n deuxcôtés de la chemise de la fournaise, et des solives, des montants ou de la charpente du bátiment. La distance indiquée concerne l

air.

Pour les fournaises de 120 et 140 taille, 1 po (25mm) dégagement des matériaux combusitbles est requis au-dessous.

ensemble serpentin, pièce nº CD5 ou CK5, ou le carter de serpentin,

est permis qúentre les lignes formées par les intersections du dessus et des

extrémité du tuyau d´arrivée d´air et l´extrémité du tuyau de sortie

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

Cette fournaise est approuvée pour l´installation HORIZONTALE et la circulation d´air VERS LE HAUT et VERS LE BAS.

Clearance arrows do not change with furnace orientation.

†

Clearance in inches Dégagement (po).

Fig. 3—Clearances to Combustibles

Les fléches de dégagement

TOP/PLENUM

DESSUS/CHAMBRE D´AIR

BOTTOM

DESSOUS

†

d´évent avec combustibles.

328066-201 REV. B LIT TOP

ne change pas avec

orientation de la

générateur d´air chaud.

0 (po) Dégagement

Vent clearance to combustibles 0".

A04110

MIN

• CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada.

Step 3—Combustion and Ventilation Air

• US: Section 5.3 of the NFGC, Air for Combustion and Ventilation

• CANADA: Part 7 of the NSCNGPIC, Venting Systems and Air Supply for Appliances

Step 4—Duct Systems

• US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34.

Step 5—Acoustical Lining and Fibrous Glass Duct

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

Step 6—Gas Piping and Gas Pipe Pressure Testing

• US: NFGC; chapters 2, 3, 4, and 9 and national plumbing codes

• CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E, and H. In the state of Massachusetts:

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

• When flexible connectors are used, the maximum length shall not exceed 36 inches.

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

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

Step 7—Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70-2002

• CANADA: Canadian Electrical Code CSA C22.1

Page 6

A05004

Fig. 4—Return-Air Temperature

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

UNIT DAMAGE HAZARD

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

1. Disconnect all power to the furnace. Multiple disconnects may

be required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in 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 to recharge 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 (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

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

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

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

MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor property damage. Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling.

INTRODUCTION

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The model 58MXB 4-way multipoise, Gas-Fired, Category IV, condensing furnace is available in model sizes ranging from input capacities of 40,000 to 138,000 Btuh as direct vent (2-pipe) application, and in model sizes ranging from input capacity of 40,000 to 120,000 Btuh as non-direct vent (1-pipe) application.

APPLICATIONS

Step 1—General

Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 1. All drain and pressure tubes are connected as shown in Fig. 6. See appropriate application instructions for these procedures.

Step 2—Upflow Applications

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

CONDENSATE TRAP LOCATION (FACTORY-SHIPPED ORIENTATION)

The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications. A factory-supplied tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment. See Condensate Trap Tubing (Factory-Shipped Orientation) section for drain tube extension details. (See Fig. 5.)

CONDENSATE TRAP TUBING (FACTORY-SHIPPED ORIENTATION)

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

1. Collector Box Drain, Inducer Housing Drain, Relief Port, and Pressure Switch Tubes. These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications. These 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

6.)

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

b. Remove and discard casing drain hole plug button from

desired side.

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

loose parts bag) in selected casing hole.

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

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

Page 7

BLOWER SHELF

CONDENSATE TRAP (INSIDE)

ALTERNATE DRAIN TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

FURNACE DOOR

FIELD

DRAIN

CONN

EXTERNAL UPFLOW APPLICATIONS

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

WIRE TIE GUIDES (WHEN USED)

CONDENSATE TRAP

FURNACE

SIDE

FURNACE DOOR

FIELD

DRAIN

CONN

FURNACE SIDE

SIDE VIEW FRONT VIEW END VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

⁄4 OD COLLECTOR BOX TO TRAP RELIEF PORT

⁄2 OD INDUCER HOUSING DRAIN CONNECTION

⁄8 OD COLLECTOR BOX DRAIN CONNECTION

SCREW HOLE FOR UPFLOW OR DOWNFLOW APPLICATIONS (OPTIONAL)

⁄2-IN. PVC OR CPVC

HORIZONTAL

APPLICATIONS

FRONT VIEW SIDE VIEW

Fig. 5—Condensate Trap

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

the rigid drain tube connection on the condensate trap. (See Fig. 6.) These elbows must be cemented together and cemented to condensate trap drain connection.

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

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 7.)

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

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

1. Remove 3 tubes connected to condensate trap.

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

A93026

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

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death. Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room.

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

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

CONDENSATE TRAP TUBING (ALTERNATE UPFLOW ORIENTATION)

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

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

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

Page 8

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄2-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE TRAP

DRAIN TUBE

DRAIN OPTION)

A94163

Fig. 6—Factory-Shipped Upflow Tube

Configuration (Shown with Blower Access Panel

Removed)

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

drain tube which was previously connected to condensate trap.

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

factory-supplied in loose parts bag) to connect LOWER

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

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

tube (factory-supplied in loose parts bag).

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

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

procedures. PRESSURE SWITCH TUBING

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

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

CONDENSATE

TRAP

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

Fig. 7—Alternate Upflow Configuration and Trap

Location

NOTE: See Fig. 6 or 7 or tube routing label on main furnace door

to check for proper connections. UPPER COLLECTOR BOX AND INDUCER HOUSING

(UNUSED) DRAIN CONNECTIONS Upper Collector Box Drain Connection Attached to the UPPER collector box drain connection is a

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

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

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

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

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

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

tions and procedures.

Step 3—Downflow Applications

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

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

blower shelf location and relocated in selected application location as shown in Fig. 2, 8, or 9.

A94164

Page 9

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE

TRAP

INDUCER HOUSING

DRAIN TUBE (VIOLET)

DRAIN TUBE COUPLING

PLUG CAP

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (PINK)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED)

COLLECTOR BOX EXTENSION TUBE

INDUCER HOUSING DRAIN TUBE (VIOLET)

CONDENSATE TRAP

COLLECTOR BOX EXTENSION DRAIN TUBE

A94165

Fig. 8—Downflow Tube Configuration (Left-Hand

Trap Installation)

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

1. Remove 3 tubes connected to condensate trap.

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

3. Remove casing hole filler cap from casing hole. (See Fig. 2, 8, or 9.)

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

CARBON MONOXIDE POISONING HAZARD

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

CONDENSATE TRAP TUBING NOTE: See Fig. 8 or 9 or tube routing label on main furnace door

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

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

drain tube (blue and white striped label).

A94166

Fig. 9—Downflow Tube Configuration (Right-Hand

Trap Installation)

b. Install removed clamp and plug into UPPER collector box

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

c. Connect LOWER collector box drain connection to con-

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

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

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

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

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

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

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

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

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

(c.) Route extended collector box drain tube directly

from collector box drain to condensate trap as

shown in Fig. 9. (d.) Determine appropriate length and cut. (e.) Connect to condensate trap. (f.) Clamp tube to prevent any condensate leakage.

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

inducer housing drain connection.

Page 10

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

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

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

e. Connect inducer housing drain connection to condensate

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

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

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

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

directly from inducer housing to condensate trap

as shown in Fig. 9. (b.) Determine appropriate length and cut. (c.) Connect tube to condensate trap. (d.) Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection procedure. CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and procedures.

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

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

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

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

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

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

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

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

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

7. Clamp tube to relief port connection.

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

tions and procedures.

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

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

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

blower shelf location and relocated in selected application location as shown in Fig. 2 or 10.

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

1. Remove 3 tubes connected to condensate trap.

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

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

CARBON MONOXIDE POISONING HAZARD

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

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

CONDENSATE TRAP TUBING NOTE: See Fig. 10 or tube routing label on main furnace door to

check for proper connections.

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

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

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

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

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

to appropriate length.

d. Clamp tube to prevent any condensate leakage.

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

drain tube which was previously connected to condensate trap.

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

factory-supplied in loose parts bag) to connect LOWER

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

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

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

b. Route extended collector box pressure tube to relief port

connection on the condensate trap.

Page 11

AUXILIARY "J" BOX

PLUG

CAP

COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040, 060, AND 080 HEATING INPUT FURNACES

Fig. 10—Horizontal Left Tube Configuration

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

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

procedures. PRESSURE SWITCH TUBING

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

NOTE: See Fig. 10 or tube routing label on main furnace door to check for proper connections.

Modify tube as described below.

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

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

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

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

COLLECTOR BOX TUBE (GREEN)

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOX DRAIN TUBE (BLUE)

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

A00215

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 11 or 12.)

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation. The condensate trap MUST be installed below furnace. See Fig. 5 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 11.)

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. 11, 12 or 38.)

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

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

Page 12

MANUAL

SHUTOFF

GAS VALVE

COMBUSTION – AIR

SEDIMENT TRAP

INTAKE

⁄

″

CONDENSATE TRAP

VENT

30″ MIN WORK AREA

DRAIN

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

ACCESS OPENING FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

Fig. 11—Attic Location and Working Platform for Direct Vent (2-Pipe) Applications--All Sizes

COMBUSTION–AIR

GAS VALVE

INTAKE

MANUAL

SHUTOFF

A 3-IN. MINIMUM CLEARANCE TO COMBUSTION-AIR INTAKE IS REQUIRED.

⁄

″

SEDIMENT TRAP

CONDENSATE TRAP

VENT

30-IN. MIN WORK AREA

DRAIN

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

ACCESS OPENING FOR TRAP

A93031

→

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

Fig. 12—Attic Location and Working Platform for Non-Direct

Vent (1-pipe) Applications-Sizes 040 Through 120 Only

A96184

Page 13

CAP

PLUG

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 13—Horizontal Right Tube Configuration

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

AUXILARY “J” BOX RELOCATED HERE

CONDENSATE TRAP

A00214

PROPERTY DAMAGE

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

NOTE: The junction box (J-Box) MUST be relocated to opposite side of furnace casing. (See Fig. 13.) See Electrical Connection section for J-Box relocation.

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

blower shelf location and relocated in selected application location as shown in Fig. 2 or 13.

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

1. Remove 3 tubes connected to condensate trap.

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

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

CARBON MONOXIDE POISONING HAZARD

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

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

CONDENSATE TRAP TUBING NOTE: See Fig. 13 or tube routing label on main furnace door to

check for proper connections.

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

drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector box

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

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

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

d. Clamp tube to prevent any condensate leakage.

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

inducer housing drain connection.

Page 14

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

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

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

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

condensate trap.

f. Clamp tube to prevent any condensate leakage.

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

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

procedures. PRESSURE SWITCH TUBING

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

NOTE: See Fig. 13 or tube routing label on main furnace door to check for proper connections.Relocate tubes as described below.

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

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

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

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

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

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

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

8. Clamp tube to relief port connection.

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

tions and procedures. CONSTRUCT A WORKING PLATFORM

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

LEVEL (0″)

⁄2″ MAX

UPFLOW OR DOWNFLOW HORIZONTAL

FRONT

MIN

⁄2″ MAX

⁄4″

FRONT

Fig. 14—Furnace Location for Proper Condensate

Drainage

UNIT MAY NOT OPERATE

NOTE: Vent pipe(s) and combustion-air pipe (when applicable)

→

are restricted to a minimum length of 5 ft. (See Table 11.) 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. 11, 12 or 38.)

→

NOTE: The 140 size may NOT be installed in non-direct vent (1-pipe) application.

LOCATION

Step 1—General

This furnace must

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

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

• be located so combustion-air and vent pipe maximum lengths are not exceeded. Refer to Table 11.

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

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

• be provided with ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on the furnace clearance-to-combustibles label.

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

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

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

A02146

Page 15

FRONT

BACK

FRONT

Fig. 15—Installation on Back is Prohibited

FIRE, INJURY OR DEATH HAZARD

→

Failure to follow this warning could result in fire, property damage, personal injury or death. Do not install furnace on its back. Safety control operation will be adversely affected. Never connect return-air ducts to back of furnace. (See Fig. 15.)

UNIT DAMAGE HAZARD

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

-The furnace is permanently installed with all electrical wiring, piping, air filters, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

-The furnace is controlled by a thermostat. It may not be ″hot wired″ to provide heat continuously to the structure without thermostatic control.

-Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

-The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

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

-The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

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

-After construction is complete, verify furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer’s instructions.

B A C K

A93043

32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED

A93058

Fig. 16—Freeze Protection

UNIT DAMAGE HAZARD

Failure to follow this caution may result in minor property or unit damage. If furnace is installed in an unconditioned space where the ambient temperatures may be 32°F or lower, freeze protection measures must be taken. (See Fig. 16.)

Step 2—Furnace Location Relative to Cooling Equipment

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

Step 3—Hazardous Locations

FIRE, EXPLOSION, INJURY OR DEATH HAZARD

Improper location or inadequate protection could result in fire or explosion. When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18 in. 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, the furnace must be installed in accordance with NFGC or NSCNGPIC. (See Fig. 17.)

→

Step 4—Furnace Location and Application

DIRECT VENT (2-PIPE) APPLICATION Furnace may be located in a confined space without special

provisions for dilution or ventilation air.

Page 16

18-IN. MINIMUM

TO BURNERS

Fig. 17—Installation in a Garage

A93044

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and from draft safeguard opening.

NON-DIRECT VENT (1-PIPE) APPLICATION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in intermittent unit operation. Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met.

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

AIR FOR COMBUSTION AND VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

• U.S. Installations: Section 8.3 of the NFGC, Air for Combus-

tion and Ventilation and applicable provisions of the local building codes.

• Canadian Installations: Part 7 of the NSCNGPIC, Venting

Systems and Air Supply for Appliances and all authorities having jurisdiction.

FURNACE CORROSION HAZARD

→

Failure to follow this warning could result in reduced furnace component life. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements could corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

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

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas If air is exposed to the following substances, it should not be used

for combustion air, and outdoor air may be required for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in peronal injury or death. The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make-up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to the Carbon Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount of make-up air is available.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

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

• Spaces having at least 50 cubic feet per 1,000 Btuh may use the

INDOOR COMBUSTION AIR, STANDARD or KNOWNAIR INFILTRATION METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 18 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air openings to the outdoors.

a. One opening MUST commence within 12″ (300 mm) of

the ceiling and the second opening MUST commence

within 12″ (300 mm) of the floor. b. Size openings and ducts per Fig. 18 and Table 1. c. TWO HORIZONTAL DUCTS require 1 square inch of

free area per 2,000 Btuh (1,100 mm

/kW) of combined input for all gas appliances in the space per Fig. 18 and Table 1.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

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

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

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

/kW)

Page 17

→

EXAMPLES: Determining Free Area

Table 1—Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

TWO HORIZONTAL DUCTS

FURNACE

INPUT

(BTUH)

44,000 22 6 14.7 5 11 4 66,000 33 7 22 6 16.5 5

88,000 44 8 29.3 7 22 6 110,000 55 9 36.7 7 27.5 6 132,000 66 10 44 8 33 7 154,000 77 10 51.3 9 38.5 8

FURNACE WATER HEATER TOTAL INPUT

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

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

(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW)

Free Area of

Opening and Duct

(Sq. In.)

Round Duct

(in. Dia)

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)

Free Area of

Opening and Duct

(sq In.)

Round Duct

(in. Dia)

TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

Free Area of

Opening and Duct

(Sq In.)

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

OTHER THAN FAN-ASSISTED TOTAL

ACH

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850

0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960 4,620

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950 5,775

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600 7,700

0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900 11,550

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800 23,100

0.00 NP NP NP NP NP NP NP NP NP

(1,000’S BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132 154

Space Volume (ft

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

)

Round Duct

(In. Dia)

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

the space. The opening shall commence within 12″ (300 mm) of the

ceiling. Appliances in the space shall have clearances of at least 1″ (25 mm) from the sides and back and 6″ (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

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

Indoor combustion air is permitted for combustion, ventilation,

and dilution, if the Standard or Known-Air-Infiltration Rate Method is used.

CARBON MONOXIDE POISONING HAZARD

Failure to supply outdoor air via grilles or ducts could result in death and/or personal injury. Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases. The furnace combustion air supply must be provided in accordance with this instruction manual.

The Standard Method:

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

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

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 2 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space.

Table 2-Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223.1-2002/NFPA 54-2002,8.3.2.2:

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

hood-equipped water heater:

Volume

Other

21ft

ACH

other

1000 Btu/hr

A04002

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

Volume

15ft

Fan

ACH

fan

1000 Btu/hr

A04003

Page 18

DUCTS

OUTDOORS

1 SQ IN. PER 4000 BTUH*

CIRCULATING AIR

DUCTS

VENT THROUGH ROOF

12″ MAX

1 SQ IN. PER 2000 BTUH*

DUCTS

OUTDOORS

1 SQ IN. PER 2000 BTUH*

12″ MAX

CIRCULA TING AIR DUCTS

*Minimum dimensions of 3 in.

NOTE:

CIRCULA TING

CLEARANCE IN FRONT

Use any of the following combinations of openings: A & B C & D D & E F & G

AIR DUCTS

OPENINGS SHALL BE

OF COMBUSTION AIR

VENT THROUGH ROOF

AT LEAST 3 IN.

OUTDOORS

DUCT

12″ MAX

1 SQ IN.

BTUH*

1 SQ IN.

BTUH*

1 SQ IN. PER 4000 BTUH*

12″ MAX

PER

4000

OUTDOORS

PER

4000

12″ MAX

→ Fig. 18—Air for Combustion, Ventilation, and

Dilution for Outdoors

A03174

12" MAX

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

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. with minimum dimensions of 3 in.

†

Minimum of 3 in. . when type-B1 vent is used.

UNCONFINED SPACE

6" MIN (FRONT)

†

1 SQ IN. PER 1000 BTUH* IN DOOR

OPENINGS SHALL B E A T LEAST 3 IN.

OR WALL

CLEARANCE IN FRONT OF COMBUSTION AIR

12" MAX

A03175

→ Fig. 19—Air for Combustion, Ventilation, and

Dilution from Indoors

If:

= combined input of all other than fan-assisted appli-

other

ances in Btu/hr

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

fan

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

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

1. Adjoining rooms can be considered part of a space if: a. There are no closable doors between rooms. b. Combining spaces on same floor level. Each opening shall

have free area of at least 1 in. of the total input rating of all gas appliances in the space, but not less than 100 in.

/1,000 Btuh (2,000 mm2/kW)

(0.06 m2). One opening shall commence within 12″ (300 mm) of the ceiling and the second opening shall commence within 12″ (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). (See Fig. 19.)

c. Combining space on different floor levels. The volumes of

spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least

2 in.

/1,000 Btuh (4,400 mm2/kW) of total input rating of

all gas appliances.

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having

free area of at least 1-in.

/4,000 Btuh of total input rating for

all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method,

infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section.

Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a continu-

ous, sealed vapor barrier. Openings are gasketed or sealed

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

around window and door frames, between sole plates and

floors, between wall-ceiling joints, between wall panels, at

penetrations for plumbing, electrical and gas lines, etc.

NOTE: In determining the free area of an opening, the blocking effect of the louvers, grilles, and screens must be considered. If the free area of a louver or grille design is unknown, it may be assumed that wood louvers have a 20 percent free area, and metal louvers or grilles have a 60 percent free area. Screens, when used, must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed.

When combustion air ducts are used, they must be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of ducts must not be less than 3 in. (80mm).

Page 19

⁄16″

1 3⁄4″

⁄4″

⁄16″

1 3⁄4″

Fig. 20—Leveling Legs

Combination of Indoor and Outdoor Air

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

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

3. Outdoor openings shall be sized as follows: a. Calculate the Ratio of all Indoor Space volume divided by

required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80 mm).

INSTALLATION

→

NOTE: The 140 size unit may NOT be installed in non-direct vent (1-pipe) application.

Step 1—Leveling Legs (If Desired)

When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 20.) Install field-supplied, corrosion-resistant 5/16-in. machine bolts and nuts.

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

1. Position furnace on its back. Locate and drill a 5/16–in. diameter hole in each bottom corner of furnace. (See Fig. 20.) Holes in bottom closure panel may be used as guide locations.

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

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

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

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

A89014

Step 2—Installation in Upflow and Downflow Applications

NOTE: For downflow applications, this furnace is approved for

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

1. Determine application being installed from Table 3.

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

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

21.

4. If downflow subbase (KGASB) is used, install as shown in Fig. 22. If Coil Assembly Part No. CD5 or CK5 or Coil Box Part No. KCAKC is used, install as shown in Fig. 20.

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 or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig.

24.)

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation. Do not bend duct flanges inward as shown in Fig. 21. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 24.

NOTE: For 140 size unit when installed in downflow orientation, cut the white jumper wire off between terminals PL1-7 and PL1-9. Do not cut white jumper between terminals PL1-7 and PLI-11. Refer to Fig. 32 for location of jumper. Cut jumper close to connector and remove wire to avoid a short circuit.

Step 3—Installation in Horizontal Applications

UNIT MAY NOT OPERATE

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

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. 25.) Cut hanger bolts (4 each 3/8-in. all-thread rod) to desired length. Use 1 X 3/8-in. flat washers, 3/8-in. lock washers, and 3/8-in. nuts on hanger rods as shown in Fig. 25. Dimples are provided for hole locations. (See Fig. 2.)

Page 20

PLENUM

OPENING

FLOOR

OPENING

A96283

Fig. 21—Floor and Plenum Opening Dimensions

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 22—Furnace, Plenum, and Subbase

Installed on a Combustible Floor

Table 3—Opening Dimensions (In.)

FURNACE

CASING

WIDTH

17-1/2

24-1/2

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

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

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

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

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

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

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

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

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box

APPLICATION

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

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

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

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96284

Fig. 23—Furnace, Plenum, and Coil

Assembly or Coil Box Installed

on a Combustible Floor

PLENUM OPENING FLOOR OPENING

ABCD

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

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

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

19 19 20 20

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

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

Page 21

PERFORATED DISCHARGE DUCT FLANGE

YES

210° MIN

YES

A93029

Fig. 24—Duct Flanges

Step 4—Air Ducts

GENERAL REQUIREMENTS The duct system should be designed and sized according to

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

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

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

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

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

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

DUCTWORK ACOUSTICAL TREATMENT Metal duct systems that do not have a 90 degree elbow and 10 ft

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 18 standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

SUPPLY AIR CONNECTIONS Upflow Furnaces Connect supply-air duct to 3/4-in. flange on furnace supply-air

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

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

supply-air duct attachment must be connected to ONLY furnace supply/outlet or air conditioning coil casing (when used), when installed on non-combustible material. When installed on combustible material, supply-air duct attachment must be connected to ONLY an accessory subbase or factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing. Supply air opening duct flanges must be modified per Fig. 24.

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

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

RETURN AIR CONNECTIONS The furnace and its return air system shall be designed and

installed so that negative pressure created by the air circulating fan cannot affect another appliance’s combustion air supply or act to mix products of combustion with circulating air. The air circulating fan of the furnace, if installed in an enclosure communicating with another fuel-burning appliance not of the direct-vent type, shall be operable only when any door or panel covering an opening in the furnace fan compartment or in a return air plenum on ducts is in the closed position.

FIRE HAZARD

A failure to follow this warning could result in fire, personal injury, or death. Never connect return-air ducts to the back of the furnace. Return-air duct connections on furnace side(s) permitted in upflow applications only.

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

right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 2. 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 end inlet opening

provided as shown in Fig. 2. DO NOT cut into casing sides or back to attach any portion of return-air duct. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

Page 22

3-IN. MINIMUM CLEARANCE TO COMBUSTION-AIR INTAKE IS REQUIRED (NON-DIRECT VENT/1-PIPE APPLICATION,SIZES 040 THROUGH 120 ONLY)

COMBUSTION-AIR INTAKE (NON-DIRECT VENT/1-PIPE APPLICATION,SIZES 040 THROUGH 120 ONLY)

COMBUSTION-AIR PIPE (DIRECT VENT/2-PIPE APPLICATION,ALL SIZES)

VENT

⁄

-IN. ROD

ANGLE IRON OR EQUIVALENT

(B)

(A)

(B)

(A) ROD LOCATION

USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS)

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

Fig. 25—Crawlspace Horizontal Application for Direct Vent/2-Pipe Installation (Sizes 040 Through 140) and for

→

/8-IN. HEX NUT

& WASHER (4)

REQD PER ROD

NOTES:

(A)

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

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

3. For non-direct vent/1-pipe application, bottom side combustion-air entry cannot be used when furnace is installed with hangers as shown.

DRAIN

(B)

⁄

″

(A)

(B)

/16-IN. MAX ALTERNATE SUPPORT LOCATION FROM BACK

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

Non-Direct Vent/1-Pipe Installation (Sizes 040 Through 120 Only)

A05054

Step 5—Filter Arrangement

FIRE, CARBON MONOXIDE AND POISONING HAZARD

Failure to follow this warning could result in fire, personal injury, or death. Never operate furnace without a filter or with filter access door removed.

The air filter arrangement will vary due to application, furnace orientation, and filter type. The filter may be installed in an external Filter/Media cabinet (if provided) or the furnace blower compartment. Factory supplied washable filters are shipped in the blower compartment.

If a factory-supplied external Filter/Media cabinet is provided, instructions for its application, assembly, and installation are packaged with the cabinet. The Filter/Media cabinet can be used with the factory-supplied washable filter or a factory-specified high-efficiency disposable filter (see cabinet instructions).

→

AIR FILTER LOCATED IN BLOWER COMPARTMENT

FURNACE

CASING

WIDTH (IN.)

17–1/2 (1) 16 X 25 X 1 (1) 16 X 25 X 1 Cleanable

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

24–1/2 (1 or 2) 16 X 25 X 1 (1) 24 X 25 X 1 Cleanable

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

filter material and support rods (3) in filters. Alternate sizes and additional filters can be ordered from your distributor or dealer.

† Upflow only. Alternate sizes and additional filters may be ordered from your

dealer.

Table 4—Filter Information

FILTER SIZE (IN.)

Side Return†* Bottom Return*

If installing the filter in the furnace blower compartment, determine location for filter and relocate filter retaining wire, if necessary. See Table 4 to determine correct filter size for desired filter location. Table 4 indicates filter size, location, and quantity shipped with this furnace. See Fig. 2 for location and size of bottom and side return-air openings.

FILTER

TYPE

Page 23

WASHABLE

FILTER

FILTER RETAINER

A93045

Fig. 26—Filter Installed for Side Inlet

CUT HAZARD

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

171⁄2-IN. WIDE CASINGS ONLY:

INSTALL FIELD-SUPPLIED FILTER FILLER STRIP UNDER FILTER.

3″

/2″

1″

21-IN. WIDE CASINGS ONLY:

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

WASHABLE FILTER

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

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

Bottom return-air opening may be used with all 4 orientations. Filter may need to be cut to fit some furnace widths. Install filter as shown in Fig. 27.

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

Step 6—Bottom Closure Panel

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

To remove bottom closure panel, perform following:

1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 28.)

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

3. Remove bottom closure panel.

4. Reinstall front filler panel and screws.

Step 7—Gas Piping

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the United States. Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction.

Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 5 for recommended

FILTER RETAINER

BOTTOM CLOSURE PANEL

→

FILTER SUPPORT

Fig. 27—Bottom Filter Arrangement

FRONT FILLER PANEL

Fig. 28—Removing Bottom Closure Panel

gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.

A00290

A93047

Page 24

Table 5—Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE SIZE

(IN.)

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

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

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

INTERNAL DIAMETER

(IN.)

LENGTH OF PIPE (FT)

10 20 30 40 50

GAS SUPPLY

MANUAL SHUTOFF VALVE (REQUIRED)

SEDIMENT TRAP

UNION

FIRE OR EXPLOSION HAZARD

→

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

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

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

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

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

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

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

Install a sediment trap in riser leading to furnace. Trap can be installed by connecting a tee to riser leading to furnace so straight-through section of tee is vertical. Then connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and manual gas shutoff valve. (See Fig. 29.)

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance.

Fig. 29—Typical Gas Pipe Arrangement

Gas line grommet (factory-supplied loose parts bag) should be

→

used when installing gas piping. Gas line entry hole filler plug should be installed in unused gas line entry hole. (See Fig. 30.)

NOTE: The gas valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. wc) stated on gas control valve. (See Fig. 55.)

Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada, local, and national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14-in. wc), turn off electric shutoff switch located on furnace gas control valve and accessible manual shutoff valve before test. After all connections have been made, purge lines and check for leakage.

The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF.

Step 8—Electrical Connections

See Fig. 31 for field wiring diagram showing typical field 115-v and 24-v wiring. Check all factory and field electrical connections for tightness.

Field-supplied wiring shall conform with the limitations of 63°F (33°C) rise.

A93324

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion could result causing property damage, personal injury or loss of life.

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

ELECTRICAL SHOCK HAZARD

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

Page 25

COMBUSTION

-AIR PIPE

COMBUSTION-AIR PIPE GROMMETS

UNUSED 1/2 -IN. DIAMETER GAS CONN. HOLE

→

VENT PIPE

FIVE WIRE

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

BLK

WHT

115-V FIELD-

SUPPLIED

BLK

WHT

GND

AUXILIARY J-BOX

DISCONNECT

Fig. 31—Typical Heating and Cooling Application Wiring Diagram

GAS LINE

GAS LINE GROMMET

VENT PIPE GROMMET

NOTE: PIPE GROMMETS AND ENTRY HOLE FILLER PLUGS ARE INCLUDED IN FACTORY-SUPPLIED LOOSE PARTS BAG

Fig. 30—Typical Gas Pipe Arrangement

GND

FURNACE

NOTE 2

C O N

T R O

24-V

TERMINAL

BLOCK

WCR GY

W R

COM

Y/Y2

NOTE 1

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

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

2. If any of the original wire, as supplied, must be replaced, use

3. same type or equivalent wire.

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

THERMOSTAT TERMINALS

CONDENSING UNIT

TWO WIRE

GAS LINE ENTRY HOLE FILLER PLUG

A05057

FIELD-SUPPLIED DISCONNECT

A05057

208/230- OR 460-V THREE PHASE

208/230-V SINGLE PHASE

GND

A99440

FURNACE MAY NOT OPERATE

Failure to follow this caution may result in furnace operation stopping and water pipes freezing during cold weather. Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green/yellow wire connected to gas valve and burner box screw.

115–V WIRING Before proceeding with electrical connections, make certain that

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

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

The furnace must be electrically grounded in accordance with local

→

codes; or in the absence of local codes, with the National Electric Code ANSI/NFPA 70 and/or the Canadian Electric Code, CSA C22.1, Part I, if an external electrical source is utilized.

Use a separate, branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace. See Table 6 for wire size and fuse specifications. A disconnecting means must be located within sight from and readily accessible to furnace.

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

Page 26

Table 6—Electrical Data

FURNACE

SIZE

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

* Permissible limits of voltage range at which unit will operate satisfactorily. † Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load amps. ‡ Length shown is a measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop. ** Time-delay type is recommended.

ELECTRIC

DISCONNECT

SWITCH

VOLTS— HERTZ—

PHASE

WIRE ONLY

ALUMINUM

Fig. 32—Disconnect Switch and Furnace

OPERATING

VOLTAGE RANGE

Max* Min*

COPPER

WIRE

A93033

MAX UNIT

AMPS

UNIT

AMPACITY†

POWER ENTRY HOLE FILLER PLUG (FACTORYSUPPLIED LOOSE PARTS BAG)

MIN

WIRE

SIZE

MAX WIRE

LENGTH

(FT)‡

UNUSED 7/8-IN. DIAMETER POWER ENTRY HOLES

MAX FUSE

OR CKT BKR

AMPS**

A05113

→ Fig. 33—Factory Installed J-Box Location

FACTORY INSTALLED LOCATION

FIRE HAZARD

Failure to follow this warning could result in serious injury, death, or property damage. Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. (See Fig. 32.)

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in serious injury, death, or property damage. The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2002 and Canadian Electrical Code CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground.

Factory Installed J-Box Location

→

Install electrical entry hole filler plugs (factory-supplied in loose parts bag) in unused power entry holes. (See Fig. 33.)

J-Box Relocation

1. Remove 2 screws holding auxiliary J-box. (See Fig. 34.)

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

3. Install electrical entry hole filler plugs (factory-supplied loose

→

parts Bag) in unused power entry holes. (See Fig. 34.)

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in serious injury, death, or property damage. If manual disconnect switch is to be mounted on furnace, select a location where a drill or fastener will not contact electrical or gas components.

24–V WIRING Connect 24-v thermostat leads to 24-v terminal block on furnace

control. For proper cooling operation, Y wire from thermostat MUST be connected to Y/Y2 terminal on furnace control, as shown in Fig. 31. The 24-v terminal block is marked for easy connection of field wiring. (See Fig. 35.) The 24-v circuit contains a 3-amp, automotive-type fuse located on furnace control. (See Fig. 36.) Any electrical shorts of 24-v wiring during installation, service, or maintenance may cause fuse to blow. If fuse replacement is required, use only a fuse of identical size (3 amp) and type. The control will flash code 24 when fuse needs replacement.

NOTE: Use AWG No. 18 color-coded copper thermostat wire for lengths up to 100 ft. For wire lengths over 100 ft, use AWG No. 16 wire.

ACCESSORIES

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

Page 27

ALTERNATE

LOCATION

POWER ENTRY HOLE FILLER PLUG (FACTORYSUPPLIED LOOSE PARTS BAG)

UNUSED 7/8-IN. DIAMETER POWER ENTRY HOLES

FIELD

→ Fig. 34—Relocating J-Box

FACTORY INSTALLED LOCATION

POWER ENTRY HOLE FILLER PLUG (FACTORYSUPPLIED LOOSE PARTS BAG)

UNUSED 7/8-IN. DIAMETER POWER ENTRY HOLES

A05058

provided for EAC connection. (See Fig. 36.) These terminals are energized with 115-v (1.0-amp maximum) during blower motor operation.

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent operation or performance satisfaction. DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidistat™, Zone Controller or similar device. See Thermidistat™, Zone Controller, thermostat, or controller manufacturer’s instructions for proper connection.

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

24V) are provided for 24-v humidifier connection. (See Fig.

36.) HUM terminal is energized with 24-v (0.5-amp maximum) when gas valve is energized.

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

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

ASTM SPECIFICATION

(MARKED ON MATERIAL)

D1527 ABS Pipe — — Schedule-40 D1785 PVC Pipe — — Schedule-40

D2235 For ABS — — D2241 PVC Pipe — — SDR-21 & SDR-26

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

D2564 For PVC — — D2661 ABS Pipe Fittings — DWV at Schedule-40 IPS sizes

D2665 PVC Pipe Fittings — DWV

F438 CPVC — Fittings — Schedule-40 F441 CPVC Pipe — — Schedule-40 F442 CPVC Pipe — — SDR

F493 For CPVC — — F628 ABS Pipe — — Cellular Core DWV at Schedule-40 IPS sizes

F656 For PVC — — Primer For PVC F891 PVC Pipe — — Cellular Core Schedule-40 & DWV

MATERIAL PIPE FITTINGS SOLVENT CEMENT AND PRIMERS DESCRIPTION

Step 9—Removal of Existing Furnaces from Common Vent Systems

When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent the remaining attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, spillage of combustion products into the living space, etc.

Step 10—Combustion Air and Vent Pipe Systems

GENERAL Vent system or vent connectors may need to be resized. For any

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

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

→

a non-direct vent (except for 140 size) application. A direct vent system shall be installed in accordance with the direct vent (2-pipe) procedures in the following Combustion Air and Vent Pipe Systems section. For non-direct vent (1-pipe) applications, refer to the non-direct vent (1-pipe) procedures in the same section.

Solvent Cement

For ABS

For PVC

For CPVC

Page 28

SCHEMATIC DIAGRAM

TO 115VAC FIELD DI SCONNECT

CAP-1

(NATURAL GAS & PROPANE)

EQUIPMENT GROUND

GND

ILK

NOTE #2

EAC-2

IDM

BLWM

START

COM

MED LO

MED HI

NOTE #10

FAN

HEAT

COOL

SPARE-1

HI/LO

FAN

HSIR

EAC-1

BLWR

AUX

HSI

PL3

PL2

24VAC

115VAC

PR1

TRAN

IDR

NOTE #3

CAP - 2

PL4

TEST/TWIN

SEC-2

SEC-1

GVR-2

NOTE #6

F U 1

HUM

NOTE #11

LGPS

PL1

PRINTED CIRCIUT BOARD

PRS

(WHEN USED)

FRS

326796-101 REV. B

GVR-1

CPU

Y/Y2

FSE9

DHUM

NOTE #5

PCB

1. If any of t he origi nal equipment wire i s replaced use wir e rated for 105˚C.

2. Use only copper wire between the disco nnect switch and the fur nace junction box (JB).

3. This wire must be connected to furnac e sheet metal for control to prov e flame.

4. Symbols are electrical representati on only.

NOTES:

optimum speed selection.

auto-res et after three hours.

5. Solid li nes inside PCB are pri nted circuit bo ard conduct ors and are not included in leg end.

6. Replace only with a 3 amp fuse.

7. Inducer (IDM) and blower (BLWM) motors contai n internal auto-reset thermal overload switches (OL).

8. Neutral connections are interchangeable within the NEUTRAL connector block.

9. Blower motor speed selecti ons are for average conditions, see i nstal lation instructions for details on

10. YELLOW lead not on al l motors.

90 seconds or 5 seconds when dehumi dify cal l is active.

11. Factory connected when LGPS is not used.

12. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will

13. Blower-on delay: gas heating 60 seconds, cool ing or heat pump 2 seconds.

14. Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, cooling or heat pump

A03229

LGPS

(WHEN USED)

PRS

ORN

PCB

120

BLOWER OFF DELAY

JUMPER SELECT

DHUM

PRINTED CIRCIUT BOARD

GRN/Y EL

YEL

BLU

NOTE #11

BLU

180

150

24V

NOTE #3

FRS

RED

ORN

TEST/TWIN

Y/Y2

BLK

WHT

CAP -2

TRAN

GRN/Y EL

RED

HUM

FU1

NOTE #6

WHT

BLU

RED

GRN/YEL

WHT

SEC-1

LED 1

EAC-2

SEC-2

NOTE #8

BRN

PL4

GRN/YEL

NEUTRAL

WHT

321

YEL

WHT

12345678910

FSE

PL1

IDM

HSI

WHT

AUX

PL3

BLK

WHT

BLK

GRN/Y EL

BLK

PL2

FAN

BLW

BHT/CLR BFANR BLWR

COOL

HEAT

WHT

BLK

WHT (COM)

BLK

PR1

EAC-1

BLWM

SPARE 2

BLK (HI)

SPARE 1

WHT

(COM)

FUSED OR CIRCUIT BREAKER

DISCONNECT SWI TCH (WHEN REQ'D)

GRN/YEL

YEL

NEUTRAL

NOTE #2

FU2

BLK

WHT

GND

BLK

WHT

CAP -1

BRN

START

RED (LO)

NOTE #10

(MED HI)

TEMPERATURE SWITCH (N.C.)

OL AUTO-RESET INTERNAL MOTOR OVERLOAD

PCB PRINTED CIRCUIT BOARD CONTROL

PL1 11-CIRCUIT PCB CONNECTOR

PL2 2-CIRCUIT CONNECTOR

ILK

BRN

BLU

(MED LO)

BFANR CONTINUOUS-FAN SELECT RELAY, SPDT

BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT

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

BLWM BLOWER MOTOR, PERMANENT-SPL IT-CAPACITOR

CAP 1, 2 CAPACIT OR

CPU MICROPROCES SOR AND CIRCUITRY

LEGEN

JUNCTION

UNMARKED TERMINAL

PCB CONTROL TERMINAL

FACTORY WIRING (115VAC)

FACTORY WIRING (24VAC)

FIELD WIRING (115VAC)

FIELD WIRING (24VAC)

CONDUCTOR ON CONTROL PCB

FIELD WIRING SCREW TERMINAL

FIELD EARTH GROUND

EQUIPMENT GROUND

FIELD SPLICE

PLUG RECEPTACLE

Fig. 35—Wiring Diagram

PL3 2-CIRCUIT HSI, CONNECTOR

PL4 3-CIRCUIT IDM EXTENSION CONNECTOR

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

TEST/TWIN C OMPONENT TEST & TWIN TERMINAL

TRAN TRANSFORMER-1 15VAC/24VAC

(FIELD INSTALLED & SUPPLIED)

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

EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)

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

FSE FLAME-PROVING ELECTRODE

FU 1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED

FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

GND EQUIPMENT GROUND

GV GAS VALVE-REDUNDANT

GVR 1, 2 GAS VALVE RELAY, DPST-(N.O.)

HSI HOT SURFACE IGNITER (115 VAC)

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

HUM 2 4VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)

IDM INDUCED DRAFT MOTOR, PSC

IDR IND UCED DRAF T MOTOR RELAY, SPST-(N.O.)

ILK BLOWER AC CESS PANEL INTERLOCK SWITCH, SPST-(N.O.)

J1 BLOWER - OFF DELAY JUMPER SELECTOR

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STATUS CODES - AMBER

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

LS LIMIT SWITCH, AU TO-RESET, SPST (N.C.)

Page 29

Multistory and common venting are prohibited.

→

DIRECT VENT/2-PIPE SYSTEM (ALL SIZES) In a direct-vent (2-pipe) system, all air for combustion is taken

directly from outdoor atmosphere, and all flue products are discharged to outdoor atmosphere. A factory accessory vent termination kit MUST be used in a direct vent (2-pipe) system.

NON-DIRECT VENT/1-PIPE SYSTEM (SIZES 040 THROUGH 120 ONLY)

In a non-direct vent (1-pipe) system, all air for combustion is taken from the area adjacent to furnace, and all flue products are discharged to outdoor atmosphere. A factory-supplied perforated disk assembly (in loose parts bag) MUST be used in combustionair pipe elbow.

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1-2002/NFPA 54-2002 or the CSA B149.1, Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

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

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

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

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

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.12002/NFPA 54-2002 and/or CSA B149.1, Natural Gas and Propane Installation Codes.

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

→

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

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

FIRE AND EXPLOSION HAZARD

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

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

In direct vent (2-pipe) systems, combustion air and vent pipes must terminate together in same atmospheric pressure zone, either through roof or sidewall (roof termination preferred), using accessory termination kit. See Table 8 for required clearances.

→

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

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in property damage, personal injury, or death. All combustion-air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 42 for direct vent (2-pipe) system and Fig. 43 for non-direct vent (1-pipe) system.

→

An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion-air (when applicable) and vent pipes. Each furnace must have its own set of combustion-air and vent pipes and be terminated individually, as shown in Fig. 42 for Direct Vent (2-Pipe) system and Fig. 43 for Non-Direct Vent (1-Pipe) system.

→

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

Other gas appliances with their own venting system may also use the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code and the vent or liner manufacturer’s installation instructions. Care must be taken to prevent the exhaust gases from one appliance from contaminating the combustion air of other gas appliances.

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation. When vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, pipe must be insulated as shown in Table 10 with Armaflex-type insulation.

→

Furnace combustion air and vent pipe connections are sized for 2-in. pipe. Any pipe size change should be made outside furnace casing in vertical pipe. The transition has to be made as close to the furnace as reasonably possible.

→

COMBUSTION AIR PIPE General Furnace combustion-air connection must be attached as shown in

Fig. 37. Combustion-air intake housing plug may need to be relocated in some applications.

Page 30

BLOWER OFF-DELAY

24-V THERMOST AT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

COOL

HEAT

BLOWER SPEED

SELECTION TERMINALS

Y1 DHUM G COM W/W1 Y/Y2 R

24V

STATUS CODE LED

FUSE 3-AMP

SEC-2 SEC-1

EAC-2 L2

NUETRAL

BLW

COOL HEAT

SPARE-1 SPARE-2

SPARE-1

SPARE-2 FAN

TWINNING AND/OR COMPONENT TEST

TERMINAL

BLOWER OFF-DELAY

90 150

120 180

TEST/TWIN

0.5 AMP@24VAC

PLT

HUM

PLT 1

1-AMP@

FAN

EAC-1

115VAC

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

PR-1

115 VAC (L1) LINE

VOLTAGE CONNECTION

Fig. 36—Furnace Control

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLT A GE MAIN

HARNESS CONNECTOR

PL2 1

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

A02142

For Non-Direct Vent (1-Pipe) system, combustion-air must terminate outside of furnace casing with 1 elbow. Orient elbow so that its opening faces down for upflow or downflow applications. Orient elbow so that its opening faces sideways (left or right) for horizontal left or horizontal right applications (See Fig. 37.) Maintain a 3-in minimum clearance between the opening of the combustion-air inlet pipe and any object.

UNIT CORROSION HAZARD

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

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

Assembly of Combustion Air Pipe (Non-Direct Vent/1-Pipe System ONLY)

1. Permanently install perforated disk assembly (factorysupplied in loose parts bag) in combustion-air elbow using RTV or by cementing, as shown in Fig. 38. For 120,000 Btuh

size units only: separate the 2 halves of perforated disk assembly and use only the shouldered disk half.

2. Determine the length of straight portion of combustion-air inlet pipe from Fig. 38.

3. Cut field-supplied 2-in. diameter PVC pipe to length as determined per Fig. 38.

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

38.

Assembly of Combustion Air Pipe (Direct Vent-2-Pipe System ONLY)

1. Using Table 11, determine the smallest combustion air diameter permitted. Pick the larger diameter and use it for both combustion and vent pipe.

NOTE: Do not count elbows or pipe sections in terminations or within furnace (All elbows shown in Fig. 42 and Fig. 43 are not to be counted).

UNIT MAY NOT OPERATE

Failure to follow this caution may result in incomplete combusiton, flame disturbance, or flame sense lockout. When installing combusiton air and vent system of short pipe length, the smallest allowable pipe diameter must be used.

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

39.

Page 31

Table 8—Direct Vent Termination Clearance

A05009

Page 32

→ Table 9—Other than Direct Vent Termination Clearance

A05013

Page 33

Table 10—Maximum Allowable Exposed Vent Pipe Length (ft) With and Without Insulation in Winter Design

Temperature Ambient*

FURNACE

SIZE

040

060

080

100

120

140

* Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 11. † Insulation thickness based on R value of 3.5 per in.

WINTER DESIGN

TEMPERATURE

(°F)

20 1.5 51 70

0 1.5 28 70

-20 1.5 16 70 20 2 45 70

0 2 22 70

-20 2 10 58 20 2 65 70

0 2 35 70

-20 2 20 70 20 2 55 55

0 2 48 55

-20 2 30 55 20 2.5 70 70

0 2.5 47 70

-20 2.5 28 70 20 2.5 40 40

0 2.5 40 40

-20 2.5 38 40 20 3 70 70

0 3 50 70

-20 3 28 70 20 3 70 70

0 3 61 70

-20 3 37 70 20 4 70 70

0 4 48 70

-20 4 23 70 20 3 60 60

0 3 60 60

-20 3 44 60 20 4 70 70

0 4 57 70

-20 4 30 70

MAX PIPE

DIAMETER

(IN.)

WITHOUT

INSULATION

WITH 3/8–IN. OR

THICKER INSULATION†

2. If required per Table 11, insert perforated disk assembly (factory-supplied in loose parts bag) in intake housing where combustion air pipe will be connected. If half disk set is required, install only shouldered disk half.

Attachment of Combustion Air Pipe

1. Determine location of combustion air intake pipe connection to combustion air intake housing as shown in Fig. 37 for application.

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

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

4. Insert assembled combustion air inlet pipe into intake housing as shown in Fig. 37.

5. Drill a 1/8-in. hole in 2-in, combustion air pipe using the hole in intake housing as a guide.

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

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

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

Attachment of Combustion Air Intake Housing Plug Fitting The combustion-air intake plug fitting must be installed in unused

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

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

A plugged drain connection has been provided on this fitting for use when moisture is found in combustion air intake pipe and combustion box. If use of this drain connection is desired, drill out fitting’s tap plug with 3/16-in. drill and connect a field-supplied 3/8-in. tube. This tube should be routed to open condensate drain for furnace and A/C (if used), and should be trapped, as shown in Fig. 40.

NOTE: (Direct Vent/2-Pipe System ONLY) Moisture in combustion air intake may be a result of improper termination. Ensure combustion air pipe termination is similar to those as shown in Fig.

Page 34

NOTE: Select 1 vent pipe connection and

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

AIR

COMBUSTION-

AIR

VENT

FLOW

COMBUSTION-

UPFLOW DOWNFLOW

COMBUSTION-

AIR

VENT

AIR

VENT

NOTE:

1 combustion-air pipe connection.

VENT

COMBUSTION-

AIR

FLOW

COMBUSTION-

VENT

AIR

FLOW

†

HORIZONTAL-LEFT DISCHARGE HORIZONTAL-RIGHT DISCHARGE

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

opening faces down.

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

opening faces sideways.

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

→

Fig. 37—Combustion-Air and Vent Pipe

†

Connections

FIELD-SUPPLIED 2-IN. DIAMETER PVC 90° ELBOW

FIELD-SUPPLIED 2-IN. DIAMETER PVC PIPE

VENT

COMBUSTION-

AIR

FLOW

A05092

VENT PIPE

→

General Furnace vent connection must be attached as shown in Fig. 37.

CARBON MONOXIDE POISONING AND PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in property damage, personal injury, or death. Vent pipes must be airtight.

NOTE: A 2-in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing per Fig. 39.

The minimum vent pipe length for these furnaces is 5 ft. Short pipe lengths (5-8 ft) may discharge condensate droplets. These condensate droplets may be undesirable. A 12-in. minimum offset pipe section is recommended to reduce excessive condensate droplets from exiting vent pipe outlet. (See Fig. 41)

Attachment of Vent Pipe

1. Determine vent pipe diameter and maximum pipe lengths using Table 11.

NOTE: (Direct Vent/2-Pipe ONLY) vent pipe system has the same diameter and same length as combustion air pipe as mentioned in section ″Assembly of Combustion Air Pipe (Direct Vent/2-Pipe system ONLY).″

NOTE: Do not count elbows or pipe sections in terminations or within furnace (all elbows shown in Fig. 42 and Fig. 43 are not be counted).

2. Determine location of vent pipe connection to inducer housing as shown in Fig. 39 for application.

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

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component damage. Inducer housing outlet cap must be installed and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage.

COMBUSTION-AIR DISC (FACTORY-SUPPLIED IN LOOSE PARTS BAG)

A96211

Length of Straight Pipe Portion of

Combustion-Air Inlet Pipe Assembly (In.)

CASING WIDTH A

17-1/2 8-1/2 ± 1/2

21 10-1/2 ± 1/2

24-1/2 12 ± 1/2

Fig. 38—Combustion-Air Inlet Pipe Assembly

40 so that it will not be susceptible to area where light snow or others sources of moisture could be pulled in.

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

5. Be certain that mating surfaces of inducer housing connection elastomeric (rubber) coupling, and 2-in. diameter vent pipe are clean and dry. Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps) onto inducer housing connection. Insert the 2-in. diameter vent pipe through the elastomeric (rubber) coupling and fully into inducer housing connection until it touches a stop inside the inducer housing outlet. Tighten the screws on both clamps to 15-in-lb. of torque. pipe to inducer housing. Tighten the clamp screws to 15 in.-lb. of torque.

NOTE: Starting at furnace, slope vent pipe a minimum of 1/4-in. per linear ft with no sags between hangers.

Page 35

→

ALTITUDE (FT)

0 to 2000

ALTITUDE (FT)

2001 to 3000

ALTITUDE (FT)

3001 to 4000

See notes at end of table

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

Table 11—Maximum Allowable Pipe Length (ft)

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric 4† no disk 4† no disk 4† no disk 70 70 70 70 70 70

2 Pipe or 3-in.

Concentric

PIPE DIA

(IN.)*

1 1 5 NANANANANA

1-1/2 1-1/2 70 70 65 60 60 55

2 2 70 70 70 70 70 70

1-1/2 1-1/2 20 15 10 5 NA NA

2 2 70 70 70 70 70 70

1-1/2 1-1/2 10 NA NA NA NA NA

2 2 55 50 35 30 30 20

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

2 2 5 NANANANANA

2-1/2 2-1/2 40 30 20 20 10 NA

3 3 70 70 70 70 70 70

2-1/2 one disk 2-1/2 10 NA NA NA NA NA

3† NA 45 40 35 30 25 20

3† no disk 3† 70 70 70 70 70 70

2-1/2 one disk NA 5 NA NA NA NA NA

3† one disk NA 40 35 30 25 20 15

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

PIPE DIA

(IN.)*

1-1/2 1-1/2 67 62 57 52 52 47

2 2 70 70 70 70 70 70

1-1/2 1-1/2 17 12 7 NA NA NA

2 2 70 67 66 61 61 61

2 2 49 44 30 25 25 15 2-1/2 2-1/2 70 70 70 70 70 70 2-1/2 2-1/2 35 26 16 16 6 NA

3 3 70 70 70 70 66 61

3 NA 14 9 NA NA NA NA

NA 3† 63 62 62 61 61 61 3† no disk NA 70 70 63 56 50 43 4† no disk 4† no disk 70 70 70 70 70 70

3† one disk NA 20 15 10 5 NA NA

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

PIPE DIA

(IN)*

1-1/2 1-1/2 64 59 54 49 48 43

2 2 70 70 70 70 70 70

1-1/2 1-1/2 16 11 6 NA NA NA

2 2 68 63 62 57 57 56

2 2 46 41 28 23 22 13 2-1/2 2-1/2 70 70 70 70 70 70 2-1/2 2-1/2 33 24 15 14 5 NA

3 3 70 70 70 66 61 56

3† no disk NA 65 58 51 44 38 31

NA 3† 59 59 58 57 57 56

3† one disk NA 11 6 NA NA NA NA

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

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

NUMBER OF 90° ELBOWS

123456

NUMBER OF 90° ELBOWS

123456

NUMBER OF 90° ELBOWS

123456

Page 36

→

ALTITUDE (FT)

4001 to 5000‡

ALTITUDE (FT)

5001 to 6000‡

ALTITUDE (FT)

6001 to 7000‡

See notes at end of table

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

Table 11—Maximum Allowable Pipe Length (ft) (Continued)

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

PIPE DIA

(IN.)*

1-1/2 1-1/2 60 55 50 45 44 39

2 2 70 70 70 70 70 70

1-1/2 1-1/2 15 10 5 NA NA NA

2 2 64 59 58 53 52 52

2 2 44 39 26 21 20 11 2-1/2 2-1/2 70 70 70 70 70 70 2-1/2 2-1/2 31 22 13 12 NA NA

3 3 70 70 67 62 57 52

3† no disk NA 53 46 40 33 26 20

NA 3† 56 55 54 53 52 52 4† no disk 4† no disk 70 70 70 70 70 70 3† no disk NA 21 17 13 9 5 NA 4† no disk NA 69 64 59 54 49 44

PIPE DIA

(IN.)*

1-1/2 1-1/2 57 52 47 42 40 35

2 2 70 70 70 70 70 70

1-1/2 1-1/2 14 9 NA NA NA NA

2 2 60 55 54 49 48 47

2 2 41 36 23 18 17 8 2-1/2 2-1/2 70 70 70 70 70 70 2-1/2 2-1/2 29 21 12 11 NA NA

3 3 70 67 62 57 52 47

3† no disk NA 42 35 29 22 15 9

NA 3† 53 52 50 49 48 47 4† no disk 4† no disk 70 70 70 70 70 70 3† no disk NA 12 8 NA NA NA NA 4† no disk NA 42 37 32 27 22 17

PIPE DIA

(IN)*

1-1/2 1-1/2 53 48 43 38 37 32

2 2 70 70 68 67 66 64

1-1/2 1-1/2 13 8 NA NA NA NA

2 2 57 52 50 45 44 43

2 2 38 33 21 16 15 6 2-1/2 2-1/2 70 70 68 67 66 64 2-1/2 2-1/2 27 19 10 9 NA NA

3 3 68 63 58 53 48 43

3† no disk NA 31 24 18 11 NA NA

NA 3† 49 48 47 45 44 43

4† no disk 4† no disk 70 70 70 70 67 62 4† no disk NA 17 12 7 NA NA NA

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN)*

NUMBER OF 90° ELBOWS

123456

NUMBER OF 90° ELBOWS

123456

NUMBER OF 90° ELBOWS

123456

Page 37

→

ALTITUDE (FT)

7001 to 8000‡

UNIT SIZE

Table 11—Maximum Allowable Pipe Length (ft) (Continued)

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

(BTUH)

40,000

60,000

80,000

100,000

120,000

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

PIPE DIA

(IN.)*

1-1/2 1-1/2 49 44 39 34 33 28

2 2 66 65 63 62 60 59

1-1/2 1-1/2 12 7 NA NA NA NA

2 2 53 48 46 41 40 38

2 2 36 31 19 14 12 NA 2-1/2 2-1/2 66 65 63 62 60 59 2-1/2 2-1/2 25 17 8 7 NA NA

3 3 63 58 53 48 43 38

3† no disk NA 20 13 7 NA NA NA

NA 3† 46 44 43 41 40 38

4† no disk 4† no disk 61 56 51 46 41 36

NUMBER OF 90° ELBOWS

123456

140,000 NA

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

NUMBER OF 90° ELBOWS

123456

ALTITUDE (FT)

8001 to 9000‡

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

PIPE DIA

(IN.)*

1-1/2 1-1/2 46 41 36 31 29 24

2 2 62 60 58 56 55 53 1-1/2 1-1/2 11 6 NA NA NA NA

2 2 49 44 42 37 35 34

2 2 33 28 17 12 10 NA 2-1/2 2-1/2 62 60 58 56 55 53 2-1/2 2-1/2 23 15 7 5 NA NA

3 3 59 54 49 44 39 34

3† no disk NA 10 NA NA NA NA NA

NA 3† 43 41 39 37 35 34

4† no disk 4† no disk 35 30 25 20 15 10

140,000 NA

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

NUMBER OF 90° ELBOWS

123456

ALTITUDE (FT)

9001 to 10,000‡

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

PIPE DIA

(IN.)*

1-1/2 1-1/2 42 37 32 27 25 20

2 2 57 55 53 51 49 47

2 2 45 40 38 33 31 29

2 2 30 25 14 9 7 NA 2-1/2 2-1/2 57 55 53 51 49 47 2-1/2 2-1/2 21 13 5 NA NA NA

3 3 54 49 44 39 34 29

NA 3† 39 37 35 33 31 29

4† no disk 4† no disk 10 5 NA NA NA NA

140,000 NA

*Disk usage-Unless otherwise specified, use perforated disk assembly (factory-supplied in loose parts bag). If one disk is stated, separate 2 halves of perforated disk assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box. †Wide radius elbow. ‡Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction. NA-Not Allowed; pressure switch will not make.

NOTES:

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

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

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

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

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

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

Page 38

reduce excessive condensate droplets from exiting the vent pipe.

FURNACE

3/8 ID TUBE

COMBUSTION – AIR INTAKE HOUSING

BURNER BOX

COMBUSTION-AIR PIPE (DIRECT VENT/2 PIPE)

NOT IN HORIZONTAL SECTION

PIPE DIAMETER

TRANSITION IN

VERTICAL SECTION

A93034

Fig. 39—Combustion-Air and Vent Pipe Diameter

Transition Location and Elbow Configuration

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1-PIPE)

12″ MIN

3/16

DRILL

TRAP

TO OPEN

DRAIN

→ Fig. 40—Air Intake Housing Plug Fitting Drain

COMBUSTION AIR PIPE (DIRECT VENT /2-PIPE)

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1-PIPE)

4″MIN

12″ MIN

COMBUSTION-AIR PIPE (NON-DIRECT VENT/1-PIPE)

A05093

VENT PIPE

COMBUSTION AIR PIPE (DIRECT VENT/2-PIPE)

HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL

COMBUSTION AIR PIPE (DIRECT VENT

COMBUSTION AIR

IPE (NON-DIRECT

VENT/1-PIPE)

/2-PIPE)

VENT PIPE

COMBUSTION AIR PIPE (DIRECT VENT /2-PIPE)

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1-PIPE)

12″ MIN

VENT PIPE

VERTICAL TO SIDEWALLVERTICAL TO ROOF

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

short (5-ft. to 8-ft) vent systems. This recommendation is to

→ Fig. 41—Short Vent (5 to 8 ft) System

A05094

Page 39

Roof Termination (Preferred)

Vertical separation between combustion air and vent 8 3/4 in. for 3 in. kit 6 3/4 in. for 2 in. kit

Maintain 12 in. min. clearance above highest anticipated snow level Maximum of 24 in. above roof

18 in. maximum

Note: "A" denotes 0 to < 2 in.

90°

At least 36 in.

At least 36 in

Concentric Vent and Combustion Air Roof Termination (preferred)

At least

Abandoned masonry used as raceway (per code)

12 in. min from

overhang or roof

in. separation

between bottom of

combustion air and bottom of vent

Maintain 12 min. clearance above highest anticipated snow level or grade whichever is greater

At least 36 in.

in.

Side wall termination

in.

of less than 12

36 in.

Maintain 12 in. min. clearance above highest anticipated snow level, maximum of 24 in. above roof

1 in. maximum (type)

t lea

in.

Concentric Vent and Combustion - Air Side Termination

12 in. minimum from overhang or roof

Maintain 12 min. clearance abo highest anticipated snow level or grade whichever is greate

in.

→

Fig. 42—Combustion Air and Vent Pipe Termination

for Direct Vent (2-pipe) System (All Sizes)

Roof Termination (Preferred)

Vent

Maintain 12 in.

minimum clearance

above highest anticipated

snow level maximum of

24 in. above roof.

Abandoned masonry used as raceway (per code)

6 in. minimum clearance

between wall and end of vent pipe.

10 in. maximum pipe length

12 in. min. from

overhang or roof

90°

Maintain 12 in. minimum clearance above highest anticipated snow level or grade

Side wall termination with 2 elbows (preferred)

whichever is greater.

Fig. 43—Vent Pipe Termination for Non-Direct

Vent (1-pipe) System (Sizes 040 Through 120 Only)

12 in. min. from overhang or roof

Sidewall Termination

with Straight Pipe (preferred)

Maintain 12 in. minimum clearance above highest anticipated snow level or grade whichever is greater

A05090

A05091

Page 40

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component damage. Vent pipe must be installed and fully seated against inducer housing internal stop. Clamp must be tightened to prevent any condensate leakage.

6. Install casing hole filler cap (factory-supplied in loose parts bag) in unused vent pipe casing hole.

Attachment of Vent Extension Pipe Furnaces with 100,000 Btuh and larger input are supplied with a

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

NOTE: See label on vent extension pipe for proper installation. This pipe may be shortened if an elbow is used to connect vent extension tube to field-installed vent pipe.

Installation Guidelines for Combustion Air Pipe and Vent Pipe It is recommended that all pipes be cut, prepared, and pre-

assembled before permanently cementing any joint.

1. Attach combustion air pipe and vent pipe per instructions in sections ″Combustion Air Pipe″ and ″Vent Pipe.″

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

3. Deburr inside and outside of pipe.

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

5. Clean and dry all surfaces to be joined.

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

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

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

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

10. Handle pipe joints carefully until cement sets.

11. Horizontal portions of the venting system shall be supported to prevent sagging support. Support combustion air piping (if applicable) and vent piping a minimum of every 5 ft (3 ft for SDR-21 or -26 PVC) using perforated metal hanging strap.

12. Slope combustion air piping (if applicable) and vent piping downward towards furnace a minimum of 1/4 in. per linear ft with no sags between hangers.

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

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

EXAMPLE:

→

An 080-12 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed as either a direct vent/2-pipe system that requires 3 elbows and 32 ft of vent pipe, along with 5 elbows and 34 ft of combustion-air pipe OR a non-direct vent/1-pipe system that requires 3 elbows and 32 ft vent pipe. For a direct vent/2-pipe system, Table 11 indicates this application would allow a 2-in. diameter vent pipe, but require a 2-1/2 in. diameter combustion air pipe. According to Table 11, 2-in. diameter pipe is good for 35 ft with 3 elbows, but only 30 ft with 5 elbows. Therefore, 2-1/2 in. diameter pipe must be used for both vent and combustionair pipes since larger required diameter must always be used for both pipes. For a non-direct vent/1-pipe system, Table 11 indicates that this application would allow a 2-in. diameter vent pipe. If same installations were in Albuquerque, elevation 5250 ft above sea level: For a direct vent/2-pipe system, Table 11 indicates that 2-1/2 in. diameter vent pipe and combustion-air pipe are required. For a non-direct vent/1-pipe system, Table 11 indicates that 2-1/2-in. diameter vent pipe is required. If same applications are to be installed at 5001- to 6000 ft elevation: For a direct vent/2-pipe system, 2-in. pipe is only good for 23 ft (with 3 elbows) and 17 ft (with 5 elbows). Therefore, 2-1/2 in. diameter combustion air and vent pipe must be used. For a non-direct vent/1-pipe system, a 2-in. diameter pipe is only good for 23 ft with 3 elbows. A 2-1/2-in. diameter vent pipe must be used.

→

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

must terminate outside structure, either through sidewall or roof. For vent termination clearance, refer to Table 8 for Direct Vent/2-Pipe system and Table 9 for Non-direct Vent/1-Pipe system. For exterior piping arrangements, refer to Fig. 42 for Direct Vent/2-Pipe system and Fig. 43 for Non-Direct/1-Pipe system.

Roof termination is preferred since it is less susceptible to damage or contamination, and it has less visible vent vapors. Sidewall termination require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system.

NOTE: (Direct Vent/2-Pipe system ONLY) A factory accessory termination kit MUST be used. See section ″Vent Termination Kit (Direct Vent/2-Pipe System Only)″ in this instruction.

When determining appropriate location for termination, consider the following guidelines:

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

2. Termination or termination kit should be positioned where vent vapors will not damage plants/shrubs or air conditioning equipment.

3. Termination or termination kit should be positioned so that it will not be affected by wind eddy, such as inside building corners, nor by recirculation of flue gases, airborne leaves, or light snow.

Page 41

→

DIRECT VENT (2-PIPE) TERMINATION KIT TERMINATION SYSTEM 2-in. Concentric Vent Kit Single Penetration of Wall or Roof 1, 1-1/2, 2, or 2-1/2

3-in. Concentric Vent Kit Single Penetration of Wall or Roof 2-1/2, 3 or 4 2-in. Termination Bracket Kit 2-Pipe Termination System 1, 1-1/2 or 2 3-in. Termination Bracket Kit 2-Pipe Termination System 2-1/2, 3 or 4

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

DIAM. OF COMBUSTION AIR AND VENT PIPES (IN INCHES)

4. Termination or termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones, balls, etc.

5. Termination or termination kit should be positioned where vent vapors are not objectionable.

Extended Exposed Sidewall Pipes Sidewall combustion air pipe termination (direct vent/2-pipe

system only) and vent pipe termination may be extended beyond area shown in Fig. 42 or in Fig. 43 per application in outside ambient by insulating pipe as indicated in Table 10.

1. Determine combustion air pipe diameter (direct vent/2-pipe system only) and vent pipe diameter, as stated above, using total pipe length and number of elbows.

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

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

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

Vent Termination Kit (Direct Vent/2-Pipe System Only) NOTE: Always refer to the instructions in termination kit for the

latest version. Combustion air and vent pipes MUST terminate outside structure.

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

NOTE: Combustion air pipe must have the same diameter as vent pipe.

Concentric Vent/Combustion Air Termination Kit (Direct Vent/ 2-Pipe System Only) Determine an appropriate location for termination kit using the

guidelines provided in section ″Vent Termination: General″ in this instruction.

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

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

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

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

Roof terminations—Locate assembly through roof to appropriate height as shown in Fig. 42.

Sidewall terminations—Locate assembly through sidewall with rain shield positioned no more than 1-in. from wall as shown in Fig. 42.

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

5. Check required dimensions as shown in Fig. 42.

Two-Pipe Termination Kit (Direct Vent/2-Pipe System Only Determine an appropriate location for termination kit using the

guidelines provided in section ″Vent Termination: General″ in this instruction.

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

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

Roof terminations—Loosely install pipe coupling on properly cut vent pipe. Coupling must be positioned so bracket will mount as shown in Fig. 42.

For applications using combustion-air pipe option, indicated by dashed lines in Fig. 42, install 90° street elbow into 90° elbow, making a U-fitting. A 180° U-fitting may be used.

Sidewall terminations—Install bracket as shown in Fig. 42. For applications using vent pipe option indicated by dashed

lines in Fig. 42, rotate vent elbow 90° from position shown in Fig. 42.

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

4. Check required dimensions as shown in Fig. 42.

Multiventing and Vent Terminations When 2 or more 58MXB Furnaces are vented near each other, each

furnace must be individually vented. NEVER common vent or breach vent 58MCB furnaces. (Direct Vent/2-Pipe System ONLY)-When 2 or more 58MCB furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 42, but next vent termination must be at least 36 in. away from first 2 terminations. It is important that vent terminations be made as shown in Fig. 42 to avoid recirculation of flue gases.

Step 11—Condensate Drain

GENERAL Condensate trap is shipped installed in the blower shelf and factory

connected for UPFLOW applications. Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications.

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

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

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

Drain pipe and fittings must conform to ANSI standards and ASTM D1785, D2466 or D2846. CPVC or PVC cement must conform to ASTM D2564 or F493. Primer must conform to ASTM F656. In Canada, use CSA or ULC listed schedule 40 CPVC or PVC drain pipe, fittings, and cement.

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

Page 42

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

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

APPLICATION The furnace, A/C, and humidifier drains may be combined and

drained together. The A/C drain must have an external, fieldsupplied trap prior to the furnace drain connection. All drain connections (furnace, A/C, or humidifier) 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. 44 for example of possible field drain attachment using 1/2-in. CPVC or PVC tee for vent and A/C or humidifier drain connection.

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

PERSONAL INJURY HAZARD

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

CONDENSATE DRAIN PROTECTION Freezing condensate left in condensate trap and drain line may

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

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

2. Locate heat tape between sides of condensate trap back. (See Fig. 45.)

CONDENSATE TRAP

WIRE TIE(S)

HEAT TAPE

(3 WRAPS MINIMUM)

A93036

Fig. 45—Condensate Trap Heat Tape

3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig. 45.)

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

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

START-UP, ADJUSTMENTS, AND SAFETY CHECK

Step 1—General

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

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

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

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

4. Blower access panel must be in place to complete 115-v electrical circuit to furnace.

OPEN STAND

PIPE FOR

A/C OR

HUMIDIFIER

DRAIN

TEE

TO OPEN DRAIN

A94054

Fig. 44—Example of Field Drain Attachment

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation. These furnaces are equipped with a manual reset limit switch in burner box. This switch will open and shut off power to gas valve if an overheat condition (flame 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 flame roll-out manual reset switch for continuity. If necessary, press button to reset switch.

Page 43

Step 2—Prime Condensate Trap With Water

UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation. 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. 46.)

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

3. Insert field-supplied funnel into tube.

4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 47.)

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

Step 3—Purge Gas Lines

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

Fig. 46—Inducer Housing Drain Tube Cap

A99118

A99119

Fig. 47—Filling Condensate Trap

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in a fire, explosion, personal injury, or death. Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.

Step 4—Sequence of Operation

FURNACE MAY NOT OPERATE

Failure to follow this caution may result in furnace operation stopping and water pipes freezing during cold weather. Furnace control must be grounded for proper operation, or control will lock out. Control is grounded through green/yellow wire connected to gas valve and burner box screw.

Using schematic diagram, follow sequence of operation through different modes. (See Fig. 35.) Read and follow wiring diagram carefully.

NOTE: If a power interruption occurs during a call for heat (W), the control will start a 90-second blower-only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The Amber status code LED light will flash code 12 during the 90-second period, after which the LED will be ON continuous, as long as no faults are detected. After the 90-second period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace

Page 44

control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot-surface igniter HSI, and gas valve GV.

HEATING MODE (See Fig. 31 for thermostat connections.)

The wall thermostat ″calls for heat,″ closing the R to W circuit. The furnace control performs a self-check, verifies the pressure switch contacts PRS are open, and starts the inducer motor IDM.

a. Inducer Prepurge Period- As the inducer motor IDM

comes up to speed, the pressure switch contacts PRS close to begin a 15-second prepurge period.

b. Igniter Warm-Up- At the end of the prepurge period, the

Hot-Surface igniter HSI is energized for a 17-second igniter warm-up period.

c. Trial-for-Ignition Sequence- When the igniter warm-up

period is completed the main gas valve relay contacts GVR-1 and -2 close to energize the gas valve GV, the gas valve opens, and 24 vac power is supplied for a fieldinstalled humidifier at the HUM terminal. The gas valve GV permits gas flow to the burners where it is ignited by the Hot Surface Igniter HSI. Five seconds after the GVR-1 closes, a 2-second flame period begins. The HSI igniter will remain energized until the flame is sensed or until the 2-second flame proving period begins.

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

flame-proving sensor electrode FSE, the furnace control CPU begins the blower-ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV, and the control CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to Ignition-Lockout. Lockout will be reset automatically after three hours, or by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W, G, R, etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM until flame is no longer proved.

e. Blower-On Delay- If the burner flame is proven, the

blower motor is energized on HEAT speed 66 seconds (040 through 120 sizes) or 45 seconds (140 size) after the gas valve GV is energized. Simultaneously, the electronic air cleaner terminal EAC-1 is energized and remains energized as long as the blower motor BLWM is energized.

f. Blower-Off Delay- When the thermostat is satisfied, the

R-to-W circuit is opened, de-energizing the gas valve GV, stopping gas flow to the burners, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 15-second (040 through 120 sizes) or 5-second (140 size) post-purge period. The blower motor BLWM and air cleaner terminal EAC-1 will remain energized for 90, 120, 150, or 180 seconds (depending on the blower-OFF delay selection). The furnace control CPU is factory-set for a 120-second blower-OFF delay.

COOLING MODE The thermostat “calls for cooling.”

a. Single-Speed Cooling

(See Fig. 27, 50, 52, and 54 for thermostat connections)

The thermostat closes the R to G-and-Y circuits. The R to Y circuit starts the outdoor unit, and the R to G-and-Y/Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC-1 is energized with 115 vac when the blower motor BLWM is operating. When the thermostat is satisfied, the R to G-and-Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the cooling off-delay to 5 seconds. (See Fig. 31.)

b. Two-Speed Cooling

(See Fig. 27, 51, 53, 55, and 56 for thermostat connections.)

The thermostat closes the R to G-and-Y1 circuits for low-cooling or closes the R to G-and-Y1-and-Y2 circuits for high-cooling. The R to Y1 circuit starts the outdoor unit on low-cooling speed, and the R to G-and-Y1 circuit starts the furnace blower motor BLWM on low-cool speed (same speed as FAN). The R to Y1-and-Y2 circuits start the outdoor unit on high-cooling speed, and the R to G-andY/Y2 circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC-1 is energized with 115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R to G and-Y1 or R to G and-Y1 and-Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC-1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the

cooling off-delay to 5 seconds. (See Fig. 31.) THERMIDISTAT MODE (See Fig. 50, 51, 52, and 53 for Thermidistat connections.)

The dehumidification output, DHUM on the Thermidistat should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM input is activated, which means 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. When 24 vac is initially detected by the furnace control on the DHUM input, the furnace control operates in Thermidistat mode. If the DHUM input is low or OFF for more than 48 hours, the furnace control reverts back to non-Thermidistat mode. The cooling operation described in item 2. above also applies to operation with a Thermidistat. The exceptions are listed below:

a. When the R to G-and-Y1 circuit is closed and there is a

demand for dehumidification, the furnace blower motor

BLWM will continue running at low-cool speed (same

speed as FAN).

b. When the R to G-and Y/Y2 circuit is closed and there is a

demand for dehumidification, the furnace blower motor

BLWM will drop the blower speed from COOL to HEAT

for a maximum of 10 minutes before reverting back to

COOL speed. If there is still a demand for dehumidification

after 20 minutes, the furnace control CPU will drop the

blower speed back to HEAT speed. This alternating 10-

minute cycle will continue as long as there is a call for

cooling.

Page 45

A00268

Fig. 48–Single-Stage Furnace with Single-Speed

Air Conditioner

A00270

Fig. 50–Single-Stage Furnace with Single-Speed

Heat Pump (Dual Fuel)

A00269

Fig. 49–Single Stage Furnace with Two-Speed

Air Conditioner

A00271

Fig. 51–Single-Stage Furnace with Two-Speed

Heat Pump (Dual Fuel)

Page 46

HUMIDFIER

(24VAC)

HUMIDFIER

(24VAC)

A02102

Fig. 52–Dual Fuel Thermostat with Single-Stage

Furnace and Single-Speed Heat Pump

A02103

Fig. 53–Dual Fuel Thermostat with Single-Stage

Furnace and Two-Speed Heat Pump

HUMIDFIER

Fig. 54–Two-Stage Thermostat with Single-Stage

Furnace and Two-Speed Air Conditioner

(24VAC)

A02161

Page 47

Notes For Figure 48-54

1. Heat pump MUST have a high pressure switch for dual fuel applications.

2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

3. Select the “ZONE” position on the two-speed heat pump control.

4. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.

5. Dip switch No. 1 on Thermidistat should be set in OFF position for air conditioner installations. This is factory default.

6. Dip switch No. 1 on Thermidistat should be set in ON position for heat pump installations.

7. Dip switch No. 2 on Thermidistat should be set in OFF position for single-speed compressor operation. This is factory default.

8. Dip switch No. 2 on Thermidistat should be set in ON position for two-speed compressor operation.

9. Configuration Option No. 10 “Dual Fuel Selection” must be turned ON in all dual fuel applications.

10. NO connection should be made to the furnace HUM terminal when using a Thermidistat.

11. The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.

12. DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two-speed heat pump control board. This is

controlled internally by the Thermidistat/Dual Fuel Thermostat.

13. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single-speed compressor operation. This is factory default.

14. Dip switch D on Dual Fuel Thermostat should be set in ON position for two-speed compressor operation.

c. When the ″call for cooling″ is satisfied while there is a

demand for dehumidification, the cooling blower-off delay is decreased from 90 seconds to 5 seconds.

CONTINUOUS BLOWER MODE

When the R to G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous-blower speed (can be adjusted to FAN, HEAT, or COOL speed) at the thermostat. Factory default is FAN speed. Terminal EAC-1 is energized as long as the blower motor BLWM is energized. During a call for heat, the blower BLWM will stop during igniter warm-up (17 seconds), ignition (7 seconds), and blower-ON delay (66 or 45 seconds for 040 through 120 sizes or for 140 size), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at HEAT speed. In heating, the furnace control CPU will hold the blower motor BLWM at HEAT speed during the selected blower-OFF delay period before reverting to continuous-blower speed. When the thermostat ″calls for low-cooling″, the blower motor BLWM will switch to operate at low-cool speed (same speed as FAN). When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on low-cool speed (same speed as FAN) before reverting back to continuous-blower speed. When the thermostat ″calls for high-cooling″, the blower motor BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds on COOL speed before reverting back to continuous-blower speed. When the R to G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation. Continuous Blower Speed Selection from Thermostat -To select different continuous-blower speeds from the room thermostat, momentarily turn off the FAN switch or pushbutton on the room thermostat for 1-3 seconds after the blower motor BLWM is operating. The furnace control CPU will shift the continuous-blower speed from the factory setting of FAN to HEAT speed. Momentarily turning off the FAN switch again at the thermostat will shift the continuous-blower speed from HEAT to COOL. Repeating the procedure will shift the continuous-blower speed from COOL back to FAN speed.

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

power interruption. HEAT PUMP MODE (See Fig. 52, 53, 54, and 55 for thermostat connections.)

When installed with a heat pump, the furnace control auto-

matically changes the blower timing sequence to avoid long

blower off times during demand defrost cycles. When the R to

W-and-Y1 or R to W-and-Y1-and-G circuits are energized the

furnace control CPU will switch to or turn on the blower

motor BLWM at HEAT speed, and begin a heating cycle. The

blower motor BLWM will remain on until the end of the

prepurge period, then shut off for 24 seconds then come back

on at HEAT speed. When the W input signal disappears, the

furnace control begins a normal inducer post-purge period and

the blower remains running at HEAT speed for the selected

blower-OFF delay period then switches to low-cool speed

(same speed as FAN). If the R to W-and-Y1-and-G signals

disappear at the same time, the blower motor BLWM will

remain on for the selected blower-OFF delay period. If the R

to W-and-Y1 signals disappear, leaving the G signal, the

blower motor BLWM will remain on for the selected blower-

OFF delay period then switch to continuous-blower speed.

When the R to W-and-Y/Y2, R to W-and-Y/Y2-and-G, R to

W-and-Y1-and-Y/Y2, or R to W-and-Y1-and-Y/Y2-and-G

circuits are energized the furnace control CPU will switch to

or turn on the blower motor BLWM at HEAT speed, and

begin a heating cycle. The blower motor BLWM will remain

on until the end of the prepurge period, then shut off for 24

seconds then come back on at HEAT speed. When the W input

signal disappears, the furnace control begins a normal inducer

post-purge period and the blower switches to COOL speed

after a 3-second delay. If the R to W-and-Y/Y2-and-G or R to

W-and-Y1-and-Y/Y2-and-G signals disappear at the same

time, the blower motor BLWM will remain on for the selected

blower-OFF delay period. If the R to W-and-Y/Y2 or R to

W-and-Y1-and-Y/Y2 signals disappear, leaving the G signal,

the blower motor BLWM will remain on for the selected

blower-OFF delay period then switch to continuous-blower

speed.

Page 48

Table 13—Model 58MXB Orifice Size and Manifold Pressure for Correct Input

For Use with 040 through 120 Size Furnaces Only

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

ALTITUDE

RANGE

(FT)

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

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

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

U.S.A. and Canada

0% 1075 45 3.2 45 3.3 45 3.4 45 3.5 45 3.6

derate 1100 47 3.6 47 3.7 45 3.2 45 3.4 45 3.5

ALTITUDE

RANGE

(Ft)

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

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

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

3000 850 44 3.6 44 3.7 44 3.8 43 3.5 43 3.6

or 875 44 3.4 44 3.5 44 3.6 44 3.7 43 3.4

Canada 900 44 3.2 44 3.3 44 3.4 44 3.5 44 3.6

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

2001 to 950 45 3.5 45 3.6 45 3.7 45 3.8 44 3.3

U.S.A. and Canada

4500 975 45 3.3 45 3.4 45 3.5 45 3.6 45 3.8

5% 1000 45 3.1 45 3.2 45 3.4 45 3.5 45 3.6

derate 1025 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

ALTITUDE

RANGE

(Ft)

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

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

U.S.A. Only

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

7% 975 45 3.0 45 3.2 45 3.3 45 3.4 45 3.5

derate 1000 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

* Orifice numbers 45 shown in BOLD are factory installed. Percents of derate are based on midpoints of U.S. altitude ranges.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

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

950 44 3.4 44 3.5 44 3.6 44 3.7 44 3.8

1000 45 3.7 45 3.8 44 3.2 44 3.4 44 3.5

1050 45 3.3 45 3.4 45 3.6 45 3.7 45 3.8

Avg GAS HEAT VALUE AT ALTITUDE

(Btu/cu ft)

Avg GAS HEAT VALUE AT ALTITUDE

(Btu/cu ft)

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

850 44 3.3 44 3.4 44 3.5 44 3.7 44 3.8

900 45 3.6 45 3.7 45 3.8 44 3.3 44 3.4

950 45 3.2 45 3.3 45 3.4 45 3.5 45 3.7

0.58 0.60 0.62 0.64 0.66

Orifice

Manifold

No.

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

No.

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

No.

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 49

TABLE 13—Model 58MXB Orifice Size and Manifold Pressure for Correct Input (Continued)

for Use With 040 Through 120 Size Furnaces Only

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

ALTITUDE

RANGE

(FT)

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

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

U.S.A. Only

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

9% 925 45 3.1 45 3.2 45 3.3 45 3.4 45 3.6

derate 950 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

ALTITUDE

RANGE

(Ft)

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

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

U.S.A. Only

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

11% 975 45 2.6 45 2.7 45 2.8 45 2.9 45 2.9

derate 1000 45 2.5 45 2.5 45 2.6 45 2.7 45 2.8

ALTITUDE

RANGE

(Ft)

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

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

U.S.A. Only

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

13% 850 45 3.1 45 3.2 45 3.4 45 3.5 45 3.6

derate 875 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

* Orifice numbers 45 shown in BOLD are factory installed. Percents of derate are based on midpoints of U.S. Altitude ranges.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

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

825 44 3.2 44 3.4 44 3.5 44 3.6 44 3.7

875 45 3.5 45 3.6 45 3.7 44 3.2 44 3.3

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

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

825 45 3.6 45 3.7 44 3.2 44 3.3 44 3.4

875 45 3.2 45 3.3 45 3.4 45 3.6 45 3.7

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

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

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

750 44 3.3 44 3.4 44 3.6 44 3.7 44 3.8

800 45 3.5 45 3.7 45 3.8 44 3.2 44 3.3

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 50

Table 13—Model 58MXB Orifice Size and Manifold Pressure for Correct Input (Continued)

For Use with 040 through 120 Size Furnaces Only

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

ALTITUDE

RANGE

(FT)

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

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

U.S.A. Only

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

15% 825 45 3.1 45 3.2 45 3.3 45 3.4 45 3.5

derate 850 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

ALTITUDE

RANGE

(Ft)

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

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

U.S.A. Only

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

17% 775 45 3.2 45 3.3 45 3.4 45 3.5 45 3.6

derate 800 45 3.0 45 3.1 45 3.2 45 3.3 45 3.4

ALTITUDE

RANGE

(ft)

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

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

U.S.A. Only

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

19% 750 45 3.1 45 3.2 45 3.3 45 3.4 45 3.5

derate 775 45 2.9 45 3.0 45 3.1 45 3.2 45 3.3

Orifice numbers 45 shown in BOLD are factory installed. Percents of derate are based on midpoints of U.S. altitude ranges.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

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

725 44 3.3 44 3.4 44 3.5 44 3.6 44 3.7

775 45 3.5 45 3.6 45 3.7 45 3.8 44 3.3

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

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

675 44 3.5 44 3.6 44 3.7 44 3.8 43 3.4

725 45 3.6 45 3.8 44 3.2 44 3.3 44 3.4

Avg GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

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

650 44 3.4 44 3.5 44 3.7 44 3.8 43 3.4

700 45 3.6 45 3.7 45 3.8 44 3.3 44 3.4

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 51

COMPONENT TEST NOTE: The furnace control component test allows all compo-

nents to run for a short time; except the gas valve and humidifier terminal HUM are not energized for safety reasons. The EAC-1 terminal is energized when the blower is energized. This feature helps diagnose a system problem in case of a component failure. The component test feature will not operate if any thermostat signal is present ant the control and not until all time delays are completed.

To Begin Component Self-Test:

ELECTRICAL SHOCK HAZARD

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

1. Remove blower access door.

2. Disconnect the thermostat R lead from furnace control.

3. Manually close blower door switch.

4. For approximately 2 sec, short (jumper) the C on control to the TEST/TWIN 3/16-inch quick-connect terminal on control until the LED goes off. Remover jumper from terminals. (See Fig. 36.)

NOTE: If TEST/TWIN and COM-24v terminals are jumpered longer than 2 sec, LED will flash rapidly and ignore component test request.

Component test sequence is as follows:

a. LED will display previous status code 4 times. b. Inducer motor starts and continues to run until Step g of

component test sequence.

c. After 7 seconds the hot surface igniter is energized for 15

sec., then off.

d. Blower motor operates on Continuous-FAN speed for 10

sec. e. Blower motor operates on HEAT speed for 10 sec. f. Blower motor operates on COOL speed for 10 sec. g. Inducer motor stops.

5. Reconnect R lead to furnace control, remove tape from blower door switch, and re-install blower door.

6. Operate furnace per instruction on outer door.

7. Verify furnace shut down by lowering thermostat setting below room temperature.

8. Verify that furnace restarts by raising thermostat setting above room temperature.

Step 5—Adjustments

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

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

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

altitudes between 2001 ft to 4500 ft above sea level. Furnace input rate must be within ± 2 percent of input on furnace

rating plate adjusted for altitude.

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

OM-24v terminal

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

local gas supplier. b. Obtain average gas specific gravity from local gas supplier. c. Verify furnace model and size. Table 13 can only be used

for model 58MXB furnaces with rating plate heating inputs

(1000’s Btuh) of 040 through 120. Table 14 can only be

used for model 58MXB furnaces with a heating size of 140. d. Find installation altitude in Table 13 or 14.

NOTE: For Canadian altitudes of 2001 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 13 or 14.

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

Table 13 or 14. f. Follow heat value and specific gravity lines to point of

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

EXAMPLE: (0-2000 ft altitude using Table 13) Heating value = 1050 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 45 and Manifold pressure 3.6-in. wc * Furnace is shipped with No. 45 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain the proper input rate.

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

2. Adjust manifold pressure to obtain input rate.

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

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

valve regulator. (See Fig. 55.)

c. Jumper R and W thermostat connections on control to start

furnace. d. Turn adjusting screw, counterclockwise (out) to decrease

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

NOTE: This furnace has been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft. For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 in. wc to 3.8 in. wc. If manifold pressure is outside this range, change burner orifices to obtain pressure in this range.

UNIT DAMAGE HAZARD

→

Failure to follow this caution may result in reduced furnace life. DO NOT bottom-out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

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

Page 52

Table 14—Model 58MXB Orifice Size and Manifold Pressure for Correct Input

For Use with 140 Size Furnaces Only

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

ALTITUDE

RANGE

(FT)

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

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

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

U.S.A. and Canada

0% 1075 44 3.5 44 3.6 43 3.2 43 3.3 43 3.4

derate 1100 44 3.3 44 3.4 44 3.5 43 3.2 43 3.3

ALTITUDE

RANGE

(ft)

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

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

2001 to 825 42 3.6 42 3.7 41 3.5 41 3.6 41 3.7 3000 or 850 42 3.4 42 3.5 42 3.6 42 3.7 41 3.5 Canada 875 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6

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

2001 to 925 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3

4500 950 43 3.3 43 3.4 43 3.5 43 3.7 43 3.8

U.S.A. and Canada

5% 1000 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4

derate 1025 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

ALTITUDE

RANGE

(ft)

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

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

U.S.A. Only

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

7% 975 43 2.9 43 3.0 43 3.1 43 3.2 43 3.3

derate 1000 43 2.8 43 2.9 43 3.0 43 3.0 43 3.1

* Orifice numbers 43 shown in BOLD are factory installed. Percents of derate are based on midpoints of U.S. altitude ranges.

AVG GAS HEAT VALUE AT ALTITUDE

(BTU/CU FT)

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

950 42 3.2 42 3.3 42 3.4 42 3.5 42 3.6

1000 43 3.5 43 3.6 43 3.7 42 3.2 42 3.3

1050 43 3.2 43 3.3 43 3.4 43 3.5 43 3.6

AVG GAS HEAT VALUE AT ALTITUDE

(Btu/cu ft)

975 43 3.1 43 3.3 43 3.4 43 3.5 43 3.6

AVG GAS HEAT VALUE AT ALTITUDE

(Btu/cu ft)

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

850 43 3.8 42 3.2 42 3.4 42 3.5 42 3.6

900 43 3.4 43 3.5 43 3.6 43 3.8 42 3.2

950 43 3.1 43 3.2 43 3.3 43 3.4 43 3.5

0.58 0.60 0.62 0.64 0.66

Orifice

Manifold

No.

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

No.

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

No.

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 53

Table 14—Model 58MXB Orifice Size and Manifold Pressure for Correct Input (Continued)

for Use With 140 Size Furnaces Only

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

ALTITUDE

RANGE

(FT)

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

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

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

U.S.A. Only

9% 925 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4

derate 950 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

ALTITUDE

RANGE

(ft)

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

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

U.S.A. Only

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

11% 975 43 2.5 43 2.6 43 2.6 43 2.7 43 2.8

derate 1000 43 2.3 43 2.4 43 2.5 43 2.6 43 2.7

ALTITUDE

RANGE

(ft)

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

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

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

U.S.A. Only

13% 850 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4

derate 875 43 2.8 43 2.9 43 3.0 43 3.1 43 3.2

* Orifice numbers 43 shown in BOLD are factory installed. Percents of derate are based on midpoints of U.S. altitude ranges.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

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

800 42 3.3 42 3.4 42 3.5 42 3.6 42 3.7

850 43 3.5 43 3.6 43 3.8 42 3.2 42 3.3

900 43 3.1 43 3.3 43 3.4 43 3.5 43 3.6

AVG GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

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

825 43 3.5 43 3.6 43 3.7 43 3.8 42 3.2

875 43 3.1 43 3.2 43 3.3 43 3.4 43 3.5

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

AVG GAS

HEAT VALUE

AT ALTITUDE

(Btu/cu ft)

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

725 42 3.4 42 3.5 42 3.6 42 3.7 42 3.8

775 43 3.6 43 3.7 43 3.8 42 3.3 42 3.4

825 43 3.2 43 3.3 43 3.4 43 3.5 43 3.6

0.58 0.60 0.62 0.64 0.66

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

0.58 0.60 0.62 0.64 0.66

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

SPECIFIC GRAVITY OF NATURAL GAS

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

Manifold

Pressure

Manifold

Pressure

Page 54

ON AND OFF SWITCH

GAS PRESSURE REGULATOR ADJUSTMENT

BURNER ENCLOSURE REFERENCE PRESSURE TAP

BURNER FLAME

BURNER

INLET PRESSURE TAP

Fig. 55—Redundant Automatic Gas Control Valve

→

MANIFOLD PRESSURE TAP

BURNER

ORIFICE

Fig. 56—Orifice Holes

UNIT DAMAGE HAZARD

Failure to follow this caution may result in component damage due to flame impingement of burners and heat exchangers. DO NOT redrill orifices. Improper drilling (burrs, out-ofround holes, etc.) can cause excessive burner noise and misdirection of burner flames. (See Fig. 56.)

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

input rate using method outlined in item 3.

g. Look through sight glass in burner enclosure and check

burner flame. Burner flame should be clear blue, almost transparent. (See Fig. 57.)

h. Remove jumper from R and W.

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

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

A95622

A93059

MANIFOLD

Fig. 57—Burner Flame

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

UNITED STATES At altitudes above 2000 ft, this furnace has been approved for a 2 percent derate for each 1000 ft above sea level. See Table 15 for derate multiplier factor.

EXAMPLE:

100,000 Btuh input furnace installed at 4300 ft.

Derate Furnace Input Rate

Furnace Input Rate X Multiplier = at Installation

at Sea Level Factor Altitude

100,000 X 0.91 = 91,000

CANADA At installation altitudes between 2001 to 4500 ft, this furnace must be derated 5 percent by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example above and use 0.95 as derate

multiplier factor. b. Reinstall burner box cover. c. Gas valve regulator seal cap MUST be on. d. Turn off all other gas applications and pilots. e. Start furnace and let operate for 3 minutes. f. Measure time (in sec) for gas meter to dial to complete 1

revolution. g. Refer to Table 16 for cu ft of gas per hr. h. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft)

using natural gas heating value from local gas utility/supplier.

A89020

Page 55

Table 15–Altitude Derate Multipler for U.S.A.

ALTITUDE

(FT)

0–2000 0 1.00 2001–3000 4–6 0.95 3001–4000 6–8 0.93 4001–5000 8–10 0.91 5001–6000 10–12 0.89 6001–7000 12–14 0.87 7001–8000 14–16 0.85 8001–9000 16–18 0.83

9001–10,000 18–20 0.81

* Derate multiplier factors are based on midpoint altitude for altitude range.

EXAMPLE: (0-2000 ft altitude) Furnace input from rating plate is 100,000 Btuh. Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 975 Btu/cu ft Time for 1 revolution of 2-cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 16) Btu heating input = 103 X 975 = 100,425 Btuh. In this example, the orifice size and manifold pressure adjustment is within ±2 percent of the furnace input rate.

SET TEMPERATURE RISE

UNIT DAMAGE HAZARD

Failure to follow this caution may result in overheating the heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate. Temperature rise must be within limits specified on furnace rating plate. Recommended operation is at midpoint of rise range or slightly above.

Determine and adjust air temperature rise as follows:

1. Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see heat exchangers so that radiant heat does not affect readings. This practice is particularly important with straight-run ducts.

2. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.

3. Adjust temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death. Disconnect 115-v electrical power before changing speed tap.

4. To change blower motor speed selections for heating mode, remove blower motor lead from control HEAT terminal. (See Fig. 36.) Select desired blower motor speed lead from 1 of the other motor leads and relocate it to HEAT terminal. See Table 17 for lead color identification. Reconnect original lead on SPARE terminal.

PERCENT

OF DERATE

DERATE MULTIPLIER

FACTOR*

Table 16—Gas Rate (cu ft/hr)

SECONDS

FOR 1

REVOLUTION

10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 124 29 58 145

SIZE OF TEST DIAL

Cu Ft2Cu Ft5Cu Ft

120 240 600 80 45 90 225

SECONDS

FOR 1

REVOLUTION

Follow this same procedure for proper selection of COOL speed selection.

ADJUST BLOWER OFF DELAY (HEAT MODE) The blower off delay has 4 adjustable settings from 90 sec to 180

sec. (See Table 18.) The blower off delay jumpers are located on the furnace control (See Fig. 31). To change the blower off delay setting, move the jumper from one set of pins on the control to the pins used for the desired blower off delay. Factory blower off delay setting is 120 sec.

SET THERMOSTAT HEAT ANTICIPATOR When using a nonelectronic thermostat, the thermostat heat

anticipator must be set to match the amp draw of the electrical components in R-W circuit. Accurate amp draw readings can be obtained at thermostat subbase terminals R and W. Fig. 58 illustrates the easy method of obtaining actual amp draw. The amp reading should be taken after blower motor has started and furnace is heating. Connect ammeter wires as shown in Fig. 58. The thermostat anticipator should NOT be in the curcuit while measuring current. If thermostat has no subbase, the thermostat must

SIZE OF TEST DIAL

Cu Ft2Cu Ft5Cu Ft

Page 56

Table 17—Speed Selector

COLOR SPEED

Black High Cool

Yellow (When Present) Medium High Spare

Blue Medium Low Heat

Red Low Fan

White Common C

FACTORY-

SHIPPED

CONNECTION

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED

HOOK-AROUND

VOLT/AMMETER

R Y W G

Table 18—Blower Off Delay Jumper Positions

PINS 1 AND 2 2 AND 3 3 AND 4 4 AND 5

Time (in sec) 90 120 150 180

be disconnected from R and W wires during current measurement. See thermostat manufacturer’s instructions for adjusting heat anticipator and for varying heating cycle length.

For an electronic thermostat, set cycle rate for 3 cycles per hour.

Step 6—Check Safety Controls

This section covers the safety controls that must be checked before the installation is complete. The flame sensor, gas valve, and pressure switch were all checked in the Start-up procedure section as part of normal operation.

CHECK PRIMARY LIMIT CONTROL This control shuts off gas control system and energizes air-

circulating blower motor if furnace overheats. Recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 5 minutes. As soon as limit control has shut off burners, return-air opening should be unblocked to permit normal air circulation. By using this method to check limit control, it can be established that limit is functioning properly and operates if there is a restricted return-air duct or motor failure. If limit control does not function during this test, cause must be determined and corrected.

CHECK PRESSURE SWITCH This control proves operation of draft inducer. Check switch

operation as follows:

1. Turn off 115-v power to furnace.

2. Remove outer furnace door and disconnect inducer motor from wire harness.

3. Turn on 115-v power to furnace.

4. Set thermostat to ″call for heat″ and wait 1 minute. When pressure switch is functioning properly, hot surface igniter should NOT glow, and control status code LED flashes a Status Code 31. If hot surface igniter glows when inducer motor is disconnected, shut furnace down immediately. Determine reason pressure switch did not function properly and correct condition.

5. Turn off 115-v power to furnace.

6. Reconnect inducer motor leads, reinstall main furnace door, and turn on 115-v power supply.

10 TURNS

FROM UNIT 24-VOLT TERMINAL BLOCK

EXAMPLE:

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

= 0.5 AMPS FOR THERMOSTAT SETTING

A80201

Fig. 58—Amp Draw Check with Ammeter

Step 7—Checklist

1. Put away tools and instruments. Clean up debris.

2. Verify flame-rollout manual reset switch has continuity.

3. Verify that blower and main outer access doors are properly installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instructions.

6. Review User’s Guide with owner.

7. Leave literature packet near furnace.

Page 57

LOAD CALCULATION

CHECKLIST—DIRECT VENT (2-PIPE) INSTALLATION

Condensate Drain

____________ Heating Load (Btuh)

____________ Cooling Load (Btuh)

____________ Furnace Model Selection

COMBUSTION AIR AND VENT PIPING

Termination Location

________ Roof or Sidewall

________ Termination Kit — 2 Pipe or Concentric

________ Combustion-Air Pipe Length

________ Combustion-Air Pipe Elbow Quantity

________ Vent Pipe Length

________ Vent Pipe Elbow Quantity

________ Pipe Diameter Determined from Sizing Table

________ Pipe Sloped To Furnace

________ Unit Level or Pitched Forward

________

________ Condensate Trap Primed before Start-Up

________ Heat Tape Installed if Required

CHECKLIST—START-UP

________

________ Temperature Rise Adjusted

Thermostat Anticipator

________ Anticipator Setting Adjusted or

________ Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Check Operation

Internal Tubing Connections Free of Kinks and Traps

External Drain Connection Leak Tight and Sloped

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

Pipe Insulation

________ Over Ceilings

________ Low-Ambient Exposed Pipes

________ Primary Limit

________ Pressure Switch

Page 58

LOAD CALCULATION

CHECKLIST—NON DIRECT VENT (1-PIPE) INSTALLATION

Condensate Drain

____________ Heating Load (Btuh)

____________ Cooling Load (Btuh)

____________ Furnace Model Selection

VENT PIPING

Termination Location

________ Roof or Sidewall

________ Vent Pipe Length

________ Vent Pipe Elbow Quantity

________ Pipe Diameter Determined from Sizing Table

________ Pipe Sloped To Furnace

Pipe Insulation

________ Over Ceilings

________ Low-Ambient Exposed Pipes

________ Unit Level or Pitched Forward

________

________ Condensate Trap Primed before Start-Up

________ Heat Tape Installed if Required

CHECKLIST—START-UP

________

________ Temperature Rise Adjusted

Thermostat Anticipator

________ Anticipator Setting Adjusted or

________ Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Check Operation

Internal Tubing Connections Free of Kinks and Traps

External Drain Connection Leak Tight and Sloped

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

________ Primary Limit

________ Pressure Switch

Page 59

Page 60

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

Book 1 4 Tab 6a 8a PC 101 Printed in U.S.A. Catalog No. 58MXB-1SI Pg 60 8-05 Replaces: 58MXA-18SI