Carrier 58MXB080F10120, 58MXB100F10116, 58MXB100F10120, 58MXB120F10120, 58MXB140F10120 Installation Guide

...

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Installation, Start-Up, and Operating Instructions

for Sizes 040-140, Series 110 & 120

Visit www.Carrier.com

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

ISO 9001:2000

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

to the Expertg_

Special Venting Requirements for Installations in Canada

Installation in Canada must conform to the requirements of CSA B149 code. Vent systems must be composed of pipe, fittings,

cements, and primers listed to ULC $636. The special vent fittings and accessory concentric vent termination kits and

accessory external drain trap have been certified to ULC $636 for use with those IPEX PVC vent components which have been

certified to this standard. In Canada, the primer and cement must be of the same manufacturer as the vent system - IPEX System

636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and IPEX System 636(1) TM, PVC Cement for Flue Gas Venting, rated

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

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

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

is based on following these installation instructions, the vent system manufacturer's installation instructions, and proper use of

primer and cement. All fire stop and roof flashing used with this system must be UL listed material. Acceptability under Canadian

standard CSA B149 is dependent upon full compliance with all installation instructions. Under this standard, it is recommended

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

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

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

Consignes sp_ciales pour l'installation de ventillation au Canada

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

tuyaux, raccords, ciments et appr_ts conformes au ULC $636. La tuyauterie de ventillation des gaz, ses accessoires, le terminal concentrique mural ainsi que l'ensemble du drain de condensat

ext_rieur ont _t_ certifies ULCS 636 pour l'application des composantes IPEX PVC qui sont certifi_es fi ce standard. Au

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

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

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

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

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

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

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

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

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

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

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

requis.

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

-1-

Required Notice for Massachusetts Installations

IMPORTANT

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

5.08: Modifications to NFPA-54, Chapter 10

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

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

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

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

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

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

the installation of hard wired carbon monoxide detectors

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

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

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

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

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

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

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

VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

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

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

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

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

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

NFPA 54 as adopted by the Board; and

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

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

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

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

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

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

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

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

satisfied by the manufacturer:

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

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

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

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

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

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

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TABLE OF CONTENTS

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

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ... 7

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

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

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

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

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

Horizontal Left (Supply-Air Discharge)

Applications ...................................... 12

Horizontal Right (Supply-Air Discharge)

Applications ...................................... 13

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

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

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

Hazardous Locations ............................... 18

Furnace Location and Application ..................... 18

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

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

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

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

Installation in Horizontal Applications ................. 22

Air Ducts ......................................... 23

General Requirements ............................. 23

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

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

Return Air Connections ............................ 23

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

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

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

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

115-v Wiring .................................... 29

24-v Wiring ..................................... 30

Accessories ..................................... 30

Removal of Existing Furnaces from

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

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

Condensate Drain .................................. 48

General ........................................ 48

Application ..................................... 49

Condensation Drain Protection ...................... 49

START-UR ADJUSTMENTS, AND SAFETY CHECK ..... 49

General .......................................... 49

Prime Condensate Trap With Water .................... 50

Purge Gas Lines ................................... 50

Sequence of Operation .............................. 50

Heating Mode ................................... 50

Cooling Mode ................................... 51

Thermidistat Mode ............................... 51

Continuous Blower Mode .......................... 54

Heat Pump Mode ................................. 54

Component Test .................................. 60

Adjustments ...................................... 60

Set Gas Input Rate ................................ 60

Set Temperature Rise .............................. 62

Adjust Blower Off Delay (Heat Mode) ................ 62

Set Thermostat Heat Anticipator ..................... 62

Check Safety Controls .............................. 63

Check Primary Limit Control ....................... 63

Check Pressure Switch ............................ 63

Checklist ......................................... 63

AIRFLOW

42>

_ HORIZONTALLEFT

AIRFLOW

A93041

Fig. 1 - Multipoise Orientations

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or

other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or

your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or

accessories when modifying this product. Refer to the individual

instructions packaged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Have a fire extinguisher available. Read these

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

building codes, the current editions of the National Fuel Gas

Code (NFGC) NFPA 54/ANSI Z223.1 and the National Electrical Code (NEC) NFPA 70.

In Canada, refer to the current editions of the National Standards of Canada CAN/CSA-B149.1 and .2 Natural Gas and Propane

Installation Codes, and Canadian Electrical Code CSA C22.1

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

Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards

which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor

personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced

installation, reliability, or operation.

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.

-3-

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.

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.

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. (25 mm) clearance from combustible materials to

supply air ductwork for a distance of 36 in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for

further requirements. 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

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 design-certified for installation in recreation vehicles

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

temperature of 60°F (1. C) db or intermittent operation down to 5 °

.5 F (13°C) db such as when used with a night setback thermometer. Return-air temperature must not exceed 80°F

(27°C) db. Failure to follow these return air limits may affect reliability of heat exchangers, motors and controls. (See Fig. 4.)

These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are

required when used in DOWNFLOW, HORIZONTAL RIGHT, or HORIZONTAL LEFT (supply-air discharge direction) applications as shown in Fig. 1. See details in

Applications section.

5 °

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

Always provide adequate combustion and ventilation air as specified in section Combustion Air and Vent Pipe Systems of

these instructions to the furnace. Combustion products must be discharged outdoors. Connect this

furnace to an approved vent system only, as specified in the Combustion Air and Vent piping sections of these instructions.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for detection of leaks to

check all connections as specified in the (iAS 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

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

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

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

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

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

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

• The furnace is controlled by a thermostat. It may not be "hot wired" to provide heat continuously to the structure with out

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. 5 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.

5 °

-4-

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

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

Installer Packet includes:

Installation, Startup, and Operating Instructions

Service and Maintenance Instructions

User's Information Manual

Warranty Certificate

Loose Parts Bag includes: Quantity

Pressure tube extension 1

Collector Box or condensate trap extension tube 1

Inducer housing drain tube 1 1/2-in CPVC street elbow 2

Drain tube coupling 1

Drain tube coupling grommet 1 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

Inducer Outlet Restrictor ....................... 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 (;as Code (NFGC) NFPA 54-2006/ANSI Z223.1-2006 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B

• CANADA: National Standard of Canada, Natural (;as 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 Safe 0, 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

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

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

Step 4--Duet 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 (;lass I Rigid Air Ducts

Step 6--Gas Piping and Gas Pipe Pressure Testing

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

national plumbing codes

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

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

state of Massachusetts.

Step 7--Electrical Connections

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

• CANADA: Canadian Electrical Code CSA C22.1

-5-

(368niq}

11a '(32ram)

(25ram)

A_RFLOW

(21ram)

e_ C/

I ' (14ram)

OUTLET

CONDENSATE DRAIN

.......... ON _

HORIZONTAL RIGHT 7

1_ IN DIAGAS CONN

(DOWNFLOW & _,

OR ALTERNATE

28 1_, (724mm) --

_26 1_6' (S94mm)_

26 1_, (667mm)

22 _6 '(567n1 m)

_'_'_19'(483mm) _ _17t_'(21mm)

I T , rq

_1..... o......... •

)

"1_ % _N DIA

,.C__/-......... |

GAS CONN --

%_':: -+-f- ............ ,_2::7

S DE NLET !

i i (25ram)

INLET

(17m m)

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

see flex duct manufacturer's recommendation for equivalent diameters.

2. Minimum return-air opening at furnace: a. For 800 CFM 16-in. (406mm) round or 14 1/a (368mm)x 12-in. (305mm) rectangle. b. For 1200 CFM 20-in. (508mm) round or 14 1/_ (368mm) x 19 1/_-in. (495mm) rectangle.

c. For 1600 CFM 22-in .(559mm) round or 14 1/a (368mm) x 23 1/o-in.(591mm)rectangte. d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data

literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate

return air openings for airflow requirements above 1800 CFM at 0.5" W.C. ESR

(Wmm)

Dimensions - IN. (mm)

UNIT SIZE D E

040-08 / 024040 15-7/8 (403) 16 (406) 040-12 / 036040 15-7/8 (403) 16 (406)

060-08 / 024060 15-7/8 (403) 16 (406) 060-12 / 036060 15-7/8 (403) 16 (406) 060-16 / 048060 15-7/8 (403) 16 (406) 080-12 / 036080 15-7/8 (403) 16 (406) 080-16 / 048080 15-7/8 (403) 16 (406)

080-20 / 060080 19-3/8 (492) 19-1/2 (495) 100-16 / 048100 19-3/8 (492) 19-1/2 (495) 100-20 / 060100 19-3/8 (492) 19-1/2 (495) 120-20 / 060120 19-3/8 (492) 23 (584)

140-20 / 060140 22-7/8 (581) 23 (584)

17-1/2 (445) 17-1/2 (445)

17-1/2 (445) 17-1/2 (445) 17-1/2 (445) 17-1/2 (445) 17-1/2 (445)

21 (533) 21 (533) 21 (533)

24-1/2 (622) 24-1/2 (622)

Fig. 2 - Dimensional Drawing

OO;OENS:TEJ./7 III_._,_:_

DRAIN LOCATION / _ 22 1_' TYP "----'--_-I 1_16' ( ram)

DIMPLE LOCATORS BOTTOM _NLET

FOR HORIZONTAL (S14mm)

HANGING

A05053

-6-

NSTALLATION

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

(0 - 2,135m).

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

• This famace is for indoor installation in a building constructed on site. This furnace may be installed in a manufactured (moble) home when stated on rating plate and using factory authorized kit..

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

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

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

roofing materials).

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

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

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

pr¢fabdqu6e (maison mobile) si prescrit par la plaque signal6tique et si'l on utilise une trousse specifi6e par le fabricent.

• C.ette foumaise pout 6tre install6e sur un piancher combustible dans un enfoncement ou un pmacerd en observant ruesD6gagernent Minimum En Pouces Avec EI6ments De Construction Combustibles.

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

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

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

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

Pour des applications de flux ascendant et descendant, la foumaise doit 61re install6e de niveau ou indin6e _ T ............ !

pas plus de 1/2" (12.7mm) du niveau. Pour une applicetion hodzontale, lafoumaise dolt 6tre inclin6e entre minimum UPFLOW OR F_0RONT_) 1/4" (6.35mm) et maximum 1/2" (12.7ram) du niveau pour le drainage appropn6. En cas d'installation en position DOWN FLOW

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

MINIMUMINCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSiTiONS:

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

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

DOWNFLOW POSITIONS:

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

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

or WENC or WTNC.

HORIZONTAL POSITIONSi

Line contact is permissible only between lines formed by intersections of top and two sides of

furnace jacket, and building joists, studs, or framing.

§ Clearance shown is for air inlet and air curet ends.

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

DEGAGEMENT IVIINII_UIVIEN POUCESAVEC I_LleMENTSDECONSTRUCTION COMBUSTIBLES

POUR TOUS LES POSITIONS:

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

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

requis au-arriere.

POUR LA POSITION COURANT DESCENDANT:

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

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

POUR LA POSmON HORIZONTALE:

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

batiment.

§ La distance indiqu6e conceme I'extr6mit_ du tuyau d'ardv_e d'air et I'extr_mit_ du tuyau de sortie d'aic Pour les foumaises de 120 et 140 taifie, 1 pc (25mm) d6cjagement des materiaux combustibles

est requis au-dessous.

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

Cette foumaise est approuv6e pour I'installation HORIZONTALE et lacirculation d'air VERS LE HAUT et VERS LE BAS.

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

furnace orientation, gen6rateur d'air chaud.

Clearanceininches 0 (pc)D_agement D6gagement(pc). d'6ventaveccombustibles.

I'orientation de la

Vent clearance to

combustibles 0".

FRONT

i°i! _ MAX80°F

Fig. 4 -Return-Air Temperature

(27° C)

MIN60°F (16oC)

A05004

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

-7-

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

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:

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

2 or 6.)

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

return duct attachment to assist in filter removal.

g. Remove and discard casing drain hole plug button

from desired side.

h. Install drain tube coupling grommet (factory-supplied

in loose parts bag) in selected casing hole.

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

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

-8-

BLOWERSHELF '_ FURNACE

CONDENSATE '_ TRAP (INSIDE)

DOOR _ CONDENSATE

X !TRAP _I;Z

FURNACE

DOOR

i URNACE

ALTERNATE DRAIN ._TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

( gmm) p" A

FIELD 26 /4 11/2

DRAIN (667mm) (38mm)

CONN

SIDE VIEW FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

SLOT O SO ETW

APPLICATION

(OPTIONAL) /

_Eg/E t (3mm) 7/821 ;

(WHEN USED) (57mm)

FRONT VIEW SIDE VIEW

4 t

(102mm)

261/4

DRAIN

CONN

1/4" (6mm) COLLECTOR BOX TO

TRAP RELIEF PORT 1/2 (13mm)

INDUCER HOUSING DRAIN CONNECTION

5/8 (16mm) COLLECTOR BOX

DRAIN CONNECTION SCREW HOLE FOR

UPFLOW OR DOWN- FLOW APPLICATIONS

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

(667mm)

END VIEW

HORIZONTAL

APPLICATIONS

IDE

4__. _5_3/4 ( 146mm )

3/4

(19mm)

FRONT VIEW

Fig. 5 - Condensate Trap

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

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

be cemented together and cemented to condensate trap drain connection.

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

k. Connect larger diameter drain tube and clamp

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

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

In. Attach tube to coupling and clamp securely.

CONDENSATE TRAP LOCATION (ALTERNATE UPFLOW ORIENTATION)

An alternate location for the condensate trap is the left-hand side of casing. (See Fig. 2 and 7.)

NOTE: If the alternate left-hand side of casing location is used, the factory-connected drain and relief port tubes must be

disconnected and modified for attachment. See Condensate Trap Tubing (Alternate Upflow Orientation) section for

tubing attachment. To relocate condensate trap to the left-hand side, perform

the following:

1. Remove 3 tubes connected to condensate trap.

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

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. (445 mm) wide furnaces ONLY, cut tube between corrugated sections to prevent kinks from occurring.

-9-

[W- NI__

PLUG--_I / III

COLLEOTORBOX "- ]11

PLUG _-,

CAP _,

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX '_

TUBE (PINK) "_

COLLECTORBO×--,4X'xL-_ _-_ I,,

DRAIN TUBE) J r_F I _ _ IIII

I!lL IIII

FACTORY-BUPPUED/! I / / IAI/

cou7 A' ' / /,/ , /111/

- FIELD-INSTALLED LLED FACTORY-SUPPLIED FACTORY-SUPPLIED

1/2-1N. CPVC STREET DRAIN TUBE

ELBOWS (2) FOR COUPLING (RIGHT

LEFT DRAIN OPTION 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)

O O

CONDENSATETRAP,.,.----.t__

INDUCER J

HOUSING

DRAIN TUBE

(VIOLET)

A94164

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 recommendations and procedures.

Step 3--Downflow Applications

A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, and

conditioned air is discharged downwards.

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.

- 10 -

COLLECTOR

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

TRAP

0 0

BOX

DRAIN TUBE (BLUE)

BOX

TUBE (PINK)

BOX

TUBE (GREEN)

BOX

EXTENSION TUBE

BOX

DRAIN TUBE (BLUE & WHITE STRIPED)

BOX

EXTENSION TUBE INDUCER HOUSING

DRAIN TUBE

(VIOLET)

INDUCER HOUSING

DRAINTUBE(VIOLET)

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, or9.)

4. Install casing hole filler cap into blower shelf hole where

trap was removed.

CARBON MONOXIDE POISONING HAZARD

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

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

A94165

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

CONDENSATE TRAP TUBING NOTE: See Fig. 8 or 9. or robe routing label on main fi_rnace

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

1. Collector Box Drain Tube

a. Remove factory-installed plug from LOWER collector

box drain tube (blue and white striped label).

TRAP

)R BOX EXTENSION DRAIN TUBE

COUPLING

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

condensate trap.

(3.) Condensate Trap Located on Left Side of Casing

a. Connect LOWER collector box drain tube (blue

and white striped label) to condensate trap.

Tube does not need to be cut.

b. Clamp tube to prevent any condensate leakage.

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

a. Install drain tube coupling (factory-supplied in

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

previously plugged.

b. Connect larger diameter drain tube

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

c. Route extended collector box drain tube

directly from collector box drain to condensate trap as shown in Fig. 9.

d. Determine appropriate length and cut. e. Connect to condensate trap.

f. Clamp tube to prevent any condensate leakage.

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

LOWER inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer

housing drain tube which was previously connected to condensate trap.

- 11-

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 robe 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.

Determine appropriate length, cut, and connect tube.

Clamp tube to relief port connection.

CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section

recommendations and procedures.

for

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

Applications

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 Failure to follow this warning could result in personal injury

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

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

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

rotating until tabs snap into locking position.

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

CONDENSATE TRAP TUBING

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

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

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

b. Connect large diameter drain tube and clamp

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

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

and cut to appropriate length.

d. Clamp tube to prevent any condensate leakage.

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

housing drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label

and factory-supplied in loose parts bag) to connect

LOWER inducer housing drain connection to the condensate trap.

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

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

previously connected to the condensate trap by splicing to small diameter tube (factory-supplied in loose

parts bag).

b. Route extended collector box pressure tube to relief

port connection on the condensate trap.

- 12-

PLUG --

AUXILIARY

"J" BOX COLLECTOR BOX

-X/ CAP

DRAIN TUBE (BLUE AND WHITE STRIPED)

_ O

CONDENSATE

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

TRAP

COLLECTC \ DRAIN TUBE (VIOLET)

BOX EXTENSION \\

DRAIN TUBE \_-- COLLECTOR BOX

COLLECTOR BOX

EXTE S,O O E

DRAIN TUBE COUPLING _

COLLECTOR BOX TUBE (PINK)

040,060, AND 080 HEATING INPUT FURNACES

Fig. 10 - Horizontal Left Tube Configuration

UCER HOUSING

DRAIN TUBE (BLUE)

A00215

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.

CONDENSATE TRAP FREEZE PROTECTION

Refer to Condensate Drain Protection section for recommendations and procedures.

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

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

UNIT MAY NOT OPERATE

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

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

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (1.5 M) (See Table 11.)

NOTE: A 12-in. (305 mm) minimum offset pipe section is recommended with short (5 to 8 ft. or 1.5 to 2.4 M) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12 or 40.)

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.

- 13 -

MAN1

SHUTOFF

GAS VALVE

SEDIMENT TRAP

COMBUSTION -

INTAKE

(146 mm)

CONDENSATE

TRAP

30" (762 mm)MIN

DRAIN

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

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

CONDENSATE DROPLETS FROM EXITING THE VENT PIPE.

ACCESS OPENING

FOR TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

Fig. 11 - Attic Location and Working Platform for Direct Vent (2-pipe) Application - All Sizes

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

IS REQUIRED.

COMBUSTION AIR

INTAKE

A 12-1N. (3O5mm) MIN HORIZONTAL PIPE

SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT / 1.5 TO 2.4M) VENT

SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM

EXITING THE VENT PIPE.

30-IN. (762mm) MIN

(146mm)

A93031

MAN[

SHUTOFF

GAS VALVE

SEDIMENT

TRAP

DRAIN

CONDENSATE

ACCESS OPENING

FOR TRAP

TRAP

NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE

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

Fig. 12 - Attic Location and Working Platform for Non-Direct Vent (1-pipe) Applications-Sizes 040 Through 120 Only

- 14-

A96184

PLUG

COLLECTOR BOX DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (GREEN)

BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

"J" BOX RELOCATED HERE

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

Fig. 13 - Horizontal Right Tube Configuration

PROPERTY DAMAGE

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

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in attic

application or over a finished ceiling.

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

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.

TRAP

_ATE

AO0214

CARBON MONOXIDE POISONING HAZARD

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

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

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

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

CONDENSATE TRAP TUBING

NOTE: See Fig. 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.

- 15 -

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

inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing

drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain

connection where molded drain tube was removed.

d. Use inducer housing drain extension tube (violet label

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

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

condensate trap.

f. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection procedure.

CONDENSATE TRAP FIELD DRAIN ATTACHMENT

Refer to Condensate Drain section for recommendations and procedures.

PRESSURE SWITCH TUBING

One collector box pressure tube (pink label) is factory connected to the 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 recommendations and procedures.

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

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

' 1

LEVEL (0")

TO 1/2" (13mm)

MAX

UPFLOW OR DOWNFLOW

Fig. 14 - Furnace Location for Proper Condensate Drainage

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

are restricted to a minimum length of 5 ft. (1.5 M) (See Table 11.)

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

This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12 or 40.)

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. (13 mm) for proper

furnace operation. For horizontal applications pitch 1/4-in. (6 mm) minimum to 1/2-in. (13 mm) maximum forward to ensure

proper condensate drainage from secondary heat exchangers. (See Fig. 14.)

1/4" (!mm)-__

MIN

TO 1/2" (13mm)

MAX HORIZONTAL

A02146

- 16-

BACK

A93043

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.)

__3//_/A2MF[EONCgFIINFIMUMz12STALLED

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.

Fig. 16 - Freeze Protection

A07911

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 (0°C) 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.

- 17-

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. (457 mm) above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, 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.

18-1N. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 17 - Installation in a Garage

NON-DIRECT VENT (1-PIPE) APPLICATION

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

unit operation. Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air

requirements are met.

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

AIR FOR COMBUSTION AND

VENTILATION

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

• U.S. Installations: Section 9.3 of the NFPA 54/ANSI

Z223.1-2006, Air for Combustion and Ventilation and applicable provisions of the local building codes.

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

authorities having jurisdiction.

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

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

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

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

fresheners, and other household products.

The following types of furnace installations may require

OUTDOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas

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

for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

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

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

safeguard opening.

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

or death.

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

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

addition to that required by the furnace. Refer to the Carbon Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount of make-up air is available.

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

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

appliances installed in the space.

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

- 18-

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

the INDOOR COMBUSTION AIR, STANDARD or KNOWN AIR INFILTRATION METHOD.

Outdoor Combustion Air Method

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

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

2. Fig. 18 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and

ventilation air openings to the outdoors.

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

Size openings and ducts per Fig. 18 and Table 1.

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 mm-'/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'-/kW) for combined input of all gas

appliances in the space per Table 1 and of the ceiling and the second opening MUST commence within 12" (300 mm) of the floor.

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

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

FURNACE (1SQ. INJ2,000BTUH) (1,100SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/K3N) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

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

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

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

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

154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24838) 8 (203)

EXAMPLE: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

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

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

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

OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL

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

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

ACH Space Volume Ft3 (M3)

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

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

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

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

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

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

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

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

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

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

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

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

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

Indoor combustion air is permitted for combustion, ventilation,

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

Method is used.

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

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.

- 19-

.4_ 1 SQIN.

DUCTS---k // B H*

PER 4000

CIRCULATING AIR

DUCTS

VENT THROUGH ROOF

OUTDOORS [ "_'[i

q .........................

, , i i

1 SQ IN. A / I z_ r./) I VENT I I L_J MAX (305mm)

PER2000 T /lIB I ___ I THROUGH I I FI_ BTUH* _ _ ROOF t

M4o00

DUCTS O

TO o

OUTDOORS

i (

SQ,N. /:ql: _ _i_ :] El I_

PER2000_,/: ]AI _ S ] _ Ul:Nl f

BTUH* T ' '

(30Smm)_ C _ [ [ MAN (305mm)

imiiiiiii ii!_iiiii/iiiiii/iiii!!i!_41iiiiiii/iiiii/iiH_i/iiiii/iiiiii/iiiiii!ii!iiiiiiiii_ii_ _2

i , ' 12"MAX / 1

T I I 1 (305mm)/ T

C,RCU T,N DUCTS

DUCT _ 1 SQ IN.

I TO PER 4000

OUTDOORS BTUH*

*Minimum dimensions of 3 in. (76 mm).

NOTE: Useany of the following combinations ofopenings:

A&BO&DD&EF&G

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

for Outdoors

1 SQ IN

A03174

l l

I I I

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

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

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

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

I I

from Indoors

£c

12" I_AX (305mm)

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

UNCONFINED SPACE

6" MIN (152mm) (FRONT)0

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

L 12" MAX (305mm)

A03175

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000

Btuh of the maximum input ratings for all gas appliances installed in the space and

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

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

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

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

ACH and shall be determined per Table 2 or Equations 1 and 2. Determine the minimum required volume for each appliance in

the space and add the volumes together to get the total minimum required volume for the space.

Table 2-Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI

Z223.1-2006/NFPA 54-2006,8.3.2.2:

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

Volume - 21ft3 f I other --"_

Other ACH 000 Btu/hrJ A04002

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

Volume -15ft3_ Ifan "_

Fan ACH _000 BtuihrJ A04003

If: Io,h_ = combined input of all other than fan-assisted appliances

in Btu/hr If_,,= combined input of all fan-assisted appliances in Btu/hr ACH = air changes per hour (ACH shall not exceed 0.60.)

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

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

b. Combining spaces on same floor level. Each opening

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

appliances in the space, but not less than 100 in. 2 (0.06 m2). One opening shall commence within 12 in. (300 mm) of the ceiling and the second opening shall commence within 12 in. (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

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

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

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

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

adequate permanent ventilation openings directly to outdoors having free area of at least 1-in.2/4,000 Btuh of

total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue

gases. However, in buildings with unusually tight

- 20 -

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

Method section. Unusually tight construction is defined as

Construction with:

a. Walls and ceilings exposed to the outdoors have a

continuous, sealed vapor barrier. Openings are gasketed or sealed and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole

plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical

and gas lines, etc.

NOTE: In determining the free area of an opening, the blocking effect of the louvers, grilles, and screens must be considered. If the free area of a louver or grille design is unknown, it may be assumed that wood louvers have a 20 percent free area, and metal louvers or grilles have a 60 percent free area. Screens, when used, must not be smaller than 1/4-in. (6 mm) 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. (80 mm).

(8rnm)

(44mm)

1 3/4"

(44mm)

(8ram)

5/16"

(44mm) 1 3/4"

(44ram)1 3/4'k'_

A89014

Fig. 20 - Leveling Legs

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply 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 (l-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. (8 mm) machine bolts and nuts. NOTE: The maximum length of bolt should not exceed 1-1/2 in.

(38 mm).

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

Fig. 20.) Holes in bottom closure panel may be used as guide locations.

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

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

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

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

Step 2--Installation in Upflow and Downflow

Applications

NOTE: For downflow applications, this furnace is approved for use on combustible flooring when special base (available from manufacturer) Part No. KGASB0201ALL is used. Special base is not required when this furnace is installed on manufacturer's Coil Assembly Part No. CD5 or CK5, or Coil Box Part No. KCAKC

is used.

1. Determine application being installed from Table 3.

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

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

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

No. KCAKC is used, install as shown in Fig. 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

PLI-7 and PLI-9. Do not cut white jumper between terminals PL1-7 and PLI-11. Refer to Fig. 32 for location of jumper. Cut

- 21 -

jumper close to connector and remove wire to avoid

short circuit.

Step 3--Installation in Horizontal Applications

FURNACE

(OR COIL CASING

WHEN USED)

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.(10 mm) all-thread rod) to desired length. Use 1 x 3/8-in.

(10 mm) fiat washers, 3/8-in. (10 mm) lock washers, and 3/8-in. (10 mm) nuts on hanger rods as shown in Fig. 25. Dimples are

provided for hole locations. (See Fig. 2.)

COMBUSTIBLE

FLOORING

SUBBASE

SHEET METAL

PLENUM

-- FLOOR -- OPENING

Fig. 22 - Furnace, Plenum, and Subbase

Installed on a Combustible Floor

FURNACE

FACTORY SUPPLIED

CASED COIL OR COIL BOX

COMBUSTIBLE --

FLOORING

A96285

Fig. 21 - Floor and Plenum Opening Dimensions

A96283

SHEET METAL

PLENUM

FLOOR

OPENING

A07586

Fig. 23 - Furnace, Plenum, and (:oil Assembly or (:oil Box

Installed on a Combustible Floor

- 22

Table 3 - Opening Dimension - In. (mm)

FURNACE

CASING

APPLICATION

WIDTH

Upflow Applications 16-5/8(422)

Downflow Applications on Non-Combustible Flooring 16-1/2(419)

17-1/2 Furnace with or without CAP,CAR, CNPV,CNRVCoil Assembly or KCAKC 16-3/4(425)

Downflow Applications on Combustible Flooring Using KGASBSubbase

(445) Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB

Subbase Furnacewith CAP,CAR,CNPV,CNRV CoilAssembly or KCAKCCoil 16-1/2(419) 20 (508)

Box

Upflow Applications 20-1/8(511) 24-3/4 (629)

Downflow Applications on Non-Combustible Flooring 20 (508) 19-5/8 (498)

21 Furnace with or without CAP,CAR,CNPV,CNRVCoil Assembly or KCAKC 20-1/4(514) 20-3/8 (518)

Downflow Applications on Combustible Flooring Using KGASBSubbase

(533) Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB

Subbase Furnacewith CAP,CAR,CNPV,CNRV CoilAssembly or KCAKCCoil 20 (508) 20 (508)

Box

Upflow Applications 23-5/8(600) 24-3/4 (629)

Downflow Applications on Non-Combustible Flooring 23-1/2(597) 19-5/8(498)

24-1/2 Furnacewith or without CAP,CAR, CNPV,CNRVCoil Assembly or KCAKC 23-3/4(603) 20-3/8 (518)

Downflow Applications on Combustible Flooring Using KGASBSubbase

(622) Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB

Subbase Furnacewith CAP,CAR,CNPV,CNRV CoilAssembly or KCAKCCoil 23-1/2(597) 20 (508)

Box

PLENUM OPENING

A B

16(406) 24-1/8 (613)

15-7/8(403) 19 (483)

15-1/8(384) 19 (483)

15-1/2(394) 19 (483)

19-1/2(495) 24-1/8 (613) 19-3/8(492) 19 (483)

18-5/8(473) 19 (483)

19(483) 19 (483)

23 (584) 24-1/8 (613)

22-7/8 (581) 19 (483)

22-1/8 (562) 19 (483)

22-1/2 (572) 19 (483)

FLOOR OPENING

24-3/4 (629)

19-5/8 (498)

20-3/8 (518)

DISCHARGE DUCT FLANGE

YES

210 DEG.

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 Guidelines reference tables available from your local

distributor. The duct system should be sized to handle the required system design CFM at the design static pressure.

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

furnace, the return air 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. (25 mm) clearance from combustible materials to

supply air ductwork for a distance of 36-in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for

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

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

such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall

prevent leaks. DUCTWORK ACOUSTICAL TREATMENT

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

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

latest edition of SMACNA construction 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. (19 mm) 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.

- 23 -

3-IN. (76 mm) MINIMUM CLEARANCE TO ___ COMBUSTION-AIR INTAKE IS REQUIRED_

_ (NON-DIRECT VENT/1 -PIPE

APPLiCATiON,)

COMBUSTION-AIR INTAKE (NON-DIRECT VEN%

CATION)

COMBUSTION-AIR PiPE

DIRECT VENT/2-PIPE

,,ALL SIZES)

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

ANGLE

IRON OR EQL

(B)

(A) ROD LOCATION

USING DIMPLE LOCATORS

(SEE DIMENSIONAL DWG FOR

LOCATIONS)

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

3/8-1N.HEX NI

& WASHER (4)

REQD PER ROD

NOTES:

5 3/4" (146 mm)

(B) ALTERNATE SUPPORT

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

1. A 1-in. (25.4 mm) 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,

ALTERNATE SUPPORT

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

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

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

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

A05054

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.

- 24 -

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.

Step 5--Filter Arrangement

Table 4 - Filter Information

AIR FILTER LOCATED IN BLOWER COMPARTMENT

FURNACE

CASING

WIDTH

IN (mm)

17 1/2

(445)

21 (533)

24 1/2

(622)

*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.

FILTER SIZE - IN (mm)

Side Return?*

(1) 16X25X3/4 (1) 16X25 X3/4 Washable (406 X 635 X 19) (406 X 635 X 19)

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

(1or 2)16 X 25 X 3/4 (1) 24 X 25 X 3/4 Washable

(406 X 635 X 19) (610 X 635 X 19)

Bottom Return*

FILTER

TYPE

FILTER

FI LTER RETAINER

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.

If a factory-supplied external Filter/Media cabinet is provided, instructions for its application, assembly, and installation are packaged with the cabinet. The Filter/Media cabinet can be used

with a factory-specified washable filter or a factory-specified high-efficiency disposable filter (see cabinet instructions).

There are provisions for an internal filter rack in these furnaces. A filter is not provided.

A field-supplied accessory washable filter is available from your distributor.

A field-supplied accessory filter rack or media cabinet may be used.

Refer to instruction supplied with media cabinet for assembly and installation options.

Refer to the instructions supplied with the external filter rack for assembly and installation options.

A08587

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.

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.

If installing the filter in the furnace blower compartment, determine location for filter and relocate filter retaining wire, if

necessary. See Table 4 to determine correct filter size for desired filter location. Table 4 indicates filter size and location for this

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

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.

- 25 -

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.

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

INSTALL FIELD-SUPPLIED FILTER FILLER STRIP UNDER FILTER.

21-iN. (533mm) WiDE CASINGS ONLY:

SUPPORT RODS (3) EXTEND 1/4" (6mm) ON

EACH SIDE OF FILTER AND REST ON CASING FLANGE

'\ ", '241j2,

! I

| I t

PANEL

Fig. 28 - Removing Bottom Closure Panel

BOTTOM CLOSURE PANEL

A93047

FILTER

SUPPORT

Fig. 27 - Bottom Filter Arrangement

Step 7--Gas Piping

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

States. Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction.

Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 5 for recommended gas pipe sizing. Risers must be used to connect to furnace and to

meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. (1.8 M) Joint

compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.

RETAINER

A08605

Table 5 - Maximum Capacity of Pipe*

NOMINAL INTERNAL LENGTH OF PIPE - FT. (M)

IRON PIPE DIA.

SIZE 10 20 30 40 50

IN. (MM) IN. (MM) (3,0) (6,0) (9.1) (12,1) (15,2)

1/2 (12.7) (158) 175 120 97 82 73

:3/4 (19.0) (20.9) 360 250 200 170 151

1 (25.4) (26.6) 680 465 375 320 285

1-1/4 1.380

(31.8) (35.0) 1400 950 770 660 580

1-1/2 1,610

(:38.1) (40.9) 2100 1460 1180 990 900

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

Chapter 6 NFPA 54/ANSI Z223.1 2006.

0,622

0,824

1.049

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. (51 mm) outside furnace casing.

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

Install a sediment trap in riser leading to furnace. Trap can be installed by connecting a tee to riser leading to furnace so straight-through section of tee is vertical. Then connect a capped

- 26 -

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.

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. (1.8 M) of furnace. A 1/8-in. (3

mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply

connection to furnace and downstream of manual shutoff valve. Gas line grommet (factory-supplied loose parts bag) should be

used when installing gas piping. Gas line entry hole filler plug should be installed in unused gas line entry hole. (See Fig. 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. 57.) 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 OFE

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.

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.

GAS SUPPLY

MANUAL _/ II

v ULv oFF

A93324

Fig. 29 - Typical Gas Pipe Arrangement

- 27 -

_ OMBUSTION

-AIR PIPE

)GAS

COMBUSTION-AIRPIPEGROMMET

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

CONN. HOLE

_VENT PIPE

NOTE: PIPE GROMMETS AND ENTRY HOLE FILLER

PLUGS ARE INCLUDED IN FACTORY-SUPPLIED LOOSE PARTS BAG

NOTE 2

THREE.WIRE .B,_ _ I i

HEATING-ONLY _ _ _ Ii

F'VEW' E

BLOWER DOOR SWITCH

C (_- .... _--_

0 I

2 N '

115-V FIELD- AUXILIARY O

SUPPLIED J-BOX L (_

DISCONNECT

24-V

TERMINAL

BLOCK

FURNACE

Fig. 31 - Typical Heating and Cooling Application Wiring Diagram

GAS LINE GROMMET

VENT PIPE GROMMET

Fig. 30 - Typical Gas Pipe Arrangement

.... FIELD 24-V WIRING

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

-- FACTORY 24-V WIRING

THERMOSTAT TERMINALS

I I

(_. -J I [

I [ I [

L l--_

I [ I

NOTE 1 J

NOTES: 1.

I I

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

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

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

:H_iiiiiiiiiiiii!iiiii_

iiiii]i!iiiii!iiiiiiiiiii_iii_ i!iiiiiiii]iiiiiii_!ii_

ii_iiiiiiiiiiiiiiiiiiiiiiiiiii_

CONDENSING UNIT

TWO WIRE

_(__ GAS LINE ENTRY

FACTORY 115-V WIRING

FIELD-SUPPLIED DISCONNECT

HOLE FILLER PLUG

208/230-OR 460-V THREE

PHASE

208/230-V SINGLE

PHASE

A05057

A99440

- 28

Table 6- Electrical Data

UNIT SIZE MAX UNIT

040-08 / 024040 6.1 8.4 15 040-12 / 036040 7.3 10.0 15 060-08 / 024060 6.1 8.4 15

060-12 / 036060 7.1 9.8 15 060-16 / 048060 9.5 12.8 15 080-12 / 036080 7.6 10.4 15 080-16 / 048080 10.0 13.4 15 080-20 / 060080 14.1 18.4 20 100-16 / 048100 10.2 13.5 15 100-20 / 060100 14.8 19.3 20

120-20 / 060120 14.6 19.1 20 140-20 / 060140 14.3 18.8 20

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

etc.) full load amps. Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 )ercent volta¢ _.** Time-dela is recommended

VOLTS- HERTZ-

PHASE

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

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

OPERATING

VOLTAGE RANGE

Max* Min*

127 104 127 104 127 104 127 104 127 104 127 104 127 104

127 104 127 104 127 104 127 104 127 104

AMPS

UNIT AM PACITY'I" MAX FUSE OR

MIN

WIRE

SIZE

14 14 14 14 14 14 14

12 14 12 12 12

MAX WIRE

LENGTH

FT (a):l:

44 (13.4) 37 (11.2)

44 (13.4) 38 (11.5)

29(8.8)

36 (10.9)

28(8.5)

31 (9.4)

27 (8.2) 30 (9.1) 30 (9.1) 30 (9.1)

CKT BKR AMPS**

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.

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

FIRE HAZARD

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

Do not connect aluminum wire between disconnect switch 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 70-2008 and Canadian

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

consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground.

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

parts bag) in unused power entry holes. (See Fig. 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.

ELECTRIC

DISCONNECT

SWITCH

Fig. 32 - Disconnect Switch and Furnace

A93033

POWER ENTRY HOLE FILLER PLUG (FACTORY

SUPPLIED LOOSE PARTS BAG)

- 29 -

Fig. 33 - Factory Installed J-Box Location

INS gALLED LOCATION

A05113

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,

and 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

ALTERNATE --

FIELD

LOCATION

POWER ENTRY HOLE __"_]_IU-- FILLER PLUG (FACTORY-

SUPPLIED LOOSE PARTS BAG)

11111111.0

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

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. (30.4 M) For wire lengths over 100 ft. (30.4 M), use AWG No. 16 wire.

ACCESSORIES

1. Electronic Air (.'leaner (EAC). Two quick-connect terminals marked EAC-1 and EAC-2 are provided for EAC connection. (See Fig. 36.) These

terminals are energized with 115-v (1.0-amp maximum) during blower motor operation.

FACTORY iNSTALLED

LOCATION _. POWER ENTRY HOLE 10[iiii"_) _-- FILLER PLUG (FACTORY-

SUPPLIED LOOSE PARTS BAG)

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

Fig. 34 - Relocating J-Box

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 Thermidistaff M, Zone Controller or

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

proper connection.

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

(COM 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.

A05058

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.

- 30 -

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

ASTM

SPECIFICATION SOLVENT CEMENT

(MARKED ON MATERIAL PIPE FITTINGS AND PRIMERS DESCRIPTION

MATERIAL)

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

D2235 ForABS -- -- Solvent Cement For ABS D2241 PVC Pipe -- -- SDR-21 & SDR-26

D2466 PVC -- Fittings -- Schedule-40 D2468 ABS -- Fittings -- Schedule-40 D2564 For PVC -- -- Solvent Cement For PVC

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

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

F493 For CPVC -- -- Solvent Cement For CPVC

F628 ABS Pipe -- -- IPS sizes F656 For PVC -- -- Primer For PVC

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

Cellular Core DWV at Schedule-40

-31 -

++o

o M_

_z m

d_-> _- _ z

Zz u _- +_

_ss _ .....

"_ PRINTED C IRC IUT BO ARD

8# 3Z ON |

I-

[

Fig. 35 - Wiring Diagram

S:_:_ _-_ 0-!1"

uo _> z

- _ _ _ __

<_ _88_=_o_oo < _

o u

caw

_8o

oo_%<_z _

_-+mm_oS_ <<_z_+_>>_uuu

=_-'_o_ _ _

A03229

- 32 -

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/I-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 combustion-air 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 Z223.1-2006/NFPA 54-2006 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 Z223.1-2006/NFPA 54-2006 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.

For Canadian installations, refer to Page 1 for instructions. In direct vent (2-pipe) systems, combustion air and vent pipes

must terminate together in same atmospheric pressure zone, either through roof or sidewall (roof termination preferred), using

accessory termination kit. See Table 8 for required clearances.

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

CARBON MONOXIDE POISONING HAZARD

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

All combustion-air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 44 for direct vent (2-pipe) system and Fig. 45 for non-direct vent 0-pipe) system.

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

applicable) and vent pipes. Each furnace must have its own set of

combustion-air and vent pipes and be terminated individually, as shown in Fig. 44 for Direct Vent (2-Pipe) system and Fig. 45 for Non-Direct Vent (1-Pipe) system.

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

Other gas appliances with their own venting system may also use

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

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

from contaminating the combustion air of other gas appliances.

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

unit operation. When vent pipe is exposed to temperatures below freezing,

such as when it passes through an unheated space or when a chimney is used as a raceway, pipe must be insulated as shown in Table 10 with Armaflex-type insulation.

Furnace combustion air and vent pipe connections are sized for 2-in. (51 mm) pipe. Any pipe size change should be made outside furnace casing in vertical pipe. The transition has to be made as close to the furnace as reasonably possible.

COMBUSTION AIR PIPE General

Furnace combustion-air connection must be attached as shown in Fig. 39. Combustion-air intake housing plug may need to be

relocated in some applications.

- 33 -

BLOWER OFF-DELAY

24-V THERMOSTAT

TERMINALS

TWINNING AND/OR COMPONENT TEST

TERMINAL

BLOWER OFF DELAY

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

3-AMP FUSE

DIAGNOSTIC LIGHT

LEDOPERATION & sEc2sEcl II!IIW

115-VAC(L2)

CONNECTIONS

Joe €DD

............ )I-.. SPARE-2 FAN \ VOLTAGECONNECTION IGNITER & INDUCER

s\ / \ CO..EOTO

For Non-Direct Vent (l-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. 39.) 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 be cemented except attachment of the combustion-air pipe to the inlet housing connection, since it may be necessary to remove pipe for servicing.

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

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

elbow using RTV or by cementing, as shown in Fig. 40. For 120,000 Btuh size units only: separate the 2 halves of

/ EAC-1 TERMINAL

_J (115-VAC 1.0AMP MAX.)

Fig. 36 - Furnace Control

PL1 -LOW VOLTAGE MAIN HARNESS CONNECTOR

11 VACtL1!UNE PL2HOTSURFAOE

perforated disk assembly and use only the shouldered disk half.

2. Determine the length of straight portion of combustion-air inlet pipe from Fig. 40.

3. Cut field-supplied 2-in. (51 mm) diameter PVC pipe to length as determined per Fig. 40.

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

shown in Fig. 40.

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

System ONLY)

1. Using Table 11, individually determine the diameter of the combustion and vent pipe allowed. If different, pick the

larger of these two diameters and use this diameter for

both combustion-air and vent pipe.

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

disturbance, or flame sense lockout may occur.

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

to be counted.) NOTE: The 60,000 model includes an inducer outlet restrictor in the loose parts bag that must be installed for certain vent system

configurations. Referring to Table 12, locate the altitude for the installation. Discard the restrictor if the vent length is greater

than that shown in Table 12; install the restrictor if the vent length is less than or equal. Refer to Fig. 37 for positioning of the restrictor in the inducer outlet. The restrictor is to be trapped between the vent pipe and inducer outlet. Certain installations

A02142

- 34 -

may require removal of the coupling for easier installation of the inducer outlet restrictor.

UNIT MAY NOT OPERATE

Failure to follow this caution may result in incomplete combustion, flame disturbance, or flame sense lockout.

When installing combustion air and vent system of short pipe length, the smallest allowable pipe diameter must be used.

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

COUPLING MAY BE REMOVED

INSTALLATION

INDUCER OUTLET

RESTRICTOR

Fig. 37 - Outlet Restrictor Installation

60,000 BTUH Models only. See Table 12.

A09328

Fig. 38 - Illustration of an Installed Outlet Restrictor

60,000 BTUH Models only. See Table 12.

A09329

P C1_ toan o_ corner

Q Cl_ to _ _nslde¢o_

J _)¢e to _-m_ _ st_p]y ;ird_ to _idtr_ o_ 12 inches (30 cm) for applieances > 10,000 Btuh(3 kW)

_ _:_111_n _ Ir_ _ _/_ al_l_ and < 100,000 Btuh(3OkW), 36 inches (91cm) for

appliances > 100,000 Btuh(3OkW)

ARF.A _ERE TERMI_ |S _ PE_D

Table 8 - Direct Vent Termination Clearance

- 36 -

A08600

25-24-65-2

[_ VENTTERMINAL \\ _ AIR SUPPLY INLET

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

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

anticipated snow level

B Clearance to a window or door that may be opened 6 inches (15 cm) for appliances _< 10,000 Btuh (3 kW) 4 feet(1.2 m) below or to the side of the opening, t foot (30 cm

C Clearance to a permanently closed window

D Vertical clearance to a ventilated soffit located above the

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

E Clearance to an unventilated soffit

F Clearance to an outside corner

G Clearance to an inside corner

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

electrical meter or gas service regulator assembly assembly assembly

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

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

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

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

L Clearance under a veranda, perch, deck, or balcony t 2 inches(30 cm) +

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

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

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

vent, or other appliances direct vent intake or exhaust.

O Clearance from a plumbing vent stack

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

driveway located on public property

(1.) In accordance with the current CSA B t49.1, Natural Gas and Propane Installation Code (2.) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

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

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA Bt 49.1, clearances shall be in accordance with local installation codes and the requirements of the gas supplier and the Manufacturer's installation instructions.

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

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

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

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

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

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

appliances > 100,000 Btuh (30 kW)

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

AREA WHERE TERMINAL IS NOT PERMITED

7 feet (2.13m)

A08601

Table 9 - Other than Direct Vent Termination Clearance

- 37 -

Table 10 - Maximum Allowable Exposed Vent Pipe Length - Ft. (M) With and Without Insulation

in Winter Design Temperature Ambient*

FURNACE SIZE TEMPERATURE DIAMETER INSULATION THICKER INSULATIONI-

040

060 0 (-18) 2 (51) 35 (11) 70 (21)

080

100

120

140

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

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

°F (°C) IN (mm) FT (a) FT (a)

20 (-7) 1.5 (38) 51 (16) 70 (21) 0 (-18) 1.5 (38) 28 (9) 70 (21)

-20 (-29) 1.5 (38) 16 (5) 70 (21)

20 (-7) 2 (51) 45 (14) 70 (21) 0 (-18) 2 (51) 22 (7) 70 (21)

-20 (-29) 2 (51) 10 (3) 58 (18)

20 (-7) 2 (51) 65 (20) 70 (21)

-20 (-29) 2 (51) 20 (6) 70 (21)

20 (-7) 2 (51) 55 (17) 55 (17) 0 (-18) 2 (51) 48 (15) 55 (17)

-20 (-29) 2 (51) 30 (9) 55 (17)

20 (-7) 2.5 (64) 70 (21) 70 (21) 0 (-18) 2.5 (64) 47 (14) 70 (21)

-20 (-29) 2.5 (64) 28 (9) 70 (21)

20 (-7) 2.5 (64) 40 (12) 40 (12) 0 (-18) 2.5 (64) 40 (12) 40 (12)

-20 (-29) 2.5 (64) 38 (12) 40 (12)

20 (-7) 3 (76) 70 (21) 70 (21) 0 (-18) 3 (76) 50 (15) 70 (21)

-20 (-29) 3 (76) 28 (9) 70 (21)

20 (-7) 3 (76) 70 (21) 70 (21) 0 (-18) 3 (76) 61 (19) 70 (21)

-20 (-29) 3 (76) 37 (11) 70 (21)

20 (-7) 4 (102) 70 (21) 70 (21) 0 (-18) 4 (102) 48 (15) 70 (21)

-20 (-29) 4 (102) 23 (7) 70 (21)

20 (-7) 3 (76) 60 (18) 60 (18) 0 (-18) 3 (76) 60 (18) 60 (18)

-20 (-29) 3 (76) 44 (13) 60 (18)

20 (-7) 4 (102) 70 (21) 70 (21) 0 (-18) 4 (102) 57 (17) 70 (21)

-20 (-29) 4 (102) 30 (9) 70 (21)

in unconditioned space cannot exceed total allowable pipe

length as specified in Table 11. 1-Insulationthickness based on Rvalue of 3.5 per in.

3. 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. 39 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. 39.

5. Drill a 1/8-in. (3 mm) hole in 2-in. (51 mm), combustion air pipe using the hole in intake housing as a guide.

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

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

NOTE: Do not attach combustion air intake pipe permanently to combustion air intake housing since it may be necessary to 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. (3 mm) hole in fitting,

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

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

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

combustion box. If use of this drain connection is desired, drill out fitting's tap plug with 3/16-in. (5 mm) drill and connect a

field-supplied 3/8-in. (10 mm) tube. This tube should be routed to open condensate drain for furnace and A/C (if used), and should

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

combustion air intake may be a result of improper termination. Ensure combustion air pipe termination is similar to those as shown in Fig. 42 so that it will not be susceptible to area where light snow or others sources of moisture could be pulled in.

- 38 -

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

AIR

COMBUSTION-AIR _ COMBUSTION-AIR

UPFLOW

NOTE: Select ! vent pipe connection and

1 combustion-air pipe connection.

VENT

COMBUSTION-

AIR

AIR AIR

FLOW

DOWNFLOW

z COMBUSTION-

VENT PIPE

General

Furnace vent connection must be attached as shown in Fig. 39.

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.

COMBUSTION-

AIR

VENT

HORIZONTAL-LEFT DISCHARGE

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

opening faces down.

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

opening faces sideways.

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

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

HORIZONTAL-RIGHT DISCHARGE

AIR

VENT

Fig. 39 - Combustion-Air and Vent Pipe Connections

_ F!ILL'1_5SUmF2)L_)ED'_ FIELD-SUPPLIED

PVC 90° ELBOWJ 2-IN. (51 mm) DIA.

_" PVC PIPE

A05092

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

The minimum vent pipe length for these furnaces is 5 ft. (1.5 M)

Short pipe lengths (5 - 8 ft. (1.5 - 2.4M)) may discharge

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

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

Attachment of Vent Pipe

1. Determine vent pipe diameter and maximum pipe lengths using Table 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. 44 and Fig. 45 are not be counted).

2. Determine location of vent pipe connection to inducer housing as shown in Fig. 41 for application.

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

connection. Tighten clamp.

(FACTORY-SUPPLIED IN

DISC

LOOSE PARTS BAG)

Length of Straight Pipe Portion of

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

CASING WIDTH A

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

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

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

Fig. 40 - Combustion-Air Inlet Pipe Assembly

A96211

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.

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. (51

mm) diameter vent pipe are clean and dry. Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps)

onto inducer housing connection. Insert the 2-in. (51 mm) diameter vent pipe through the elastomeric (rubber)

coupling and fully into inducer housing connection until it touches a stop inside the inducer housing outlet. Tighten

the screws on both clamps to 15-in-lb. of torque, pipe to inducer housing. Tighten the clamp screws to 15 in.-lb, of

torque.

NOTE: Starting at furnace, slope vent pipe a minimum of 1/4-in. (6 mm) per linear ft with no sags between hangers.

- 39 -

ALTITUDE UNIT SIZE

FT (i) (BTUH)

TERMINATION

40,000

60,000

80,000

O to 2000 (O to 610)

100,000

120,000

140,000

ALTITUDE UNIT SIZE

FT (i) (BTUH) TERMINATION

40,000

60,000

80,000

2001 to 3000

100,000

(610 to 914)

120,000

140,000

See notes at end of table.

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

DIRECT VENT (2-PIPE) ONLY VENT (1-PIPE) NUMBER OF 90 ° ELBOWS

TYPE 1 2 3 4 5 6

PIPE DIA

IN. (mm)*

1 (25)

2 Pipe or 2-in.

(51 mm)

Concentric

1-1/2 (38)

2 (51)

2 Pipe or 2-in.

(51 mm)

Concentric

1-1/2 (38)

2 (51)

1-1/2 (38)

2 Pipe or 2-in.

(51 mm)

Concentric

2 (51)

2-1/2 (64)

2 (51)

2 Pipe or 3-in.

(76 mm)

Concentric

2-1/2 (64)

3 (76)

2-1/2 (64)

one disk

2 Pipe or 3-in.

(76 mm)

Concentric

3 (76)1-

3 (76) 1- no disk

2-1/2 (64)

one disk

2 Pipe or 3-in.

(76 mm)

Concentric

3 (76)1-

3 (76) 1- no disk

4 (102) 1-no

disk

DIRECT VENT (2-PIPE) ONLY NUMBER OF 90 ° ELBOWS

TYPE 1 2 3 4 5 6

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

3 (76)1- no disk

4 (102)1- no

disk

3 (76) one

disk1-

3 (76)1- no disk

4 (102)1- no

disk

NON-DIRECT

ONLY

PIPE DIA

IN. (mm)*

1 (25) (1.5)

1-1/2 (38) (21.3)

2 (51) (21.3)

1-1/2 (38) (6.1)

2 (51) (21.3)

1-1/2 (38) (3.0)

2 (51) (16.8)

2-1/2 (64) (21.3)

2 (51) (1.5)

2-1/2 (64) (12.2)

3 (76) (21.3)

2-1/2 (64) (3.0)

NA (13.7)

3 (76)1- (21.3)

NA (1.5)

NA (12.1)

NA (18.3)

NA (21.3)

NON-DIRECT

VENT (1-PIPE)

ONLY

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

4 (102)1- no disk

NA NA NA NA NA

70 65 60 60 55

(21.3) (19.8) (18.3) (18.3) (16.8)

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

15 10 5

(4.6) (3.0) (1.5) NA NA

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

NA NA NA NA NA

50 35 30 30 20

(15.2) (10.7) (9.1) (9.1) (6.1)

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

NA NA NA NA NA

30 20 20 10

(9.1) (6.1) (6.1) (3.0) NA

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

NA NA NA NA NA

40 35 30 25 20

(12.2) (10.7) (9.1) (7.6) (6.1)

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

NA NA NA NA NA

35 30 25 20 15

(10.6) (9.1) (7.6) (6.1) (4.6)

56 52 48 44 40

(17.0) (15.8) (14.6) (13.4) (12.2)

70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3)

67 62

(20.4) (18.9)

70 70

(21.3) (21.3)

17 12

(5.2) (3.7)

70 67

(21.3) (20.4)

49 44

(14.9) (13.4)

70 70

(21.3) (21.3)

35 26

(10.7) (7.9)

70 70

(21.3) (21.3)

14 9

(4.3) (2.7)

63 62

(19.2) (18.9)

70 70

(21.3) (21.3)

70 70

(21.3) (21.3)

20 15

(6.1) (4.6)

39 35

(11.8) (10.6)

70 70

(21.3) (21.3)

57 52 52 47

(17.4) (15.8) (15.8) (14.3)

70 70 70 70

(21.3) (21.3) (21.3) (21.3)

(2.1) NA NA NA

66 61 61 61

(20.1) (18.6) (18.6) (18.6)

30 25 25 15

(9.1) (7.6) (7.6) (4.6)

70 70 70 70

(21.3) (21.3) (21.3) (21.3)

16 16 6

(4.9) (4.9) (1.8) NA

70 70 66 61

(21.3) (21.3) (20.1) (18.6)

NA NA NA NA

62 61

(18.9) (18.6)

63 56

(19.2) (17.1)

70 70

(21.3) (21.3)

10 5

(3.0) (1.5)

31 27

(11.9) (8.2)

70 70

(21.3) (21.3)

61 61

(18.6) (18.6)

50 43

(15.2) (13.1)

70 70

(21.3) (21.3)

NA NA

(7.0)

(21.3)

(5.8)

(21.3)

- 40 -

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

ALTITUDE UNIT SIZE

FT (i) (BTUH)

40,000

60,000

80,000

3001 to 4000 (914 to 1219)

ALTITUDE UNIT SIZE

FT (M) (BTUH) TERMINATION

4001 to 50005 (1219 to 1524)

See notes at end of table.

100,000

120,000

140,000

40,000

60,000

80,000

100,000

120,000

140,000

TERMINATION

DIRECT VENT (2-PIPE) ONLY VENT (1-PIPE) NUMBER OF 90 ° ELBOWS

TYPE 1 2 3 4 5 6

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

41- no disk

2 Pipe or 3-in.

(76 mm)

Concentric

DIRECT VENT (2-PIPE) ONLY VENT (1-PIPE) NUMBER OF 90 ° ELBOWS

TYPE 1 2 3 4 5 6

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

PIPE DIA -

IN (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1- no disk

4 (102)1- no

disk

3 (76) one

disk1-

3 (76)1- no disk

4 (102)1- no

disk

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

no disk

4 (102)1- no

disk

3 (76)1- no disk

4 (102)1- no

disk

NON-DIRECT

ONLY

PIPE DIA -

IN (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

4 (102) 1-no disk

NON-DIRECT

ONLY

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

4 (102)1- no disk

64 59 54 49 48 43

(19.5) (18.0) (16.5) (14.9) (14.6) (13.1)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

16 11 6

(4.9) (3.4) (1.8) NA NA NA

68 63 62 57 57 56

(20.7) (19.2) (18.9) (17.4) (17.4) (17.1 )

46 41 28 23 22 13

(14.0) (12.5) (8.5) (7.0) (6.7) (4.0)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

33 24 15 14 5

(10.1) (7.3) (4.6) (4.3) (1.5) NA

70 70 70 66 61 56

(21.3) (21.3) (21.3) (20.1) (18.6) (17.1)

65 58 51 44 38 31

(19.8) (17.7) (15.5) (13.4) (11.6) (9.4)

59 59 58 57 57 56

(18.0) (18.0) (17.7) (17.4) (17.4) (17.1)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

11 6

(3.4) (1.8) NA NA NA NA

30 26 22 18 14 10

(9.1) (7.9) (6.7) (5.5) (4.3) (3.0)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

60 55 50 45 44 39

(18.3) (16.8) (15.2) (13.7) (13.4) (11.9)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

15 10 5

(4.6) (3.0) (1.5) NA NA NA

64 59 58 53 52 52

(19.5) (18.0) (17.7) (16.2) (15.8) (15.8)

44 39 26 21 20 11

(13.4) (11.9) (7.9) (6.4) (6.1) (3.4)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

31 22 13 12

(9.4) (6.7) (4.0) (3.7) NA NA

70 70 67 62 57 52

(21.3) (21.3) (20.4) (18.9) (17.4) (15.8)

53 46 40 33 26 20

(16.2) (14.0) (12.2) (10.1) (7.9) (6.1)

56 55 54 53 52 52

(17.1) (16.8) (16.5) (16.2) (15.8) (15.8)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

21 17 13 9 5

(6.4) (5.1) (3.9) (2.7) (1.5) NA

69 64 59 54 49 44

(21.0) (19.5) (17.9) (16.4) (15.0) (13.4)

- 41 -

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

ALTITUDE UNIT SIZE

FT (i) (BTUH)

40,000

60,000

80,000

5001 to 60005 (1524 to 1829)

ALTITUDE UNIT SIZE

FT (i) (BTUH) TERMINATION

6001 to 70005 (1829 to 2134)

See notes at end of table.

100,000

120,000

140,000

40,000

60,000

80,000

100,000

120,000

140,000 (76 mm) (5.1) NA NA

TERMINATION

DIRECT VENT (2-PIPE) ONLY VENT (1-PIPE) NUMBER OF 90 ° ELBOWS

TYPE 1 2 3 4 5 6

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

DIRECT VENT (2-PIPE) ONLY VENT (1-PIPE) NUMBER OF 90 ° ELBOWS

TYPE 1 2 3 4 5 6

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in. 17

Concentric

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

no disk

4 (102)1- no

disk

3 (76)1- no disk

4 (102)1- no

disk

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

no disk

4 (102)1- no

disk

NON-DIRECT

ONLY

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

4 (102)1- no disk

NON-DIRECT

ONLY

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

57 52 47 42 40 35

(17.4) (15.8) (14.3) (12.8) (12.2) (10.7)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

14 9

(4.3) (2.7) NA NA NA NA

60 55 54 49 48 47

(18.3) (16.8) (16.5) (14.9) (14.6) (14.3)

41 36 23 18 17 8

(12.5) (11.0) (7.0) (5.5) (5.2) (2.4)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

29 21 12 11

(8.8) (6.4) (3.7) (3.4) NA NA

70 67 62 57 52 47

(21.3) (20.4) (18.9) (17.4) (15.8) (14.3)

42 35 29 22 15 9

(12.8) (10.7) (8.8) (6.7) (4.6) (2.7)

53 52 50 49 48 47

(16.2) (15.8) (15.2) (14.9) (14.6) (14.3)

70 70 70 70 70 70

(21.3) (21.3) (21.3) (21.3) (21.3) (21.3)

12 8

(3.6) (2.4) NA NA NA NA

42 37 32 27 22 17

(12.8) (11.2) (9.7) (8.2) (6.7) (5.1)

53 48 43 38 37 32

(16.2) (14.6) (13.1 (11.6) (11.3) (9.8)

70 70 68 67 66 64

(21.3) (21.3) (20.7) (20.4) (20.1) (19.5)

13 8

(4.0) (2.4) NA NA NA NA

57 52 50 45 44 43

(17.4) (15.8) (15.2) (13.7) (13.4) (13.1)

38 33 21 16 15 6

(11.6) (10.1) (6.4) (4.9) (4.6) (1.8)

70 70 68 67 66 64

(21.3) (21.3) (20.7) (20.4) (20.1) (19.5)

27 19 10 9

(8.2) (5.8) (3.0) (2.7) NA NA

68 63 58 53 48 43

(20.7) (19.2) (17.7) (16.2) (14.6) (13.1)

31 24 18 11

(9.4) (7.3) (5.5) (3.4) NA NA

49 48 47 45

(14.9) (14.6) (14.3) (13.7)

12 7

(3.6) (2.1) NA

44 43

(13.4) (13.1)

- 42 -

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

ALTITUDE UNIT SIZE NON-DIRECT

FT (i) (BTUH)

40,000

60,000

80,000

7001 to 8000:[: (2134 to 2438)

100,000

120,000

140,000

ALTITUDE UNIT SIZE

FT (i) (BTUH)

40,000

60,000

8001 to 90005 (2438to 2743)

See notes at end of table.

80,000

100,000

120,000

140,000

DIRECT VENT (2-PIPE) ONLY VENT (1-PIPE) NUMBER OF 90 ° ELBOWS

TERMINATION

TYPE 1 2 3 4 5 6

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

DIRECT VENT (2-PIPE) ONLY NUMBER OF 90° ELBOWS

TERMINATION

TYPE 1 2 3 4 5 6

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1- no disk

4 (102)1- no

disk

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1- no disk

4 (102)1- no

disk

PIPE DIA

IN. (mm)*

1-1/2 (38)

2-1/2 (64)

3 (76)1-

4 (102)1- no disk

NON-DIRECT

VENT (1-PIPE)

PIPE DIA

IN. (mm)*

1-1/2 (38)

2-1/2 (64)

3 (76)1-

41-no disk

ONLY

2 (51)

3 (76)

ONLY

2 (51)

3 (76)

49 44 39

(14.9) (13.4) (11.9)

66 65 63

(20.1) (19.8) (19.2)

12 7

(3.7) (2.1) NA

53 48 46

(16.2) (14.6) (14.0)

36 31 19

(11.0) (9.4) (5.8)

66 65 63

(20.1) (19.8) (19.2)

25 17 8

(7.6) (5.2) (2.4)

63 58 53

(19.2) (17.7) (16.2)

20 13 7

(6.1) (4.0) (2.1)

46 44 43

(14.0) (13.4) (13.1)

61 56 51

(18.6) (17.1) (15.5)

46 41 36 31 29 24

(14.0) (12.5) (11.0) (9.4) (8.8) (7.3)

62 60 58 56 55 53

(18.9) (18.3) (17.7) (17.1) (16.8) (16.2)

11 6

(3.4) (1.8) NA NA NA NA

49 44 42 37 35 34

(14.9) (13.4) (12.8) (11.3) (10.7) (10.4)

33 28 17 12 10

(10.1) (8.5) (5.2) (3.7) (3.0) NA

62 60 58 56 55 53

(18.9) (18.3) (17.7) (17.1) (16.8) (16.2)

23 15 7 5

(7.0) (4.6) (2.1) (1.5) NA NA

59 54 49 44 39 34

(18.0) (16.5) (14.9) (13.4) (11.9) (10.4)

(3.0) NA NA NA NA NA

43 41 39 37 35 34

(13.1) (12.5) (11.9) (11.3) (10.7) (10.4)

35 30 25 20 15 10

(10.7) (9.1) (7.6) (6.1) (4.6) (3.0)

34 33 28

(10.4) (10.1) (6.5)

62 60 59

(18.9) (18.3) (18.0)

NA NA NA

41 40 38

(12.5) (12.2) (11.6)

14 12

(4.3) (3.7) NA

62 60 59

(18.9) (18.3) (18.0)

(2.1) NA NA

48 43 38

(14.6) (13.1) (11.6)

NA NA NA

41 40 38

(12.5) (12.2) (11.6)

46 41 36

(14.0) (12.5) (11.0)

- 43 -

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

ALTITUDE UNIT SIZE NON-DIRECT

FT (i) (BTUH)

40,000

60,000 (51 mm) (13.7) (12.2) (11.6) (10.1) (9.4) (8.8)

9001 to 10,0005

(2743 to 3048)

* Disk usage-Unless otherwise specified, use perforated disk assembly (factory-supplied in loose parts bag). # If one disk is stated, separate 2 halves of perforated disk assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box. 1-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 wilt 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. (1.5 M) for all applications.

6. Use 3-in. (76 mm) diameter vent termination kit for installations requiring 4-in (102 mm) diameter pipe.

80,000

100,000

120,000

140,000

DIRECT VENT (2-PIPE) ONLY VENT (1-PIPE) NUMBER OF 90 ° ELBOWS

TERMINATION

TYPE

2 Pipe or 2-in.

(51 ram)

Concentric

2 Pipe or 2-in. 45 40 38 33 31 29

Concentric

2 Pipe or 2-in.

(51 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

2 Pipe or 3-in.

(76 mm)

Concentric

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

4 (102)1- no

disk

ONLY

PIPE DIA

IN. (mm)*

1-1/2 (38)

2 (51)

2-1/2 (64)

3 (76)

3 (76)1-

4 (102)1- no disk

1 2 3 4 5 6

42 37 32 27 25 20

(12.8) (11.3) (9.8) (8.2) (7.6) (6.1)

57 55 53 51 49 47

(17.4) (16.8) (16.2) (15.5) (14.9) (14.3)

30 25 14 9 7

(9.1) (7.6) (4.3) (2.7) (2.1)

57 55 53 51 49 47

(17.4) (16.8) (16.2) (15.5) (14.9) (14.3)

21 13 5

(6.4) (4.0) (1.5) NA NA NA

54 49 44 39 34 29

(16.5) (14.9) (13.4) (11.9) (10.4) (8.8)

39 37 35 33 31 29

(11.9) (11.3) (10.7) (10.1) (9.4) (8.8)

10 5

(3.0) (1.5) NA NA NA NA

Table 12 - Vent Length for Outlet Restrictor Usage (60,000 btu model only) - Ft. (M)_

ALTITUDE - FT. (M)

0 - 2000 (0 - 610)

2001 - 3000 (610 - 914)

3001 - 4000 (914 - 1219)

4001 - 5000 (1219 - 1524) 5001 - 6000 (1524 - 1829) 60,000

6001 - 7000 (1829 - 2134) 7001 - 8000 (2134 - 2438)

8001 - 9000 (2438 - 2743)

9001 - 10000 (2743 - 3048)

:Discard outlet restrictor if vent lengths or elbows exceed the

for proper installation.

UNIT SIZE

DIRECT VENT

(2-PIPE)

PIPE DIA.

(IN / mm)

2-in. (51) 2-in. (51)

2-in. (51) 2-in. (51) 2-in. (51)

2-in. (51) 2-in. (51)

above table Discard restrictor if usinc

NON-DIRECT

VENT

(1 -PIPE ONLY)

PIPE DIA.

(IN / mm)

2-in. (51) 2-in. (51)

2-in. (51) 2-in. (51) 2-in. (51)

2-in. (51) 2-in. (51)

NO. OF 90° ELBOWS

28 (8.5) 24 (7.3)

21 (6.4)

17 (5.1) 14 (4.2)

10 (3)

6(1.8)

11/2-in. (38mm) diameter pipe. See Fig..3"7 and .38 and

20 (6) 15 (4.2) 10 (3) iii

17(5.1) 12(3.6) 7(2.1)

13t39/ 8(2.4) ....

10 (3) 5 (1.5)

6(1.8) ....

iiiiiii!i!i!j_!_i!_i!:!ii,iiii

iiiiiiii_'_iiiiiiiiiii_iiiiiliii!iiiiiiiiiiii!iiiiiiiiiiiiiiiiiiiiiiiiiiiii_iiiiiiiiiiiiiiiliiiiiiiiiii!

- 44 -

_ L--_--_--_--_mFURNACE L__ :_J_]__

HORIZONTAL NOT IN ii I E_

SECTION

EDI

TRANSITION IN

VERTICAL SECTION

Fig. 41 - Combustion-Air and Vent Pipe Diameter

Transition Location and Elbow Configuration

A93034

COMBUSTION AIR PIPE (DIRECT VENT

/2-PIPE)

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1-PIPE) "_

VENT PIPE

COMBUSTION AIR

3/8 ID TUBE --

D31L 6

TRAP JI

TO OPEN

DRAIN

INTAKE HOUSING BURNER

\ ./- BO×

_'_ r_ _ [q COMBUSTION-AIR

_ --__ ............j_# VENT/2 PIPE)

i- _ [ PIPE (NON-DIRECT

IN I ,o_ [ o

_J [--_ r i _"_ PIPE (DIRECT

_ COMBUSTION-AIR

_ _ _ VENT/I-PIPE)

Fig. 42 - Air Intake Housing Plug Fitting Drain

-._v--_ 12" MIN ---_

(305 mm_ _

_ :_i':;[E::::::::'"_'COM'BUS TIO N AIR

A05093

PIPE (DIRECT

VENT/2-PI PE)

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1 -PIPE)

VERTICAL TO ROOF VERTICAL TO SIDEWALL

HORIZONTAL TO ROOF

COMBUSTION AIR

PIPE (DIRECT VENT

/2-PIPE)

====================================

:__v---- 12" MIN,-----_

NOTE: A 12-in. (305 mm) minimum offset pipe section is recommended with

short (5-ft. to 8-ft (1.5 to 2.4 M)) vent systems. This recommendation is

to reduce excessive condensate droplets from exiting the vent pipe

HORIZONTAL TO SIDEWALL

f VENT PIPE

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1 -PIPE)

(305 mm)

Fig. 43 - Short Vent (5 to 8 ft. (1.5 to 2.4M)) System

VENT PIPE

A05094

- 45 -

Roo_ _ rmlnafion (Preferred)

Con c_mtric V#nt and Combustion Air

Roo f T#rruination (preferred} ............

Vertical separation between combustion

air and vent

¢4

...................Ix,0ZI.

w 24 in above roof of

Fig. 44 - Combustion Air and Vent Pipe Termination for Direct Vent (2-pipe) System

A05090

Roof Termination (Preferred)

Maintain 12 in (305ram) " ""-

above highest anticipated

snow level maximum of ' ,

24 in (610ram) abov_ roof ..

'\\

Side wall termination with 2 elbows (preferred)

.... I"'-.

.....:i ......}_-:,i

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

Abandoned masonry used as raceway

(per code)

I overhang or roof / whichever is greater

Maintain 12 in (3O5mm)

above highest anticipated

minimu m clearance s_qow level or grade

"_whichever is greater

Sidewall Termination

with Shaight Pipe (preferred)

above highestanticip ....

eEor glaoe

A05091

Fig. 45 - Vent Pipe Termination for Non-Direct Vent (1-pipe) System

- 46 -

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. (51 mm) diameter by 12-in. (305 mm) long). This pipe has a built-in channel to assist vent condensate disposal. When this vent extension pipe is supplied, it

MUST be used to connect the field vent pipe to furnace inducer housing on ALL upflow and downflow applications.

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

Installation Guidelines for Combustion Air Pipe and Vent

Pipe

It is recommended that all pipes be cut, prepared, and pre-assembled before permanently cementing any joint.

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

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

3. Deburr inside and outside of pipe.

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

5. Clean and dry all surfaces to be joined.

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

7. After pipes have been cut and preassembled, apply generous layer of cement primer to pipe fitting socket and

end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fitting socket (over primer).

Apply cement in a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat.

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

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

made joint.

10. Handle pipe joints carefully until cement sets.

11. Horizontal portions of the venting system shall be supported to prevent sagging support. Support combustion

air piping (if applicable) and vent piping a minimum of every 5 ft. (1.5 M) (3 ft. (.9 M) for SDR-21 or -26 PVC)

using perforated metal hanging strap.

12. Slope combustion air piping (if applicable) and vent piping downward towards furnace a minimum of 1/4 in. (6 mm)

per linear ft with no sags between hangers.

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

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

through roof or sidewall.

EXAMPLE: An 080-12 size furnace located in Indianapolis, elevation

650 ft. (198 M) above sea level, could be installed as either a direct vent/2-pipe system that requires 3 elbows and 32 ft. (9.7 M) of vent pipe, along with 5 elbows and

34 ft. (10.3 M) of combustion-air pipe OR a non-direct vent/I-pipe system that requires 3 elbows and 32 ft. (9.7

M) vent pipe. For a direct vent/2-pipe system, Table 11 indicates this

application would allow a 2-in. (51 mm) diameter vent pipe, but require a 2-1/2 in. (64 mm) diameter combustion air pipe. According to Table 11, 2-in. (51

mm) diameter pipe is good for 35 ft. (10.6 M) with 3 elbows, but only 30 ft. (9.1 M) with 5 elbows. Therefore,

2-1/2 in. (64 mm) diameter pipe must be used for both vent and combustion-air pipes since larger required diameter must always be used for both pipes.

For a non-direct vent/I-pipe system, Table 11 indicates that this application would allow a 2-in. (51 mm)

diameter vent pipe. If same installations were in Albuquerque, elevation 5250 ft. (1600 M) above sea

level: For a direct vent/2-pipe system, Table 11 indicates that

2-1/2 in. (64 mm) diameter vent pipe and combustion-air pipe are required.

For a non-direct vent/l-pipe system, Table 1 indicates that 2-1/2-in. (64 mm) diameter vent pipe is required.

If same applications are to be installed at 5001 to 6000 ft. (1524 to 1829 M) elevation:

For a direct vent/2-pipe system, 2-in. (51 mm) pipe is only good for 23 ft (7.0 M) (with 3 elbows) and 17 ft.

(5.1 M) (with 5 elbows). Therefore, 2-1/2 in. (64 mm) diameter combustion air and vent pipe must be used.

For a non-direct vent/I-pipe system, a 2-in. (51 mm) diameter pipe is only good for 23 ft. (7.0 M) with 3

elbows. A 2-1/2-in. (64 mm) 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/I-Pipe system. For exterior piping arrangements, refer to Fig. 44 for

Direct Vent/2-Pipe system and Fig. 45 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.

- 47 -

Table 13 - Vent Termination Kit for Direct Vent/2-Pipe System

DIRECT VENT (2-PIPE) TERMINATION KIT TERMINATION SYSTEM

2-in. (51 ram) Concentric Vent Kit Single Penetration of Wall or Roof

3-in. (76 ram)Concentric Vent Kit Single Penetration of Wall or Roof

2-in. (51 ram)Termination Bracket Kit 2-Pipe Termination System

3-in. (76 ram) Termination Bracket Kit 2-Pipe Termination System

4. Termination or termination kit should be positioned where

it will not be damaged by or subjected to foreign objects such as stones, balls, etc.

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

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

system only) and vent pipe termination may be extended beyond area shown in Fig. 44 or in Fig. 45 per application in outside ambient by insulating pipe as indicated in Table 10.

1. Determine combustion air pipe diameter (direct vent/2-pipe system only) and vent pipe diameter, as stated

above, using total pipe length and number of elbows.

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

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

NOTE: Pipe length (it) 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 13. There are four options of vent/combustion air

termination kits available as shown in Table 13. NOTE: Combustion air pipe must have the same diameter as

vent pipe. Concentric Vent/Combustion Air Termination Kit (Direct Vent/2-Pipe System Only)

Determine an appropriate location for termination kit using the guidelines provided in section "Vent Termination:General" in this

instruction.

1. Cut one 4-in. (102 mm) diameter hole for 2-in. 51 mm) kit, or one 5-in. (127 mm)diameter hole for 3-in. (76 mm) kit.

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

3. Slide assembled kit with 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. 44. Sidewall terminations -- Locate assembly through sidewall with

rain shield positioned no more than 1-in. (25 mm) from wall as shown in Fig. 44.

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

5. Check required dimensions as shown in Fig. 44.

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

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

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. 44, but next vent termination must be at least 36 in. (914 mm) away from first 2 terminations. It is

important that vent terminations be made as shown in Fig. 44 to

avoid recirculation of flue gases.

Step ll--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 1/2-in. (13 mm) CPVC, 1/2-in. (13 mm) PVC, or 5/8-in. (16 mm) ID tube connection.

Drain pipe and fittings must conform to ANSI standards and ASTM D1785, D2466 or D2846. CPVC or PVC cement must

conform to ASTM D2564 or F493. Primer must conform to ASTM F656. In Canada, use CSA or ULC listed schedule 40

CPVC or PVC drain pipe, fittings, and cement.

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

approved for condensing furnace applications. To avoid

condensate spillage, select a pump with an overflow switch.

DIAM. OF COMBUSTION AIR AND VENT

PIPES - IN (mm)

1, 1-1/2, 2, or2-1/2 (25, 38, 51,64 mm)

2-1/2, 3or4 (64, 76, 102 mm)

1, 1-1/2 or 2 (25, 38, 51mm)

2-1/2, 3or4 (64, 76, 102 mm)

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

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

Roof terminations --Loosely install pipe coupling on properly cut vent pipe. Coupling must be positioned so

bracket will mount as shown in Fig. 44.

For applications using combustion-air pipe option, indicated by dashed lines in Fig. 44, install 90 ° street elbow into 90 ° elbow, making a U-fitting. A 180 ° U-fitting

may be used. Sidewall terminations --Install bracket as shown in

Fig. 44. For applications using vent pipe option indicated by

dashed lines in Fig. 44, rotate vent elbow 90 ° from position shown in Fig. 44.

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

4. Check required dimensions as shown in Fig. 44.

- 48 -

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

3.2 to 4.5. Due to corrosive nature of this condensate, a condensate pH neutralizing filter may be desired. Check with

local authorities to determine if a pH neutralizer is required. APPLICATION

The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, field-

supplied trap prior to the furnace drain connection. All drain connections (furnace, A/C, or humidifier) must be terminated into

an open or vented drain as close to the respective equipment as possible to prevent siphoning of the equipment's drain.

See Fig. 46 for example of possible field drain attachment using 1/2-in. (13 mm) CPVC or PVC tee for vent and A/C or humidifier

drain connection. Outdoor draining of the furnace is permissible if allowed by local

codes. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining.

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 (5°C) self-regulating, shielded, and waterproof heat tape. See

Installation Instructions supplied with accessory or heat tape manufacturer's recommendations.

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

2. Locate heat tape between sides of condensate trap back. (See Fig. 47.)

/ \

PIPEFOR

A/COR

HUMIDIFIER

OPENSTANDy

DRAIN

CONDENSATE

WIRE TIE

HEAT

(3 WRAPS MINIMUM)

A93036

Fig. 47 - 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. 47.)

4. Wrap field drain pipe with remaining heat tape, approximately 1 wrap per ft.

5. When using field-supplied heat tape, follow heat tape manufacturer's instructions for all other

installation guidelines.

START-UP, 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, controlled 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.

Fig. 46 - Example of Field Drain Attachment

A94054

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.

- 49 -

A99118

Fig. 48 - Inducer Housing Drain Tube Cap

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.48.)

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

3. Insert field-supplied funnel into tube.

4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and

flow into open field drain. (See Fig. 49.)

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

Step 3--Purge Gas Lines

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

FIRE AND EXPLOSION HAZARD

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

Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of

leaks to check all connections.

A99119

Fig. 49 - Filling Condensate Trap

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 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.)

- 50 -

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 field-installed 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 SECI 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, 52, 54 and 56 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, 53, 55, 57, and 58 for thermostat connections.)

The thermostat closes the R to G-and-Yl circuits for low-cooling or closes the R to G-and-Yl-and-Y2

circuits for high-cooling. The R to YI circuit starts the outdoor unit on low-cooling speed, and the R to

G-and-Yl circuit starts the furnace blower motor

BLWM on low-cool speed (same speed as FAN). The R to Yl-and-Y2 circuits start the outdoor unit on

high-cooling speed, and the R to G-and-Y/Y2 circuits start the furnace blower motor BLWM on COOL

speed. The electronic air cleaner terminal EAC-1 is energized

with 115 vac whenever the blower motor BLWM is operating.

When the thermostat is satisfied, the R to G and-Yl or R to G and-Yl and-Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and

electronic air cleaner terminal EAC-1 will remain energized for an additional 90 seconds. Jumper Y1 to

DHUM to reduce the cooling off-delay to 5 seconds. (See Fig. 31.)

THERMIDISTAT MODE

(See Fig. 52, 53, 54, and 55 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-Yl circuit is closed and there is

a demand for dehumidification, the furnace blower

motor BLWM will continue running at low-cool speed (same speed as 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.

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.

-51 -

THERMIDISTAT SINGLE-STAGE SINGLE-SPEED THERMIDISTAT SINGLE-STAGE SINGLE-SPEED

FURNACE AIR CONDITIONER FURNACE HEAT PUMP

N/A N/A

HEAT STAGE 1

COOL STAGE 1

FAN [_

24 VAC HOT [_

DEHUMIDIFY [_

24 VAC COMM [_

HUM

HUMIDIFY [_

N/A [_

°S_E_#°°#_

_ HUM,D,F,ER_ i

(24 VAC)

/_ OUTDOOR

SENSOR

CONNECT,ONL[Z_

See notes 2, 5, 7, and 10

Fig. 50 - Single-Stage Furnace with Single-Speed

Air Conditioner

THERMIDISTAT SINGLE-STAGE TWO-SPEED

FURNACE AIR CONDITIONER

RVS COOLING

N/A [_

HEAT STAGE 2

(FURNACE)

H EA Z/ _ cOoQMLpSTAsGoER1)

FAN [_

24 VAC HOT [_

DEHUMIDIFY

24 VAC COMM [_

HUMIDIFY [_

N/A [_

i i

°s_T#°°#_

E2_

[] HUM

_ HUM'D'F'ER_ i

(24 VAC)

o tooo

SENSOR

CONNECT,O.L_

A00268

Fig. 52 - Single-Stage Furnace with Single-Speed

Heat Pump (Dual Fuel)

THERMIDISTAT SINGLE-STAGE TWO-SPEED

See notes 1, 2, 4, 6, 7, 9, 10 and 12

A00270

FURNACE HEAT PUMP

COOL STAGE 1 _.

HEAT STAGE 1 [_-.

COOL STAGE 2 _.

FAN [_-.

24 VAC HOT _-.

DEHUMIDIFY [_.

24 VAC COMM [_-.

HUMIDIFY [_.

N/A [_

%T_sOOR_-Fq

........ '_ HUMIDIFIER(24VAC)

........ _ OUTDOORsENSOR

-I_q

- [_c_-.

HUM

CONNECT,ONLI_q-

See notes 2, 5, 8, and 10

Fig. 51 - Single Stage Furnace with Two-Speed

Air Conditioner

___C_

___ _i

A00269

RVS COOLING [_

HEAT/COOL STAGE 1) _

(COMPRESSOR LC

HEAT STAGE 3

(FURNACE)

HEAT/COOL STAGE 2

(COMPRESSOR HI)

FAN [_

24 VAC HOT [_

DEHUMIDIFY [_

24 VAC COMM [_

HUMIDIFY [_

N/A [_

NOTE 12

_[ OUTDOOR }_

SENSOR

OONNECT'ON

See notes 1, 2, 3, 4, 6, 8, 9, 10 and 12

Fig. 53 - Single-Stage Furnace with Two-Speed

Heat Pump (Dual Fuel)

A00271

- 52 -

DUAL FUEL SINGLE-STAGE SINGLE-SPEED DUAL FUEL SINGLE-STAGE TWO-SPEED

THERMOSTAT FURNACE HEAT PUMP THERMOSTAT FURNACE HEAT PUMP

RVS COOLING

N/A [_

HEAT STAGE 2

(FURNACE)

HEAT/COOL STAGE 1

(COMPRESSOR)

FAN [_

24 VAC HOT [_

24 VAC COMM [_

N/A [_

RVS SENSING [_

OUTDOOR _[_

coSE_S°,"oQi2_

See notes 1, 2, 4,11,12, and 13

Fig. 54 - Dual Fuel Thermostat with Single-Stage Furnace

and Single-Speed Heat Pump

TWO-STAGE SINGLE-STAGE TWO-SPEED

THERMOSTAT FURNACE AIR CONDITIONER

A02102

RVS COOLING [_

HEAT/COOL STAGE 1

(COMPRESSOR LO)

HEAT STAGE 3 [_

(FURNACE)

HEAT/COOL STAGE 2

(COMPRESSOR HI)

FAN [_

24 VAC HOT [_

24 VAC COMM [_

N/A [_

RVS SENSING [_

°s_.°s°°R_[Z_

DONNEDT'ONLE2_

Fig. 55 - Dual Fuel Thermostat with Single-Stage Furnace

See notes 1,2, 3, 4,11,12, and 14

and Two-Speed Heat Pump

A02103

-F_-II

-I-_--_............Tr---E]

E_-

F-I I

.I-_--H............Tr--E]

P_I

-I-_--_............Tr--E]

0HUM1.....................................

Seenote2 i ,_ HUMIDFIER(24VAC)_"""

Fig. 56 - Two-Stage Thermostat with Single-Stage

Furnace and Two-Speed Air Conditioner

A02161

- 53 -

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 '%" 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.

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 push-button on the room

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

continuous-blower speed from the factory setting of 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. 54, 55, 56, and 57 for thermostat connections.) When installed with a heat pump, the furnace control automatically

changes the blower timing sequence to avoid long blower off times during demand defrost cycles. When the R toW-and-Yl or R to

W-and-Yl-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-Yl-and-G signals disappear at the same time, the blower motor BLWM will remain on for the selected

blower-OFF delay period. If the R to W-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-Yl-and-Y/Y2, or R to W-and-Yl-and-Y/Y2-and-G circuits

are energized the furnace control CPU will switch to or turn on the blower motor BLWM at 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-Yl-and-Y/Y2-and-G signals

disappear at the same time, the blower motor BLWM will remain on for the selected blower-OFF delay period. If the R to W-and-Y/Y2 or R to W-and-Yl-and-Y/Y2 signals disappear, leaving the G signal,

the blower motor BLWM will remain on for the selected blower-OFF delay period then switch to continuous-blower speed.

- 54 -

Table 14 - 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 Burne_; Derated 2% for Each 1000 Ft. (305 M) Above Sea Level) *

ALTITUDE

RANGE

Ft (i)

o To

2000

_: to 610)

_." 0%

D derate

ALTITUDE

RANGE

Ft (i)

U.S.A.

Altitudes

2001 to

3000

(610 to

0 914)

"_ Canada

_" Altitudes (n 2001 to

::5 4500

(610 to

1372)

5% derate

ALTITUDE

RANGE

Ft (i)

>, 3001

"_ to 4000 O (914 to _ 1219)

D derate

*Orifice numbers 45 shown in BOLD are factory installed. Percents of derate are based on midpoints of altitude ranges.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

850 875

900 925

950 975

1000 1025

1050 1075

1100

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

775 800

825 850

875 900

925 950

975

1000

1025

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

750

775 800

825 850

875 900

925 950

975

1000

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No Pressure No Pressure

43 3.7 43 3.8 42 3.2 43 3.5 43 3.6 43 3.7

44 3.7 43 3.4 43 3.5 44 3.5 44 3.7 44 3.8

44 3.4 44 3.5 44 3.6 44 3.2 44 3.3 44 3.4

45 3.7 45 3.8 44 3.2 45 3.5 45 3.6 45 3.7

45 3.3 45 3.4 45 3.6 45 3.2 45 3.3 45 3.4

47 3.6 47 3.7 45 3.2

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

43 3.8 42 3.2 42 3.3 43 3.5 43 3.7 43 3.8

44 3.8 43 3.4 43 3.6 44 3.6 44 3.7 44 3.8

44 3.4 44 3.5 44 3.6 44 3.2 44 3.3 44 3.4

45 3.7 45 3.8 44 3.2 45 3.5 45 3.6 45 3.7

45 3.3 45 3.4 45 3.5 45 3.1 45 3.2 45 3.4

45 3.0 45 3.1 45 3.2

0.58

Orifice Manifold

No. Pressure

43 3.7 43 3.5

44 3.7 44 3.5

44 3.3 45 3.8

45 3.6 45 3.4

45 3.2 45 3.0 45 2.9

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

43 3.8 42 3.3 43 3.6 43 3.7

43 3.4 43 3.5 44 3.6 44 3.8

44 3.4 44 3.5 44 3.2 44 3.3

45 3.7 45 3.8 45 3.5 45 3.6

45 3.3 45 3.4 45 3.2 45 3.3 45 3.0 45 3.1

0.64 0.66

Orifice Manifold Orifice Manifold

No Pressure No Pressure 42 3.3 42 3.4 43 3.8 42 3.2

43 3.6 43 3.7 43 3.4 43 3.5

44 3.7 44 3.8 44 3.5 44 3.6

44 3.4 44 3.5 44 3.2 44 3.3

45 3.7 45 3.8 45 3.5 45 3.6

45 3.4 45 3.5

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.4 42 3.5 42 3.2 42 3.3

43 3.7 43 3.8 43 3.5 43 3.6

44 3.7 43 3.4 44 3.5 44 3.6

44 3.3 44 3.4

45 3.8 44 3.3 45 3.6 45 3.8

45 3.5 45 3.6 45 3.3 45 3.4

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.4 42 3.5 43 3.8 42 3.2

43 3.6 43 3.7 43 3.4 43 3.5

44 3.7 44 3.8 44 3.5 44 3.6

44 3.3 44 3.4

45 3.7 44 3.2 45 3.5 45 3.7

45 3.4 45 3.5 45 3.2 45 3.3

- 55 -

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. (305 M) Above Sea Level)*

ALTITUDE

RANGE

Ft (i)

4001

5000

(1219 to

1524) 9%

derate

ALTITUDE

RANGE

Ft (i)

5001

_>,

6000

(1524 to

1829)

11%

derate

ALTITUDE

RANGE

Ft (i)

6001

-->" To 7000

(1829 to

2134)

-; 13%

derate

*Orifice numbers 45 shown in BOLD are factory installed. Percents of derate are based on midpoints of altitude ranges.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725 750

775 800

825 850

875 900

925 950

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

700 725

750 775

800 825

850 875

900 925

950 975

1000

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650 675

700 725

750 775

800 825

850 875

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No Pressure No Pressure

43 3.7 43 3.8 42 3.2 43 3.4 43 3.5 43 3.7 44 3.7 44 3.8 43 3.4

44 3.5 44 3.6 44 3.7 44 3.2 44 3.4 44 3.5

45 3.7 45 3.8 44 3.3 45 3.5 45 3.6 45 3.7

45 3.3 45 3.4 45 3.5 45 3.1 45 3.2 45 3.3

45 3.0 45 3.1 45 3.2

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

43 3.6 43 3.7 42 3.2 43 3.4 43 3.5 43 3.6

44 3.6 44 3.7 43 3.4 44 3.4 44 3.5 44 3.6

44 3.2 44 3.3 44 3.4 45 3.6 45 3.7 44 3.2

45 3.4 45 3.5 45 3.6 45 3.2 45 3.3 45 3.4

45 3.0 45 3.1 45 3.3 45 2.9 45 3.0 45 3.1

45 2.7 45 2.8 45 2.9 45 2.6 45 2.7 45 2.8

45 2.5 45 2.5 45 2.6

0.58

Orifice Manifold

No. Pressure

42 3.2 43 3.6

44 3.8 44 3.6

44 3.3 45 3.8

45 3.5 45 3.3

45 3.1 45 3.0

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

45 3.7 45 3.8 45 3.4 45 3.6

45 3.2 45 3.4 45 3.1 45 3.2

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

42 3.3 42 3.4 43 3.7 43 3.8

43 3.4 43 3.6 44 3.7 44 3.8

44 3.4 44 3.6 44 3.2 44 3.3

0.64 0.66

Orifice Manifold Orifice Manifold

No Pressure No Pressure 42 3.3 42 3.4 43 3.8 42 3.2 43 3.5 43 3.7

44 3.8 43 3.4 44 3.6 44 3.7

44 3.4 44 3.5 44 3.2 44 3.3

45 3.6 45 3.8 45 3.4 45 3.6

45 3.3 45 3.4

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.3 42 3.4 43 3.7 43 3.8

43 3.5 43 3.6 44 3.7 43 3.4

44 3.5 44 3.6

44 3.3 44 3.4 45 3.7 44 3.2 45 3.6 45 3.7

45 3.4 45 3.5 45 3.2 45 3.3

45 3.0 45 3.1 45 2.9 45 2.9

45 2.7 45 2.8

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.5 42 3.6

42 3.2 42 3.3

43 3.7 43 3.8

43 3.4 43 3.5

44 3.7 44 3.8

44 3.4 44 3.5

44 3.2 44 3.3 45 3.7 45 3.8

45 3.5 45 3.6 45 3.3 45 3.4

- .56 -

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. (305 M) Above Sea Level) *

ALTITUDE

RANGE

Ft (i)

7001

8000

(2134 to

2438)

5 15%

derate

ALTITUDE

RANGE

Ft (i)

8001

-->" To 9000

(2438 to

2743)

:5 17%

derate

ALTITUDE

RANGE

Ft (i)

9001

10_000

_ (2743 to

3048)

-; 19%

derate

*Orifice numbers 45 shown in BOLD are factory installed.

Percents of derate are based on midpoints of altitude ranges.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

625 650

675 700

725 750

775 800 825

850

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

600 625

650 675 700

725 750

775 800

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

575 600

625 650

675 700 725

750 775

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No Pressure No Pressure

43 3.8 42 3.3 42 3.4 43 3.5 43 3.7 43 3.8

44 3.8 43 3.4 43 3.5 44 3.5 44 3.6 44 3.8

44 3.3 44 3.4 44 3.5 45 3,7 45 3,8 44 3.3

45 3,5 45 3,8 45 3,7

45 3.3 45 3.4 45 3.5 45 3.1 45 3,2 45 3,3

45 2.9 45 3.0 45 3.1

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

43 3.8 42 3.3 42 3.4 43 3.5 43 3.6 43 3.8

44 3.7 43 3.4 43 3.5 44 3.5 44 3.6 44 3.7 44 3.2 44 3.3 44 3.4

45 3,8 45 3,8 44 3.2 45 3,4 45 3,5 45 3,8

45 3.2 45 3.3 45 3.4 45 3.0 45 3.1 45 3.2

0.58

Orifice Manifold

No. Pressure

43 3.8 43 3.5

44 3.7 44 3.4

45 3.8 45 3,6 45 3,3

45 3.1 45 2.9

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

45 3,7 45 3,8 45 3,4 45 3,8

45 3.2 45 3.3 45 3.0 45 3.1

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

42 3.2 42 3.3 43 3.6 43 3.7

44 3.8 43 3.4 44 3.5 44 3.7

44 3.3 44 3.4

0.64 0.66

Orifice Manifold Orifice Manifold

No Pressure No Pressure 42 3.5 42 3.6

42 3.2 42 3.3 43 3.6 43 3.7 43 3.4 43 3.5

44 3.6 44 3.7 44 3.4 44 3.5

45 3,8 44 3.3 45 3,8 45 3,7 45 3,4 45 3,5

45 3.2 45 3.3

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.5 42 3.6 42 3.2 42 3.3

43 3.6 43 3.7 44 3.8 43 3.4 44 3.6 44 3.7

44 3.3 44 3.4

45 3,8 44 3.2 45 3,5 45 3,8

45 3.3 45 3.4

0.64 0.88

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

42 3.5 42 3.6 42 3.2 42 3.3

43 3.6 43 3.7 44 3.8 43 3.4

44 3.5 44 3.6 44 3.3 44 3.4

45 3,7 45 3,8 45 3,4 45 3,5

45 3.2 45 3.3

- 5"7-

Table 15 - 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 Burne_; Derated 2% for Each 1000 Ft. (305 M) Above Sea Level) *

ALTITUDE

RANGE

Ft (i)

-o

2000

-o

(0 to 610)

derate

ALTITUDE

RANGE

Ft (i)

U.S.A.

Altitudes

2001 to

3000

(810 to

914) or

Canada

Altitudes

2001 to

4500

(810 to

1372)

5% derate

ALTITUDE

RANGE

Ft (i)

>, 3001

to 4000

• (914 to

_. 1219)

"_ derate

*Orifice numbers 43 shown in BOLD are factory installed. Percents of derate are based on midpoints of altitude ranges.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

850 875

900 925

950 975

1000 1025

1050 1075

1100

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

775 800

825 850

875 900

925 950

975

1000 1025

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

750

775 800

825 850

875 900

925 950

975

1000

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No Pressure No Pressure

41 3.6 41 3.7 41 3.8 42 3.8 41 3.5 41 3.6

42 3.5 42 3.7 42 3.8 42 3.4 42 3.5 42 3.6

42 3.2 42 3.3 42 3.4 43 3.7 43 3.8 42 3.2

43 3.5 43 3.6 43 3.7 43 3.3 43 3.4 43 3.6

43 3.2 43 3.3 43 3.4 44 3.5 44 3.6 43 3.2

44 3.3 44 3.4 44 3.5

0.58 0.60 0.62

Orifice Manifold Orifice Manifold Orifice Manifold

No. Pressure No. Pressure No. Pressure

41 3.7 41 3.8 40 3.6 42 3.8 41 3.6 41 3.7

42 3.6 42 3.7 41 3.5 42 3.4 42 3.5 42 3.6

42 3.2 42 3.3 42 3.4 43 3.7 43 3.8 42 3.2

43 3.5 43 3.6 43 3.7 43 3.3 43 3.4 43 3.5

43 3.1 43 3.3 43 3.4 43 3.0 43 3.1 43 3.2

43 2.8 43 2.9 43 3.0

0.58

Orifice Manifold

No. Pressure

41 3.6 42 3.8

42 3.5 42 3.3

43 3.8 43 3.6

43 3.4 43 3.2

43 3.1 43 2.9 43 2.8

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

41 3.8 40 3.6 41 3.5 41 3.6

42 3.7 42 3.8 42 3.4 42 3.6

42 3.2 42 3.4

43 3.7 42 3.2 43 3.5 43 3.6

43 3.3 43 3.5 43 3.2 43 3.3

43 3.0 43 3.1 43 2.9 43 3.0

0.64 0.66

Orifice Manifold Orifice Manifold

No Pressure No Pressure 40 3.6 40 3.8 41 3.7 41 3.8

41 3.5 41 3.6 42 3.7 42 3.8

42 3.5 42 3.6 42 3.3 42 3.4

42 3.2 42 3.3 43 3.7 43 3.8

43 3.5 43 3.6 43 3.3 43 3.4

43 3.2 43 3.3

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

40 3.7 39 3.6 41 3.8 40 3.6

41 3.6 41 3.7 42 3.7 41 3.5

42 3.5 42 3.6 42 3.3 42 3.4

42 3.2 42 3.3

43 3.7 43 3.8 43 3.5 43 3.6

43 3.3 43 3.4 43 3.1 43 3.2

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

40 3.7 40 3.8 41 3.7 40 3.6

41 3.5 41 3.6 42 3.7 42 3.8

42 3.5 42 3.6 42 3.3 42 3.4

43 3.8 42 3.2 43 3.6 43 3.7

43 3.4 43 3.5 43 3.2 43 3.3 43 3.0 43 3.1

- 58 -

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. (305 M) Above Sea Level) *

ALTITUDE

RANGE

Ft (i)

4001

5000

(1219 to

1524) 9%

derate

ALTITUDE

RANGE

Ft (i)

5001

_>,

6000

(1524 to

1829)

11%

derate

ALTITUDE

RANGE

Ft (i)

6001

-->" To 7000

(1829 to

2134)

::5 13%

derate

*Orifice numbers 43 shown in BOLD are factory installed.

Percents of derate are based on midpoints of altitude ranges.

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725 750

775 800

825 850

875 900

925 950

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

700 725

750 775

800 825

850 875

900 925

950 975

1000

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650 675

700 725

750 775

800 825

850 875

0.58

Orifice Manifold

No. Pressure

41 3.6 42 3.7

42 3.5 42 3.3

43 3.7 43 3.5

43 3.3 43 3.1

43 3.0 43 2.8

0.58

Orifice Manifold

No. Pressure

41 3.5 42 3.7

42 3.4 42 3.2

43 3.7 43 3.5

43 3.3 43 3.1

43 2.9 43 2.7

43 2.6 43 2.5

43 2.3

0.58

Orifice Manifold

No. Pressure

41 3.8 41 3.5

42 3.6 42 3.4

43 3.8 43 3.6

43 3.4 43 3.2

43 3.0 43 2.8

Orifice Manifold Orifice Manifold

No Pressure No Pressure

43 3.6 43 3.8 43 3.4 43 3.6

43 3.3 43 3.4 43 3.1 43 3.2

43 2.9 43 3.0

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

43 3.8 42 3.2

43 3.6 43 3.7 43 3.4 43 3.5

43 3.2 43 3.3 43 3.0 43 3.1

43 2.8 43 2.9 43 2.7 43 2.8

43 2.6 43 2.6 43 2.4 43 2.5

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

43 3.7 43 3.8 43 3.5 43 3.6

43 3.3 43 3.4 43 3.1 43 3.2 43 2.9 43 3.0

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

41 3.7 41 3.8 42 3.8 41 3.6

42 3.6 42 3.7 42 3.4 42 3.5

42 3.2 42 3.3

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

41 3.7 41 3.8 42 3.8 41 3.5

42 3.5 42 3.7 42 3.3 42 3.4

SPECIFIC GRAVITY OF NATURAL GAS

0.60 0.62

40 3.6 40 3.7 41 3.6 41 3.7

42 3.7 41 3.5 42 3.5 42 3.6

42 3.3 42 3.4

0.64 0.66

Orifice Manifold Orifice Manifold

No Pressure No Pressure 40 3.6 40 3.8 41 3.7 41 3.8

42 3.8 41 3.6 42 3.6 42 3.7

42 3.4 42 3.5 42 3.2 42 3.3

43 3.7 43 3.8 43 3.5 43 3.6

43 3.3 43 3.4 43 3.1 43 3.2

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

40 3.6 40 3.7 41 3.6 41 3.8

42 3.8 42 3.5 42 3.5 42 3.7

42 3.3 42 3.4

43 3.8 42 3.2

43 3.6 43 3.7 43 3.4 43 3.5

43 3.2 43 3.3 43 3.0 43 3.1

43 2.9 43 3.0 43 2.7 43 2.8

43 2.6 43 2.7

0.64 0.66

Orifice Manifold Orifice Manifold

No. Pressure No. Pressure

40 3.8 39 3.7 40 3.6 40 3.7

41 3.6 41 3.7 42 3.7 42 3.8

42 3.5 42 3.6 42 3.3 42 3.4

43 3.7 43 3.8 43 3.5 43 3.6

43 3.3 43 3.4 43 3.1 43 3.2

- .59 -

COMPONENT TEST NOTE: The fi_rnace control component test allows all

components to run for a short time; except the gas valve and humidifier terminal HUM are not energized for safety reasons. The EAC-1 terminal is energized when 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. Determine natural gas orifice size and manifold pressure for correct input.

a. Obtain average gas heat value (at installed altitude)

from local gas supplier.

b. Obtain average gas specific gravity from local

gas supplier.

c. Verify furnace model and size. Table 14 can only be

used for model 58MXB furnaces with rating plate heating inputs (1000's Btuh) of 040 through 120. Table

15 can only be used for model 58MXB furnaces with a

heating size of 140.

d. Find installation altitude in Table 14 or 15.

NOTE: For Canadian altitudes of 2001 to 4500 ft. (610 to 1372 M), use U.S.A. altitudes of 2001 to 3000 ft. (610 to 914 M) in

Table 14 or 15.

e. Find closest natural gas heat value and specific gravity

in Table 14 or 15.

f. Follow heat value and specific gravity lines to point of

intersection to find orifice size and manifold pressure settings for proper operation.

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 COM-24v terminal on control to the TEST/TWIN 3/16-inch

quick-connect terminal on control until the LED goes off. Remove 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. (610 M).

In the U.S.A., the input ratings for altitudes above 2000 ft. (610 M) must be reduced by 2 percent for each 1000 ft. (305 M) above

sea level. In Canada, the input ratings must be derated by 5 percent for

altitudes between 2001 ft to 4500 ft. (610 to 1372 M) above sea level.

Furnace input rate must be within - 2 percent of input on furnace rating plate adjusted for altitude.

EXAMPLE: (0-2000 ft. (0-610 M) altitude using Table 14)

Heating value = 1050 Btu/cu fl 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. 57.)

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. (610 M). For altitudes above 2000 ft. (610 M), the manifold

3ressure can be adjusted from 2.0 in. wc to 3.8 in. wc. If manifold 3ressure is outside this range, change burner orifices to obtain 3ressure 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.

- 60 -

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.

ONiO['[" Switch Regulator Seal Cap

% "NPT Inlet Under Cap

I/8 NPT Inlet

Pressure 'Yap

!/," NPT Outlet

BURNER

I/8" NPT Manitbld

Pressure Tap

A07536

Fig. 57 - Redundant Automatic Gas Control Valve

ORIFICE

_ BURNER

A93059

Fig. 58 - 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-of round holes, etc.) can cause excessive burner noise and misdirection of burner flames. (See Fig. 58.)

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. 59.)

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.

MANIFOLD

Fig. 59 - Burner Flame

Table 16- Altitude Derate Multiplier for USA.

ALTITUDE PERCENT OF DERATE MULTIPLIER

FT (M) DERATE FACTOR*

0-2000

(0-810) 0 1.00

2001-3000

(810-914) 4-6 0.95

3001-4000

(914-1219) 6-8 0.93

4001-5000

(1219-1524) 8-10 0.91

5001-6000

1524-1829) 10-12 0.89

8001-7000

(1829- 2134) 12-14 0.87

7001-8000

(2134- 2438) 14-16 0.85

8001-9000

(2438- 2743) 16-18 0.83

9001-10,000 18-20 0.81

(2743 -3048)

Derate multiplier factors are based on mid 3oint altitude for altitude range.

a. Calculate high-altitude adjustment (if required)

UNITED STATES At altitudes above 2000 ft. (610 M), this furnace has

been approved for a 2 percent derate for each 1000 ft. (305 M) above sea level. See Table 16 for derate

multiplier factor.

EXAMPLE:

100,000 Btuh input furnace installed at 4300 ft.

Furnace Input X Derate = Furnace Input

Rate Multiplier Rate at Installation

at Sea Level Factor Altitude

100,000 X 0.91 = 91,000

CANADA

At installation altitudes between 2001 to 4500 ft. (610 to 1372 M), 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.

Reinstall burner box cover.

Gas valve regulator seal cap MUST be on.

Turn off all other gas applications and pilots.

Start furnace and let operate for 3 minutes.

A89020

- 61 -

f. Measure time (in sec) for gas meter to dial to complete

1 revolution.

g. Refer to Table 17 for cu fl 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.

EXAMPLE: (0-2000 ft. (0-610 M) altitude) Furnace input from rating plate is 100,000 Btuh.

Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 975 Btu/cu ft

Time for 1 revolution of 2-cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 17)

Btu heating input = 103 X 975 = 100,425 Btuh. In this example, the orifice size and manifold

pressure adjustment is within ---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 18 for lead color identification. Reconnect original lead on SPARE terminal.

Table 17 - Gas Rate (cu ft/hr)

SECONDS

FOR 1

REVOLUTION

lO 11 12

13 14 15

16 17 18

19 20

21 22 23 24

25 26 27

28 29

30 31 32

33 34 35

36 37 38

40 41

42 43 44

47 48

Follow this

SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL

1 2 5 FOR 1 1 2 5

Cu Ft Cu Ft Cu Ft REVOLUTION Cu Ft Cu Ft Cu Ft

360 720 1800 50 72 144 360 327 655 1636 51 71 141 355 300 600 1500 52 69 138 346

277 555 1385 53 68 136 340 257 514 1286 54 67 133 333 240 480 1200 55 65 131 327

225 450 1125 56 64 129 321 212 424 1059 57 63 126 316 200 400 1000 58 62 124 310

189 379 947 59 61 122 305 180 360 900 60 60 120 300

171 343 857 62 58 116 290 164 327 818 64 56 112 281 157 313 783 66 54 109 273 150 300 750 68 53 106 265

144 288 720 70 51 103 257 138 277 692 72 50 100 250 133 267 667 74 48 97 243

129 257 643 76 47 95 237 124 248 621 78 46 92 231

120 240 600 80 45 90 225 116 232 581 82 44 88 220 113 225 563 84 43 86 214

109 218 545 86 42 84 209 106 212 529 88 41 82 205 103 206 514 90 40 80 200

100 200 500 92 39 78 196

97 195 486 94 38 76 192 95 189 474 96 38 75 188

92 185 462 98 37 74 184 90 180 450 100 36 72 180 88 176 439 102 35 71 178

86 172 429 104 35 69 173 84 167 419 106 34 68 170 82 164 409 108 33 67 167

80 160 400 110 33 65 164 78 157 391 112 32 64 161 76 153 383 116 31 62 155

75 150 375 120 30 60 150 73 147 367 124 29 58 145

of COOL speedsame procedure for proper selection

selection.

ADJUST BLOWER OFF DELAY (HEAT MODE)

The blower off delay has 4 adjustable settings from 90 sec to 180 sec. (See Table 19.) 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. 60

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. 60. The thermostat anticipator should NOT be in the circuit while

measuring current. If thermostat has no subbase, the thermostat must be disconnected from R and W 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.

- 62 -

Table 18 - Speed Selector

COLOR SPEED SHIPPED

Black High Cool

Yellow (When

Present) Medium High Spare

Blue Medium Low Heat

Red Low Fan

White Common COM

Table 19 - Blower Off Delay Jumper Positions

PINS 1 AND 2 2 AND 3 3 AND 4 4AND 5

Time (in sec) 90 120 150 180

FACTORY

CONNECTION

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 thermostatto "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.

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED

HOOK-AROUND

VO LT/AM M ETER

10TURNS

FROM UNIT 24-VOLT

TERMINAL BLOCK

EXAMPLE:

5.0 AMPS ON AMMETER - 0.5 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS

Fig. 60 - Amp Draw Check with Ammeter

Step 7--ChecMist

1. Put away tools and instruments. (.'lean 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.

A80201

- 63 -

CHECKLIST_DIRECT VENT (2-PIPE) INSTALLATION

LOAD CALCULATION

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

COMBUSTION AIR AND VENT PIPING Termination Location

Roof or Sidewall

Termination Kit -- 2 Pipe or Concentric

Combustion-Air Pipe Length

Combustion-Air Pipe Elbow Quantity

Vent Pipe Length

Vent Pipe Elbow Quantity

Pipe Diameter Determined from Sizing Table

Pipe Sloped To Furnace

Pipe Insulation

Over Ceilings

Condensate Drain

Unit Level or Pitched Forward

Internal Tubing Connections Free

of Kinks and Traps

External Drain Connection Leak Tight and sloped

Condensate Trap Primed before Start-Up

Heat Tape Installed if Required

CHECKLIST--START-UP

(;as Input Rate

(Set Within 2 percent of Rating Plate)

Temperature Rise Adjusted

Thermostat Anticipator

Anticipator Setting Adjusted or

Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Check Operation

Primary Limit Pressure Switch

Low-Ambient Exposed Pipes

CHECKLISTmNON DIRECT VENT (1-PIPE) INSTALLATION

LOAD CALCULATION

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

VENT PIPING

Termination Location

Roof or Sidewall

Vent Pipe Length

Vent Pipe Elbow Quantity

Pipe Diameter Determined from Sizing Table

Pipe Sloped To Furnace

Pipe Insulation

Over Ceilings

Low-Ambient Exposed Pipes

Condensate Drain

Unit Level or Pitched Forward

Internal Tubing Connections Free of Kinks and Traps

External Drain Connection Leak Tight and Sloped

Condensate Trap Primed before Start-Up

Heat Tape Installed if Required

CHECKLIST--START-UP

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

Temperature Rise Adjusted

Thermostat Anticipator

Anticipator Setting Adjusted or

Cycle Rate (3 Cycles per Hr) Selected

Safety Controls Check Operation

Primary Limit

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

- 64 -

Pressure Switch

Catalog No: 58MXB-4SI

Replaces: 58MXB-3Sl

Carrier 58MXB080F10120, 58MXB100F10116, 58MXB100F10120, 58MXB120F10120, 58MXB140F10120 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual