Carrier WEATHERMAKER 8000 58WAV Owner's Manual
WeatherMaker 8000™
Upflow Induced-Combustion Furnaces
Visit www.carrier.com
Installation, Start-Up, and Operating Instructions
Sizes 045-155, Series 140 (LIMITED)
NOTE: Read the entire instruction manual before starting the
installation.
Index Page
SAFETY CONSIDERATIONS.....................................................1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE........................................................................2-3
Dimensional Drawing...............................................................2
Clearances From Combustible Materials.................................3
INTRODUCTION.....................................................................3
LOCATION ..............................................................................4
General.................................................................................4
Location Relative to Cooling Equipment...........................4
Hazardous Locations ...........................................................4
AIR FOR COMBUSTION AND VENTILATION..............4-6
Unconfined Space................................................................4
Confined Space....................................................................5
AIR DUCTS..............................................................................6
General Requirements .........................................................6
Ductwork Acoustical Treatment .........................................6
Supply-Air Connections......................................................6
Return-Air Connections.......................................................6
FILTER ARRANGEMENT .....................................................6
LEVELING LEGS (IF REQUIRED).......................................7
GAS PIPING .........................................................................7-8
ELECTRICAL CONNECTIONS.............................................8
115-v Wiring........................................................................8
24-v Wiring..........................................................................8
Accessories.......................................................................8-9
VENTING.................................................................................9
START-UP, ADJUSTMENT, AND SAFETY CHECK..12-20
General...............................................................................12
Sequence Of Operation................................................12-15
Heating Mode....................................................................13
Cooling Mode...............................................................13-15
Continuous Blower Mode .................................................15
Continuous Blower Speed Selection from Thermostat....15
Heat Pump Mode...............................................................15
Start-Up Procedures .....................................................15-16
Adjustments..................................................................16-20
Set Gas Input Rate.......................................................16-19
Set Temperature Rise...................................................19-20
Set Thermostat Heat Anticipator ......................................20
Check Safety Controls............................................................20
Checklist..................................................................................21
REGISTERED QUALITY SYSTEM
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA
54-1999/ANSI Z223.1-1999 and the Installation Standards, Warm
Air Heating and Air Conditioning Systems (NFPA 90B)
ANSI/NFPA 90B.
In Canada, refer to CAN/CGA-B149.1- and .2-M95 National
Standard of Canada, Natural Gas and Propane Installation Codes
(NSCNGPIC).
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing residential construction practices. We require these instructions as a
minimum for a safe installation.
Wear safety glasses and work gloves. Have fire extinguisher
available during start-up and adjustment procedures and service
calls.
Recognize safety information. This is the safety-alert symbol
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. 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 a hazard
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which would result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
ama
58WAV
CERTIFIED
.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 6a 8a
PC 101 Catalog No. 535-757 Printed in U.S.A. Form 58WAV-9SI Pg 1 1-00 Replaces: New
39 7⁄8″
28 1⁄2″
VENT CONN
7
⁄8-IN. DIA HOLE
POWER ENTRY
7
⁄8-IN. DIA
ACCESSORY
1 3⁄4-IN. DIA HOLE
GAS ENTRY
1
⁄2-IN. DIA HOLE
THERMOSTAT
WIRE ENTRY
2 1⁄16″
1″
5 3⁄8″
5 13⁄16″
2 3⁄8″
12 5⁄16″
AIRFLOW
A
D
13
⁄16″
5 3⁄8″
5 13⁄16″
2 3⁄8″
2 11⁄16″
2 1⁄16″
1″
OUTLET
7
⁄8-IN. DIA
POWER ENTRY
1 1⁄2-IN. DIA
R.H. GAS ENTRY
7
⁄8-IN. DIA ACCESSORY
1
⁄2-IN. DIA THERMOSTAT
WIRE ENTRY
19″
13
⁄16″
SIDE INLET
TYP 1″
11
11
⁄16″
NOTES:
24 5⁄16″
AIR INLET
1. Two additional 7⁄8-in. dia holes are located in the top plate.
2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used,
see flex duct manufacturer's recommendations for equivalent diameters.
3. Minimum return-air opening at furnace:
a. For 800 CFM–16-in. round or 141⁄2 x 12-in. rectangle.
b. For 1200 CFM–20-in. round or 141⁄2 x 191⁄2-in. rectangle.
c. For 1600 CFM–22-in. round or 141⁄2 x 231⁄4-in. rectangle.
d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific
use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the
bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.
3″
11
⁄16″
E
⁄16″
5
TYP
⁄8″
SIDE INLET
231⁄4″
SIDE RETURN
DUCT LOCATION
Fig. 1—Dimensional Drawing
Table 1—Dimensions (In.)
UNIT SIZE A D E VENT CONN SHIP. WT (LB)
045-08 14-3/16 12-9/16 12-11/16 4 119
045-12 14-3/16 12-9/16 12-11/16 4 121
070-08 14-3/16 12-9/16 12-11/16 4 126
070-12 14-3/16 12-9/16 12-11/16 4 129
091-14 17-1/2 15-7/8 16 4 147
091-16 21 19-3/8 19-1/2 4 159
111-12 17-1/2 15-7/8 16 4 155
111-16 21 19-3/8 19-1/2 4 164
111-20 24-1/2 22-7/8 23 4 182
136-16 21 19-3/8 19-1/2 5 173
136-20 24-1/2 22-7/8 23 5 186
155-20 24-1/2 22-7/8 23 5 196
141⁄2″
3
⁄4″
1
1″
A99060
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools
which are held during the procedure. These precautions will
help to avoid exposing the control to electrostatic discharge
by putting the furnace, the control, and the person at the same
electrostatic potential.
1. Disconnect all power to the furnace. DO NOT TOUCH THE
CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.
2. Firmly touch a clean, unpainted, metal surface of the furnace
chassis which is close to the control. Tools held in a person’s
hand during grounding will be satisfactorily discharged.
3. After touching the chassis you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch ungrounded
objects, etc.).
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching
control or wires.
5. Use this procedure for installed and uninstalled (ungrounded)
furnaces.
6. Before removing a new control from its container, discharge
your body’s electrostatic charge to ground to protect the
control from damage. If the control is to be installed in a
furnace, follow items 1 through 5 before bringing the control
or yourself into contact with the furnace. Put all used AND
new controls into containers before touching ungrounded
objects.
7. An ESD service kit (available from commercial sources) may
also be used to prevent ESD damage.
2
MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION
This forced air furnnace is equipped for use with
atural gas at altitude s 0 - 10,000 f t (0-3,050m).
An accessory kit , supplied by the mmanuf acturer ,
hall be used to convert to propane gas use or
ay be required for some natural gas applications.
Thiss furnace is for indoor installation in
building constructed on site.
This f
urnace may be installled on combustible
oorring in alcove or closet at minimum clearance
f
om combustible material.
f
This furnace ma
a
nd may be vented in common with other gas-fired
a
ppliances.
For furnaces wider than 14.25 inches
#
(362mm) ma y be 0 inches.
For s in g le w all ven t ty p e 6 inc h es.
#
#
For Type B-1 v ent type 3 inches.
y be used with a Type B-1 Vent
Fig. 2—Clearances to Combustibles
This furnace is approved for UPFL OW installations only.
1"
0"
B
A
C
K
E
D
I
S
TOP / PLENUM
N
R
U
F
F
R
1" #
BOTTOM
Clearance in inches.
Vent Clearance to comb ustibles:
For Single Wall vents 6 inches (6 po).
For Type B-1 ve nt type 1 inch (1 po).
DESSOUS
"
0
E
C
A
T
N
O
R
F
O
N
T
##
320325-101 RE V. H
S
1"
#
E
D
I
S
E
R
V
I
C
E
30"
MIN
A98122
INTRODUCTION
The Model 58WAV, Series 140 Limited Furnace is available in
sizes 44,000 through 154,000 Btuh input capacities.
The design of the upflow gas-fired furnace is A.G.A./C.G.A.
certified for natural and propane gas and for installation on
combustible flooring, in alcoves, attics, basements, closets, or
utility rooms. The furnace is factory-shipped for use with natural
gas. A factory accessory gas conversion kit, as listed on the
furnace rating plate is required to convert furnace for use with
propane gas. The design of this furnace line is not A.G.A./C.G.A.
certified for installation in mobile homes, recreation vehicles, or
outdoors.
Before installing the furnace in the United States, refer to the
current edition of the NFGC and the NFPA 90B. For copies of the
NFGC and NFPA 90B, contact the National Fire Protection
Association Inc., Batterymarch Park, Quincy, MA 02269; or for
only the NFGC contact the American Gas Association, 400 N.
Capitol St., N.W., Washington DC 20001.
Before installing the furnace in Canada, refer to the NSCNGPIC.
For a copy of the NSCNGPIC, contact Standard Sales, CSA
International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada.
Installation must comply with regulations of serving gas supplier
and local building, heating, plumbing or other codes in effect in the
area in which installation is made. In absence of local building
codes, installation must comply with NFGC in the United States
and the NSCNGPIC and all authorities having jurisdiction in
Canada.
Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, and unit sizing. Improper installation or
misapplication of the furnace can require excessive servicing
or cause premature component failure.
FRONT
°F °F
RETURN
AIR
MAX 85°F MIN 55°F
A93042
This furnace is designed for a minimum continuous return-air temperature of 60°F db or an intermittent operation down to 55°F db such
as when used with a night setback thermostat. Return-air temperature
must not exceed a maximum of 85°F db.
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.
For accessory installation details, refer to the applicable instruction
literature.
3
NOTE: Remove all shipping brackets and materials before
operating the furnace.
Step 1—Location
GENERAL
Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.
Do not use this furnace during construction when adhesives,
sealers, and/or new carpets are being installed. If the furnace
is required during construction, use clean outside air for
combustion and ventilation. Compounds of chlorine and
fluorine when burned with combustion air form acids which
cause corrosion of the heat exchangers and metal vent system.
Some of these compounds are found in paneling and dry wall
adhesives, paints, thinners, masonry cleaning materials, and
many other solvents commonly used in the construction
process.
Excessive exposure to contaminated combustion air will
result in safety and performance related problems.
DO NOT install the furnace on its back or sides. Safety
control operation will be adversely affected. A failure to
follow this warning can cause fire, personal injury, or death.
This furnace must be installed so the electrical components are
protected from water. This furnace shall not be installed directly on
carpeting, tile, or any combustible material other than wood
flooring.
Locate furnace as close to the chimney/vent and as near the center
of the air distribution system as possible. The furnace should be
installed as level as possible.
Provide ample space for servicing and cleaning. Always comply
with the minimum fire protection clearances shown on the unit
rating plate.
LOCATION RELATIVE TO COOLING EQUIPMENT — The
cooling coil must be installed parallel with or on the downstream
side of the unit to avoid condensation in the heat exchangers.
When installed parallel with a furnace, dampers or other means
used to control the flow of air must prevent chilled air from
entering the unit. If the dampers are manually operated, they must
be equipped with means to prevent operation of either unit unless
the damper is in the full-heat or full-cool position.
HAZARDOUS LOCATIONS
When furnace is installed in a residential garage, it must be
installed so that burners and ignition sources are located a
minimum of 18 in. above floor. The furnace must be located
or protected to avoid physical damage by vehicles. When
furnace is installed in a public garage, airplane hangar, or
other building having a hazardous atmosphere, unit must be
installed in accordance with requirements of National Fire
Protection Association, Inc.
18-IN. MINIMUM
TO BURNERS
Step 2—Air For Combustion and Ventilation
Provisions for adequate combustion and ventilation air must be
provided in accordance with Section 5.3 of the NFGC, Air for
Combustion and Ventilation, or applicable provisions of the local
building codes.
Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride, bromide, and
iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and
other household products.
All fuel-burning equipment must be supplied with air for combustion of the fuel. Sufficient air MUST be provided to ensure there
will not be a negative pressure in the equipment room or space. In
addition, a positive seal MUST be made between the furnace
cabinet and the return-air duct to prevent pulling air from the
burner area and blocked vent safeguard opening.
The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, 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.
The requirements for combustion and ventilation air depend upon
whether the furnace is located in an unconfined or confined space.
UNCONFINED SPACE
An unconfined space has volume of at least 50 cu ft for each 1000
Btuh of total input for all appliances (such as furnaces, clothes
dryers, water heaters, etc.) in the space.
For Example:
58WAV FURNACE
INPUT BTUH
44,000 293
66,000 440
88,000 587
110,000 733
132,000 880
154,000 1026
MINIMUM SQ FT WITH
7-1/2 FT CEILING
If the unconfined space is of unusually tight construction, air for
combustion and ventilation MUST come from either the outdoors
or spaces freely communicating with the outdoors. Combustion
and ventilation openings must be sized the same as for a confined
4
A93044
SUPPLY
AIR
VENT THROUGH ROOF
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 4000
BTUH*
12″ MAX
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
INTERIOR
HEATED
SPACE
RETURN AIR
* Minimum opening size is 100 sq in. with
minimum dimensions of 3 in.
†
Minimum of 3 in. when type-B1 vent is used.
UNCONFINED
SPACE
CONFINED
SPACE
6″ MIN
(FRONT)
1 SQ IN.
PER 1000
BTUH* IN DOOR
OR WALL
†
12″ MAX
A89012
Fig. 3—Confined Space: Air for Combustion and
Ventilation from an Unconfined Indoor Space
12″ MAX
1 SQ IN.
PER 2000
BTUH*
DUCTS
TO
OUTDOORS
1 SQ IN.
PER 2000
BTUH*
12
″ MAX
RETURN AIR
*Minimum dimensions of 3 in.
Use any of the following
NOTE:
combinations of openings:
A & B C & D D & E F & G
A
SUPPLY
AIR
B
D
VENT
THROUGH
ROOF
C
DUCT
TO
OUTDOORS
CONFINED
SPACE
E
12″ MAX
12″
MAX
F
1 SQ IN.
PER
4000
BTUH*
OUTDOORS
1 SQ IN.
PER
4000
BTUH*
G
12″
MAX
1 SQ IN.
PER 4000
BTUH*
A89013
Fig. 4—Confined Space: Air for Combustion and
Ventilation from Outdoors
space as defined below. Return air must not be taken from the
room unless an equal or greater amount of air is supplied to the
room.
CONFINED SPACE
A confined space is defined as a space whose volume is less than
50 cu ft per 1000 Btuh of total input ratings of all appliances
installed in that space. A confined space MUST have provisions
for supplying air for combustion, ventilation, and dilution of flue
gases using 1 of the following methods. (See Fig. 3, 4, and Table
2.)
NOTE: In determining free area of an opening, the blocking
effect of louvers, grilles, and screens must be considered. If free
area of louver or grille design is unknown, assume that wood
louvers have a 20 percent free area and metal louvers or grilles
have a 60 percent free area. Screens, when used, must not be
smaller than 1/4-in. mesh. Louvers and grilles must be constructed
so they cannot be closed.
The size of the openings depends upon whether air comes from
outside of the structure or an unconfined space inside the structure.
1. All air from inside the structure requires 2 openings (for
structures not usually tight):
a. Each opening MUST have at least 1 sq in. of free area per
1000 Btuh of total input for all equipment within the
confined space, but not less than 100 sq in. per opening.
(See Fig. 3 and Table 2.) The minimum dimension of air
openings shall not be less than 3 in.
b. If building is constructed unusually tight, a permanent
opening directly communicating with the outdoors shall be
provided. See item 2 below.
c. If furnace is installed on a raised platform to provide a
return-air plenum, and return air is taken directly from
hallway or space adjacent to furnace, all air for combustion
must come from outdoors.
2. Air from outside the structure requires 1 of the following
methods:
a. If combustion air is taken from outdoors through 2 vertical
ducts, the openings and ducts MUST have at least 1 sq in.
of free area per 4000 Btuh of total input for all equipment
within the confined space. (See Fig. 4 and Table 2.)
b. If combustion air is taken from outdoors through 2 hori-
zontal ducts, the openings and ducts MUST have at least 1
sq in. of free area per 2000 Btuh of total input for all
equipment within the confined space. (See Fig. 4 and Table
2.)
c. If combustion air is taken from outdoors through a single
opening or duct (horizontal or vertical) commencing within
12 in. of the top of the confined space, opening and duct
MUST have at least 1 sq in. of free area per 3000 Btuh of
the total input for all equipment within the confined space
and not less than the sum of the areas of all vent connectors
in the confined space. (See Fig. 4 and Table 2.) Equipment
clearances to the structure shall be at least 1 in. from the
sides and back and 6 in. from the front of the appliances.
5
Table 2—Minimum Free Area Of Combustion Air Opening*
58WAV
FURNACE
INPUT
(BTUH)
44,000 100 11.0 4 22.0 6 14.67 5
66,000 100 16.5 5 33.0 7 22.00 6
88,000 100 22.0 6 44.0 8 29.33 7
110,000 110 27.5 6 55.0 9 36.67 7
132,000 132 33.0 7 66.0 10 44.00 8
154,000 154 38.5 8 77.0 10 51.33 9
* Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space. Opening area must be increased if other gas appliances
in the space require combustion air.
AIR FROM INDOOR
UNCONFINED SPACE
Free Area
of Opening
(Sq In.)
OUTDOOR AIR THROUGH
VERTICAL DUCTS
Free Area of
Opening and Duct
(Sq In.)
Round
Pipe
(In. Dia)
OUTDOOR AIR THROUGH
HORIZONTAL DUCTS
Free Area of
Opening and Duct
(Sq In.)
Round
Pipe
(In. Dia)
OUTDOOR AIR THROUGH
SINGLE DUCT
Free Area of
Opening and Duct
(Sq In.)
Round
Pipe
(In. Dia)
When 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. (See Fig.
4.)
AIR DUCTS
Step 1—General Requirements
The duct system should be designed and sized according to
accepted national standards such as those published by: Air
Conditioning Contractors Association (ACCA), Sheet Metal and
Air Conditioning Contractors National Association (SMACNA) or
American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE). Or consult factory The Air Systems Design
Guidelines reference tables available from your local distributor.
The duct system should be sized to handle the required system
design airflow CFM at the design external static pressure.
When a furnace is installed so that the supply ducts carry air to
areas outside the space containing the furnace, the return air must
also be handled by a duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
Secure ductwork with proper fasteners for type of ductwork used.
Seal supply- and return-duct connections to furnace with code
approved tape or duct sealer.
Flexible connections should be used between ductwork and
furnace to prevent transmission of vibration. Ductwork passing
through unconditioned space should be insulated to enhance
system performance. When air conditioning is used, a vapor
barrier is recommended.
Maintain a 1-in. clearance from combustible materials to supply air
ductwork for a distance of 36 in. horizontally from the furnace. See
NFPA 90B or local code for further requirements.
Step 4—Return Air Connections
Never connect return-air ducts to the back of the furnace. A
failure to follow this warning can cause a fire, personal injury,
or death.
The return-air duct must be connected to bottom , sides (left or
right), or a combination of bottom and side(s) of main furnace
casing as shown in Fig. 1. Bypass humidifier may be attached into
unused side return air portion of the furnace casing. DO NOT
connect any portion of return-air duct to back of furnace casing.
Step 5—Filter Arrangement
The factory-supplied filter(s) is shipped in the blower compartment. Determine location for the filter and relocate filter retaining
wire if necessary. See Fig. 5 for side return application and Fig. 6
for bottom return application. See Table 3 to determine correct
filter size for desired filter location. Table 3 indicates filter size,
location, and quantity shipped with the furnace.
WASHABLE
FILTER
FILTER
RETAINER
Step 2—Ductwork Acoustical Treatment
Metal duct systems that do not have a 90 degree elbow and 10 ft
of main duct to the first branch take-off may require internal
acoustical lining. As an alternative, fibrous ductwork may be used
if constructed and installed in accordance with the latest edition of
SMACNA construction standard on fibrous glass ducts. Both
acoustical lining and fibrous ductwork shall comply with NFPA
90B as tested by UL Standard 181 for Class 1 Rigid air ducts.
Step 3—Supply Air Connections
Connect supply-air duct to 3/4-in. flange on furnace supply-air
outlet. The supply-air duct attachment must ONLY be connected
to furnace supply-/outlet-air duct flanges or air conditioning coil
casing (when used). DO NOT cut main furnace casing to attach
supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.
A93045
Fig. 5—Side Filter Arrangement
(Control Removed for Clarity)
For bottom air-return applications, filter may need to be cut to fit
some furnace casing widths. A bottom closure panel is factory
installed in the bottom of the furnace. When bottom return inlet is
desired, remove and discard the bottom closure panel. Two sets of
hardware are needed for furnaces in 24-1/2-in. wide casings using
2 filters for bottom return. All hardware is provided for filter
installation.
NOTE: Furnaces with a 17-1/2-in. wide casing require an additional procedure when locating the filter for bottom return-air
application. Field fabricate a sheet metal filler strip1X3X24-1/2
in. and install it along side of the filter as shown in Fig. 6. Drive
2 screws through the casing side and into the filler strip to secure
6
171⁄2-IN. WIDE
CASINGS ONLY:
INSTALL FIELD-SUPPLIED
FILTER FILLER STRIP
UNDER FILTER.
3″
1
24
/2″
1″
FILTER
SUPPORT
241⁄2-IN. WIDE
CASINGS ONLY:
CUT AND FOLD
FACTORY-PROVIDED
FILTERS AS SHOWN
TO DESIRED SIZE.
FILTER
RETAINER
Fig. 6—Bottom Filter Arrangement
(Control Removed for Clarity)
WASHABLE
FILTER
A96030
5
⁄16″
5
⁄16″
1 3⁄4″
3
⁄4″
1
5
⁄16″
5
⁄16″
1 3⁄4″
1 3⁄4″
A89014
Fig. 7—Leveling Leg Installation
NOTE: The length of the bolt should not exceed 1-1/2 in.
1. Lay furnace on its back. Locate and drill 5/16-in. diameter
hole in each bottom corner of furnace as shown in Fig. 7.
2. Install nut on bolt and 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.
Step 7—Gas Piping
Gas piping must be installed in accordance with national and local
codes. Refer to the current edition of the NFGC. Canadian
installations must be installed in accordance with NSCNGPIC and
all authorities having jurisdiction.
Refer to Table 4 for the recommended gas pipe size. Risers must
be used to connect to the furnace and the meter.
Table 3—Filter Information (In.)
FURNACE
CASING WIDTH
14-3/16 (1) 16 X 25 X 1† (1) 14 X 25 X 1 Cleanable
17-1/2 (1) 16 X 25 X 1† (1) 16 X 25 X 1 Cleanable
21 (1) 16 X 25 X 1 (1) 20 X 25 X 1† Cleanable
24-1/2 (2) 16 X 25 X 1† (1) 24 X 25 X 1 Cleanable
* Filters can be field modified by cutting the frame as marked and folding to the
desired size. Alternate sizes can be ordered from your distributor or dealer.
† Factory provided with the furnace.
it in place. Filter should rest on the top of the filler strip when
installed.
Never operate unit without a filter or with filter access door
removed. Failure to follow this warning can cause fire,
personal injury, or death.
Step 6—Leveling Legs (If Required)
When the furnace is used with side inlet(s) and leveling legs are
required, refer to Fig. 7, and install field-supplied, corrosionresistant 5/16-in. machine bolts and nuts.
FILTER SIZE*
Side Return Bottom Return
FILTER
TYPE
If a flexible connector is required or allowed by the authority
having jurisdiction, black iron pipe shall be installed at the
gas valve and extend a minimum of 2 in. outside the furnace
casing.
Use the proper length of pipes to avoid stress on the gas
control manifold. Failure to follow this warning can result in
a gas leak, causing fire, explosion, personal injury, or death.
Connect the gas pipe to the furnace using a backup wrench to
avoid damaging gas controls.
7
Never purge a line into a combustion chamber. Never use
matches, candles, flame, or other sources of ignition for the
purpose of checking leakage. Use a soap-and-water solution
to check for leakage. Failure to follow this warning can cause
a fire, explosion, personal injury, or death.
Table 4—Maximum Capacity of Pipe*
NOMINAL IRON
PIPE SIZE
(IN.)
1/2 0.622 175 120 97 82 73
3/4 0.824 360 250 200 170 151
1 1.049 680 465 375 320 285
1-1/4 1.380 1400 950 770 660 580
1-1/2 1.610 2100 1460 1180 990 900
* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a
pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table
10-2 NFPA 54-1999.
Install a sediment trap in the riser leading to the furnace. The trap
can be installed by connecting a tee to the riser leading from the
furnace. Connect a capped nipple into the lower end of the tee. The
capped nipple should extend below the level of the gas controls.
(See Fig. 8.)
Apply joint compound (pipe dope) sparingly and only to the male
threads of each joint. The compound must be resistant to the action
of propane gas.
An accessible manual shutoff valve MUST be installed upstream
of the furnace gas controls and within 72 in. of the furnace. A
1/8-in. NPT plugged tapping, accessible for test gage connection,
MUST be installed immediately upstream of the gas supply
connection to the furnace and downstream of the manual shutoff
valve. Place ground joint union between the gas control manifold
and the manual shutoff valve.
Piping should be pressure tested in accordance with local and
national plumbing and gas codes before the furnace has been
attached. If the pressure exceeds 0.5 psig (14-in. wc), the gas
supply pipe must be disconnected from the furnace and capped
before the pressure test. If the test pressure is equal to or less than
0.5 psig (14-in. wc), turn off electric shutoff switch located on the
gas valve before the test. It is recommended that the ground joint
union be loosened before pressure testing. After all connections
have been made, purge the lines and check for leakage with
regulated gas supply pressure.
Step 8—Electrical Connections
115-V WIRING — Refer to the unit rating plate or Table 5 for
equipment electrical requirements. The control system requires an
earth ground for proper operation.
Do not connect aluminum wire between disconnect switch
and furnace. Use only copper wire.
Make all electrical connections in accordance with the National
Electrical Code (NEC) ANSI/NFPA 70-1999 and local codes or
ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with CSA C22.1
Canadian Electrical Code, or authorities having jurisdiction.
INTERNAL
DIAMETER
(IN.)
LENGTH OF PIPE (FT)
10 20 30 40 50
GAS
SUPPLY
MANUAL
SHUTOFF
VALVE
(REQUIRED)
SEDIMENT
TRAP
UNION
A89417
Fig. 8—Typical Gas Pipe Arrangement
The cabinet MUST have an uninterrupted or unbroken ground
according to NEC, ANSI/NFPA 70-1999 and Canadian
Electrical Code, CSA C22.1 or local codes to minimize
personal injury if an electrical fault should occur. This may
consist of electrical wire or conduit approved for electrical
ground when installed in accordance with existing electrical
codes. Do not use gas piping as an electrical ground. Failure
to follow this warning could result in electrical shock, fire, or
death.
The junction box (J-box) can be moved to the left-hand side of the
furnace when a left-side power supply is desired. Remove the 2
screws holding the auxiliary J-box. Mount the J-box on the
left-hand side of the furnace (holes have been pre-drilled in
casing). When moved, tuck the wiring harness behind the clip
provided to keep extra wire lengths out of the way.
NOTE: Proper polarity must be maintained for 115-v wiring. If
polarity is incorrect, control status indicator light will flash rapidly
and the furnace will not operate.
24-V WIRING
Make field 24-v connections at the 24-v terminal strip. (See Fig.
15.) Connect terminal Y/Y2 as shown in Fig. 9 for proper cooling
operation. Use only AWG No. 18, color-coded, copper thermostat
wire.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the main control board. Any 24-v shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3-amp fuse of identical size.
ACCESSORIES
1. Electronic Air Cleaner (EAC)
Two quick-connect terminals, marked EAC-1 and EAC-2, are
provided for EAC connection. (See Fig. 15). These terminals
are energized with 115-v, (1.0-amp maximum) during blower
motor operation.
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