Home

Installation, Start---up, Operating and Service and

Contents

1. Cooling Switch Settings External Static Pressure 5 BTUH SW2 3 SW2 2 SW2 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 OFF OFF OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730 OFF OFF ON 765 745 740 705 680 OFF ON OFF 930 925 915 900 885 OFF ON ON 1095 1100 1110 1105 1085 ON OFF OFF 1265 1255 1265 1280 1275 1285 1270 1260 1250 1230 1200008 ON OFF ON 1465 1455 1470 1465 1465 1470 1455 1450 1435 1415 ON ON OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730 ON ON ON 2200 2200 2200 2190 2185 2170 2145 2085 1990 1890 Maximum Cooling Airflow2 2200 2200 2200 2190 2185 2170 2145 2085 1990 1890 High Heat Airflow 1815 1820 1825 1820 1815 1795 1775 1745 1720 1700 Low Heat Airflow 1640 1640 1645 1650 1645 1645 1630 1620 1600 1580 Nominal 350 CFM ton cooling airflow is delivered with SW1 5 and SW4 2 set to OFF Set SW1 5 to ON for nominal 400 CFM ton 15 airflow Set SW4 3 to ON for nominal 325 CFM ton 7 airflow Set both SW1 5 and SW4 3 to ON for nominal 370 CFM ton 7 airflow Maximum cooling airflow is achieved when switches SW3 1 SW3 2 SW3 3 and SW1 5 are set to ON and SW4 3 is set to OFF All heating CFM s are when low heat rise adjustment switch SW1 3 and comfort efficiency adjustment switch SW1 4 are both set to OFF Ductwork must be sized for high heating CFM within the operational range of E S P Operation within the blank areas of the chart is not recommended because high heat o
2. 9500 Buiqqny dais 1xeu ay 0 1514 eui x2eu Jamod ajejs Apeays buunp spuodas Ua JO NO Bureq 5 5 Alu swij euim pequoseJd y 941 10 OSZ y seye rpu 11074 YOLOW 83MO 18 SAA smejs 995 PAJIMSILU SI SLD aq 2945 Q3N3dO3H 4501 LON GIG AV T3H 5 34055344 LV3H HOIH JO ZLA UOISJaA 5 SI 043002 221195 adeUINy OML 9 LMS pue L LMS 9 LMS 2 5 NO L LMS 5 043002 951415 uo g1d jepou ay je3su 0 ji ueddeu 5141 jueueuujed paJ0js ou s pue Hulssiw 51 ay Aue seusej Sz apo snjeis J 5 y si pue japow sii
3. 91 16 81 720545 8 899 ns e 9 6592 18 899 loves 919 92 1026 1 8 9us L 6 1 WOLLOS a g 9 90 Tos i d 4d d 1 i d i d Y leozv P 9 02 6188 ouszt Lor lezel Lreogl le ozv Ez 2809 76891 teers 90891 NI 9 9 82 91 92 02 N Word 87 8882 D 22 4 224 8 6 ILE SZ NNOO H3MOd 2 22 ra 1 1 842 AHLINI LVLSONHSH L NNOO 12221 222 8 BILD LYLSONYSHL 2 2 BILD ez 52 1 1 1 1 2 22 Y NOILYOO1 3LVSN30NOO 53441 1 17 mrg DIVINI a E NNOO SY9 57 94 Ie vel MOT le si 612 2224 85 BILD DIVINI Te ees 1629 0 029 911 h yv 2 00 6 92
4. 10 AY JI 511220 n0207 10103201 LINDY Jamojq eu suado 10 gt LAVM 10 e dn SI JI 5 2 5 06 suni ASLL H3MOd 83 14V NO H3MO 18 Ulais s o1 gt Jo e ujajs s ung s 11 5 snoauegnuuis zA A pue LAVM y pue uonisod NO ayy Ul L LMS U21iMs Aq pasesa Ajjenuew aq ue Jo ZZ Jaye gt 511815 JAOD SNOIAAYd ON L L A11326B Troubleshooting Guide Continued 83 291 pue a2euinj aui MOTIAA 9 uo 10 uado ue SAA iC N33u5 pue MOTI3A ld DAA S S ON ay pue e euunj y usa aq M JO 3H 991 Jaya uo Jo aam uado ue pue 32euuoosip axou NOK j y pue e euinj eui 5 ja Mod 31IHM JO 32 V8 991 1 uo 10
5. 10 ainssaid 10 pe12euuoosiq 5 5491 JI aanssaid seb pue ajnqnseA yea 5 10 uo BOD poued suado j S MUIU 10 sinus uey uado j q3N3dO3H 35072 LON HOLIMS 38155384 LV3H MOT1 8JIM seb 01 110 5 JO uo seb gt JMS 0 pue Jamod 4o uin 10103201 9NILV3H SVD Lp gt sinou Jaye 1959 IM 033005 5 Duneau OM NO 5 5 OE 10 Wd OSZ 0 4 eui 10103201 YOLOW pg 54645 98S sinoU E Jaye 19591 pue seb ureis S 10103201 gt 995 5 1952 O1 UOD 1299 OL 10 uey u do 51 UDUMS
6. 11 Filter Size Information 22 Opening Dimensions 24 Air Delivery oss beds i E 29 Maximum Capacity of Pipe 32 Electrical Data ssc ibo shes bee seek CIE A 34 Vent Termination Kit for Direct Vent 2 Pipe Systems 41 Combustion Air Vent Pipe Fitting amp Cement Material 45 Maximum Allowable Exposed Vent Lengths Insulation 46 Maximum Equivalent Vent Length 47 Deductions from Maximum Equivalent Vent Length 47 Altitude Derate Multiplier for U S A 67 Blower Off Delay Setup Switch 67 Po 67 vn 68 Always Ask For FACTORY THORIZE AUIS Use of the AHRI Certified TM Mark indicates a manufacturer s participation in the program For verification of certification for individual products go to 150 9001 www ahridirectory org gt N E 5 QMI SAI Global Portions of the text and tables are reprinted from NFPA 54 ANSI Z223 1 2009 with permission of National Fire Protection Association Quincy MA 02269 and American Gas Association Washington DC 20001 This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject which is represented only by the standard in its ent
7. 1 pue AJY 1 1 DGA ZL F424 S 46 N338D 11 114 pue AJY Z EL 1d DGA ZL 91943 5 544 pUe 11 DVASLL S UO amod 9 169 SAA 0 saop J9MO q y ains ay BY 4010uu aui 0 ay e ejday ideis snoad ay ui pequosep se ay 5200 54915 ow paquosap se ayenjony ayy seoq z e1d pue 3018 14 SsoJ2e PauUOD gt aui e ejday 1010UJ J2MO q y pue 041uo2 e euinj Y M 3118 991 uo Jeuruua 10 Uado ue 0 y 0 aui suon2najsui BY 04 4010Uu 24 0 ay e ejday uini seoq pue 4030UJ J2MO Q y 5 01 09 12euuoosip e euunj aui UJOJJ UONIBUUOD e SOWWAY Y 991 03 043002
8. l gt SEF v 5 SECZ almi EM z SH pP T SECO SEIT e usi Lo 5 EAC 2 z A T EAC 1 i D AL 5 12 FRS2 LS FRS1 TRAN m 29 m to HUM HUMR T 9 8 2 a Ox E olde tele x COMMR e ACR i ute PLL2 LPS e ww Q e NOTE 8 Nh 4 ___ g E Q 3 LGPS w2 95 WHEN HPS gt BRN BRN 2 CPU e Pits 8 g 1 Mc CAP 1 Y1 9 GVR PL1 10 es COM NOTE 3 mC NOTE 5 Pm 9 Prise Lom a 2i 502 L 5248 JUNCTION TERMINAL FACTORY POWER WIRING 115VAC EL TT 9 G CONTROL TERMINAL FACTORY CONTROL WIRING 24VAC 3 S 4 4 ig 5289 E CONTROL TERMINAL a 2 a9 d mee TES 8 645 N FIELDEARTH GROUND FIELD WIRING SCREW TERMINAL EQUIPMENT GROUND PLUG RECEPTACLE NOTES 7 AC HigondlnngdussbeAow CH Blower Door rterock wih SPST 1 If any of the original equipment wire is replaced use wire rated for 105 C ACR Air Conditioning Relay SPST N O IND Inductor Note 7 2 Use only copper wire between the disconnect switch and the Re ay Defeat Jumper SPOT NO furnace junction box JB CF Continuous Fan Atow 25 Low Heat Pressure Switch SPST
9. 3 This wire must be connected to furnace sheet metal for control CAP 1 Capacitor LS Limit Switch Auto Reset SPST N C to prove flame a SPDT a Board i i icroprocessor Circult Circuit Connector 4 Symbols are electrical representation only DHUM Connection 24VAC 4 Circuit HSI amp IDM Connector 5 Solid lines inside PCB are printed circuit board conductors and EAC 1 Electronic Air Cleaner Connection 4 Circuit ECM BLWM Connector are not included in legend 10 Max fin Model Plug Connector 6 Replace only with a 3 amp fuse EAC 2 Electronic Air Cleaner Connection Common Circuit Communication Connector FRS Flame Rollout Switch Man Reset SPST N C _ PL9 2 Circuit OAT Connector T Inductor is used with 3 4 hp and 1 hp ECM Blower motors FSE e Proving Sensor Electrode PLIO 2 Circuit HSI Connector 8 Factory connected when LGPS not used FUSE Fuse 3 Amp Automotive Blade Type PL11 12 Circuit IDM Connector 9 Blower off delay gas heating selections are 90 120 150 180 Factory reial seconds cooling or heat pump 90 seconds or 5 seconds when AC Blower Power Connector GVR Gas Valve Relay DPST dehumidify call is active High Heat Pressure Switch SI SW1 1 Manual Switch Status Code Recall 10 Ignition lockout will occur after four consecutive usuccessful HESR Hi
10. 33 AGCCESSOTIOS PHP AO b OPI bp ero 33 Alternate Power Supplies 34 VENTING etes nem ee RU p e teure ptos in 40 Special Venting Requirements for Installations in Canada 40 Materials ee pm UR 41 Venting Systems sies eere Rene 41 Locating Vent Termination 41 Size the Vent and Combustion Air 42 Combustion Air and Vent Piping Insulation Guidelines 42 Configure the Furnace 43 Installing the Vent Termination 44 Venting System Length Calculations 47 START UP ADJUSTMENT AND SAFETY CHECK 60 Select Setup Switch Positions 60 Prime Condensate Trap 60 Purge Gas Lines eee Ree 60 Adj stiments sa 52 REF Ree ache dh 61 Check Safety Controls 63 Checklist icon bee PERDERE DUE 63 SERVICE AND MAINTENANCE PROCEDURES 70 Cleaning Heat Exchangers 75 SEQUENCE OF OPERATION 78 PARTS REPLACEMENT 86 TABLE Loose Parts Bag Contents 6 Minimum Clearances to Combustible Materials 6 Minimum Free Area Required 11 Minimum Space Volumes
11. 51 o 3u02 ay dn j amp od uo saw y seusep apo smeis J 47135 NOIL2313S TAGOW Le Sc A11326C Troubleshooting Guide Continued 84 CONNECTION DIAGRAM SCHEMATIC DIAGRAM me RNTED BOND TO 115VAC SWITCH p wi gt ON ILK GROUND 77 sw4 Ser mm SE eB t SEE RATING PLATE FOR x HSIR B wal a 8Lz MODEL PLUG USE 5 R95 IHILOR lt m 8 Eo IDR 1012 kid Gre m 55888 8 E S BU g ex 5 5 YEL MIS 1 eel is CPU FL E T gt 3 8 d t 58 og 5 1121314 2 5 H o i o 8506 D 59 5502 2 iL Ss 21 8 5 NOTE 47 EusEsAMP 218188 109 E o a
12. R i F DEHUMDIFY p _______ __ DHUM HOU FH R DEHUMIDIFYY p L1 24VAC COMM C 1 1 LI 24VAC COMM Li 1 1 121 HUM s HUM ep lt HUMIDIFIER gt HUMIDIFY HUM L1 AC Scd power HUMIDIFY _____ J 24 VAC NE NA B 1O L NA B St Eins OUTDOOR 4 OUTDOOR SENSOR i OUTDOOR ST SENSOR SENSOR SENSOR 52 4 CONNECTION eee See notes 2 5 7 10 11 and 16 See notes 1 2 4 6 7 9 10 11 15 and 16 Modulating and 2 Stage Furnace with Single Speed Air Conditioner Modulating and 2 Stage Furnace with Single Speed Heat Pump TWO STAGE TWO SPEED THERMOSTAT TWO STAGE TWO SPEED THERMOSTAT FURNACE AIR CONDITI
13. air for combustion 15 piped directly to the furnace from a space that is well ventilated with outdoor air such as an attic or crawl space and the space is well isolated from the living space or garage Combustion air requirements for this option are the same as the requirements for providing outside air for combustion for a single pipe vent system Refer to the Air For Combustion and Ventilation Section Provisions for adequate combustion ventilation and dilution air must be provided in accordance with U S A Installations Section 9 3 NFPA 54 ANSI Z223 1 2009 Air for Combustion and Ventilation and applicable provisions of the local building codes Canadian Installations Part 8 of CAN CSA B149 1 10 Venting Systems and Air Supply for Appliances and all authorities having jurisdiction Non Direct Vent 1 pipe System 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 Air for combustion must be supplied as described in the Air For Combustion and Ventilation Section Do not use an abandoned chimney to supply outside air to the furnace See Fig 46 for required clearances Provisions for adequate combustion ventilation and dilution air must be provided in accordance with U S A Installations Section 9 3 NFPA 54 ANSI Z223 1 2009 Air for Combustion and Ventilation and applicable provisions of the local building co
14. 25 29 eos oo 5 on e e 77 101914 5099 7 e pes pem IW mmo m perj veo EE gt per s pempm pes pm Ie Gase Lor m peer ae per p me mem ie Not all families have these models NOTES See notes at end of venting tables See Table 15 for altitudes over 4500 ft 1370 M Altitude Unit Size FT M BTU Hr 19 Table 14 Deductions from Maximum Equivalent Vent Length Ft M __ meae ___ ea s 5 230 38 Venting System Length Calculations The maximum length for each vent pipe inlet or exhaust equals the Maximum Equivalent Vent Length MEVL from Table 13 or Table 15 minus the number of elbows multiplied by the deduction for each elbow in Table 14 Standard vent terminations and concentric vent terminations count for zero deductions Example A direct vent 60 000 Btuh furnace installed at 2100 ft 640 M with 2 in 51 mm vent piping Venting system includes FOR EACH PIPE 3 90 long radius elbows 2 45 long radius elbows and a concentric vent kit Maximum Equivalent Vent Length 127 ft From Table 13 Deduct 3 90 long radius 3x 3 ft _ 94 From Table 14 Deduct 2 45 long radius
15. WA WA 56 WA 09 W CD IET WA A 182 28 17 WA WA 252 155 33 WA m 39 os WA WA 389 5 WA 460 W L ss ws es zo WA WA S nes 2A ones ps ot uos wen I 309 5 185 666 W ias ps props pus e pns we a ars s pw 309 6 569 340 60 550 2er er er por pr wes w 389 56 WA 309 50 50 L LC se os WA s we 22 ss si 05 Ediz 2 22 ud is a d res fir ies s 37 oar 583 ae 148 98 LM e 3 sc 255 24 213 378 97 250 e I 56 25 05 OD e 22 63 213 262 79 58 59 240 205 560 959 L2 sepsis s Pree isa ee zs ss num w WA re es reo WA vs ss ser sz NA v
16. uado ue SJA ON pesn ay uo Bulpuadap apnyubew dy pue yanuq e moys 5 no j 5 e ay uo apnyubew e moys IM 31 Ydesb e no j 5 e uiu ay ue j 5 e 5 PNPNY JM 31 3nq aq pjnous L EL 1d pue 30118 91 6114 550106 J919UnJOA aUUOD UO uni uau1 J8 O Q 91 UJOJJ t 11 pue 11 12euuoosip yo 49915 ay ui pip uey aow ayen ony y N3385 pue MOTT3A 14 55009 DG aUUOD UO peq Jamod 293 01 114 pue 171 Yo amod uin Buipea oud zup e 196 5193 uey sejeniony au DGA ZO aow PNPNY pjnous pue 15 HA 5 15 941 SJA C L EL 1d pue MOTT3A 9L EL 1d DAA S S e euinj aui e ejdag ON C
17. clear water to check for proper operation before re starting furnace Propylene glycol need not be removed before re starting furnace A11405 Manifold A11461 Fig 57 Burner Flame Fig 58 Igniter Position Side View Fig 59 Priming Condensate Trap A11272 A11392 76 Fig 60 Cleaning Heat Exchanger Cell A11273 GROMMET MOTOR ARM MOTOR SHAFT FLAT BLOWER COLLAR WHEEL SET SCREW REW SPECIAL REF SEE DETAIL A SCREW LOCATION BLO HSG ASSY BRACKET KET ENGAGEMENT CUTOFF BLOWER WHEEL BLOWER BRACKET BLO HSG ASSY ey S ai CHOKE POWER Y WHEN n 5 MOTOR 6 BLOWER SCREW GND 11347 Fig 61 Blower Assembly 2 1O BURNER ASSY BURNER SUPT ASSY SENSOR BELOW BURNER IGNITER BRACKET IGNITER FLAME ROLLOUT SWITCH A11403 Fig 62 Burner Assembly SEQUENCE OF OPERATION NOTE Furnace control must be grounded for proper operation or else contro will lock out Control is grounded through green yellow wire routed to gas valve and burner box screw Using the schematic diagram in Fig 64 follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If a power interruption occurs during a call for heat W W1 W Wi and W2 the control will start a 90 sec
18. 4 Configure the switches for the required cooling airflow NOTE Excessive airflow caused by improper A C switch setup may cause condensate blow off in cooling mode 5 Replace blower door Continuous Fan CF Setup Switches SW3 The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode or to select low cooling airflow for two speed cooling units This setup feature allows continuous fan airflow or low cooling airflow to be adjusted To set desired continuous fan airflow or low cooling airflow 1 Remove blower door 2 Locate CF setup switches on furnace control 3 Determine desired continuous fan airflow or low cooling airflow 4 Configure the switches for the required continuous fan or low cooling airflow 5 Replace blower door Setup Switch SW4 Setup switches SW4 are used for applications using a communicating User Interface and to adjust airflow Refer to the communicating User Interface instructions for configuration of SW4 for communications Refer to Fig 55 for configuration of SW4 airflow options Prime Condensate Trap with Water CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in intermittent unit operation or performance satisfaction Condensate trap must be PRIMED or proper draining may not occur The condensate trap has two internal chambers which can ONLY be primed by pouring water into the inducer drain side of condensate tra
19. T0079 1 849 7 aege OL LL 92 7829 92 vie Ie 6vzl WW HONI NI SNOISN3HIG TIY 30N ZIL 949 EN 8 8 9881 ves ez 185 8 4 229 22 021 d Ovi G9 192 sev 6b 26 61 ees iz 02 001 679 0081 1 080 zez tieg 90 9 8 4 91 Spy 069 001 1 090 INIA sa ww seuout seuout seuout 69 HLGIM L3 INI WOLLOS 1871100 HLGIM SNIddlHS 2 v 3ZIS 30vNund L pss rez 9 89 11441 ing i 1 Draw Imensiona Fig 1 D NOTE Doors may vary by model a For 800 16 406 mm round or 14 1 2 x 12 368 x 305 mm rectangle b For 1200 CFM 20 in 508 mm round or 14 1 2 x 19 1 2 368 495 mm rectangle For 1600 CFM 22 in 559 mm round 14 1 2 x 22 1 16 in 368 x 560mm rectangle d For airflow requirements above 1800 CFM see Air Delivery table in these installation instructions 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 return air openings may be required for airflow requirements above 1800 CFM at 0 5 E S P 59TN6A THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT 8 UUAN lt 1 HORIZONTAL LEF
20. or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 2005 Fundamentals Handbook Chapter 35 Acoustical Lining and Fibrous Glass Duct US and CANADA current edition of SMACNA NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Gas Piping and Gas Pipe Pressure Testing US NFPA 54 ANSI Z223 1 2009 NFGC Chapters 5 6 7 and 8 and national plumbing codes CANADA CAN CSA B149 1 2010 Parts 4 5 6 and 9 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 in 914 mm When lever type gas shutoffs are used they shall be T handle type The use of copper tubing for gas piping is not approved by the state of Massachusetts Electrical Connections US National Electrical Code NEC ANSI NFPA 70 2011 CANADA Canadian Electrical Code CSA C22 1 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE CAUTION FURNACE RELIABILITY HAZARD Failure to follow this caution may result in unit component damage 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 di
21. 5 127 10 6452 4 102 60 000 30 19355 6 152 20 13043 5 127 15 9678 5 127 80 000 40 25807 7 178 27 17391 6 152 20 12904 5 127 100 000 50 32258 8 203 34 21739 7 178 25 16130 6 152 120 000 60 38709 9 229 40 26087 7 178 30 19355 6 152 140 000 70 45161 10 254 47 80435 8 203 85 22581 7 178 Not all families have these models EXAMPLES Determining Free Area FURNACE 100 000 60 000 80 000 WATER HEATER 30 000 40 000 30 000 TOTAL INPUT 130 000 divided by 4 000 100 000 divided by 3 000 110 000 divided by 2 000 32 5 Sq In for each two Vertical Ducts or Openings 33 3 Sq In for each Single Duct or Opening 55 0 Sq In for each two Horizontal Ducts Table 4 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 AGH 30 40 50 40 60 80 100 120 140 Space Volume Ft3 M3 0 60 1 050 1 400 1 750 1 400 1 500 2 000 2 500 3 000 3 500 29 7 39 6 49 5 39 6 42 5 56 6 70 8 84 9 99 1 0 50 1 260 1 680 2 100 1 680 1 800 2 400 3 000 3 600 4 200 35 6 47 5 59 4 47 5 51 0 67 9 84 9 101 9 118 9 0 40 1 575 2 100 2 625 2 100 2
22. 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 S636 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 CAN 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 PEX System 636 is a trademark of IPEX Inc Consignes sp ciales pour l installation de ventilation au Canada L installation faite au Canada doit se conformer aux exigences du code CAN CSA B149 2010 Ce syst me de ventillation doit se composer de tuyaux raccords ciments et appr ts conformes au ULC 5636 La tuyauterie de ventillation des gaz ses accessoires le terminal concentrique mural ainsi que l ensemble du drain de condensat ext rieur on
23. It is not necessary to remove the tube from the inducer assembly Remove the pressure switch tube from the front pressure switch and discard the tube A new pressure switch tube is shipped in the loose parts bag Loosen the clamp around the inlet of the vent elbow on the inducer Remove the middle and bottom plugs from the lower right side of the collector box and set aside Do Not Discard Plugs Refer to the appropriate figure to begin the trap conversion Install the 2 plugs previously removed from the collector box in the ports where the condensate trap was removed Install the trap over the ports on the lower right side of the collector box Secure the trap to the collector box with the screw Connect the relief tube to the condensate trap to the relief port of the condensate trap If necessary slide the relief tube in the inducer stand offs to adjust the position of the tube Connect the relief tube to the relief port of the condensate trap Connect the new pressure switch tube to the port on the front pressure switch Route the tube through the stand offs on the inducer assembly and connect to the port on the collector box Trim Off any excess tube to avoid sags or kinks in the tube Rotate the vent elbow to the desired position and tighten the clamp 15 Ib in Refer to Condensate Drain section for information how to install the condensate drain Condensate Trap Horizontal Orientation When the f
24. Refer to Fig 56 58 and 62 1 8 9 10 Flushing Collector Box and Drainage System Turn off gas and electrical supplies to furnace 2 Remove control door 3 4 Check igniter resistance Igniter resistance is affected by Disconnect igniter wire connection temperature Only check resistance when the igniter is at room temperature a Using an ohm meter check resistance across both igniter leads in connector b Cold reading should be between 40 ohms and 70 ohms Remove igniter assembly a Using a 1 4 in driver remove the two screws securing the igniter mounting bracket to the burner assembly See Fig 62 b Carefully withdraw the igniter and bracket assembly through the front of the burner assembly without striking the igniter on surrounding parts c Inspect igniter for signs of damage or failure d If replacement is required remove the screw that secures the igniter on igniter bracket and remove the igniter To replace igniter and bracket assembly reverse items 5a through 5d Reconnect igniter harness to the igniter dressing the igniter wires to ensure there is no tension on the igniter itself See Fig 62 Turn on gas and electrical supplies to furnace Verify igniter operation by initiating control board self test feature or by cycling thermostat Replace control door 4 WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal i
25. Remove the relief tube from the condensate trap Remove the screw that secures the condensate trap to the collector box Remove the trap Remove the relief tube from the port on the collector box It is not necessary to remove the tube from the inducer assembly For Horizontal Left only Remove the pressure switch tube from the front pressure switch and discard the tube A new pressure switch tube is shipped in the loose parts bag For Horizontal Right only pressure switch tube location is not modified Loosen the clamp around the inlet of the vent elbow on the inducer Remove the plugs from the collector box and set aside Do Not Discard Plugs For Horizontal Left only Remove the middle and right plug from the ports at the bottom of the collector box For Horizontal Right only Remove the plug to the right of the condensate trap Refer to the appropriate figure to begin the trap conversion nstall the plugs previously removed from the collector box in the ports where the condensate trap was removed nstall the trap over the ports on the lower side of the collector box Secure the trap to the collector box with the screw Connect the relief tube to the condensate trap to the relief port of the condensate trap f necessary slide the relief tube in the inducer stand offs to adjust the position of the tube Connect the relief tube to the relief port of the condensate trap For
26. are performed 28 Table 7 Air Delivery CFM With Filter SW1 5 and SW4 3 set to OFF except as indicated See notes 1 and 2 INPUT Cooling Switch Settings External Static Pressure 5 BTUH SW2 3 SW2 2 SW2 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 OFF OFF OFF 1060 1070 1080 1080 1075 1065 1050 1035 1025 1010 OFF OFF ON 545 530 520 525 510 OFF ON OFF 710 710 710 695 690 OFF ON ON 875 880 890 895 895 890 885 880 870 855 ON OFF OFF 1060 1070 1080 1080 1075 1065 1050 1035 1025 1010 60000 ON OFF ON 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115 ON ON OFF 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115 ON ON ON 1235 1240 1250 1255 1255 1250 1230 1190 1155 1115 Maximum Cooling Airflow2 1425 1425 1405 1370 1335 1300 1260 1225 1190 1155 High Heat Airflow3 1075 1085 1095 1095 1090 1080 1065 1050 1035 1020 Low Heat Airflow3 855 855 860 870 870 865 860 855 845 785 INPUT Cooling Switch Settings External Static Pressure 5 BTUH SW2 3 SW2 2 SW2 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 OFF OFF OFF 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005 OFF OFF ON 520 505 505 495 490 OFF ON OFF 665 685 680 660 665 OFF ON ON 885 895 905 900 900 895 885 875 860 845 ON OFF OFF 1055 1065
27. concentric vent or a 5 in diameter 127 mm flashing for a 3 in 76 mm concentric vent kit For two pipe or single pipe vent systems a flashing for each pipe of the required diameter will be necessary It is recommended that the flashing be installed by a roofer or competent professional prior to installing the concentric vent The terminations can be installed on a flat or pitched roof Concentric Vent Single or multiple concentric vent must be installed as shown in Fig 47 Maintain the required separation distance between vents or pairs of vents as shown in Fig 47 and all clearance shown in Fig 45 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 in the desired location Loosely assemble concentric vent combustion air termination components together using instructions in kit Slide assembled kit with rain shield REMOVED through hole in wall or roof flashing NOTE Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping Two Pipe and Single Pipe Terminations Single and two pipe vent must be installed as shown in Fig 47 and 48 Maintain the required separation distance between vents or pairs of vents as shown in Fig 47 and 48 and all clearance shown in Fig 45 and 46 Cut the required number of ho
28. 1080 1075 1065 1050 1045 1035 1025 1005 80000 ON OFF ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185 ON ON OFF 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185 ON ON ON 1245 1245 1255 1255 1260 1255 1250 1235 1220 1185 Maximum Cooling Airflow2 1520 1485 1450 1415 1375 1335 1300 1265 1225 1190 High Heat Airflow3 1520 1485 1450 1415 1375 1335 1300 1265 1225 1190 Low Heat Airflow 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005 INPUT Cooling Switch Settings External Static Pressure 5 BTUH SW2 3 SW2 2 SW2 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 OFF OFF OFF 1815 1810 1805 1800 1785 1765 1745 1720 1710 1685 OFF OFF ON 765 775 755 730 710 OFF ON OFF 930 940 935 930 935 OFF ON ON 1095 1120 1120 1105 1095 1100 1085 1075 1055 1050 ON OFF OFF 1245 1270 1275 1280 1290 1280 1285 1270 1260 1245 100000 OFF ON 1440 1445 1455 1445 1450 1440 1440 1425 1415 1405 ON ON OFF 1815 1810 1805 1800 1785 1765 1745 1720 1710 1685 ON ON ON 1815 1810 1805 1800 1785 1765 1745 1720 1710 1685 Maximum Cooling Airflow 2055 2055 2050 2045 2030 2015 1995 1940 1870 1805 High Heat Airflow3 1495 1515 1515 1520 1525 1520 1515 1505 1490 1480 Low Heat Airflow3 1325 1335 1355 1365 1370 1355 1360 1345 1330 1310 29 59TN6A Table 7 Air Delivery CFM With Filter Continued SW1 5 and SW4 3 set to OFF except as indicated See notes 1 and 2 59TN6A
29. 12 30 9 1 20 120 000 115 60 1 127 104 12 8 19 2 12 30 9 1 20 Permissible limits of the voltage range at which the unit operates 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 TTime delay type is recommended XLength shown is as measured one way along wire path between furnace and service panel for maximum 2 percent voltage drop Z cS J BOX MOUNTING SCREWS J BOX MOUNTING BRACKET J BOX COVER Fig 31 Installing J Box When Used A11299 LINE VOLTAGE GROUND 35 ELECTRIC DISCONNECT SWITCH A11146 Fig 32 Field Supplied Electrical Box on Furnace Casing 59TN6A To HUM Terminal On Furnace Control Board To Humidifier Leads on Thermostat Strip A11157 Fig 33 Field supplied Isolation Relay for Humidifiers with Internal Power Supply FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING 1 STAGE FIVE W 9 8 SENA FIELD SUPPLIED WIRE m i FUSED DISCONNECT 1 l BLOWER THREE WIRE D
30. 250 3 000 3 750 4 500 5 250 44 5 59 4 74 3 59 4 63 7 84 9 106 1 127 3 148 6 0 30 2 100 2 800 3 500 2 800 3 000 4 000 5 000 6 000 7 000 59 4 79 2 99 1 79 2 84 9 113 2 141 5 169 8 198 1 0 20 3 150 4 200 5 250 4 200 4 500 6 000 7 500 9 000 10 500 89 1 118 9 148 6 118 9 127 3 169 8 212 2 254 6 297 1 0 10 6 300 8 400 10 500 8 400 9 000 12 000 15 000 18 000 21 000 178 0 237 8 297 3 237 8 254 6 339 5 424 4 509 2 594 1 0 00 NP NP NP NP NP NP NP NP NP NP Not Permitted 1SQIN PER 4000 BTUH Moe AIR __ VENT THROUGH ROOF OUTDOORS MM m m a c 305mm 12 MAX D 12 c 1 o NT Max 805mm lt MAX 305mm zo Ez PER 2000 B THROUGH FE 5 BTUH 59 ROOF o 8 1 1SQIN 1501 PER 50 PER 1000 ps lt 4000 a BTUH IN DOOR BTUH ORWALL g LE E 9 INTERIOR UNCONFINED ac 9 HEATED SPACE OUTDOORS m 5 SPACE 55 SOS TE 6 MIN 152mm SLE 1SQIN FRONT U WOOD PER 8 9 4000 2254 5 1 LOS BTUH 2 PER 1000 1SQIN Soak E ul IN R PER 2000 o _BTUH Y 12 U g 305mm 12 MAXI C i MAX 305mm o 12 Li 305mm L 12 MAX 305mm CIRCULATING AIR DUCTS NT DUCT oe CIRCULATING AIR DUCTS OUTDOORS BTUH Minimum dimensions of 3 in 76 mm pride Size is 100 sq 6
31. 2x 1 5 ft 9ft From Table 14 Maximum Vent Length z 115ft For EACH vent or inlet pipe 47 59TN6A m lt r 4501 to 5000 5001 to 6000 60 000 6001 to 7000 60 000 7001 to 8000 60 000 8001 to 9000 60 000 Not all families e NOTE Maximum Equivalent Vent Length MEVL does NOT include elbows or terminations Use Table 14 Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application Table 15 Maximum Equivalent Vent Length Ft M 4501 to 10 000 Ft 1371 to 3048 M Altitude DIRECT VENT 2 AND NON DIRECT VENT 1 Vent Pipe Diameter opo uos T ens we 9 1s 221 679 120 000 ess par 642 Altitude FT M 40 000 60 000 1370 to 80 000 ws 667 27 0947 Ges 19 Gon 9 14 680 1 G95 er een 120 000 1524 to 80 000 1829 100 000 120 000 40 000 2134 to 80 000 en s eso we 612 35 noz wr eae we urs 120 000 2743 to 80 000 1 8 3048 100 000 47 4 8 120 000 se mode 2438 to 80 000 2743 100 000 NOTES 1 2 3 and 4 Vent pipe systems require long radius elbows Total equivalent vent lengths under 1
32. 3001 915 to 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to 7000 2133 A11252A 68 Table 19 Orifice Size and Manifold Pressure In W C for Gas Input Rate Continued TWO STAGE FURNACE TABULATED DATA BASED ON 20 000 BTUH HIGH HEAT 13 000 BTUH LOW HEAT PER BURNER DERATED 2941000 FT 305M ABOVE SEA LEVEL ALTITUDE AVG GAS RANGE ft m 2134 to 8000 2438 8001 2439 2744 to Orifice numbers shown in BOLD are factory installed A11252B 69 59TN6A SERVICE AND MAINTENANCE PROCEDURES 4 WARNING FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury death and or property damage The ability to properly perform maintenance on this equipment requires certain knowledge mechanical skills tools and equipment If you do not possess these do not attempt to perform any service and maintenance on this equipment other than those procedures recommended in the Owner s Manual CAUTION ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental pollution Remove and recycle all components or materials i e oil refrigerant control board etc before unit final disposal 4 WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD F
33. 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 67 Table 19 Orifice Size and Manifold Pressure In W C for Gas Input Rate TWO STAGE FURNACE TABULATED DATA BASED ON 20 000 BTUH HIGH HEAT 13 000 BTUH LOW HEAT PER BURNER DERATED 29741000 FT 305M ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE ft m U S A and Canada U S A 2001 611 to 3000 914 Canada 2001 611 to 4500 1372 U S A and Canada
34. 5 ul 31045 340 SI 3504 9 AHVQNOD3S peso onis YIUMs eqni eunsseJd peion isqo N3dO LON GIG H2LIMS 34055384 seb Ayea 10 Uado JINIS S hun uni jm 2 SI seb si 4 IVNDIS TVWHONS8V ule1s s 10 ou 10 yms indui seb 10 UOI128UUO2 YIUMS 1eMo q 25001 195294 enueuu 1noj o1 4 sinus usej senunuoo ees epoo 511615 uiu uey 559 J 21 1n0x20 0 sebueu apod uey j 49buo 51 JAAaYDIYM 5 u 1iMs usado un t Uni IM 501 Je9U MO 55 2215 Ajuo yeay ybiy ur 6uneiedo 51 e euunj y 10 uado 51 YMS e 10 y seyeorpul LINWA LINDYID ASLL 122npul 5 ajqissod juan 41936 ujep ayesuapuod aAI5se x3 S9U21IMS
35. Fig 36 Thermostat Wiring Diagrams 38 A11274 00 109 tA 12 13 14 15 16 NOTES FOR THERMOSTAT WIRING DIAGRAMS Heat pump MUST have a high pressure switch for dual fuel applications Refer to outdoor equipment Installation Instructions for additional information and setup procedure If the heat pump date code is 1501E or earlier select the ZONE position on the two speed heat pump control Heat pumps with date code 1601E and later do not have or require a ZONE selection Outdoor Air Temperature Sensor must be attached in all dual fuel applications Configure the thermostat for air conditioner installations Refer to thermostat instructions Configure thermostat for heat pump installations Refer to thermostat instructions Configure thermostat for single stage compressor operation Refer to thermostat instructions Configure thermostat for two stage compressor operation Refer to thermostat instructions Configuration thermostat for Dual Fuel Operation Refer to thermostat instructions 10 11 NO connection should be made to the furnace HUM terminal when using a thermostat with a 24 volt humidifier output Optional connection If wire is connected to W2 on furnace control board either dip switch SW1 2 or SW1 LHT on furnace control should be set in ON position to allow thermostat to control furnace staging Optional connection If wire is connected ACRDJ jumper on furnace contro
36. Fig 45 or Fig 46 per application 2 Termination or termination kit should be positioned where vent vapors will not damage plants shrubs or air condi tioning 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 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 Direct Vent 2 Pipe System Direct vent 2 pipe vent and combustion air pipes must terminate outside the structure Follow all clearances as shown Fig 45 41 59TN6A Allowable vent and combustion air terminations are shown in Fig 47 Ventilated Combustion Air The vent pipe for a Ventilated Combustion Air System must terminate outdoors Follow all vent termination clearances shown in Fig 46 Allowable vent terminations are shown in Fig 48 The combustion air pipe terminates in a well ventilated attic or crawl space Follow the clearances as shown in Fig 50 The combustion air pipe cannot terminate in attics or crawl spaces that use ventilation fans designed to operate in the heating season If ventilation fans are present in these areas the combustion air pipe must terminate outdoors as a Direct Vent System N
37. Horizontal Left only Connect the new pressure switch tube to the port on the front pressure switch Route the tube through the stand offs on the inducer assembly and connect to the port on the collector box Trim Off any excess tube to avoid sags or kinks in the tube Rotate the vent elbow to the desired position and tighten the clamp 15 Ib in Refer to Condensate Drain section for information how to install the condensate drain 12 Vent Pipe Clamp Condensate Trap Relief Port Collector Box Plugs Vent Elbow Collector Box Plug Condensate Trap Relief Port Condensate Trap Outlet Port UPFLOW TRAP CONFIGURATION 1 amp 2 Stage Units Fig 8 Upflow Trap Configuration 13 Vent Elbow Clamp A11307 59TN6A Remove pressure switch tube from front pressure switch and discard Remove relief tube from relief 3 Remove tube from relief port port on collector trap Remove trap from o collector box o and 2 Stage Units Loosen clamp on inlet 6 Remove middle and bottom to vent elbow plugs DO NOT DISCARD Unconverted Factory Configuration As Viewed in the Downflow Orientation Connect tube from Loose Parts bag 7 to port on front pressure switch 8 Route tube through inducer stand offs 9 Trim excess tube Connect pressure switch tube to port on collector box Install plugs in open ports on collector box to port on collector F 3 with sc
38. OUTLET CHOKE 40 000 BTUH MODELS ONLY A11285 Fig 38 Inducer Vent Elbow 49 59TN6A Any other unused knockout may be used for combustion air connection Any other unused knockout may be used Rotate vent elbow to for combustion air required position connection d A11309 required position A11308 UPFLOW LEFT CONFIGURATION UPFLOW RIGHT CONFIGURATION Any other unused knockout may be used for combustion air connection A11310 UPFLOW VERTICAL VENT 9 Attach vent pipe adapter with gasket to furnace casing Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling Slide vent pipe through adapter and coupling into vent elbow Insert vent pipe into vent elbow Torque all clamps 15 Ib in Attach combustion air pipe adapter with gasket to furnace Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw A11399 Fig 39 Upflow Configurations Appearance may vary 50 Rotate vent elbow to 3 required position Rotate vent elbow to required position Any other unused knockout may be used for combustion air connection A11311 A11312 DOWNFLOW LEFT CONFIGURATION DOWNFLOW RIGHT CONFIGURATIO A11313 Downflow Vertical Requir
39. a call for low heat or opened during low heat If opens during 5 minutes after ignition the next heating cycle will be restricted to high heat Check for Proper vent sizing Excessive wind Plugged condensate drain Low inlet gas pressure if LGPS used Restricted combustion air supply Improper pressure switch wiring Water in vent piping possible sagging pipe Disconnected or obstructed pressure tubing Failed or Out of Calibration pressure switches 33 LIMIT CIRCUIT FAULT Indicates the limit or flame rollout is open or the furnace is operating in high heat only mode due to 2 successive low heat limit trips Blower will run for 4 minutes or until open switch remakes whichever is longer If open longer than 3 minutes code changes to lockout 13 If open less than 3 minutes status code 33 continues to flash until blower shuts off Flame rollout switch requires manual reset Check for Improper limit switch or no limit gasket Defective switch or connections Loose blower wheel Improper low heat or high heat gas input adjustment Stuck high heat solenoid in gas valve 34 IGNITION PROVING FAULT Control will try three more times before a lockout 14 occurs If flame signal is lost during blower on delay period blower will come on for the selected blower off delay Check for Gas valve defective or turned OFF Defective Hot Surface Igniter Manual valve shut off Low inlet gas pressure Flame sensor mu
40. and W2 circuits always causes high heat operation regardless of the setting of the low heat only switch The wall thermostat calls for heat closing the R to W1 circuit for low heat or closing the R to Wl and W2 circuits for high heat The furnace control performs a self check verifies the low heat and high heat pressure switch contacts LPS and HPS are open and starts the inducer motor IDM in high speed The start up and shut down functions and delays described in item 1 above apply to the 2 stage heating mode as well except for switching from low to high Heat and vice versa a Switching from Low to High Heat If the thermostat R to W1 circuit is closed and the R to W2 circuit closes the furnace control CPU will switch the inducer motor IDM speed from low to high The high heat pressure Switch relay HPSR is de energized to close the NC contact When sufficient pressure is available the high heat pres sure switch HPS closes and the high heat gas valve solen oid GV HI is energized The blower motor BLWM will transition to high heat airflow five sec after the R to W2 circuit closes Switching from High to Low Heat the thermostat R to W2 circuit opens and the 1 circuit remains closed the furnace control CPU will switch the inducer motor IDM speed from high to low The high heat pres sureswitch relay HPSR is energized to open the NC contact and de energize the high heat gas valve solenoid GV HI Whe
41. and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace door and turn on 115 v power h Blower will run for 90 sec before beginning the call for heat again 1 Furnace should ignite normally Checklist 1 Put away tools and instruments Clean up debris 2 Verify that switches SW1 1 and SW1 6 are OFF and other setup switches are set as desired Verify that switches SW1 7 and SW1 8 for the blower OFF DELAY are set as desired per Table 17 3 Verify that blower and control doors are properly installed 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer s instruc tions 6 Review Owner s Manual with owner 7 Attach literature packet to furnace 63 59TN6A 59TN6A TWO STAGE THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED Regulator Seal Cap ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT Regulator Adjustment 1 2 NPT Inlet Regulator Seal Cap under Cap HOOK AROUND AMMETER 1 8 NPT Inlet Pressure Tap 1 2 NPT Outlet 1 8 NPT Manifold Pressure Tap A11152 c FROM UNIT 24 V Fig 51 Gas Valve CONTROL TERMINALS EXAMPLE 5 0 AMPS ON 0 5 AMPS FOR THERMOSTAT 7 10 TURNS AROUND JAWS ANTICIPATOR SETTING 96316 Fig 53 Amp Draw Check with Ammeter D N BURNER ES ORIFICE A93059 Fig 52 Orifice Hole 64 SERVICE If status
42. 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 7 c Combining space on different floor levels The volumes of spaces on different floor levels shall be considered as com municating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in 2 1 000 Btuh 4 400 mm2 kW of total input rating of all gas appliances 2 An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are ad equate 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 in filtration should be adequate to provide air for combustion permanent ventilation and dilution of flue gases However in buildings with unusually tight construction additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section 4 Unusually tight construction is defined as Construction with a Walls and ceilings exposed to the outdoors have a continu ous sealed vapor barrier Openings ar
43. code recall is needed disconnect the R thermostat lead reset power and put setup switch SW1 1 ON position To dear the status code history put setup switch SW1 1 in the ON position and jumper thermostat terminals R and YIY2 simultaneously until status code 11 is flashed LED CODE STATUS CONTINUOUS OFF Checfor115 VAC atL1 and L2 and 24 VAC at SEC 1 and 5 2 CONTINUOUS ON Control has 24 VAC power RAPID FLASHING Line voltage 115 VAC polarity is reversed EACH OF THE FOLLOWING STATUS CODES IS A SINGLE OR TWO DIGIT NUMBER WITH THE FIRST NUMBER DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND NUMBER AFTER THE PLUS SIGN IS THE NUMBER OF LONG FLASHES 11 NO PREVIOUS CODE Stored status codes are erased automatically after 72 hours or as specified above 12 BLOWER ON AFTER POWER UP 115 VAC or 24 VAC Blower runs for 90 seconds if unit is powered up during a call for heat R WIW1 closed or R W W1 opens during the blower on delay period 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if the limit or frame rollout switch is open longer than 3 minutes or 10 successive limit trips occurred during high heat Control will auto reset after 3 hours Refer to status code 33 14 IGNITION LOCKOUT Control will auto reset after 3 hours Refer to status code 34 15 BLOWER MOTOR LOCKOUT Indicates the blower failed to reach 250 RPM or the blower failed to communicate within 30 seconds after being turned
44. 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 Safety US National Fuel Gas Code NFGC NFPA 54 2009 ANSI 7223 1 2009 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA National Standard of Canada Natural Gas and Propane Installation Code NSCNGPIC CAN CSA B149 1 2010 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 CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario 1R3 Canada Combustion and Ventilation Air US Section 9 3 of the NFPA54 ANSI Z223 1 2009 Air for Combustion and Ventilation CANADA Part 8 of the CAN CSA B149 1 2010 Venting Systems and Air Supply for Appliances Duct Systems US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA
45. cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oiling or coating of the filter is not recommended 5 If equipped with factory specified disposable media filter replace only with a factory specified media filter of the same size 6 Slide filter into cabinet 7 Replace filter cabinet door 8 Turn on electrical supply to furnace Blower Motor and Wheel Maintenance To ensure long life economy and high efficiency clean accumulated dirt and grease from blower wheel and motor annually The inducer and blower motors are pre lubricated and require no additional lubrication These motors can be identified by the absence of oil ports on each end of the motor The following items should be performed by a qualified service technician Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove blower door 3 factory wires can be left connected but field thermostat and accessory wiring may need to be disconnected depend ing on their length and routing 4 If the vent and combustion air pipe passes through the blower compartment it will be necessary to remove the pipes from the blower compartment Disconnect the vent combustion air pipe by a Loosen the clamps on the vent couplings and combustion air pipe external to the furnace b Separate the pipes from the couplings and move them aside c Loosen the clamps on the vent couplings a
46. collector box ports Cleaning Condensate Drain and Trap NOTE If the condensate trap is removed a new gasket between the trap and collector box is required Verify a condensate trap gasket is included in the service kit or obtain one from your local distributor 1 amp Disconnect power at external disconnect fuse or circuit breaker Turn off gas at external shut off or gas meter Remove control door and set aside Turn electric switch on gas valve to OFF Disconnect external drain from condensate drain elbow or drain extension pipe inside the furnace and set aside Disconnect the condensate trap relief hose from collector box port and condensate trap NOTE If condensate has a heat pad attached to the trap trace the wires for the pad back to the connection point and disconnect the wires for the heat pad 7 9 10 11 12 13 Remove the screw that secures the condensate trap to the collector box remove the trap and set aside Remove the trap gasket from the collector box if it did not come off when the trap was removed Discard the old trap gasket Rinse condensate trap in warm water until trap is clean Flush condensate drain lines with warm water Remember to check and clean the relief port on the collector box Shake trap dry Clean port on collector box with a small wire To re install Condensate Drain and Trap 1 2 3 Remove adhesive backing from condensate
47. control valve See Fig 51 If pressure exceeds 0 5 psig 14 In W C gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test If test pressure is equal to or less than 0 5 psig 14 In W C turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test After all connections have been made purge lines and check for leakage at furnace prior to operating furnace The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF Some installations require gas entry on right side of furnace as viewed in upflow See Fig 29 Gas Pipe Grommet For direct vent 2 pipe applications the knockout for the gas pipe must be sealed to prevent air leakage Remove the knockout install the grommet in the knockout then insert the gas pipe The grommet is included in the loose parts bag See Fig 29 31 59TN6A z 1O Table 8 Maximum Capacity of Pipe NOMINAL LENGTH OF PIPE FT M IRON PIPE SIZE 10 20 30 40 50 IN MM 3 0 6 0 9 1 12 1 15 2 1 2 13 175 120 97 82 73 3 4 19 360 250 200 170 151 1 25 680 465 375 320 285 1 1 4 32 1400 950 770 660 580 1 1 2 39 2100 1460 1180 990 900 Cubic ft of gas per hr for gas pre
48. crawl space CRAWL SPACE Ventilated Combustion Air intake pipe Vent through roof flashing 12 305 mm min above highest level of insulation ATTIC 10497 Fig 50 Vent Terminations for Ventilated Combustion Air 59 10O START UP ADJUSTMENT AND SAFETY CHECK General 1 Furnace must have a 115 v power supply properly connec ted and grounded NOTE Proper polarity must be maintained for 115 v wiring Control status indicator light flashes rapidly and furnace does not operate if polarity is incorrect 2 Thermostat wire connections at terminals W W1 and Y Y2 must be made at 24 v terminal block on furnace con trol 3 Natural gas service pressure must not exceed 0 5 psig 14 in w c but must be no less than 0 16 psig 4 5 in w c 4 Blower door must be in place to complete 115 v electrical circuit to furnace CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in intermittent unit operation or performance satisfaction These furnaces are equipped with a manual reset limit switch in burner assembly This switch opens and shuts off power to the gas valve is an overheat condition flame rollout occurs in burner assembly Correct inadequate combustion air supply or improper venting condition before resetting switch DO NOT jumper this switch Before operating furnace check flame rollout manual reset switch for continuity If necessa
49. d partement des incendies etc devraient tre consult es avant l installation afin de d terminer si un permis est requis 4 WARNING 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 54 ANSI 7223 1 2009 and these instructions In Canada refer to CAN CSA B149 1 2010 Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 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 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 Follow the lighting instructions Place the appliance being inspec
50. eau e 5 uny 251246 pue LA LIWM puodsai ay JeuuoJsuen e e day ll uey e SEM apoo 5 5 sn uonisod 440 ay U L LMS Q21Ms dnjas ind auop uauM paysey S 11 epo 5 15 Ajsnoaueynuuls zA A pue y buueduunf pue uonisod NO y ur L LMS Pms dny s Bunand Ajjenuew aq ue 10 sanoy ZZ Jaye paseJe sepoo snieis aui 59 5 LL epo 1 usey pue 11045 L 11 epo sepoo 503245 e2u8Jn220 JO JaPsO Y SAPO SNIS au usej Iw Q31 u38WV 941 uonisod NO ul L LMS ind pue 19591 uon euuoo Y 991 32euuoosip sapoo 504815 OL paysey sem ey SNIS Y 10 uonpes 0 05 s ysey jo 1equunu Aq 1161p puodas ay pue saysey uoys Jaquinu ay Aq ysay 991 YUM Jaquinu Z e si epo smeis apo 501015 buiseud MO Jadoid 104 peuuiM J aul 1224102 10J 4234 Joop e2ejdey pums
51. equipment installation instructions and 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 SAFETY CONSIDERATIONS WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation personal injury death or property damage 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 service agency local gas supplier or your distributor or branch for information or assistance The qualified service agency must use only factory authorized and listed kits or accessories when modifying this product CAUTION FURNACE RELIABILITY HAZARD F
52. in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 4 screws holding bottom plate See Fig 22 2 Remove bottom plate 3 Remove bottom closure panel 4 Reinstall bottom plate and screws Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when only side return air is used NOTE Side return air openings can be used in UPFLOW and some HORIZONTAL configurations Do not use side return air openings in DOWNFLOW configuration See Fig 24 25 26 Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 21 Install field supplied 5 16 x 1 1 2 in 8 x 38 mm max corrosion resistant machine bolts washers and nuts NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure panel to install leveling legs To remove bottom closure panel see Item 1 in Bottom Return Air Inlet section in Step 1 above To install leveling legs 1 Position furnace on its back Locate and drill a hole in each bottom corner of furnace 2 For each leg install nut on bolt and then install bolt with nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if de
53. ing KGASB subbase not required 495 549 511 565 Downflow Applications on Noncombustible Flooring KGASB 19 3 8 19 20 19 5 8 21 subbase not required 492 483 508 498 533 Downflow applications on combustible flooring KGASB sub 18 5 8 19 20 1 4 20 5 8 base required 473 483 514 600 Downflow Applications on Combustible Flooring with CNPV 19 19 20 20 CNRV CAR or CAP Coil Assembly or KCAKC coil box KGASB 483 483 508 508 subbase not required Upflow Applications on Combustible or Noncombustible Floor 23 21 1 8 23 5 8 22 1 4 ing KGASB subbase not required 584 537 600 565 Downflow Applications on Noncombustible Flooring KGASB 22 7 8 19 23 1 2 19 5 8 24 1 2 subbase not required 581 483 597 498 622 Downflow applications on Combustible flooring KGASB sub 22 1 8 19 23 3 4 20 5 8 base required 562 483 603 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR CAP Coil Assembly or KCAKC coil box KGASB 224 2 485 An 600 subbase not required Not all families have these models 24 UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT s FLANGE 90 90 TERREA L N YES YES YES YES YES NO NO NO A10493 Fig 20 Duct Flanges 5 16 8mm ths 1 3 4 44mm 8mm 5 16 BOTTOM amp CLOSURE ta PANEL 44mm 1 3 4 5 44mm 1
54. not pinch wires between cover and bracket 9 Complete external disconnect wiring and installation Con nect line voltage leads as shown in Fig 32 Use best prac tices in U S A for wire bushings strain relief etc CANADA Canadian Electrical Code CSA C22 1 Power Cord Installation in Furnace J Box NOTE Power cords must be able to handle the electrical requirements listed in Table 9 Refer to power cord manufacturer s listings 1 Install J Box mounting bracket to inside of furnace casing See Fig 31 2 Route listed power cord through 7 8 in 22 mm diameter hole in casing and J Box bracket 3 Secure power cord to J Box bracket with a strain relief bushing or a connector approved for the type of cord used 4 Pull furnace power wires through 1 2 in 12 mm diameter hole in J Box If necessary loosen power wires from strain Trelief wire tie on furnace wiring harness 5 Connect field ground wire and factory ground wire to green ground screw on J Box mounting bracket as shown in Fig 31 6 Connect power cord power and neutral leads to furnace power leads as shown in Fig 34 7 Attach furnace J Box cover to mounting bracket with screws supplied in loose parts bag Do not pinch wires between cover and bracket See Fig 31 BX Cable Installation in Furnace J Box 1 Install J Box mounting bracket to inside of furnace casing See Fig 31 2 Route BX connector through 7 8 in 22 mm diameter hole in
55. not see heat ex changer so that radiant heat does not affect readings This practice is particularly important with straight run ducts b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE Temperature rise can be determined for low heat operation by placing setup switch SW1 2 on furnace control in ON position For high heat operation place setup switch SW1 2 in OFF position and jumper R W2 on furnace control DO NOT forget to return setup switch to OFF position and remove R W2 jumper upon completion of testing This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on furnace rating plate If temperature rise is out side this range proceed as follows 1 Check gas input for low and high heat operation 2 Check derate for altitude if applicable 3 Check all return and supply ducts for excessive restrictions causing static pressure greater than 0 5 In W C 4 Ensure Low Heat Rise Adjust switch SW1 3 on furnace control is in ON position when a bypass humidifier is used See Fig 35 for switch loca tion 5 Make sure proper model plug is installed d Remove thermostat jumpers and release blower door Switch e Repeat Steps a through c as required to adjust for high heat temperature rise f When correct high heat input rate and temperature rise is ach
56. property damage or death Consult a qualified installer service agency or your local gas supplier for information or assistance The qualified installer or service agency must use only factory authorized replacement parts kits or accessories when modifying this product Copyright 2011 Carrier Corp 7310 W Morris St Indianapolis IN 46231 Printed in U S A Edition Date 08 11 Catalog 59TN6A 035 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces 59 6 02651 86
57. service or maintenance to the accessories as recommended in the ac cessory instructions Cleaning and or Replacing Air Filter The air filter type may vary depending on the application or orientation The filter is external to the furnace casing There are no provisions for an internal filter with this furnace See Filter Arrangement under the Installation section of this manual 4 WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Never operate furnace without a filter or filtration device installed Never operate a furnace with filter or filtration device access doors removed NOTE If the filter has an airflow direction arrow the arrow must point toward the blower To clean or replace filters proceed as follows 4 WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death or property damage Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing Turn off electrical supply to furnace Remove filter cabinet door Slide filter out of cabinet If equipped with permanent washable filter clean filter by spraying
58. 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 4 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 4 Minimum Space Volumes were determined by using the following equations from the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 9 3 2 2 1 For other than fan assisted appliances such as a draft hood equipped water heater 2113 other Volume ACH 1000 Btu hr A04002 2 For fan assisted appliances such as this furnace 8 Volume 1585 Fan ACH 1000 Btu hr 04003 If Iother combined input of all other than fan assisted appliances in Btuh hr combined input of all fan assisted appliances in Btuh 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 There are no closeable doors between rooms b Combining spaces on same floor level Each opening shall have free area of
59. the furnace the return air shall also be handled by 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 NOTE 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 Ductwork Acoustical Treatment NOTE Metal duct systems that do not have a 90 degree elbow and 10 ft 3 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 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 NOTE For horizontal applications the top most flange may be bent past 90 allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil
60. valve GV M and the control CPU will repeat the ignition sequence for up to three more Trials For Ignition before going to Igni tion Lockout Lockout will be reset automatically after three hours or by momentarily interrupting 115 vac power to the furnace or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU notat 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 on high speed until flame is no longer proved Blower On delay If the burner flame is proven the blower ON delays for low heat and high heat are as fol lows Low heat 45 sec after the gas valve GV M is opened the blower motor BLWM is turned ON at low heat airflow humidifier terminal HUM The inducer motor IDM will re main energized for a 15 sec post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized at low heat airflow or transition to low heat airflow for 90 120 150 or 180 sec depending on se lection at blower OFF delay switches The furnace con trol CPU is factory set for a 120 sec blower OFF delay 2 Two Stage Thermostat and Two Stage Heating See Fig 35 and 36 for thermostat connections NOTE In this mode the low heat only switch SW1 2 must be ON to select the low heat only operation mode in response to closing the thermostat R to W1 circuit Closing the thermostat R to Wl
61. 0 for 40 000 BTUH furnaces require the use of an outlet choke plate at altitudes 0 to 2000 ft 0 to 610 M Failure to use an outlet choke when required may result in flame disturbance or flame sense lockout Vent sizing for Canadian installations over 4500 ft 1370m above sea level are subject to acceptance by the local authorities having jurisdiction NA Not allowed pressure switch will not close or flame disturbance may result Do not use pipe size greater than those specified in table or incomplete combustion flame disturbance or flame sense lockout may occur Size both the combustion air and vent pipe independently then use the larger diameter for both pipes Assume the two 45 elbows equal one 90 elbow Wide radius elbows are desirable and may be required in some cases Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count The minimum pipe length is 5 ft 1 5 M for all applications Use 3 76 mm diameter vent termination kit for installations requiring 4 in 102 mm diameter pipe 48 Attach gaskets to vent pipe and combustion air adapters Vent Coupling and Adapter 11314 Fig 37 Vent Coupling and Adapter with Gaskets INDUCER OUTLET VENT ELBOW CLAMP TORQUE 15 LB IN VENT PIPE CLAMP TORQUE 15 LB IN PSC INDUCER ASSEMBLY VENT ELBOW INDUCER
62. 01 3194 S o43u02 adeUIN SAA iC 23S pue L DAS 91944 S SJA ON S3A SJA gsaysey pue 11045 Jo uoneuiquuoo e 5 440 NO 3461 513235 q31 u3glwv SI e K pidei 573235 q31 YIAWY 51 SJA Joop S ZT pue 138 ASLL 5 ON opino VONL6S uo 146 503235 q31 u3gwv SI LYVLS A11326A Fig 63 Troubleshooting Guide 82 epouj2eje Josuas pue jeuunq paup YO J eunsseud MOJ 0 u21IMs ua 3eau ubiu ul j e2ej dai uo 15 100 5 5 J yeay Yybiy ur 1eedai LIS JOU pue jeuruou 0 9 0 p je id 1eau si qua Juno jl pue suon auuoo uonejedo 10 1581 Jeadas pue uo Buy eunssaJd seb MOT u6noi 10 JoA oKaJe5 ayenbapeu uo pausny seb ey xau o 3u02 e e da4 JI suon2euuo2 jueuoduuo2 aAn2sjep e ejdey pu
63. 149 1 clearances shall be in accordance cm from the centerline of the terminal with local installation codes and the requirements of with local installation codes and the requirements of E Clearance to an unventilated soffit the gas supplier and the manufacturer s installation the gas supplier and the manufacturer s installation F Clearance to an outside corner instructions instructions G Clearance to an inside corner Clearance to each side of the centerline extended T T H above electrical meter or gas service regulator as 3 ft 9 M within 15 ft 4 6 M above the meter 3 ft 9 M within 15 ft 4 6 M above the meter regulator assembly regulator assembly sembly 3 ft 9 M For clearances not specified in ANSI 2223 1 NFPA 54or CSA B149 1 clearances shall be in Clearance to service regulator vent outlet 3 ft 9 M accordance with local installation codes and the requirements of the gas supplier and the manufacturer s installation instructions Clearance to mechanical air supply inlet to 12 in 305 mm for appliances gt 10 000 Btuh 3kW 9 in 229 mm for appliances gt 10 000 Btuh 8kW J building or the combustion air inlet to any other appli and lt 100 000 Btuh 30 kW 36 914 mm for and lt 50 000 Btuh 15 kW 12 in 305 mm for ance appliances gt 100 000 Btuh 30 kW appliances gt 500 000 Btuh 15 kW K Clearance to a mechanical air supply inlet 6 ft 1 8 M 3 ft 9 M For clearances not specified
64. 4 in turn Be sure pipe is fully inserted into fitting socket 14 Wipe excess cement from joint A continuous bead of ce ment will be visible around perimeter of a properly made joint 15 Handle pipe joints carefully until cement sets 16 Horizontal portions of the venting system shall be suppor ted to prevent sagging Support combustion air piping and vent piping a minimum of every 5 ft 1 5M 3 ft 91M for SDR 21 or 26 PVC using perforated metal hanging strap or commercially available hangars designed to support plastic pipe 17 Prevent condensate from accumulating in the pipes by slop ing the combustion air piping and vent piping downward towards furnace a minimum of 1 4 in per linear ft with no sags between hangers 18 Complete the vent and combustion air pipe installation by connecting the concentric vent or by installing the required termination elbows as shown in Fig 47 48 and 49 For Ventilated Combustion Air Termination See Fig 50 19 Use appropriate methods to seal openings where combus tion air pipe and vent pipe pass through roof or sidewall Optional Installation of the vent pipe This option provides a disconnect point for the vent pipe The vent pipe must be cemented to the plastic vent pipe adapter to maintain a sealed vestibule See Fig 43 1 Insert a length of vent pipe through the casing into the outlet of the vent elbow 43 z 10O 59TN6A 2 Slide the plastic vent p
65. 4516 sq mm with minimum dimensions T of3 in mm NOTE evens eee of openings t Minimum of 3 in 76 mm when type B1 vent is used 03174 03175 Fig 6 Air for Combustion Ventilation and Dilution for Outdoors 11 Indoors Fig 7 Air for Combustion Ventilation and Dilution from 59TN6A CONDENSATE TRAP Condensate Trap Upflow Orientation When the furnace is installed in the upflow position it is not necessary to relocate the condensate trap or associated tubing Refer to Fig 8 for upflow condensate trap information Refer to Condensate Drain section for information how to install the condensate drain Condensate Trap Downflow Orientation When the furnace is installed in the downflow position the factory installed trap will be located at the upper left corner of the collector box When the furnace is installed in the downflow orientation the factory installed trap must be relocated for proper condensate drainage To Relocate the Condensate Trap Orient the furnace in the downflow position Fig 9 shows the condensate trap and tubing before and after relocation Remove the relief tube from the condensate trap Remove the screw that secures the condensate trap to the collector box Remove the trap Remove the relief tube from the port on the collector box
66. 59TN6A Two Stage Variable Speed Multipoise Gas Furnace Series 100 turn to the experts Installation Start up Operating and Service and Maintenance Instructions NOTE Read the entire instruction manual before starting the installation SAFETY CONSIDERATIONS 3 INTRODUCTION cong cis Heme ones 4 CODES AND 5 85 4 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 4 ACCESSORIES rr he hr 5 LOCATION itane eM ensem does ee 5 AIR FOR COMBUSTION AND VENTILATION 9 CONDENSATE 12 UpfloW oi eee er RR Re IO RE Une as 12 DowhntlOW S e Ra P REOR REUS 12 Horizontal Hea ie ewe 12 CONDENSATE DRAIN 17 INSTALLATION 65 m dex ee s gu 19 lini ms 19 DowntloW 5252 0845 ex ER er ER E eR 19 Horizontal bp eR Rey CU ERR 20 Filter Arrangement 20 AIR DUCTS E RE bade eae 27 Ductwork Acoustical Treatment 27 GAS PIPING 31 ELECTRICAL CONNECTIONS 32 115 V Wirhg eee Ime Re eR eee 32 J Box Installation 33 24 V Wing i cis sce
67. 8 Check the igniter alignment See Fig 56 58 and 62 9 Attach the wires to the roll out switches 0 Align the burner assembly with the openings in the primary cell inlet panel and attach the burner assembly to the cell panel 11 Connect the wire for the flame sensor 12 Connect the wire for the Hot Surface Igniter NOTE Use propane resistant pipe dope to prevent leaks Do not use Teflon tape 1 13 Install the gas pipe to the gas valve amp WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 A fire or explosion may result causing property damage personal injury or loss of line 14 Check for gas leaks with a commercially available soap solution made specifically for the detection of leaks 73 z 10O 15 16 17 18 Turn gas on at electric switch on gas valve and at external shut off or meter Turn power on at external disconnect fuse or circuit break er Run the furnace through two complete heating cycles to check for proper operation Install control door when complete Servicing Hot Surface Igniter The igniter does NOT require annual inspection Check igniter resistance before removal
68. Bend flange inward past 90 with wide duct pliers See Fig 20 The supply air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY factory approved 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 to duct external to furnace casing Return Air Connections WARNING FIRE HAZARD A failure to follow this warning could cause personal injury death and or property damage Never connect return air ducts to the back of the furnace Follow instructions below The return air duct must be connected to return air opening bottom inlet DO NOT cut into casing sides left or right Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace See Fig 25 Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when 20 bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 4 screws holding bottom plate See Fig 22 2 Remove bottom plate 3 Remove bottom closure panel 4 Reinstall bottom plate and screws Horizontal Installation NOTE The furnace
69. Clean wheel per instructions on degreaser cleaner Do not get degreaser in motor 8 Reassemble motor and blower wheel by reversing items 7b through 7f Ensure wheel is positioned for proper rotation 9 Torque motor mounting bolts to 40 10 Ib in when reas sembling 10 Torque blower wheel set screw to 160 20 Ib in when reassembling 11 Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 12 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 13 Reinstall blower assembly in furnace 14 Reinstall 2 screws securing blower assembly to blower deck 15 Reconnect blower leads to furnace control Refer to furnace wiring diagram and connect thermostat leads if previously disconnected NOTE sure to attach ground wire and reconnect blower harness plugs to blower motor 72 A WARNING ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death Blower door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes 16 Downflow or horizontal furnaces with vent pipe through furnace only a Install and connect short piece of vent pipe inside furnace to existing vent b Connect vent connector to vent elbo
70. DAPTER VENT PIPE FLUSH WITH ADAPTER VENT PIPE FLUSH SHOWING COUPLING 11339 Fig 43 Vent Pipe Flush with Adaptor 54 Point elbow down towards back of furnace 256 0 mm CASING SIDE ATTACHMENT COMBUSTION AIR PIPE NON DIRECT VENT TOP PLATE ATTACHMENT COMBUSTION AIR PIPE NON DIRECT VENT A11345 Fig 44 Combustion Air Pipe Attachment VENT TERMINAL A Xj AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITED 25 24 65 2 Item Clearance Description Canadian Installation 1 U S Installation 2 Clearance above grade veranda porch deck bal A aud 12 in 305 mm 18 in 457 mm above roof surface 12 in 305 mm cony or anticipated snow level 12 in 305 mm for appliances gt 10 000 Btuh 3kW 9 in 229 mm for appliances gt 10 000 Btuh 8kW B Clearance to a window or door that may be opened and lt 100 000 30 kW 36 914 mm for and lt 50 000 Btuh 15 kW 12 in 305 mm for appliances gt 100 000 Btuh 30 kW appliances gt 500 000 Btuh 15 kW C Clearance to a permanently closed window Vertical clearance to a ventilated soffit located above For clearances not specified in ANSI Z223 1 NFPA 54 For clearances not specified in ANSI Z223 1 NFPA 54 D the terminal within a horizontal distance of 2 feet 61 or CSA B149 1 clearances shall be in accordance or CSA B
71. ER 24 VAC CONNECTIONS E N 115 12 NEUTRAL d V17 HK42FZ0433411 VS HSI HI LO CONNECTIONS 24 PART NUMBER AND 115 VAC L1 LINE PL1 LOW VOLTAGE MAIN DATE CODE WWYY VOLTAGE CONNECTIONS PL2 HOT SURFACE HARNESS CONNECTOR IGNITER amp INDUCER EAC 1 TERMINAL MOTOR CONNECTOR SOFTWARE VERSION 115 VAC 1 0 AMP MAX A11426 Fig 35 Variable Speed Furnace Control 37 TWO STAGE SINGLE SPEED TWO STAGE SINGLE SPEED THERMOSTAT THERMOSTAT FURNACE AIR CONDITIONER FURNACE HEAT PUMP HEAT STAGE 2 2 NOTE 11 wa RVS COOLING 2 1 E xl HEAT STAGE 3 2 NOTE 11 wa FURNACE HEAT STAGE 1 WWI __________ WWT vi COOL STAGE 1 Y Y2 L4J eee L I Y HEAT STAGE 2 LIwiw1L 4 1 I W2 FURNACE LO LN G _________ HEAT COOL STAGE 1 YIY2 _ ____ _1 Y COMPRESSOR 24VACHOT R
72. Equivalent Vent Length 1 Measure the individual distance from the furnace to the ter mination for each pipe 2 Select a Maximum Equivalent Vent Length MEVL longer than the measured distance of the individual vent and com bustion air connections to the vent termination 3 Count the number of elbows for each pipe 4 For each pipe multiply the number of elbows by the equi valent length for the type of elbow used Record the equi valent length of all the elbows for each pipe 5 If a Tee is used on the termination record the equivalent length of the Tee used 6 Record the equivalent length of the termination to be used 7 Subtract the equivalent lengths of the fittings and termina tions from the Maximum Equivalent Vent Length 8 If the Maximum Vent Length calculated is longer than the individual measured length of the vent pipe and combustion air pipe then the diameter of pipe selected may be used 9 If the Maximum Vent Length calculated is shorter than the individual measured length of either the vent pipe or the combustion air pipe recalculate the Maximum Vent Length using the next larger diameter pipe NOTE The vent pipe and combustion air pipe must be the same diameter NOTE If the Maximum Vent Length for diameter of the pipe selected is longer than the measured length and the equivalent length of all the fitting and terminations recalculate using the next smaller diameter If the recalculated Maximum Vent Length
73. Fig 41 Horizontal Left Appearance may vary 52 e TT ON ls ppt 24 ALTERNATE N COMBUSTION ed LSM CONNECTIONS TGH HORIZONTAL RIGHT HORIZONTAL RIGHT A11336 VERTICAL VENT CONFIGURATION LEFT VENT CONFIGURATION Requires Internal Vent Kit See Product Data for Current Kit Number ALTERNATE COMBUSTION AIR CONNECTIONS h p 65 TOI 4 Sa 7 f 4 p EX Lp E LEN e M A11335 HORIZONTAL RIGHT RIGHT VENT CONFIGURATION Attach vent pipe adapter with gasket to furnace casing Align notches rubber coupling over standoffs on adapter Slide clamps over the coupling Slide vent pipe through adapter and coupling into vent elbow Insert vent pipe into vent elbow 5 Torque all clamps 15 Ib in Attach combustion air pipe adapter with gasket to furnace Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw A11341 Fig 42 Horizontal Right Appearance may vary 53 ALIGN NOTCHES IN VENT COUPLING OVER 5 ON ADAPTER TORQUE LOWER CLAMP 15 LB IN WHEN REMAINING VENT PIPE IS INSTALLED TORQUE UPPER CLAMP TO 15 LB IN VENT PIPE ADAPTER WITH GASKET INSTALLED ON FURNACE VENT PIPE IS CUT FLUSH WITH TOP A
74. M below or to the side of the opening 1 ft B Clearance to window or door fhatmaybe opened and lt 100 000 30kW 36 in 914 mm for 3 M above the opening appliances gt 100 000 Btuh 30 kW Clearance to permanently closed window Vertical clearance to a ventilated soffit located above For clearances not specified in ANSI Z223 1 NFPA 54 For clearances not specified in ANSI Z223 1 NFPA 54 the terminal within a horizontal distance of 2 feet 61 or CSA B149 1 clearances shall be in accordance or CSA B149 1 clearances shall be in accordance cm from the centerline of the terminal with local installation codes and the requirements of with local installation codes and the requirements of E Clearance to an unventilated soffit the gas supplier and the manufacturer s installation the gas supplier and the manufacturer s installation F Clearance to an outside corner instructions instructions G Clearance to an inside corner Clearance to each side of the centerline extended H above electrical meter or gas service regulator as 3 ft 9 M within 15 ft 4 6 M above the meter 3 ft 9 M within 15 ft 4 6 M above the meter regu regulator assembly lator assembly sembly 3 ft 9 M For clearances not specified in ANSI Z223 1 NFPA 54 or CSA B149 1 clearances shall be in 1 Clearance to service regulator vent outlet 3 ft 9 M accordance with local installation codes and the requirements of the gas supplier and the manu
75. Media Filter Cabinet The Media Filter Cabinet uses either a standard 1 in 25 mm filter or 4 in 102 mm wide Media Filter which can be purchased separately A field supplied accessory air cleaner may also be used in place of the media cabinet The Media Cabinet is sized for bottom return applications for use in upflow downflow and horizontal applications A 16 in 406 mm Media Cabinet is shipped with the 14 3 16 in 360 mm furnace and includes block off plates For upflow side return applications the Media Cabinet or field supplied accessory air cleaner can be installed on the side of the furnace or side and bottom when a bottom plenum is used See Fig 18 and 24 For downflow applications the Media Cabinet or field supplied accessory air cleaner must only be connected to the bottom opening on the furnace See Fig 18 and 25 For horizontal applications the Media Cabinet or field supplied accessory air cleaner for all models can be connected to the bottom opening on the furnace For side return use in the horizontal position refer to Fig 26 If both side and bottom openings are used in Fig 26 each opening used will require a filter The media cabinet or field supplied accessory air cleaner can also be installed in the common return duct prior to entering the return air opening in any orientation Refer to the instructions supplied with Media Cabinet or accessory air filter for assembly and other details See Ta
76. NT CONFIGURATIONS A11154 Fig 27 Working Platform for Attic Installation COMBUSTION AIR PIPE SEE VENTING SECTION 1 4 IN ROD NOTE EXTEND ANGLE IRON OUT FOR COIL SUPPORT HEX NUT amp WASHER 4 REQD PER ROD ROD LOCATION USING DIMPLE NOTES 1 1 In 25mm clearance minimum between LOCATORS 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 Furnace shown is a direct vent application Refer to the Venting section for allowable vent configurations A11155 Fig 28 Suspended Furnace Installation 27 59TN6A 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 external static pressure The furnace airflow rates are provided in Table 7 Air Delivery CFM With Filter When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing
77. ON in two successive heating cycles Control will auto reset after 3 hours Refer to status code 41 21 GAS HEATING LOCKOUT Control wil NOT auto reset Check for Mis wired gas valve Defective control valve relay 22 ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve 23 PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Pressure switch stuck closed 24 SECONDARY VOLTAGE FUSE 15 OPEN Check for Short circuit in secondary voltage 24 VAC wiring 25 MODEL SELECTION OR SETUP ERROR Either indicates the model plug PL4 is missing or incorrect or setup switch or SW1 6 is positioned improperly If code flashes only 4 times on power up control is defaulting to mode selection stored in memory Check the following Thermostat call with SW1 1 ON Thermostat call with SW1 6 ON SW1 1 and SW1 6 both ON together Two different furnace models twinned See Rating Plate for model plug number and resistance values if code flashes continuously HIGH HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED Indicates the high heat pressure switch input failed to close or opened during high heat Control relay may be defective or gas valve is mis wired Refer to status code 32 32 LOW HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED Indicates the low heat pressure switch input failed to close on
78. ONER FURNACE HEAT PUMP HEAT STAGE 2 ojw2 __ w2 RVS COOLING O W2 ________________________ L COOL STAGE 1 ___________ m 1 72 HEAT STAGE 1 W W1 1 4 W W1 HEAT COOL STAGE 1 Y1 W2L JAVA nd L Yi COMPRESSORLO 12 COOL STAGE 2 2 2 l l Y2 HEAT STAGE 3 WWI Jwwil 11 wa FURNACE 12 G Ll HEAT COOL STAGE 2 viva NOTE 12__ l Y2 f COMPRESSOR HI 24VACHOT R _ ___________ Lb R 18 F ws 24 VAC HOT Re 2 EE ne ere _1 R DEHUMIDIFY p __________ DHUM LN DEHUMIDIFYE p L4 24VAC COMM C 4 4 L 24 COMM _________ Cou 1 E HUM HUM p PES i HUMIDIFY 1 L HUMIDIFIER 24 HUMIDIFY HUM 1 1 24 VAC Liu NA B B le OUTDOOR mi T OUTDOOR m OUTDOOR SENSOR OUTDOOR j eese SENSOR SENSOR SENSOR CONNECTION COMMI CR CONNECTION S2 1 See notes 2 5 8 10 11 12 and 16 See notes 1 2 3 4 6 8 9 10 12 13 15 and 16 Modulating and 2 Stage Furnace with Two Speed Air Conditioner Modulating and 2 Stage Furnace with Two Speed Heat Pump
79. OOR HEATING x 9 208 230 OR SWITCH ONLY e i e e e 460 VOLT L e i e THREE 030 0 O O EM zd 4 Q HT S EE a a e 208 230 GND R NOTE 1 _ m ole e NOE 115 VOLT FIELD JUNCTION PHASE SUPPLIED BOX P 4t tle t 9 ND FUSED 1 CONDENSING DISCONNECT S4t UNIT 24 VOLT TERMINAL NOTES 1 Connect Y Y2 terminal as shown for proper operation BLOCK 2 Some thermostats require a C terminal connection as shown FURNACE 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A11401 Fig 34 Typical Two Stage Field Wiring Diagram 36 COMMUNICATION CONTINUOUS FAN OUTDOOR SW4 SETUP CONNECTOR CF AIRFLOW AIR TEMP SWITCHES MODEL PLUG SETUP SWITCHES CONNECTOR CONNECTOR SW1 SETUP KoY SWITCHES AND PLA BLOWER OFF gt DELAY swi o AIR CONDITIONING SW A C AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX ACRDJ AIR CONDITIONING RELAY DISABLE JUMPER 24 V THERMOSTAT TERMINALS ANY A FLASH UPGRADE CONNECTOR FACTORY ONLY STATUS AND COMM 8 n LED LIGHTS i FUSE BLOWER n HARNESS n CONNECTOR n 1 115 1 TRANSFORM
80. OUTDOOR OPENING requires a 1 sq in 645 sq mm of free area per 3 000 Btuh 734 mm_2 kW for combined input of all gas appliances in the space per Fig 6 and Table 3 b Not less than the sum of the areas of all vent connectors in the space The opening shall commence within 12 in 300 mm of the ceiling Appliances in the space shall have clearances of at least 1 in 25 mm from the sides and back and 6 in 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 z 10O Indoor Combustion Air amp Standard and Known Air Infiltration Rate Methods Indoor air is permitted for combustion ventilation and dilution if the Standard or Known Air Infiltration Method is used WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death 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 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
81. T AIRFLOW THE BLOWER IS LOCATED ABOVE THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED DOWNWARD AIRFLOW AN THE BLOWER IS Qr LOCATED BELOW THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED UPWARD UPFLOW Zo DOWNFLOW AIRFLOW HORIZONTAL RIGHT a THE BLOWER IS LOCATED TO THE LEFT OF THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED TO THE RIGHT A02097 Fig 2 Multipoise Orientations SUPPLY AIR 32 F 0 C MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED M TX 2 MAX80 F 27 mmm 1 o RETURN AIR MIN60 F 16 tit i NIA 10490 Fig 3 Freeze Protection and Return Air Temperature Fig 4 Prohibited Installations 18 IN 457 2 mm MINIMUM TO BURNERS A10494 93044 Fig 5 Installation a Garage AIR FOR COMBUSTION AND VENTILATION Introduction Direct Vent 2 pipe Applications When the furnace is installed as a direct vent 2 pipe furnace no special provisions for air for combustion are required However other gas appliances installed in the space with the furnace may require outside air for combustion Follow the guidelines below to insure that other gas appliances have sufficient air for combustion Non Direct Vent 1 pipe Applications When the furnace i
82. User Interface Refer to the instructions supplied with the User Interface for complete details See Fig 35 4 Outside Air Thermistor OAT The OAT connection is used in conjunction with commu nicating User Interface It is not required when the furnace is controlled by a standard type thermostat Refer to the in structions supplied with the User Interface for complete de tails Alternate Power Supplies This furnace is designed to operate on utility generated power which has a smooth sinusoidal waveform If the furnace is to be operated on a generator or other alternate power supply the alternate power supply must produce a smooth sinusoidal waveform for compatibility with the furnace electronics The alternate power supply must generate the same voltage phase and frequency Hz as shown in Table 9 or the furnace rating plate Power from an alternate power supply that is non sinusoidal may damage the furnace electronics or cause erratic operation Contact the alternate power supply manufacturer for specifications and details 34 Table 9 Electrical Data TWO STAGE ECM FURNACES UNIT SIZE VOLTS OPERATING VOLTAGE MAXIMUM UNIT MINIMUM MAXIMUM MAXIMUM HERTZ RANGE UNIT AMPACITY WIRE WIRE FUSE OR CKT PHASE AMPS SIZE LENGTH BKR Maximum Minimum AWG FT M AMPSt 60 000 115 60 1 127 104 7 7 12 8 14 29 8 8 15 80 000 115 60 1 127 104 7 7 12 8 14 29 8 8 15 100 000 115 60 1 127 104 12 8 19 2
83. aJd pa4lMSIlA aqny aunssaid 1540 10 pa1 euuoosti uado nis ainssaid 13e2u wo1 40j5p9U5 43501 SI HOLIMS 38055384 1V3H H5IH IHM N3dO HOLIMS 38055344 LV3H MO1 ponad puodas aui jo pue y q ay 5200 1591 JUBUOdWOD y 5 0 uonisod NO 941 Ul 9 1 MS Yyoums dn3es pue 19594 0 3 02 BY uon2auuo 3 350 ay ay 1591 1ueuoduuoo ui ue 5 5 dy 105 95 10 seb y s y OL pepuno4b aq jou 15 10595 4 SJ J 38Uu JaaYs e euunj pa1 euuoo 9q ISAW AIM MOTI3A N3389 e JeAjo inus days ay 0 1514 eui gt 5 ay 10 UO ay 150 s jeubis awe sin220 14 30320 say e uenbas ON uoniubi y 013002 ay uoniubi 104 je y pasuas jou 5 owe 3dfYTlV34 DNIAOSd NOILINDI 31045 5 0 spea 1e150uu8t PUUSA
84. ace gas control valve and extend a minimum of 2 in 51 mm outside the furnace CAUTION FURNACE DAMAGE HAZARD Failure to follow this caution may result in furnace damage Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls and burner misalignment An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft 1 8 M of furnace Install a sediment trap in riser leading to furnace as shown in Fig 30 Connect a capped nipple into lower end of tee Capped nipple should extend below level of furnace gas controls Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve 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 equipment shutoff valve Piping should be pressure and leak tested in accordance with the current addition of the NFGC in the United States local and national plumbing and gas codes before the furnace has been connected Refer to current edition of NSCNGPIC in Canada After all connections have been made purge lines and check for leakage at furnace prior to operating furnace NOTE The furnace gas control 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 W C stated on gas
85. age 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 CAUTION FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life DO NOT orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of heat exchangers causing failures See Fig 52 For proper operation and long term reliability the Furnace input rate must be within 2 percent of input rate on furnace rating plate The gas input rate on rating plate is for installations at altitudes up to 2000 ft 609 6M In the USA the input rating for altitudes above 2000 ft 609 6M must be reduced by 2 percent for each 1000 ft 304 8M above sea level Refer to Table 16 In Canada the input rating must be derated by 5 percent for altitudes of 2000 ft 609 6M to 4500 ft 1371 6M above sea level To adjust manifold pressure to obtain the proper input rate first determine if the furnace has the correct orifice installed At higher altitudes or different gas heat contents it may be necessary to change the factory orifice to a different orifice Tables have been provided in the furnace installation instructions to match the required orifice to the manifold pressure to the heat content and specific gravity
86. ailure to follow this caution may result in unit component damage Application of this furnace should be indoors with special attention given to vent sizing and material gas input rate air temperature rise unit leveling and unit sizing Improper installation 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 Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified personnel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in literature on tags and on labels attached to or shipped with furnace and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and o
87. ailure to follow this warning could result in personal injury or death or property damage Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing CAUTION ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper furnace operation or failure of furnace Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation General These instructions are written as if the furnace is installed in an upflow application An upflow furnace application is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can be installed in any of the 4 positions shown in Fig 2 you must revise your orientation to component location accordingly Electrical Controls and Wiring 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death There may be more than one electrical supply to the furnace Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing Lock out and tag switch with a suitable warning label The electrical ground and pola
88. and SW2 3 either ON or OFF Select the required airflow from Fig 55 Fig 55 is based on 350 CFM per ton For other CFM per ton See Fig 35 and Fig 55 and Fig 64 NOTE 6 ton airflow will truncate at 2200 CFM on applicable models For a complete explanation of cooling airflow refer to the section titled Sequence of Operation 4 The continuous fan airflow is adjusted by turning CF setup switches SW3 1 3 2 and 3 1 either ON or OFF See Table 7 Air Delivery CFM With Filter Select the required continuous fan airflow from Fig 55 The continuous fan speed is also the fan speed for low speed cooling when furnace is used with a 2 speed cooling unit Adjust the Continuous Fan CFM to match the airflow required for low speed cooling Select the required airflow from Fig 55 For other CFM per ton See Fig 55 and Fig 64 The airflow selected for low speed cooling will also be the airflow used for continuous fan The continuous fan speed can be further adjusted at the ther mostat using the Comfort Fan select function Changing the continuous fan speed at the thermostat DOES NOT change the low speed cooling airflow selected at the control board Adjust Continuous Fan Airflow Low Speed Cooling Airflow The ECM blower motor can be adjusted for continuous fan speeds different than heating or cooling fan speed See Table 7 Air Delivery CFM With Filter Select the required continuous fan airflow from Fig 55 The contin
89. and drain line Remove the knock out for the condensate trap in the side of the casing Install the drain trap grommet in the casing If necessary remove the trap install the grommet and re install the trap Remove the pre formed drain tube the offset 1 2 in CPVC pipe and two spring clamps from the loose parts bag Remove the formed grommet on the tube to create an elbow or straight connector See Fig 15 Connect the cut tube to the outlet of the condensate trap with 1 spring clamp Slide the other spring clamp down the plain end of the drain tube Connect additional 1 2 in CPVC piping to the open end of the tube Slide the spring clamp down over the 1 2 in CPVC pipe 10 Connect additional 1 2 in CPVC piping to a condensate pump approved for use with acidic furnace condensate or to a code approved drain When a condensate pump is not used slope the pipe away from the furnace to allow for proper drainage INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAP PULL DRAIN STUB THROUGH CASING N 11305 DA lt 5 CAUTION 2 o OPEN SPRING CLAMP 10 CUT HAZARD INSERT FIELD SUPPLIED 1 2 CPVC DRAIN PIPE Failure to follow this caution may result in personal injury CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN TUBE RIGHT SIDE DRAIN INSTALLATION Sheet metal parts may have sharp edges or burrs Use care and wear appr
90. appliances have sufficient air for combustion Provisions for adequate combustion ventilation and dilution air must be provided in accordance with U S A Installations Section 9 3 of the NFPA 54 ANSI Z223 1 2009 Air for Combustion and Ventilation and applicable provisions of the local building codes Canada Part 8 of the CAN CSA B149 1 2010 Venting Systems and Air Supply for Appliances CAUTION FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace damage Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can 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 4 WARNING 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 u
91. ate 1 Adjust manifold pressure to obtain low fire input rate See Fig 51 a Turn gas valve ON OFF switch to OFF b Remove manifold pressure tap plug from gas valve c Connect a water column manometer or similar device to manifold pressure tap d Turn gas valve ON OFF switch to ON e Move setup SW1 2 on furnace control to ON position to lock furnace in low heat operation See Fig 55 and Fig 35 f Manually close blower door switch g Jumper and W W1 thermostat connections on control to start furnace See Fig 35 h Remove regulator adjustment cap from low heat gas valve pressure regulator See Fig 51 and turn low heat adjust ing screw 3 16 or smaller flat tipped screwdriver coun terclockwise out to decrease input rate or clockwise in to increase input rate NOTE DO NOT set low heat manifold pressure less than 1 3 in W C or more than 1 7 in W C for natural gas If manifold pressure is outside this range change main burner orifices i Install low heat regulator adjustment cap j Move setup switch SW1 2 to off position after completing low heat adjustment k Leave manometer or similar device connected and proceed to Step 4 2 Adjust manifold pressure to obtain high fire input rate See Fig 51 a Jumper R to W W1 and W2 thermostat connections on fur nace control This keeps furnace locked in high heat oper ation b Remove regulator adjustment cap from high heat gas valve pressure regul
92. ation and position as spe cified in the Location section of these instructions 3 Provide adequate combustion and ventilation air to the fur nace space as specified in for Combustion and Ventila tion section 4 Combustion products must be discharged outdoors Con nect this furnace to an approved vent system only as spe cified in the Venting section of these instructions 5 Never test for gas leaks with an open flame Use a commer cially available soap solution made specifically for the de tection of leaks to check all connections as specified in the Gas Piping section 6 Always install furnace to operate within the furnace s inten ded temperature rise range with a duct system which has an external static pressure within the allowable range as spe cified in the Start Up Adjustments and Safety Check section See furnace rating plate 7 When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space contain ing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace See Air Ducts section 8 A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section 9 The furnace may be used for construction heat provided that the furnace installation and operation complies with the fi
93. ator See Fig 51 and turn high heat adjusting screw 3 16 in or smaller flat tipped screw driver counterclockwise out to decrease input rate or clockwise in to increase input rate NOTE DO NOT set high heat manifold pressure less than 3 2 in W C or more than 3 8 in W C for natural gas If manifold pressure is outside this range change main burner orifices to obtain manifold pressure in this range 61 z 10O 59TN6A c When correct input is obtained replace caps that conceal gas valve regulator adjustment screws Main burner flame should be clear blue almost transparent See Fig 57 d Remove jumpers R to W W1 and R to W2 3 Verify natural gas input rate by clocking meter a Turn off all other gas appliances and pilots served by the meter b Move setup switch SW1 2 to ON position This keeps fur nace locked in low heat operation c Jumper to W W1 d Run furnace for 3 minutes in low heat operation e Measure time in sec for gas meter to complete 1 revolu tion and note reading The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow f Refer to Table 18 for cubic ft of gas per hr 2 Multiply gas rate cu ft hr by heating value Btuh cu ft to obtain input If clocked rate does not match required in put from Step 1 increase manifold pressure to increase in put or decrease manifold pressure to decrease input Repeat steps b through e until correct low hea
94. behind the inducer and out through the left side of the casing A pre formed 27 pipe is provided in the loose parts bag shipped with the furnace The Z pipe is long enough to extend out of the casing on the 14 3 16 in 360 mm wide furnace Larger casings will require a field supplied CPVC pipe and to extend the drain line out of the furnace The 2 pipe is connected to the condensate trap by modifying the formed rubber drain tube Connect the drain line as shown below Remove the knock out from the left side of the casing See Fig 12 Install the grommet for the 1 2 in CPVC drain line in the 7 8 knockout in the casing Remove the pre formed drain tube the offset 1 2 in CPVC pipe and two spring clamps from the loose parts bag Remove the formed grommet on the tube by cutting the tube along the vertical line located about 1 in 25 mm away from the formed grommet See Fig 15 Slide a spring clamp 1 in 25 mm down the plain end of the drain tube With the bend in the tube oriented horizontally and plain end of the tube pointing away from you insert the 1 2 in CPVC pipe into the other end of the drain tube Rotate the tube so the offset in the tube points away from you Slide a spring clamp over the open end of the 1 2 in CPVC tube 11 12 13 14 15 16 17 18 and secure the cut end of drain tube to the pipe See Fig 16 Prime the bare end o
95. ble 5 for filter size details 21 z 10O 59TN6A Table 5 Filter Size Information In mm FILTER SIZE FURNACE CASING WIDTH SIDE RETURN BOTTOM RETURN FILTER TYPE 16 x 25 x 3 4 14 25 3 4 14 3 161 360 406 x 635 x 19 856 x 635 x 19 Washable 16 25 x 3 4 16 25 3 4 17 1 2 445 406 635 19 406 635 19 Washable 16 25 3 4 20 25 3 4 21 533 406 x 635 x 19 508 x 635 x 19 Washable 16 x 25 x 3 4 24 x 25 x 3 4 24 1 2 622 406 x 635 x 19 610 x 635 x 19 Washable Recommended to maintain air filter face velocity See Product Data for part number Not all families have these models Air Filter Located in Filter Cabinet FILTER CABINET HEIGHT IN MM FILTER SIZE IN MM FILTER TYPE 16 406 1 16 x 25 x 3 4 406 x 635 x 19 or 1 16 x 25 x 4 5 16 406 x 635 x 110 Washable or Media 20 508 1 20 x 25 x 3 4 508 x 635 x 19 or 1 20 x 25 x 4 5 16 508 x 635 x 110 Washable or Media 24 610 1 24 x 25 x 3 4 or 610 x 635 x 19 or 1 24 x 25 x 4 5 16 610 x 635 x 110 Washable or Media Filters with a side return air may have a different filter size Measure the filter to obtain the correct size Recommended to maintain air filter face velocity See Product Data for part number 22 14 3 16 and 17 1 2 in Furnace 16 in Media Cabinet M
96. blower only ON period two sec after power is restored if the thermostat is still calling for gas heating The amber LED light will flash code 12 during the 90 sec period after which the LED will be ON continuous as long as no faults are detected After the 90 sec 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 1 Two Stage Heating Adaptive Mode with Single Stage Thermostat See Fig 35 and 36 for thermostat connections NOTE The low heat only switch SW1 2 selects either the low heat only operation mode when ON see item 2 below or the adaptive heating mode when OFF in response to a call for heat See Fig 55 When the W2 thermostat terminal is energized it will always cause high heat operation when the R to W circuit is closed regardless of the setting of the low heat only switch This furnace can operate as a two stage furnace with a single stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation which selects low heat or high heat operation This selection is based upon the stored history of the length of previous gas heating periods of the single stage thermostat The furnace will start up in either low or high heat If the furnace s
97. carbon monoxide detectors 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 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 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 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 in in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 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
98. casing and J Box bracket 3 Secure BX cable to J Box bracket with connectors ap proved for the type of cable used 4 Connect field ground wire and factory ground wire to green ground screw on J Box mounting bracket as shown in Fig 31 5 Connect field power and neutral leads to furnace power leads as shown in Fig 34 6 Attach furnace J Box cover to mounting bracket with screws supplied in loose parts bag Do not pinch wires between cover and bracket 24 Wiring Make field 24 v connections at the 24 v terminal strip See Fig 35 Connect terminal Y Y2 as shown in Fig 34 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire NOTE Use AWG No 18 color coded copper thermostat wire for lengths up to 100 ft 30 5 M For wire lengths over 100 ft use No 16 wire The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct 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 See Fig 35 Thermostats A single stage heating and cooling thermostat can be used with the furnace The furnace control board CPU will control the furnace and outdoor unit staging A two stage heating and cooling thermostat can also be used to control the staging For two stage thermostat control of the furnace staging turn SW1 2 ON at the furnace control board For two s
99. ce The furnace condensate drain can be connected to the Air Conditioning condensate drain as shown in Fig 13 NOTE On narrower casings it may be easier to remove the condensate trap connect the drain line components and re install the condensate trap Read the steps thoroughly to familiarize yourself with the required steps For Right Side Condensate Drain 1 Remove the 7 8 in knock out from the right side of the casing See Fig 12 Remove the pre formed drain tube and two spring clamps from the loose parts bag Slide a spring clamp 1 in 25 mm down the plain end of the drain tube From inside the casing insert the formed grommet end of the tube through the 7 8 in knockout in the casing Pull the tube through the casing from the outside until it is seated in the knockout Attach the plain end of the drain tube to the outlet stub on the drain trap Secure the drain tube to the trap with the spring clamp Slide a spring clamp over the open end of the drain tube outside the casing Open the spring clamp and connect a field supplied 1 2 in CPVC street elbow to the open end of the drain tube See Fig 14 Connect additional 1 2 in CPVC piping to a condensate pump approved for use with acidic furnace condensate or to a code approved drain For Left Side Condensate Drain Connection 1 For left side condensate drainage the drain line is routed from the condensate trap
100. clamp 15 Ib in 44 Table 11 Approved Combustion Air and Vent Pipe Fitting and Cement Materials U S A Installations MARKED ON MATERIAL MATERIAL PIPE FITTINGS DESCRIPTION D1527 ABS Pipe Schedule 40 D1785 PVC Pipe Schedule 40 D2235 For ABS Solvent Cement For ABS D2241 PVC Pipe SDR 21 amp 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 493 Solvent Cement For CPVC F628 ABS Pipe De Cellular Core DAY ren F656 For PVC Primer For PVC F891 PVC Pipe Cellular Core Schedule 40 amp DWV 45 Table 12 Maximum Allowable Exposed Vent Lengths Insulation Table Ft M Maximum Length of Uninsulated and Insulated Vent Pipe Ft M Design Temp o oeoo 15 2 2s 32 ao 22 25 35 US por por WA WA 287 WA NA 152 are 355 NA ouo pes pee pes WA wA sso WA WA 505 740 558 WA WA dn e 43 7 WA WA 52 186 165 152 85 W e o ss
101. cuit is opened de energizing the gas valve GV M stopping gas flow to the burners and de energizing the 79 See Fig 35 and 36 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 cooling airflow Cooling airflow is based on the selection shown in Fig 55 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 cir cuits are opened The outdoor unit will stop and the fur nace blower motor BLWM will continue operating at cool ing airflow for an additional 90 sec Jumper Y Y2 to DHUM to reduce the cooling off delay to 5 sec See Fig 35 Single Stage Thermostat and Two Speed Cooling Adaptive Mode See Fig 35 and 36 for thermostat connections This furnace can operate a two speed cooling unit with a single stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled 59TN6A operation which selects low cooling or high cooling eration This selection is based upon the stored history of the length of previous cooling period of the single stage thermostat NOTE The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to a call for cooling See Fig 35 When i
102. d as shown in Fig 23 for proper condensate drainage Supply Air Connections 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 Connect supply air duct to flanges on furnace supply air outlet Bend flange upward to 90 with wide duct pliers See Fig 20 The supply air duct must be connected to ONLY the furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing side to attach supply air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace main casing Return Air Connections WARNING FIRE HAZARD A failure to follow this warning could cause personal injury death and or property damage Never connect return air ducts to the back of the furnace Follow instructions below 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 Bypass humidifier may be attached into unused return air side of the furnace casing See Fig 24 25 26 Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed
103. d glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials 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 z 10O 4 WARNING FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury death and or property damage When the furnace is installed in a residential garage the burners and ignition sources must be located at least 18 in 457 mm above the floor The furnace must be located or protected to avoid damage by vehicles When the furnace is installed in a public garage airplane hangar or other building having a hazardous atmosphere the furnace must be installed in accordance with the NFPA 54 ANSI 7223 1 2009 or CAN CSA B149 2 2010 See Fig 5 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace See Fig 4 Location Relative to Cooling Equipment The cooling coil must be installed parallel with or on the down
104. dapter 5 Insert a length of vent pipe through the coupling into the outlet of the vent elbow 6 Tighten the clamp around the outlet of the vent elbow Torque the clamp to 15 Ib in Install the remaining vent and combustion air pipes as shown below It is recommended that all pipes be cut prepared and preassembled before permanently cementing any joint 1 Working from furnace to outside cut pipe to required length s 2 Deburr inside and outside of pipe Chamfer outside edge of pipe for better distribution of primer and cement Clean and dry all surfaces to be joined Check dry fit of pipe and mark insertion depth on pipe Insert the vent pipe into the vent elbow Torque clamp on vent elbow 15 Torque clamp on vent coupling 15 Ib in 00 10 tA FS Insert the combustion air pipe into the adapter 10 Pilot drill a screw hole through the adapter into the combus tion air pipe and secure the pipe to the adapter with sheet metal screws 11 Seal around the combustion air pipe with silicone or foil tape 12 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 13 While cement is still wet twist pipe into socket with 1
105. des Canadian Installations Part 8 of CAN CSA B149 1 10 Venting Systems and Air Supply for Appliances and all authorities having jurisdiction A combustion air pipe to the outdoors is not required for a single pipe vent system A 12 in 304 mm long pipe with a 2 in 51 mm tight radius 90 degree elbow is required to be attached to the combustion air pipe adapter on the furnace See Fig 44 Locating the Vent Termination General NOTE Termination Requirements for the Provinces of Alberta and Saskatchewan are located at the end of this section 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 Fig 45 for Direct Vent 2 Pipe system and Fig 46 for Non direct Vent 1 Pipe system For exterior termination arrangements refer to Fig 47 for Direct Vent 2 Pipe system and Fig 48 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 terminations 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 When determining appropriate location for termination consider the following guidelines 1 Comply with all clearance requirements stated in
106. e In this situation a concentric vent kit cannot be used A 2 pipe termination or single pipe termination when permitted that re directs the flue gas away by use of an elbow or tee certified to ULC 5636 from the adjacent property line must be used See Fig 49 The concentric vent kit currently cannot be modified to attach an elbow to the vent portion of the rain cap A tee attached to the rain cap could potentially direct the flue gas plume toward the intake air stream and contaminate the incoming combustion air for the furnace Refer to Fig 49 for terminations approved for use in Alberta and Saskatchewan Size the Vent and Combustion Air Pipes General Furnace combustion air and vent pipe connections are sized for 2 in 51 mm pipe Any pipe diameter change should be made outside furnace casing in vertical pipe Any change is diameter to the pipe must be made as close to the furnace as reasonably possible The Maximum Vent Length for the vent and combustion air pipe when used is determined from the Maximum Equivalent Vent Length in Table 13 or 15 minus the number of fittings multiplied by the deduction for each type of fitting used from Table 14 The measured length of pipe used in a single or 2 pipe termination is included in the total vent length Include a deduction for a Tee when used for Alberta and Saskatchewan terminations Concentric vent terminations pipe lengths or elbows do not require a deduction from the Maximum
107. e sss 88 55 980 wa zs ss wa s sss sz 62 re 355 ss __ NA pozo puo 60 260 sro WA so 660 w WA ross so vs arr 25 165 NA ve 274 DIS DO S EE ING ES REO OO EE v em Iu pw pue ss pres ps n pue rs ux 5 w WA NA ss sr zr WA WA 48 387 255 NA 258 aou sso 70 oo wA w sso 5 WA WA 150 eso Fw Tus as zi oo WA WA a8 ero 46 258 565 Not all families have these models Pipe length ft specified for maximum pipe lengths located in unconditioned spaces Pipes located in unconditioned space cannot exceed total allowable pipe length calculated from Table 13 or 15 59TN6A T Insulation thickness based on R value of 3 5 per in 46 NOTE Maximum Equivalent Vent Length MEVL does NOT include elbows or terminations Use Table 14 Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application Table 13 Maximum Equivalent Vent Length Ft M 0 to 4500 Ft 0 to 1370 M Altitude DIRECT VENT 2 PIPE AND NON DIRECT VENT 1 Vent Pipe Diameter in C E a 000 s s 25 265 EM 0 to 610 30000 5
108. e clamp around the vent elbow Torque the clamp to 15 Ib in See Fig 39 42 Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death To route the vent pipe and combustion air pipe through the furnace the manufacturer supplied kit must be used Failure to properly seal the blower compartment from the furnace vestibule could result in the circulation of carbon monoxide throughout the structure The vent pipe and combustion air pipe must be a continuous pipe while passing through the blower compartment Seals supplied in this kit must be installed per the instructions provided Follow all procedures outlined in these instructions NOTE The rubber coupling that attaches to the vent pipe adapter must be used The adapter seals the vent pipe to the casing and reduces the strain on the vent elbow attached to the inducer 1 Apply the gaskets to the vent pipe and combustion air pipe adapters See Fig 37 NOTE The vent pipe adapter has a larger ID than the combustion air pipe adapter 2 Align the screw holes in the plastic vent pipe adapter with the dimples in the casing 3 Pilot drill the screw holes for the adapter in the casing and attach the vent pipe adapter to the furnace with sheet metal Screws 4 Slide the end of the rubber vent coupling with notches in it over the standoffs on the vent pipe a
109. e control will turn the inducer ON The inducer motor will run for the entire test The hot surface igniter and blower motor will be turned ON for 15 seconds each When the blower is turned OFF the inducer will be turned OFF When the component test is completed one or more of the following codes will flash DESCRIPTION 11 Indicates blower motor tested OK Visual check of hot surface igniter and inducer required 25 SETUP ERROR Same as code 25 above 41 BLOWER MOTOR FAULT Indicates blower motor failed test Check blower wiring and furnace control To repeat component test turn setup switch SW1 6 OFF and then back ON After component test is completed put setup switch SW1 6 in the OFF position and reconnect the R thermostat lead 338308 2 Rev C 11430 Fig 54 Service Label Information 65 59TN6A Furnace Setup Switch Description SETUP SWITCH SWITCH NAME NORMAL POSITION DESCRIPTION OF USE Turn ON to retrieve up to 7 stored status codes for 5 1 1 Status Code Recovery troubleshooting assistance when R thermostat lead is disconnected When 5 1 2 is OFF allows low heat operation with Low Heat Only a single stage thermostat Turn ON when using Adaptive Heat Mode when two stage thermostat to allow Low Heat operation 5 1 2 is OFF when W W1 closes and High Heat operation when R to W W1 and 2 close Turn ON to increase Low Heat airflow by 18 percent This compensates for increased return air Low H
110. e for pipe size being used 2 Loosely install elbow in bracket and place assembly on combustion air pipe 3 Install bracket as shown in Fig 47 and 49 NOTE For applications using vent pipe option indicated by dashed lines in Fig 47 and 48 rotate vent elbow 90 from position 4 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping Direct Vent 2 Pipe System ONLY When 2 or more furnaces are vented near each other 2 vent terminations may be installed as shown in Fig 47 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 47 to avoid recirculation of flue gases Inducer Outlet Restrictor To improve efficiency and operation of 40 000 BTUH input models on very short vent systems an inducer outlet restrictor is required to be installed on the outlet of the inducer assembly The outlet restrictor is shipped in the loose parts bag To determine if the outlet restrictor is required see Table 13 and Table 15 Failure to use an outlet choke when required may result in flame disturbance or flame sense lockout To install the outlet restrictor 1 Remove the vent elbow from the inducer outlet 2 Align the lock tabs on the outlet restrictor with the slots on inside outlet of the inducer assembly 3 Snap the outlet restrictor in place 4 Re install the vent elbow 5 Torque vent elbow
111. e furnace control CPU will drop the blower motor BLWM to low heat airflow during the selected blower OFF delay period before transitioning to continuous blower airflow When the thermostat calls for low cooling the blower motor BLWM will switch to operate at low cooling airflow When the thermostat is satisfied the blower motor BLWM will operate an additional 90 sec at low cooling airflow be fore transitioning back to continuous blower airflow When the thermostat calls for high cooling the blower motor BLWM will operate at high cooling airflow When the thermostat is satisfied the blower motor BLWM will op erate an additional 90 sec at high cooling airflow before transitioning back to continuous blower airflow When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 sec if no other func tion requires blower motor BLWM operation Continuous Blower Speed Selection from Thermostat To select different continuous blower airflow from the room thermostat momentarily turn off the FAN switch or push button on the room thermostat for 1 3 sec after the blower motor BLWM is operating The furnace control CPU will shift the continuous blower airflow from the factory setting to the next highest CF selection airflow as shown in Fig 55 Momentarily turning off the FAN switch again at the ther mostat will shift the continuous blower airflow up one more increment If you repeat this procedure enough you wi
112. e 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 Combination of Indoor and Outdoor Air 1 Indoor openings shall comply with the Indoor Combus tion Air Method below and 2 Outdoor openings shall be located as required in the Out door Combustion Air Method mentioned previously and 3 Outdoor openings shall be sized as follows Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method be low b Outdoor opening size reduction Factor is 1 minus the Ra tio in a above c Minimum size of Outdoor openings shall be the size re quired in Outdoor Combustion Air Method above multi plied by reduction Factor in b above The minimum di mension of air openings shall be not less than 3 in 80 mm 10 Table 3 Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO OPENINGS OR IN72 000 SING SO IN 3000 BTUH qa YERTICAL DUCTS INPUT 1 100 SQ MM KW 734 SQ MM KW 650 SQ MM KW BTUH Free Area of Free Area of Free Area of Open OpenngandDuc OpenngandDuc mm Dia ing and Duct inc bia 40 000 20 12904 5 127 14 8696
113. e mounting to the burner assembly WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service Follow the operating instructions on the label attached to the furnace Refer to Fig 62 1 Disconnect power at external disconnect fuse or circuit breaker Turn off gas at external shut off or gas meter Remove control door and set aside Turn electric switch on gas valve to OFF Disconnect the gas pipe from gas valve and remove pipe from the furnace casing Remove individual wires from terminals on gas valve 7 Disconnect Hot Surface Igniter HSI wires from HSI 8 Disconnect Flame Sensor wire from Flame Sensor a 9 Support the manifold and remove the 4 screws that secure the manifold assembly to the burner assembly and set aside Note the location of the green yellow wire and ground ter minal 10 Inspect the orifices in the manifold assembly for blockages or obstructions Remove orifice and clean or replace orifice 11 Remove the four screws that attach the top plate of the cas ing to the furnace 12 Raise top plate up slightly and prop it up with a small piece of wood or folded cardboard 13 Support the burner assembly and remove the screws that at tach the burner assembly to t
114. e sseujeu y u 10 4230 e2euunj e e day SJA 91 16 uo Keys pue siauing JIM seau S 09 010 SI 2 pue OO 9915 Buy 1050 5 WLY ULD 4 lt 0 eui S uoniubi 104 eu yuan Josues pue 10 2 Jeaday Keys saauanq ay sjeuunq ay seb pue uado seb 5200 NYZ 9 I2281 seb 5900 suonbeuuoo seb SSODL 1 euuo eau 104 e 0 350 1991 195 pue pea 1e150U418U1 Y ay 128uuo2ay ipoued 5 aui 10 Juasaid ASLL SEM 3y uo CT TVHID3N pue uid uaamjaq ASL 10 2942 uaui pue 440 9 LMS YUMs dnjas uruan Aq 1591 3ueuoduuo pue 041002 sseuJeu apod e ejdey 2 Ja 01 Jamod jasay 4049 xpms seo eJnjrej 4 0 ANP 1no xpo Jaye 19521 01nV 101034201 TOHLNOO edid 5 a qissod 1uaA 19M gt pesn 5491 JI aunssaid seb S9u21IMS a4nss
115. eat Rise Adjustment temperature caused with bypass humidifier This also increases the low heat inducer speed 15 Turn ON to decrease low heat airflow by 7 percent Comfort Efficiency Adjustment and high heat airflow 10 percent for maximum ere TH Component Self Test ON to initiate Component Self Test for troubleshooting assistance when thermostat lead is disconnected Turn OFF when Self Test is Blower Off Delay time adjustable 90 seconds to SW1 7 amp SW1 8 Blower OFF delay ON or OFF 180 seconds See table in Adjustments section or refer to unit wiring diagram Allows additional CFM per ton selections when used with SW 1 5 325 per ton nominal when SW 4 3 ON and SW 1 5 OFF 350 per ton nominal when SW 4 3 OFF and SW 1 5 OFF Intermediate OFF CFM per ton Adjust 370 per ton nominal when SW4 3 ON and SW 1 5 ON 400 per ton nominal when SW 1 5 ON and SW 4 3 OFF See Air Delivery Tables for model specific CFM vs static pressure AIR CONDITIONING A C SETUP SWITCHES SW 2 AC Cooling Airflow SETUP SWITCHES AC setup switch selects desired cooling high stage cooling two stage units airflow See Air Delivery Tables for specific switch settings CONTINUOUS FAN CF SETUP SWITCHES SW 3 CF Continuous Fan SETUP SWITCHES CF setup switch selects desired Continuous Fan Airflow CF switch position is the low cooling airflow selection for two stage co
116. edia Cabinet Installation Side Return 21 or 24 1 2 in Furnace Up to 5 Ton AC capacity airflow 20 or 24 in Media Cabinet Bottom Return Plenum 20 or 24 in Media Cabinet Installation for Combination Side and Bottom Return 14 3 16 in Furnace 14 3 16 in Furnace with Filler Plates Centered 4 in Block Off Plate 21 Furnace 4 or less AC capacity airflow 1 2 in Screws 20 in Media Cabinet Media Cabinet Installation Option for 4 Ton or Less A C Capacity 21 in Furnace up to 5 Ton AC Capacity 24 1 2 in Furnace up to 4 Ton AC Capacity lt 45 _ 20 or 24 in Media Cabinet Transition 20 or 24 in Media Cabinet Installation with Angled Transition 14 3 16 in Furnace Filler plate 14 3 16 in Furnace with Filler Plates Off Set to Right 11437 Fig 18 Media Filter 23 59TN6A FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING OPENING D DOWNFLOW A SUBBASE T FLOOR N SHEET ___ OPENING AT PLENUM C ____ FLOOR p OPENING m FURNACE 2222222 APPROVED COIL ASSEMBLY OR COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR _____41 OPENING Fig 19 Installatio
117. ent edition of CAN CSA B149 1 in Canada Installations must be made in accordance with all authorities having jurisdiction If possible the gas supply line should be a separate line running directly from meter to furnace NOTE Use a back up wrench on the inlet of the gas valve when connecting the gas line to the gas valve NOTE In the state of Massachusetts 1 Gas supply connections MUST be performed by a licensed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 in 915 mm 3 When lever handle type manual equipment shutoff valves are used they shall be T handle valves 4 The use of copper tubing for gas piping is NOT approved by the state of Massachusetts Refer to Table 8 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 the action of propane gas WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could result in personal injury death and or property damage 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 Black iron pipe shall be installed at the furn
118. er our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the gas input 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 Verify proper furnace operating conditions including ignition gas input rate air temperature rise and venting according to these installation instructions General These furnaces are shipped with the following materials to assist in proper furnace installation These materials are shipped in the main blower compartment See Table 1 for loose parts bag contents 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 close to the chimney or vent and attached to an air distribution system Refer to Air Ducts section be provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown in Table 2 or on the furnace clearance to combustible construction label 4 WARNING CARBON MONOXIDE POISONING COMPONENT DAMAGE HAZARD Failure
119. es Look at burners Burner flames should be clear blue almost transparent See Fig 57 12 Check for gas leaks WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 A fire or explosion may result causing property damage personal injury or loss of line 13 Replace main furnace door Secondary Heat Exchangers The condensing side inside of the secondary heat exchanger CANNOT be serviced or inspected without complete removal of the heat exchanger assembly Detailed information on heat exchanger removal can be obtained from your Distributor WINTERIZATION UNIT AND PROPERTY DAMAGE HAZARD Failure to follow this caution may result in unit component or property damage If the 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 to prevent minor property or product damage Since the furnace uses a condensing heat exchanger some water will accumulate in the unit as a result of the heat transfer process Therefore once it has been operated it cannot be turned off and left off for an extended period of time when temperatu
120. es Accessory Internal Vent Kit See Product Data for current kit number 9 Attach vent pipe adapter with gasket to furnace casing Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling Q Slide vent pipe through adapter and coupling into vent elbow Insert vent pipe into vent elbow 5 Torque all clamps 15 Ib in Attach combustion air pipe adapter with gasket to furnace Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw A11400 Fig 40 Downflow Configurations Appearance may vary 51 59TN6A ALTERNATE COMBUSTION HORIZONTAL LEFT HORIZONTAL LEFT VERTICAL VENT CONFIGURATION LEFT VENT CONFIGURATION A11328 a WAG MO HORIZONTAL LEFT RIGHT VENT CONFIGURATION Requires Accessory Internal Vent Kit See Product Data for Current Kit Number Attach vent pipe adapter with gasket to furnace casing 2 Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling Q Slide vent pipe through adapter and coupling into vent elbow Insert vent pipe into vent elbow Torque all clamps 15 Ib in Attach combustion air pipe adapter with gasket to furnace Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw A11340
121. f the pipe with CPVC primer 10 Route the offset pipe behind the inducer assembly and through the grommet in the casing if the Z pipe is long enough If the Z pipe is not long enough continue with installation Attach the plain end of the drain tube to the outlet stub on the drain trap Secure the drain tube to the trap with the spring clamp If the Z pipe does not extend through the casing slide a piece of field supplied CPVC through the grommet in the casing otherwise go to Step 17 Cement a 1 2 in CPVC coupling to the end of the CPVC pipe Apply cement to the end of the 27 pipe connected to the condensate trap Connect the field supplied CPVC pipe to the CPVC pipe connected to the condensate trap Cut off excess CPVC pipe outside the casing Connect additional 1 2 in CPVC piping to a condensate pump approved for use with acidic furnace condensate or to a code approved drain When a condensate pump is not used slope the pipe away from the furnace to allow for proper drainage Horizontal Orientation 17 1 11 In the Horizontal orientation a field supplied accessory drain trap grommet is required to seal the gap between the casing and the condensate trap The condensate trap outlet extends 2 in 51 mm below the furnace casing To allow for servicing the trap the condensate drain tube in the loose parts bag can be modified to make a coupler to allow for future service of the condensate trap
122. facturer s installation instructions _ 2 2 6 in 152 mm for appliances lt 10 000 Btuh 3kW J pn pli 12 in 305 mm for appliances 10 000 Btuh 3kW 4 ft 1 2 M below or to the side of the opening 1 ft ance 9 y P and lt 100 000 30kW 36 914 mm for 3 M above the opening appliances gt 100 000 Btuh 30 kW K Clearance to a mechanical air supply inlet 6 ft 1 8 M 3ft 9 M For clearances not specified in ANSI Z223 1 NFPA 54 12 in 305 mm Permitted only if veranda porch or CSA B149 1 clearances shall be in accordance L Clearance under a veranda porch deck or balcony deck or balcony is fully open on a minimum of two with local installation codes and the requirements of sides beneath the floor the gas supplier and the manufacturer s installation instructions 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 12 in 305 mm 12 in 305 mm intake or exhaust Clearance to the vent terminal of a dryer vent water N heater vent or other appliances direct vent intake or 3 ft 9 M 3 ft 9 M exhaust Clearance from plumbing vent stack 3 ft 9 M 3 ft 9 M b d sid Ik d dri 7 ft 2 1 M A vent shall not terminate above a side P earance g9ove Paved sidewall OF aveo dnveway walk or paved driveway that is located between two 7 ft 2 1 M located on public proper
123. front of burner area for furnaces closer than 12 in 305 mm above the combustible deck or suspended furnaces closer than 12 in 305 mm to joists The sheet metal MUST extend underneath the furnace casing by 1 in 25 mm with the door removed The bottom closure panel on furnaces of widths 17 1 2 in 445 mm and larger may be used for flame roll out protection when bottom of furnace is used for return air connection See Fig 27 for proper orientation of roll out shield Supply Air Connections 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 Connect supply air duct to flanges on furnace supply air outlet Bend flange upward to 90 with wide duct pliers See Fig 20 The supply air duct must be connected to ONLY the furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing side to attach supply air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace main casing Return Air Connections The return air duct must be connected to bottom of the furnace The side of casing that faces downward may also be u
124. furnace is factory shipped for use with natural gas The furnace can be converted in the field for use with propane gas when a factory supplied conversion kit is used Refer to the furnace rating plate for conversion kit information This furnace is not approved for installation in mobile homes recreational vehicles or outdoors This furnace is designed for minimum continuous return air temperature of 60 F 15 C db or intermittent operation down to 55 F 13 C db such as when used with a night setback thermostat Return air temperature must not exceed 80 F 27 C db Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls See Fig 3 The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive oversizing of the furnace could cause the furnace and or vent to fail prematurely For accessory installation details refer to the applicable instruction literature NOTE Remove all shipping materials loose parts bag and literature before operating the furnace See Table 1 CODES AND STANDARDS Follow all national and local
125. gh Heat dise Relay PST N C Manual Swich Minimum hear ony 9 ianiti i ot Surface igniter anual owltch Min int Heat Rise trials for ignition Control will auto reset after three hours HS e S STNO SW1 4 Switch Comfort Effy Adj 11 Inducer motor IDM contains internal auto reset thermal overload switch 24VAC Humidifier Connection 0 5 Amp Max SW1 5 Manual Switch Cooling CFM Ton 12 Any of the 5 wires shown within the NEUTRAL L2 box can be HUMR Humidifier Relay SPST N O SW1 6 Manual Switch Component Test DM Induced Draft Motor 2 Speed PSC SW1 7 8 Manual Switches Blower Off Dela connected to any terminal within the box 13 Blower motor BLWM is locked rotor overload protected by redundant electronic control circuits DR Inducer Motor Relay SPST SW4 1 Manual Switch Twinning Main OFF Sec HI LOR Inducer Motor Speed Change Relay SPDT SW4 283 For Future Use TRAN Transformer 115VAC 24VAC 338308 2 Rev C A11431 Fig 64 Wiring Diagram 85 10O Casing Group Blower door Bottom plate Control door Door knob assembly PARTS REPLACEMENT INFORMATION GUIDE Gas Control Group Burner Flame sensor Gas valve Hot surface igniter Top filler plate Manifold Orifice Electrical Group 3 Amp fuse Heat Exchanger Group Circuit board Control box Door switch Junction box Limit switch es Transformer Blower Gr
126. ght side of the casing as viewed from the upflow position Remove the J Box cover and mounting bracket from the loose parts bag Select a 7 8 in 22 mm knock out on the desired side of the casing Remove the knock out from the casing Drill two 2 1 8 in 3 mm pilot holes in the casing dimples by the desired 7 8 22 mm knock out Align the J Box mounting bracket against the inside of the casing and secure the mounting bracket with the screws See Fig 31 Electrical Box on Furnace Casing Side NOTE Check that duct on side of furnace will not interfere with installed electrical box 1 Fasten a field supplied external electrical box to the outside of the casing by driving two field supplied screws from in side electrical box into casing See Fig 32 2 Route field power wiring into external electrical box 3 Pull furnace power wires through 1 2 in 12 mm diameter hole in J Box If necessary loosen power wires from strain relief wire tie on furnace wiring harness 4 Connect any code required external disconnect s to field power wiring 5 Route external field power wires through holes in electrical box and casing 6 Connect field ground wire and factory ground wire to green ground screw on J Box mounting bracket as shown in Fig 31 7 Connect field power and neutral leads to furnace power leads as shown in Fig 34 8 Attach furnace J Box cover to mounting bracket with screws supplied in loose parts bag Do
127. h as nicks cuts abrasions gnawing by animals etc 2 Check for discolored heat tape insulation If any damage or discolored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on Cleaning Heat Exchangers The following items must be performed by a qualified service technician Primary Heat Exchangers If the heat exchangers get an accumulation of light dirt or dust on the inside they may be cleaned by the following procedure NOTE If the heat exchangers get a heavy accumulation of soot and carbon both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate design A build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger primary or secondary Action must be taken to correct the problem 1 Turn off gas and electrical supplies to furnace WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death or property damage Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position and install a lockout tag There may be more than one disconnect switch Loc
128. he current edition of the Canadian Electrical Code CSA C22 1 and any local codes or ordinances that might apply WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage Do not connect aluminum wire between disconnect switch and furnace Use only copper wire See Fig 32 Use a separate fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace See Table 9 for wire size and fuse specifications A readily accessible means of electrical disconnect must be located within sight of the furnace 32 J Box Installation 4 WARNING FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death or property damage If field supplied manual disconnect switch is to be mounted on furnace casing side select a location where a drill or fastener cannot damage electrical or gas components The J Box is used when field line voltage electrical connections are made to the furnace wiring harness inside the furnace casing The J Box is not required if a field supplied electrical box is attached to the outside of the furnace casing and the box is grounded to the green ground wire of the main wiring harness and the earth ground of the field electrical supply The J Box cover mounting bracket and screws are shipped in the loose parts bag included with the furnace The J Box can be mounted on the left or ri
129. he heat exchanger cell panel 14 Remove wires from both rollout switches 15 Slide one piece burner out of slots on sides of burner as sembly 16 Remove the flame sensor from the burner assembly 17 Optional Remove the Hot Surface Igniter HSI and bracket from the burner assembly 18 Check igniter resistance Nominal resistance is 40 to 70 ohms at room temperature and is stable over the life of the igniter 19 Clean burner with a brush and a vacuum 20 Clean the flame sensor with fine steel wool 0000 grade Do not use sand paper or emery cloth To reinstall burner assembly 1 Install the Hot Surface Igniter HSI and bracket in burner assembly 2 Install flame sensor on burner 3 Align the edges of the one piece burner with the slots in the burner assembly and slide the burners forward until they are fully seated in the burner assembly 4 Align the orifices in the manifold assembly with the support rings on the end of the burner 5 Insert the orifices in the support rings of the burners NOTE If manifold does not fit flush against the burner do not force the manifold on the burner assembly The burners are not fully seated forward in the burner assembly Remove the manifold and check burner positioning in the burner assembly assembly before re installing the manifold 6 Attach the green yellow wire and ground terminal to one of the manifold mounting screws 7 Install the remaining manifold mounting screws
130. hing or a code composed of 2 digits The first digit is the number of short flashes the second digit is the number of long flashes For an explanation of status codes refer to service label located on control door or Fig 54 and the troubleshooting guide which can be obtained from your distributor Retrieving Stored Fault Codes The stored status codes will NOT be erased from the control memory when 115 or 24 v power is interrupted The control will store up to the last 7 Status Codes in order of occurrence 1 To retrieve status codes proceed with the following NOTE NO thermostat signal may be present at control and all blower OFF delays must be completed a Leave 115 v power to furnace turned on b Look into blower door indicator for current LED status c Remove blower door NOTE The Status Codes cannot be retrieved by disconnecting the limit switch To retrieve Status Codes follow the procedure below 70 Turn Setup Switch SW1 1 Manually close blower door switch Control will flash up to 7 Status Codes The last Status Code or 8th Code will be Code 11 Turn SW1 1 OFF A continuously lit Amber LED will appear and indicates proper operation Mo RU 8 Release blower door switch install blower door and refer to the SERVICE label on the control door for more inform ation Component Self Test Component Test can ONLY be initiated by performing the following 1 Remove b
131. ieved turn gas valve ON OFF switch to OFF g Release blower door switch h Remove manometer or similar device from gas valve i Re install manifold pressure tap plug in gas valve See Fig 51 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Reinstall manifold pressure tap plug in gas valve to prevent gas leak j Remove thermostat jumper wire from furnace control board k Turn gas valve ON OFF switch to ON CAUTION FURNACE OVERHEATING HAZARD Failure to follow this caution may result in reduced furnace life Recheck temperature rise It must be within limits specified on the rating plate Recommended operation is at the mid point of rise range or slightly above 1 Proceed to Set Blower Off Delay before installing blower door Adjust Blower Off Delay Heat Mode a Remove blower door if installed 62 b Turn Dip switch SW 7 or SW 8 ON or OFF for desired blower off delay See Table 17 and Fig 35 Fig 55 and Fig 64 Adjust Cooling Airflow Single Stage and High Stage Cooling The ECM blower can be adjusted for a range of airflow for Low Speed or High Speed cooling See Table 7 Air Delivery CFM With Filter Depending on the model size the cooling airflow can be adjusted from 1 5 to 6 tons of nominal cooling based on 350 CFM ton The cooling airflow is adjusted by turning AC setup switches SW2 1 SW2 2
132. in ANSI Z223 1 NFPA 54 12 in 305 mm Permitted only if veranda porch or CSA B149 1 clearances shall be in accordance L Clearance under a veranda porch deck or balcony deck or balcony is fully open on a minimum of two with local installation codes and the requirements of sides beneath the floor the gas supplier and the manufacturer s installation instructions Clearance to each side of the centerline extended above or below vent terminal of the furnace to a dryer E M or water heater vent or other appliance s direct vent 12 in 805 mm 12 in 805 mm intake or exhaust Clearance to the vent terminal of a dryer vent water N heater vent or other appliances direct vent intake or 3 ft 9 M 3 ft 9 M exhaust Clearance from a plumbing vent stack 3 ft 9 M 3 ft 9 M For clearances not specified in ANSI Z223 1 NFPA 54 Clearance aboveipaved sidewalk or paved drivews 7 ft 2 1 M A vent shall not terminate above a side or CSA B149 1 clearances shall be in accordance P y walk or paved driveway that is located between two located on public property single family dwellings and serves both dwellings with local installation codes and the requirements of the gas supplier and the manufacturer s installation instructions 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code Notes 1 The
133. ipe adapter over the length of the vent pipe down to the furnace casing Mark the pipe where it is flush with the outlet of the adapter 3 Remove the pipe from the furnace and the adapter and cut off any excess pipe 4 Clean and prime the end of the pipe that is flush with the vent adapter with a primer that is appropriate for the type of pipe being used 5 the pipe through the casing into the vent elbow 6 Tighten the clamp around the outlet of the vent elbow Torque the clamp to 15 Ib in 7 Apply cement to the end of the pipe and to the inside of the plastic vent adapter 8 Slide the adapter over the vent pipe and align the screw holes in the adapter with the dimples in the furnace casing 9 Pilot drill 1 8 in screw holes for the adapter in the casing and secure the adapter to the furnace with sheet metal screws 10 Loosen the clamps on the rubber vent coupling 11 Slide the end of the coupling with notches in it over the standoffs in the vent pipe adapter 12 Tighten the clamp of the coupling over the vent pipe adapter Torque the lower clamp around the vent pipe adapter to 15 Ib in 13 Pilot drill a 1 8 in hole in the combustion air pipe adapter 14 Complete the vent and combustion air pipe as shown in Install the Vent and Combustion Air Pipe Installing the Vent Termination Roof Terminations A roof termination of any type will require a 4 in 102 mm flashing for a 2 in 51 mm
134. irety 59TN6A 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 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
135. is longer than the measured length of the vent pipe and combustion air pipe then that diameter of pipe selected may be used When installing vent systems of short pipe lengths 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 Combustion Air and Vent Piping Insulation Guidelines NOTE Use closed cell neoprene insulation or equivalent The vent pipe may pass through unconditioned areas The amount of exposed pipe allowed is shown in Table 12 1 Using winter design temperature used in load calculations find appropriate temperature for your application and fur nace model 2 Determine the amount of total and exposed vent pipe 3 Determine required insulation thickness for exposed pipe length s 4 When combustion air inlet piping is installed above a sus pended ceiling the pipe MUST be insulated with moisture resistant insulation such as Armaflex or other equivalent type of insulation 5 Insulate combustion air inlet piping when run in warm hu mid spaces 6 Install the insulation per the insulation manufacturer s in stallation instructions NOTE Pipe length ft M specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as calculated from Table 13 or 15 42 Configure the Furnace A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow thi
136. k out and tag switch with a suitable warning label Verify proper operation after servicing 4 WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service Follow the operating instructions on the label attached to the furnace 2 Remove control door 3 Disconnect wires or connectors to flame rollout switch gas valve igniter and flame sensor 4 Using backup wrench disconnect gas supply pipe from fur nace gas control valve 5 Remove two screws attaching top filler plate and rotate up wards to gain access to screws attaching burner assembly to cell panel 6 Remove screws attaching burner assembly to cell panel See Fig 62 NOTE Burner cover manifold gas valve and burner assembly should be removed as one assembly 7 Clean heat exchanger openings with a vacuum and a soft brush See Fig 60 NOTE After cleaning inspect the heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products 8 Reverse items 6 through 1 for reassembly 9 Refer to furnace wiring diagram and reconnect wires to flame rollout switch gas valve igniter and flame sensor 10 Turn on gas and electrical supplies to furnace 11 Check furnace operation through 2 complete heat operating cycl
137. kit must be used for all direct vent terminations Termination kits are available for 2 in or 3 in pipe See Table 10 for available options Table 10 Vent Termination Kit for Direct Vent 2 pipe Systems DIRECT VENT DIAM OF COMBUS 2 PIPE TION AIR AND VENT TERMINATION KIT PIPES IN mm 2 1 51 mm Single Penetration of 1 1 1 2 2 or 2 1 2 Concentric Vent Kit Wall or Roof 24 36 51 64 mm 3 in 76 mm Single Penetration of 2 1 2 3o0r4 Concentric Vent Kit wall or Roof 64 76 102 mm 2 51 mm 2_Pi m Pipe Termination 1 1 1 20r2 Termination Bracket System 25 36 51 mm 3 in 76 mm mU Pipe Termination 2 1 2 3o0r4 Bracket System 64 76 102 mm Direct Vent 2 Pipe System 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 Combustion air and vent pipes must terminate together in the same atmospheric pressure zone either through the roof or a sidewall roof termination preferred A factory accessory vent termination kit MUST be used in a direct vent 2 pipe system See Fig 45 for required clearances Ventilated Combustion Air Systems In a ventilated combustion air option the vent terminates and discharges the flue products directly to the outdoors similar to a direct vent system See Fig 46 for required clearances
138. l should be removed to allow thermostat to control outdoor unit staging Furnace must control its own staging operation via furnace control algorithm This is factory default The RVS Sensing terminal L should not be connected This is used internally to sense defrost operation If thermostat has internal control of heat pump balance point DO NOT SELECT the FURNACE INTERFACE or BALANCE POINT option on the two speed heat pump control board Refer to thermostat instructions Configure Dehumidify function to remove 24 VAC from Dehum terminal on a demand to dehumidify 59TN6A 39 59TN6A VENTING Furnace is set in place in the required orientation Special Venting Requirements for Installations in Canada Installation in Canada must conform to the requirements of CAN CSA B149 code Vent systems must be composed of pipe fittings cements and primers listed to ULC 5636 The special vent fittings and accessory concentric vent termination kits and accessory external drain trap have been certified to ULC S636 for use with those Royal Pipe and 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 GVS 65 Primer Purple for Royal Pipe or IPEX System 636 PVC CPVC Primer Purple Violet for Flue Gas Venting and GVS 65 PVC Solvent Cement for Royal Pipe or IPEX System 6366 PVC Cement for Flue Gas Venting rated Class 65 deg
139. lated combustion air option 40 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 Do not take combustion air from inside the chimney when using ventilated combustion air or single pipe vent option These furnaces can be vented as either direct vent furnace ventilated combustion air system or non direct single pipe vent system Each type of venting system is described below Common venting between furnaces or other appliances prohibited Materials U S A 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 11 for approved materials for use in the U S A Canada Special Venting Requirements for Installations in Canada Installation in Canada must conform to the requirements of CAN CSA B149 code Vent systems must be composed of pipe fittings cements and primers listed to ULC S636 Venting Systems A factory accessory KGAVT vent termination
140. les in the roof or sidewall for vent and when used combustion air pipes Sidewall holes for two pipe vent terminations should be side by side allowing space between the pipes for the elbows to fit on the pipes Holes in the roof for two pipe terminations should be spaced no more than 18 in 457 mm apart Termination elbows will be installed after the vent and if used combustion air pipe is installed Sidewall Terminations Concentric Vent Determine an appropriate location for termination kit using the guidelines provided in section Locating The Vent Termination in this instruction 1 Cut one 4 diameter hole for 2 in kit or one 5 in dia meter hole for 3 in kit 2 Loosely assemble concentric vent combustion air termina tion 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 4 Locate assembly through sidewall with rain shield posi tioned no more than 1 in 25 mm from wall as shown in Fig 47 5 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping 2 Pipe and 1 Pipe Vent Termination Determine an appropriate location for termination kit using the guidelines provided in section Locating The Vent Termination in this instruction 1 Cut 2 holes 1 for each pipe of appropriate siz
141. ll eventually shift the continuous blower airflow to the NOTE lowest CF selection as shown in Fig 55 The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power inter ruption If the blower off delay is set to the maximum the adjustable continuous fan feature is locked i e fan speed cannot be changed from its current setting 7 Heat pump See Fig 35 and 36 for thermostat connections When installed with a heat pump the furnace control auto matically changes the timing sequence to avoid long blower off times during demand defrost cycles Whenever W W1 is energized along with Y1 or Y Y2 the furnace control CPU will transition to or bring on the blower motor BLWM at cooling airflow low heat airflow or the mid range airflow whichever is lowest The blower motor BLWM will remain on until the main burners ignite then shut OFF and remain OFF for 25 sec before coming back on at heating airflow When the W W1 input signal disappears the furnace con trol begins a normal inducer post purge period while chan ging the blower airflow If Y Y2 input is still energized the furnace control CPU will transition the blower motor BLWM airflow to cooling airflow If Y Y2 input signal dis appears and the Y1 input is still energized the furnace con trol CPU will transition the blower motor BLWM to low cooling airflow If both the Y1 and Y Y2 signals disappear at the same ti
142. lower door 2 Remove the wire from the R terminal of the control board 3 Turn Setup Switch SW 1 6 ON 4 Manually close blower door switch Blower door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower door switch opens 115 v power to furnace control No component operation can occur unless switch is closed Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes 5 Component Test sequence will function as follows a The furnace control CPU turns the inducer motor ON at high heat speed and keeps it ON through step c b After waiting 10 sec the furnace control CPU turns the hot surface igniter ON for 15 sec then OFF c The furnace control CPU then turns the blower motor BLWM on at mid range airflow for 15 sec then OFF d After shutting the blower motor OFF the furnace control CPU switches the inducer to low heat speed for 10 sec then OFF NOTE The EAC terminals are energized when the blower is operating After the component test is completed 1 or more status codes 11 or 25 will flash See component test section or Service Label Fig 54 for explanation of status codes NOTE To repeat component
143. me the blower motor BLWM will remain on at low heat airflow for the selected blower OFF delay period At the end of the blower OFF delay the blower motor BLWM will shut OFF unless is still energized in which case the blower motor BLWM will operate at continuous blower airflow Component Self Test Refer to page 71 for instructions 81 59TN6A ON dU a2e dai JO AY 03 jeur SOWA ApZWOD 991 122uu0 1015 5591 ise eq e jesur e euinj 291 YUM e gneduioo 51 1150 ON 1eadai ay 5900 Y 5 15 AY 129002517 SJA 932euJnj y uo sjeuruJ9 1e1souustu 5 JO ZA A LA LIW M 1 S ON ejqe JO 3e350uJ8U WOO 1 15 01 peq pue 1exeaiq 25015 e euinj 0 10 ipasop 1axeaJq UNI YMS 100P S e ejdey peusey 51 LL SMAS hun snoeueg nuuis pue LWM Y buusduinf pue uonisod NO y LMS U21IMs dnies Bund Aq Ajjenuew aq ue 10 SJnOU ZZ Jaye sapod 501816 2 0 Huljoo Jo
144. min clearance above At least 36 in amp 914mm 24 in above roof highest anticipated snow level maximum of Maintain 12 in 305mm min clearance above highest anticipated snow level Maximum of 24 in 614mm above roof 1 in 25mm maximum typ from wall to inlet Abandoned masonry used as raceway per code 12 in 805mm minimum overhang or rooi Note A denotes 0 to lt 2 in 51mm Between the first 2 vents Third vent must be gt 36 in away 914mm Maintain 12 in 305mm min clearance above 1 highest anticipated snow level or grade whichever is greater 12 in min from overhang or roof Jj typ Concentric Vent and Combustion Air Side Termination At least 36 in 12 in 305mm 914mm DOSEN anal Side wall termination 1 OE Vah BRI of less than 12 in 305mm above highest snow level Maintain 12 305mm min clearance above highest anticipated snow level or grade whichever is greater typ A05090 Fig 47 Combustion Air and Vent Pipe Termination for Direct Vent 2 Pipe System Roof Termination Preferred Maintain 12 in 305mm minimum clearance above highest anticipated snow level maximum of 24 in 610mm above roof Abandoned masonry used as raceway per code 12 in min 305 mm from overhang or roof 6 in 152mm minimum clearance between wall and end of vent pipe 10 in 254mm ma
145. must be pitched forward as shown in Fig 23 for proper condensate drainage 4 WARNING FIRE EXPLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace The furnace can be installed horizontally in an attic or crawlspace on either the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or trusses or installed on a non combustible platform blocks bricks or pad Platform Furnace Support Construct working platform at location where all required furnace clearances are met See Table 2 and Fig 27 For furnaces with 1 25 mm clearance requirement on side set furnace on non combustible blocks bricks or angle iron For crawlspace installations if the furnace is not suspended from the floor joists the ground underneath furnace must be level and the furnace set on blocks or bricks Suspended Furnace Support The furnace must be supported under the entire length of the furnace with threaded rod and angle iron See Fig 28 Secure angle iron to bottom of furnace as shown Roll Out Protection Provide a minimum 12 in x 22 305 x 559 mm piece of sheet metal for flame roll out protection in
146. n on Combustible Flooring Table 6 Opening Dimensions In mm 225502222 A10491 PNG PLENUM OPENING FLOOR OPENING WIDTH APPLICATION IN mm A B D Upflow Applications on Combustible or Noncombustible Floor 12 11 16 21 5 8 13 5 16 22 1 4 ing KGASB subbase not required 322 549 338 565 Downflow Applications on Noncombustible Flooring KGASB 12 9 16 19 13 3 16 19 5 8 14 3 16 subbase not required 319 483 335 498 360 Downflow applications on combustible flooring KGASB sub 11 13 16 19 13 7 16 20 5 8 base required 284 483 341 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR or CAP Coil Assembly or KCAKC coil box KGASB 5 483 5 608 subbase not required Upflow Applications on Combustible or Noncombustible Floor 16 21 5 8 16 5 8 22 1 4 ing KGASB subbase not required 406 549 422 565 Downflow Applications on Noncombustible Flooring KGASB 15 7 8 19 16 1 2 19 5 8 17 42 subbase not required 403 483 419 498 445 Downflow applications on combustible flooring KGASB sub 15 1 8 19 16 3 4 20 5 8 base required 384 483 425 600 Downflow Applications on Combustible Flooring with CNPV _ CNRV CAR or CAP Coil Assembly or KCAKC coil box KGASB yos 483 pr ar 508 subbase not required Upflow Applications on Combustible or Noncombustible Floor 19 1 2 21 5 8 20 1 8 22 1 4
147. n the inducer motor IDM reduces pressure suffi ciently the high heat pressure switch HPS will open The gas valve solenoid GV M will remain energized as long as the low heat pressure switch LPS remains closed The blower motor BLWM will transition to low heat airflow five sec after the R to W2 circuit opens 59TN6A 3 Cooling mode The thermostat calls for cooling a Single Speed Cooling High heat 25 sec after the gas valve GV M is opened the BLWM is turned ON at high heat airflow Simultan eously the humidifier terminal HUM and electronic air cleaner terminal EAC 1 are energized and remain ener gized throughout the heating cycle Switching from Low to High Heat If the furnace con trol CPU switches from low heat to high heat the furnace control CPU will switch the inducer motor IDM speed from low to high The high heat pressure switch relay HPSR is de energized to close the NC contact When suffi cient pressure is available the high heat pressure switch HPS closes and the high heat gas valve solenoid GV HI is energized The blower motor BLWM will transition to high heat airflow five sec after the furnace control CPU switches from low heat to high heat Switching from High to Low Heat The furnace con trol CPU will not switch from high heat to low heat while the thermostat R to W circuit is closed when using a single stage thermostat Blower Off Delay When the thermostat is satisfied the R to W cir
148. nd combustion air pipe located on the blower shelf d Separate the pipes from the blower compartment and set aside e Remove the couplings from the pipe adapters and set aside f After servicing the blower reverse steps a through e g Tighten all clamps 15 lb in See Fig 61 For Steps 5 through 14 5 Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace Detach ground wire and disconnect blower motor harness plugs from blower motor NOTE Blower wheel is fragile Use care 6 Clean blower wheel and motor by using a vacuum with soft brush attachment Be careful not to disturb balance weights clips on blower wheel vanes Do not bend wheel or blades as balance will be affected 7 If greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel a Mark blower wheel location on shaft before disassembly to ensure proper reassembly b Loosen setscrew holding blower wheel on motor shaft NOTE Mark blower mounting arms and blower housing so each arm is positioned at the same hole location during reassembly c Mark blower wheel orientation and cutoff plate location to ensure proper reassembly d Remove screws securing cutoff plate and remove cutoff plate from housing e Remove bolts holding motor mounts to blower housing and slide motor and mounts out of housing f Remove blower wheel from housing g
149. ng airflow is based on the A C selection shown in Fig 35 NOTE When transitioning from low cooling to high cooling the outdoor unit compressor will shut down for 1 minute while the furnace blower motor BLWM transitions to run at high cooling airflow 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 Y circuit 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 sec Jumper Y1 to DHUM to reduce the cooling off delay to 5 sec See Fig 35 c Two Stage Thermostat and Two Speed Cooling See Fig 35 and 36 for thermostat connections NOTE The air conditioning relay disable jumper ACRDJ must be disconnected to allow thermostat control of the outdoor unit staging See Fig 35 The thermostat closes the R to G and Y1 circuits for low cooling or closes the R to G and Y1 and Y2 circuits for high cooling The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and Y1 circuit starts the furnace blower motor BLWM at low cooling airflow which is the true on board CF continuous fan selection as shown in Fig 56 The R to Y1 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 at high cooling airflow High cooling airflow is based on the A C ai
150. njury death and or property damage Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service Follow the operating instructions on the label attached to the furnace 1 2 3 Turn off gas and electrical supplies to furnace Remove control door Disconnect pressure switch tube from pressure switch port NOTE Ensure the pressure switch tube disconnected from the pressure switch is higher than the collector box opening or water will flow out of tube 4 7 8 Remove the collector box plug from the top port on the up per corner of the collector box See Fig 59 Attach a funnel with a flexible tube to port on the collector box Flush inside of collector box with water until discharge water from condensate trap is clean and runs freely Repeat steps 4 thru 6 with middle plug on upper corner of collector box Remove the pressure switch tube from the collector box NOTE Do NOT blow into tube with tube connected to the pressure switch 10 11 12 13 Clean pressure switch port on collect box with a small wire Shake any water out of pressure switch tube Reconnect tube to pressure switch and pressure switch port Remove the relief tube from the port on the collector box and the trap Clean the relief port on collect box and the trap with a small wire Shake any water out of the tube Reconnect relief tube to trap and
151. o prevent ESD damage ACCESSORIES See Product Data Sheet for a list of accessories for this product LOCATION CAUTION PERSONAL INJURY AND OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may result in premature furnace component failure This gas furnace may be used for heating buildings under construction provided that The furnace is permanently installed with all electrical wiring piping 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 p
152. ode CSA C22 1 This may consist of electrical wire conduit approved for electrical ground or a listed grounded power cord where permitted by local code when installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gauge Do not use gas piping as an electrical ground CAUTION FURNACE MAY NOT OPERATE HAZARD Failure to follow this caution may result in intermittent furnace operation Furnace control must be grounded for proper operation or else control will lock out Control must remain grounded through green yellow wire routed to gas valve and manifold bracket screw 115 V Wiring Furnace must have a 115 v power supply properly connected and grounded NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control LED status indicator light will flash rapidly and furnace will NOT operate Verify that the voltage frequency and phase correspond to that specified on unit rating plate Also check to be sure that service provided by utility is sufficient to handle load imposed by this equipment Refer to rating plate or Table 9 for equipment electrical specifications U S A Installations Make all electrical connections in accordance with the current edition of the National Electrical Code NEC ANSI NFPA 70 and any local codes or ordinances that might apply Canada Installations Make all electrical connections in accordance with t
153. of the gas To do this a Obtain average yearly gas heat value at installed altitude from local gas supplier b Obtain average yearly gas specific gravity from local gas supplier c Find installation altitude in Table 19 d Find closest natural gas heat value and specific gravity in Table 19 e Follow heat value and specific gravity lines to point of in tersection to find orifice size and low and high heat mani fold pressure settings for proper operation f Check and verify burner orifice size in furnace NEVER ASSUME ORIFICE SIZE ALWAYS CHECK AND VERIFY NOTE For Canadian altitudes of 2000 to 4500 ft 609 6 to 1371 6M use USA altitudes of 2001 to 3000 ft 609 6 to 914 4 NOTE If orifice hole appears damaged or it is suspected to 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 g Replace orifice with correct size if required by Table 19 Use only factory supplied orifices See EXAMPLE 1 EXAMPLE 1 EXAMPLE 0 2000 ft 0 609 6M altitude Heating value 1050 Btu cu ft Specific gravity 0 62 Therefore Orifice No 44 Manifold pressure 3 4 in w c for high heat 1 4 in w c for low heat Furnace is shipped with No 44 orifices In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input r
154. oling units values in the Air Delivery Tables for SW 3 settings are the same as SW 2 settings SW cannot be set for airflow higher than SW 2 See Air Delivery Tables for specific switch settings A11364 A2V96 Fig 55 Furnace Setup Switch Description 66 Table 16 Altitude Derate Multiplier for U S A Table 17 Blower Off Delay Setup Switch ALTITUDE PERCENT DERATE SETUP SWITCH OF MULTIPLIER DESIRED HEATING MODE SW1 7 AND 8 FT M DERATE FACTOR BLOWER OFF DELAY SEC POSITION 0 2000 0 610 0 1 00 SW1 7 SW1 8 2001 3000 610 914 4 6 0 95 90 OFF OFF 3001 4000 914 1219 6 8 0 93 120 ON OFF 4001 5000 1219 1524 8 10 0 91 150 OFF ON 5001 6000 1524 1829 10 12 0 89 180 ON ON 6001 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 2743 3048 18 20 0 81 Derate multiplier factors are based midpoint altitude for altitude range Table 18 Gas Rate CU ft hr SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 REVOLUTION 1 Cu Ft 2 Cu Ft 5 Cu Ft FOR 1 REVOLUTION 1 Cu Ft 2 Cu Ft 5 Cu Ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133
155. on Direct Vent 1 Pipe System The vent pipe for a Non Direct Vent 1 system must terminate outdoors Follow all vent termination clearances shown in Fig 46 Allowable vent terminations are shown in Fig 48 A combustion air pipe to the outdoors is not required for a Non Direct Vent System A 12 in long section of pipe with a tight radius 2 in 50 8 mm 90 degree elbow is required to be attached to the furnace Termination Requirements for the Provinces of Alberta and Saskatchewan The Provinces of Alberta and Saskatchewan require a minimum unobstructed distance of 4 ft 1 2 M from the foundation to the property line of the adjacent lot for vent termination of any appliance with an input over 35 000 btuh If there is less than 4 ft 1 2 M of unobstructed distance to the property line of the adjacent lot no type of vent termination is permitted for appliances with inputs greater than 35 000 btuh There are no additional restrictions on unobstructed distances greater than 8 ft 2 4 M AII single two pipe and concentric vents may be used providing all other Code and manufacturer s requirements in these instructions are adhered to Refer to the appropriate Vent Termination section above for locating the vent termination If the unobstructed distance from the foundation to the property line of the adjacent lot is no less than 4 ft 1 2 M and no greater than 8 ft 2 4 M it will be necessary to re direct the flue gas plum
156. opriate protective clothing safety glasses and 11342 gloves when handling parts and servicing furnaces Fig 14 Formed Tube Grommet Fig 12 Knockout Removal Cut and remove formed end of drain tube for left side and horizontal drain connection OPEN STAND PIPE FOR OR HUMIDIFIER DRAIN amp 2 y RIGHT SIDE DRAIN ELBOW 11388 Fig 15 Modify Drain Tube L R re A11276 Fig 13 Example of Field Drain Attachment 18 Attach tube to condensate trap Cut formed end off condensate drain tube Field supplied 1 2 CPVC Connect short end coupling amp drain extension of Z pipe to modified 17 1 2 21 and 24 1 2 casing TRAP DRAIN ELBOW WITH DISCHARGE PIPE Modified drain tube connect to condensate trap and Z pipe Field supplied 1 2 CPVC to drain Casing grommet from Field supplied 1 2 CPVC coupling amp drain parts bag pipe 17 1 2 21 and 24 1 2 casings LEFT SIDE DRAIN ROUTED BEHIND INDUCER A11344 Fig 16 Drain Trap Connection and Routing 19 Remove knockout Install grommet before relocating condensate trap 11348 Fig 17 Horizontal Drain Trap Grommet z 10O INSTALLATION Upflow Installation NOTE The furnace must be pitched forwar
157. oses and the high heat gas valve solenoid GV HI is energized The furnace control CPU begins a 15 sec prepurge period after the low heat pressure switch LPS closes If the high heat pressure switch HPS fails to close and the low heat pressure switch LPS closes the fur nace will operate at low heat gas flow rate until the high heat pressure switch closes for a maximum of 2 minutes after ignition b Igniter Warm Up At the end of the prepurge period the Hot Surface Igniter HSI is energized for a 17 sec igniter warm up period Trial For Ignition Sequence When the igniter warm up period is completed the main gas valve relay contact GVR closes to energize the gas valve solenoid GV M The gas valve solenoid GV M permits gas flow to the burners where it is ignited by the HSI Five sec after the GVR closes a 2 sec flame proving period begins The HSI ig niter will remain energized until the flame is sensed or until the 2 sec flame proving period begins If the furnace con trol CPU selects high heat operation the high heat gas valve solenoid GV HI is also energized Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the inducer motor IDM switches to low speed unless the furnace is operating in high heat and the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV M open If the burner flame is not proved within two sec the control CPU will close the gas
158. oup Blower housing Blower motor Blower wheel Capacitor when used Capacitor strap when used Cut off plate Power choke where used Filter Group Filter s Media Cabinet when used Containment plate Coupling box Heat exchanger assembly Primary HX cell panel Secondary HX assembly Tubing gaskets Inducer Group Collector box Condensate trap Condensate trap elbow Gaskets Inducer Inducer assembly Inducer motor capacitor when used Inducer motor module when used Pressure switch es TO OBTAIN INFORMATION ON PARTS Consult your installing dealer or classified section of your local telephone directory under Heating Equipment or Air Conditioning Contractors and Systems headings for dealer listing by brand name or contact CARRIER CORPORATION Consumer Relations Department P O Box 4808 Syracuse New York 13221 1 800 CARRIER Have available the model number series number and serial number located on the unit rating plate to ensure correct replacement part Model Nomenclature COOLING MODEL HEATING MOTOR WIDTH VOLTAGE MINOR SERIES AIRFLOW SIZE CFM 59TN6A 120 V 24 22 A WARNING FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation personal injury death or property damage Improper installation adjustment alteration service or maintenance can cause personal injury
159. ower door b Electronic thermostat Set cycle rate for 3 cycles per hr Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switch This control shuts off combustion system and energizes air circulating blower motor if furnace overheats By using this method to check limit control it can be established that lim it is functioning properly and will operate if there is a re stricted return air supply or motor failure If limit control does not function during this test cause must be determined and corrected a Run furnace for at least 5 minutes b Gradually block off return air with a piece of cardboard or sheet metal until the limit trips c Unblock return air to permit normal circulation d Burners will re light when furnace cools down 2 Check Pressure Switch es This control proves operation of the draft inducer blower Turn off 115 v power to furnace b Disconnect inducer motor lead wires from wire harness c Turn on 115 v power to furnace d Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface igniter should NOT glow and control diagnostic light flashes a status code 32 If hot surface igniter glows when inducer motor is disconnected shut down furnace immediately e Determine reason pressure switch did not function prop erly
160. p 1 Remove upper and middle collector box drain plugs oppos ite of the condensate trap See Fig 59 2 Connect field supplied 1 2 in 13 mm OD tube to upper collector box drain connection 3 Insert field supplied funnel into tube 4 Pour one quart of water into funnel tube Water should run through collector box overfill condensate trap and flow in to open field drain 5 Remove funnel replace collector box drain plug 6 Connect field supplied 1 2 in 13 mm OD tube to middle collector box drain port 7 Pour one quart of water into funnel tube Water should run through collector box overfill condensate trap and flow in to open field drain 8 Remove funnel and tube from collector box and replace col lector box drain plug Purge Gas Lines If not previously done purge the lines after all connections have been made and check for leaks 60 WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 A fire or explosion may result causing property damage personal injury or loss of line Adjustments 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property dam
161. peration will be above 1 0 E S P All airflows on 21 533 mm casing size furnaces are 5 less on side return only installations Side returns for 24 5 622 mm casing sizes require two sides or side and bottom to allow sufficient airflow at the return of the furnace 30 GAS PIPING WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage 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 A fire or explosion may result causing property damage personal injury or loss of line WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Use proper length of pipe to avoid stress on gas control manifold and gas valve WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Gas valve inlet and or inlet pipe 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 Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S A Refer to curr
162. pon 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 4 8 cubic meters per kW require the Outdoor Combustion Air Method Spaces having at least 50 cubic feet per 1 000 Btuh 4 8 cubic meters per kW 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 hori zontal or vertical duct s or opening s directly communicat ing with the outdoors or spaces that freely communicate with the outdoors 2 Fig 6 illustrates how to provide TWO OUTDOOR OPENINGS one inlet and one outlet combustion and vent ilation air opening to the outdoors a One opening MUST commence within 12 in 300 mm of the ceiling and the second opening MUST commence within 12 in 300 mm of the floor b Size openings and ducts per Fig 6 and Table 3 c TWO HORIZONTAL DUCTS require 1 sq in 645 sq mm of free area per 2 000 Btuh 1 100 mm2 kW of com bined input for all gas appliances in the space per Fig 6 and Table 3 d TWO OPENINGS OR VERTICAL DUCTS require 1 sq in 645 sq mm of free area per 4 000 Btuh 550 mm_2 kW for combined input of all gas appliances in the space per Fig 6 and Table 3 3 ONE
163. port on condensate trap ni R 5 s 2 4 Remove front pressure switch tube and discard Remove relief tube 1 from port on collector 2 box o Remove middle and right 6 plug from collector box 1 AND 2 STAGE UNITS Unconverted Factory Trap Configuration As Viewed in the Horizontal Left Orientation Install plug in open ports on collector box Rotate elbow to desired position bs 2460 and torque clamp Connect relief tube to port on inlet 15 Ib in 5 4 on collector box 2 o Slide relief tube in 2 4 Connect tube from Loose 7 Parts bag to port on front pressure switch stand offs to adjust length Route pressure switch tube underneath relief tube and connect to port on trap with screw to 2 8 collector box 3 Attach condensate o o o collector box 17 Align trap over middle and right hand port on 9 collector box 6 Connect relief tube to relief 1 AND 2 STAGE UNITS port on condensate trap Horizontal Left Trap Configuration 11282 Fig 11 Horizontal Left Configuration 16 CONDENSATE DRAIN CONNECTION Upflow Downflow Orientation In the Upflow or Downflow orientation the condensate trap is inside the furnace casing The condensate drain must be routed from the trap through the furnace casing The condensate drain can be routed through the left or right side of the casing The left or right side is as you are viewing the furna
164. r BLWM will drop the blower airflow to 65 percent of high cooling airflow for a maximum of 10 minutes each cooling cycle or until the R to G circuit closes or the demand for dehumidification is satisfied High cooling airflow is based on the A C air condition ing selection shown in Fig 55 c When the call for cooling is satisfied and there is a de mand for dehumidification the cooling blower off delay is decreased from 90 sec to 5 sec 6 Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate at continuous blower air flow Continuous blower airflow selection is initially based on the CF continuous fan selection shown in Fig 55 Factory default is shown in Fig 55 Terminal EAC 1 is en ergized as long as the blower motor BLWM is energized During a call for heat the furnace control CPU will trans ition the blower motor BLWM to continuous blower air flow low heat airflow or the mid range airflow whichever is lowest The blower motor BLWM will remain ON until 80 the main burners ignite then shut OFF and remain OFF for the blower ON delay 45 sec in low heat and 25 sec in high heat allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at low heat or high heat airflow respectively The blower motor BLWM will revert to continuous blower airflow after the heating cycle is completed In high heat th
165. r airflow to 86 percent of low cooling airflow which is the true on board CF continuous fan selection as shown in Fig 55 b High cooling When the R to G and Y Y2 circuit is closed and there is a demand for dehumidification the fur nace blower motor BLWM will drop the blower airflow to 86 percent of high cooling airflow High cooling airflow is based on the A C air conditioning selection shown in Fig 55 c Cooling off delay When the call for cooling is satisfied and there is a demand for dehumidification the cooling blower off delay is decreased from 90 sec to 5 sec 5 Super Dehumidify Mode Super Dehumidify mode can only be entered if the furnace control is in the Thermidistat mode and there is a demand for dehumidification The cooling operation described in item 3 above also applies to operation with a dehumidifica tion thermostat The exceptions are listed below a When the R to Y1 circuit is closed R to G circuit is open and there is a demand for dehumidification the fur nace blower motor BLWM will drop the blower airflow to 65 percent of low cooling airflow for a maximum of 10 minutes each cooling cycle or until the R to G circuit closes or the demand for dehumidification is satisfied Low cooling airflow is the true on board CF continuous fan selection as shown in Fig 55 b When the R to Y Y2 circuit is closed R to G circuit is open and there is a demand for dehumidification the fur nace blower moto
166. r conditioning selection shown in Fig 55 The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM is operating When the thermostat is satisfied the R to G and Y1 or R to G and Y1 and Y2 circuits are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 sec Jumper Y1 to DHUM to reduce the cooling off delay to 5 sec See Fig 35 4 Dehumidification Mode See Fig 35 and 36 for thermostat connections The dehumidification output D or DHUM on the Thermo stat 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 re moved 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 Once 24 vac is de tected by the furnace control on the DHUM input the fur nace control dehumidification capability is activated If the DHUM input is removed for more than 48 hours the fur nace control reverts back to non dehumidification mode The cooling operation described in item 3 above also ap plies to operation with a dehumidification thermostat The exceptions are listed below a Low cooling When the R to G and Y1 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blowe
167. rdinances especially those that may not have kept up with changing residential construction practices We require these instructions as a minimum for a safe installation 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 included in literature and attached to the unit CAUTION 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 safety glasses and gloves when handling parts and servicing furnaces 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 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 a hazard which could result in personal injury or death CAUTION is used to identify hazards 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 1 Use only with type of gas approved for this furnace Refer to the furnace rating plate 2 Install this furnace only in a loc
168. res will reach 32 F 0 or lower unless winterized Follow these procedures to winterize your furnace CAUTION UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the furnace and other property damage Do not use ethylene glycol automotive antifreeze coolant or equivalent Failure of plastic components may occur 1 Obtain propylene glycol RV swimming pool antifreeze or equivalent 2 Turn off gas and electrical supplies to your furnace 3 Remove furnace control door 75 59TN6A 59TN6A 10 11 12 13 14 Remove the top unused rubber plug from the port on the collector box opposite the condensate trap See Fig 59 Connect a field supplied 3 8 in 9 5 mm ID tube to the open port on the collector box Insert a field supplied funnel into the tube Pour 1 quart of anti freeze solution into the funnel tube Antifreeze should run through the inducer housing overfill condensate trap and flow to an open drain Replace the rubber plug in the port on the collector box Remove the middle unused rubber plug from the port on the collector box opposite the condensate trap See Fig 59 Repeat Steps 5 through 8 If a condensate pump is used check with pump manufacturer to verify pump is safe for use with antifreeze used Allow pump to start and pump anti freeze to open drain Replace main door When furnace is re started flush condensate pump with
169. rew to collector box box o 2 5 Connect relief tube to Rotate elbow to i 5 relief port on condensate desired position and tighten clamp to 15 Ib in trap 6 Connect relief tube Attach condensate Q 1 and 2 Stage Units Align condensate trap 2 over middle and bottom ports of collector box Slide tube in stand offs to adjust length Downflow Trap Configuration 11280 Fig 9 Downflow Trap Configuration 14 Remove plug from collector box 2 DO DISCARD If alternate vent position 9 is required loosen clamp on inlet of vent elbow 1 Remove trap from collector box 1 AND 2 STAGE UNITS Unconverted Factory Trap Configuration As Viewed in the Horizontal Right Orientation e o o o OO o ES 4 Slide relief tube in stand offs o to adjust length Attach condensate e Vent elbow shown in alternate trap with screw to 2 orientation Tighten clamp on collector box inlet to vent elbow 15 Ib in i Install plug in 1 open port on Align trap over middle and collector box 1 AND 2 STAGE UNITS right hand post on collector box Horizontal Right Trap Configuration 11402 Fig 10 Horizontal Right Trap Configuration 15 59TN6A 3 Remove trap from collector box If alternate vent position is required loosen clamp Remove relief tube from on vent elbow inlet 2 relief
170. rity for 115 v wiring must be properly maintained Refer to Fig 34 for field wiring information and to Fig 64 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash rapidly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 35 Any shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control LED will display status code 24 when fuse needs to be replaced Troubleshooting Refer to the service label See Fig 54 Service Label The Troubleshooting Guide See Fig 63 can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and follow the appropriate arrow to the next item The Guide will help to identify the problem or failed component After replacing any component verify correct operation sequence Proper instrumentation is required to service electrical controls The control in this furnace is equipped with a Status Code LED Light Emitting Diode to aid in installation servicing and troubleshooting Status codes can be viewed at the indicator in blower door The amber furnace contro LED is either ON continuously rapid flas
171. rst CAUTION in the LOCATION section of these instruc tions 10 These Multipoise Gas Fired Furnaces are CSA design cer tified for use with natural and propane gases see furnace rating plate and for installation in alcoves attics base ments closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A CSA A G A and C G A listed accessory gas conversion kit is required to convert furnace for use with propane gas 11 See Table 2 for required clearances to combustible con struction 12 Maintain a 1 in 25 mm clearance from combustible ma terials 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 13 These furnaces SHALL NOT be installed directly on carpet ing tile or any other combustible material other than wood flooring In downflow installations factory accessory floor base MUST be used when installed on combustible materi als and wood flooring Special base is not required when this furnace is installed on manufacturer s Coil Assembly Part No CNRV CNPV CAP or CAR or when Coil Box Part No KCAKC is used See Table 2 for clearance to com bustible construction information z 10O 59TN6A INTRODUCTION This 4 way multipoise Category IV condensing furnace is CSA design certified as a direct 2 pipe or non direct vent 1 pipe furnace See Fig 2 The
172. ry press button to reset switch EAC 1 terminal is energized whenever blower operates HUM terminal is only energized when blower is energized in heating Select Setup Switch Positions There are four sets of setup switches on the furnace control board These switches configure the furnace for correct application requirement They also select the airflow settings for Air Conditioning and Continuous Fan CFMs The Setup Switch locations are shown and described on Fig 55 The set up switches are also shown on the unit wiring label Setup Switches SW1 The furnace control has 8 setup switches that may be set to meet the application requirements To set these setup switches for the appropriate requirement Remove blower door Locate setup switches on furnace control Configure the set up switches as necessary for the application Replace blower door NOTE Ifa bypass humidifier is used setup switch SW1 3 Low Heat Rise Adjust should be in ON position This compensates for the increased temperature in return air resulting from bypass NOTE If modulating dampers are used blower motor automatically compensates for modulating dampers Air Conditioning A C Setup Switches SW2 The air conditioning setup switches are used to match furnace airflow to cooling unit used To set the desired cooling airflow 1 Remove blower door 2 Locate A C setup switches on furnace control 3 Determine air conditioning tonnage used
173. s in place the furnace control CPU can turn on the air conditioning relay ACR to energize the Y Y2 terminal and switch the outdoor unit to high cooling The furnace control CPU can start up the cooling unit in either low or high cooling If starting up in low cooling the furnace control CPU determines the low cooling on time from 0 to 20 minutes which is permitted before switching to high cooling If the power is interrupted the stored history is erased and the furnace control CPU will select low cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the Y Y2 terminal and switch the outdoor unit to high cooling as long as the thermostat continues to call for cooling Subsequent selection is based on stored history of the thermostat cycle times The wall thermostat calls for cooling closing the R to G and Y circuits The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and Y1 circuits starts the furnace blower motor BLWM at low cooling airflow which is the true on board CF selection as shown in Fig 35 If the furnace control CPU switches from low cooling to high cooling the furnace control CPU will energize the air conditioning relay ACR When the air conditioning relay ACR is energized the R to Y1 and Y2 circuits switch the outdoor unit to high cooling speed and the R to G and Y1 and Y Y2 circuits transition the furnace blower motor BLWM to high cooling airflow High cooli
174. s installed as a non direct vent 1 pipe furnace it will be necessary to insure there is adequate air for combustion Other gas appliances installed with the furnace may also require air for combustion and ventilation in addition to the amount of combustion air and ventilation air required for the furnace Follow the guidelines below to insure that the furnace and other gas appliances have sufficient air for combustion Ventilated Combustion Air Applications When the furnace is installed using the ventilated combustion air option the attic or crawlspace must freely communicate with the outdoor to provide sufficient air for combustion The combustion air pipe cannot be terminated in attics or crawlspaces that use ventilation fans designed to operate during the heating season If ventilation fans are present in these areas the combustion air pipe must terminate outdoors as a Direct Vent 2 Pipe system air for combustion is piped directly to the furnace from a space that is well ventilated with outdoor air such as an attic or crawl space and the space is well isolated from the living space or garage In addition other gas appliances installed in the space with the furnace may require outside air for combustion Follow the guidelines below to insure that the roof or crawlspace walls have sufficient free area to provide sufficient air for combustion and ventilation for the furnaces The guidelines below can be used to insure that other gas
175. s warning could result in personal injury or death To route the vent pipe and combustion air pipe through the furnace the manufacturer supplied kit must be used Failure to properly seal the blower compartment from the furnace vestibule could result in the circulation of carbon monoxide throughout the structure The vent pipe and combustion air pipe must be a continuous pipe while passing through the blower compartment Seals supplied in this kit must be installed per the instructions provided Follow all procedures outlined in these instructions Install the Vent and Combustion Air Pipe With the furnace installed in the required position remove the desired knockouts from the casing It will be necessary to remove one knockout for the vent pipe and the other knockout for the combustion air connection See Fig 12 Use a flat blade screwdriver and tap on the knockout on opposite sides where the knockout meets the casing Fold the knockout down with duct pliers and work the knockout back and forth until it is removed Trim any excess metal from the knockout with tin snips The vent elbow can be rotated to the required location on the casing if necessary See Fig 38 To rotate the vent elbow 1 Loosen the clamp on the inlet of the vent elbow attached to the inducer 2 Rotate the vent elbow to the required position There are rounded notches in the vent elbow to align it with the inducer housing for each orientation 3 Tighten th
176. scharge by putting the furnace the control and the person at the same electrostatic potential 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch the clean unpainted metal surface of the fur nace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily dis charged 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 ungroun ded 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 con trol 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 t
177. sed for return air connection A combination of the bottom and downward facing side may also be used The side of the casing cannot be used as a return air connection Bypass humidifier may be attached into unused return air side of the furnace casing See Fig 26 Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 4 screws holding bottom plate See Fig 22 2 Remove bottom plate 3 Remove bottom closure panel 4 Reinstall bottom plate and screws Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when side return air inlet s are used without a bottom return air inlet Not all horizontal furnaces are approved for side return air connections See Fig 26 Filter Arrangement WARNING FIRE CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in fire personal injury or death Never operate a furnace without a filter or filtration device installed Never operate a furnace with filter or filtration device access doors removed There are no provisions for an internal filter rack in these furnaces An external filter is required The furnace is shipped with a factory supplied
178. sired 4 Adjust outside nut to provide desired height and tighten in side nut to secure arrangement 5 Reinstall bottom closure panel if removed Downflow Installation NOTE The furnace must be pitched forward as shown in Fig 23 for proper condensate drainage Supply Air Connections NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the following 3 accessories are used e Special Base KGASB e Cased Coil Assembly Part No CNPV CNRV CAP or CAR e Coil Box Part No KCAKC 1 Determine application being installed from Table 6 2 Construct hole in floor per Table 6 and Fig 19 3 Construct plenum to dimensions specified in Table 6 and Fig 19 4 Install special base coil assembly or coil box as shown in in Fig 19 NOTE It is recommended that the perforated supply air duct flanges be completely removed from furnace when installing the furnace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange back and forth until it breaks off Be careful of sharp edges See Fig 20 CAUTION 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 safety glasses and gloves when handling parts and servicing furnaces Connect supply air duct to supply air outlet on furnace
179. sla BOTTOMPLATE A89014 11092 Fig 21 Leveling Legs Fig 22 Removing Bottom Closure Panel LEVEL 0 0 MM TO 1 2 IN 13 MM MAX MIN 1 4 IN 6 MM TO 1 2 IN 13 MM MAX 4 UPFLOW OR DOWNFLOW HORIZONTAL 11237 Fig 23 Furnace Pitch Requirements 25 59TN6A SUPPLY AIR gt lt RETURN RETURN AIR AIR ANY COMBINATION OF 1 2 OR 3 PERMITTED RETURN AIR A11036 Fig 24 Upflow Return Air Configurations and Restrictions RETURN NOT PERMITTED FOR ANY MODEL RETURN AIR NOTE RESTRICTION SAME FOR HORIZONAL LEFT ul RETURN AIR 1 RETURN AIR SIDE RETURN NOT PERMITTED FOR ANY MODEL 3 RETURN AIR SIDE RETURN NOT PERMITTED SUPPLY AIR 11037 Fig 25 Downflow Return Air Configurations and Restrictions HORIZONAL RETURN AIR RESTRICTIONS 11038 Fig 26 Horizontal Return Air Configurations and Restrictions 26 COMBUSTION AIR PIPE SEE VENTING SECTION A 12 IN 305 mm MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH A SHORT 5 8 FT 1 5 2 4 M VENT SYSTEM TO REDUCE EXCESSIVE 30 IN 762 mm MANUAL SHUTOFF GAS VALVE ROLLOUT PROTECTION REQUIRED Install 12 x 22 305 x 559 mm sheet metal in front of burner compartment area CONDENSATE TRAP TRAP NOTE FURNACE SHOWN AS DIRECT VENT APPLICATION REFER TO THE VENTING SECTION FOR ALLOWABLE VE
180. ssures of 0 5 psig 14 1 W C or less and a pressure drop of 0 5 In based on 0 60 specific gravity gas Ref Table 8 above and 6 2 of NFPA54 ANSI 2223 1 2009 Left Side Gas Entry Gas Pipe Grommet Required For Direct Gas Pipe Grommet Required Vent Applications For Direct Vent Applications A11338 Fig 29 Gas Entry GAS SUPPLY FRONT MANUAL SHUT OFF VALVE REQUIRED NOTE Union may be inside the vestibule where permitted by local codes SEDIMENT UNION TRAP A11035 Fig 30 Typical Gas Pipe Arrangement ELECTRICAL CONNECTIONS 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower door switch opens 115 v power to control No component operation can occur Do not bypass or close Switch with blower door removed See Fig 34 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 F 33 rise 4 WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death or property damage The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 2011 or local codes to minimize personal injury if an electrical fault should occur In Canada refer to Canadian Electrical C
181. st not be grounded Control ground continuity Inadequate flame carryover or rough ignition Green Yellow wire MUST be connected to furnace sheet metal Oxide buildup on flame sensor clean with fine steel wool Proper flame sense micro amps 5 micro amps DC min 4 0 6 0 nominal 41 BLOWER MOTOR FAULT Indicates the blower failed to reach 250 RPM or the blower failed to communicate within he prescribed time limits Thirty seconds after being turned ON or ten seconds during steady state operation 43 LOW HEAT PRESSURE SWITCH OPEN WHILE HIGH HEAT PRESSURE SWITCH IS CLOSED Check for Plugged condensate drain Low inlet gas pressure if LGPS used Water in vent piping possibly sagging pipe Improper pressure switch wiring Stuck open low heat pressure switch Disconnected or obstructed pressure tubing 45 CONTROL CIRCUITRY LOCKOUT Auto reset after 1 hour lockout due to Flame sense circuit failure Gas valve relay stuck open Software check error Reset power to clear lockout Replace control if status code repeats COMPONENT TEST To initiate the component test sequence shut OFF the room thermostat or disconnect the R thermostat lead Reset power and then put setup switch SW1 6 in the ON position to start the component test sequence Once initiated the furnac
182. stream side of the unit to avoid condensation in the heat exchangers When installed parallel with the furnace dampers or other flow control must prevent chilled air from entering the furnace 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 Table 1 Loose Parts Bag Contents Provided in the blower compartment DESCRIPTION QUANTITY Air Intake Pipe Flange Vent Pipe Flange Coupling Flange Gaskets Sharp Tip Screws Vent and Inlet Flanges Vent Pipe Coupling Vent Pipe Coupling Clamps Pressure Switch Tube Outlet Choke Plate used with 40k BTUH furnaces only Drain Tube Elbow Drain Extension Tube Drain Tube Clamps Drain Line Grommet Gas Line Grommet Gas Line Knockout Plug Junction Box Cover Junction Box Base Green Ground Screw Blunt Tip Screws Junction Box Thermostat Wire Grommet 19 Table 2 Minimum Clearances to Combustible Materials for All Units POSITION CLEARANCE Rear 0 0 mm Front Combustion air openings in furnace and in structure 1 in 25 mm Required for service 24 in 610 mm Sides of Supply Plenum 1 25 mm Sides 0 0 mm Vent 0 0 mm Top of Furnace 1in 25 mm Recommended
183. t t certifi s ULCS 636 pour l application des composantes Royal Pipe IPEX PVC qui sont certifi es ce standard Au Canada l appr t et le ciment doivent tre du m me fabricant que le syst me d vacuation L appr t GVS 65 Purple et le ciment solvant GVS 65 doivent tre utilis avec les Royal Pipe Syst me IPEX 636 appr t PVC CPVC Purple pour vacuation des gaz de combustion et syst me IPEX 636 1 t ciment PVC pour vacuation des gaz de combustion cot classe IIA 65 deg C doivent tre utilis s avec le syst me d vacuation IPEX 636 Ne pas combiner 1 appr t et le ciment d un manufacturier avec un syst me d vacuation d un manufacturier diff rent 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 L op ration s curitaire tel que d finit par ULC 5636 du syst me de ventilation est bas 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 L acceptation du standard Canadien CAN CSA B149 est directement reli l installation conforme aux instructions ci haut mentionn es Le standard Canadien recommande inspection par un personnel qualifi et ce une fois par ann e Les autorit es ayant juridiction inspecteurs de gas inspecteurs en b timents
184. t input is achieved Re install low heat regulator seal cap on gas valve h Move setup switch SW1 2 to OFF position and jumper to W W1 and W2 This keeps furnace locked in high heat operation Repeat items d through g for high heat opera tion Adjust Temperature Rise NOTE Blower door must be installed when taking temperature rise reading Leaving blower door off will result in incorrect temperature measurements CAUTION FURNACE OVERHEATING HAZARD Failure to follow this caution may result in shortened furnace life Set air temperature rise within limits specified on the rating plate to prevent reduced life of furnace components Operation is within a few degrees of the mid point of rise range when setup switch SW1 4 is OFF CAUTION FURNACE 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 unit rating plate Operation is within a few degrees of midpoint of rise range when setup switch SW1 4 is OFF When setup switch SW1 4 is ON operation will be near the high end of the rise range for improved comfort Furnace must operate within ranges of temperature rise specified on the furnace rating plate Determine air temperature rise as follows a Place thermometers in return and supply ducts as near fur nace as possible Be sure thermometers do
185. tached to the furnace 4 WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Never operate furnace without a filter or filtration device installed Never operate a furnace with filter or filtration device access doors removed CAUTION 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 safety glasses and gloves when handling parts and servicing furnaces The minimum maintenance on this furnace is as follows 1 Check and clean air filter each month or more frequently if required Replace if torn 2 Check blower motor and wheel for cleanliness each heating and cooling season Clean as necessary 3 Check electrical connections for tightness and controls for proper operation each heating season Service as necessary 4 Inspect burner compartment before each heating season for rust corrosion soot or excessive dust If necessary have furnace and burner serviced by a qualified service agency 71 59TN6A 5 Inspect the vent pipe vent system before each heating sea son for water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency 6 Inspect any accessories attached to the furnace such as a hu midifier or electronic air cleaner Perform any
186. tage thermostat control of a 2 stage outdoor unit remove the ACRDJ jumper from the furnace control board Refer to typical thermostat wiring diagrams and the Sequence of Operation section for additional details Consult the thermostat installation instructions for specific information about configuring the thermostat See Fig 35 and 36 Accessories See Fig 33 and 35 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 and EAC 2 The terminals are rated for 115VAC 1 0 amps maximum and are energized during blower motor operation 2 Humidifier HUM The HUM terminal is a 24 VAC output energized when the blower is operating during a call for heat 33 59TN6A Connect an accessory 24 VAC 0 5 amp maximum humidifier if used to the male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip NOTE If the humidifier has its own 24 VAC power supply an isolation relay may be required Connect the 24 VAC coil of the isolation relay to the HUM and COM 24V screw terminal on the control board thermostat strip See Fig 33 3 Communication Connector ABCD connection This connection is used when the furnace is controlled by an optional communicating User Interface instead of a standard thermostat The ABCD plug is supplied with the
187. tarts up in low heat the control CPU determines the low heat on time from 0 to 16 minutes which is permitted before switching to high heat If the power is interrupted the stored history is erased and the control CPU will select low heat for up to 16 minutes and then switch to high heat as long as the thermostat continues to call for heat Subsequent selection is based on stored history of the thermostat cycle times The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the low heat and high heat pressure switch contacts LPS and HPS are open and starts the inducer motor IDM in high speed a Inducer Prepurge Period 1 Ifthe furnace control CPU selects low heat opera tion the inducer motor IDM comes up to speed the low heat pressure switch LPS closes and the fur nace control CPU begins a 15 sec prepurge period If the low heat pressure switch LPS fails to remain closed the inducer motor IDM will remain running at high speed After the low heat pressure switch re closes the furnace control CPU will begin a 15 sec prepurge period and continue to run the inducer motor IDM at high speed 2 If the furnace control CPU selects high heat opera tion the inducer motor IDM remains running at high speed and the high heat pressure switch re lay HPSR is de energized to close the NC contact 78 When sufficient pressure is available the high heat pressure switch HPS cl
188. ted into operation Adjust the thermostat 50 appliance is operating continuously 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 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 NFPA 54 ANSI Z223 1 2009 In Canada refer to CAN CSA B149 1 2010 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 General If this furnace replaces a furnace that was connected to a vent system or chimney the vent or vent connectors of other remaining appliances may need to be re sized Vent systems or vent connectors of other appliances must be sized to the minimum size as determined using appropriate table found in the current edition of National Fuel Gas Code NFPA 54 ANSI Z 223 1 In Canada refer to CAN CSA B149 1 An abandoned masonry chimney may be used as a raceway for properly insulated 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 47 for Direct Vent 2 Pipe system or Fig 48 for venti
189. test turn setup switch SW1 6 OFF then back ON 6 RELEASE BLOWER DOOR SWITCH reattach wire to terminal on furnace control board and replace blower door Care and Maintenance 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never store flammable or combustible materials on near or in contact with the furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning compounds plastic or plastic containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluids Paint thinners and other painting compounds paper bags or other paper products Exposure to these materials could lead to corrosion of the heat exchangers z 10O For continuing high performance and to minimize possible furnace failure periodic maintenance must be performed on this furnace Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service Follow the operating instructions on the label at
190. the provisions of 248 CMR 5 08 2 a 1 through 4 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 Detailed instructions for the installation of the venting system design or the venting system components and complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS 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 The referenced special venting system instructions shall be included with the appliance or
191. to follow this warning could result in personal injury or death and unit component damage Corrosive or contaminated air may cause failure of parts containing flue gas which could leak into the living space Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products 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 59TN6A 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 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 an
192. trap gasket Install gasket on collector box Align the condensate trap with the drain opening on the col lector box and secure the trap with the screw Attach the relief hose to the relief port on the condensate trap and collector box 5 Secure tubing to prevent any sags or traps in the tubing 6 Connect condensate drain elbow or drain extension elbow to the condensate trap 7 Connect the leads of the condensate heat pad if used 10 11 12 Connect external drain piping to the condensate drain elbow drain extension pipe Turn gas on at electric switch on gas valve and at external shut off or meter Turn power on at external disconnect fuse or circuit break er Run the furnace through two complete heating cycles to check for proper operation Install control door when complete Checking Heat Pad Operation If Applicable In applications where the ambient temperature around the furnace is 32 F or lower freeze protection measures are required If this application is where heat tape has been applied check to ensure it will operate when low temperatures are present 74 NOTE The Heat Pad when used should be wrapped around the condensate drain trap There is no need to use heat tape within the furnace casing Most heat tapes are temperature activated and it is not practical to verify the actual heating of the tape Check the following 1 Check for signs of physical damage to heat tape suc
193. ty single family dwellings and serves both dwellings 1 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code 2 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code Notes 1 The vent for this appliance shall not terminate Over public walkways b Near soffit vents of crawl space vents or other areas where condensate or vapor could create a nuisance 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 conditions which may cause recirculation of the combustion 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 A11047 Fig 46 Ventilated Combustion Air and Non Direct Vent Termination Clearance 56 Roof Termination Preferred 8 3 4 in 222mm for 3 in 76mm kit __ 6 3 4 in 172mm for 2 in 51mm kit 18 in pei 457mm At least 36 in 914mm Concentric Vent and Combustion Air Roof Termination preferred Vertical separation A lt between combustion air and vent Maintain 12 in 305mm Ee
194. uous fan speed is also the fan speed for low speed cooling when furnace is used with a 2 speed cooling unit Adjust the Continuous Fan CFM to match the airflow required for low speed cooling Select the required airflow from Fig 55 For airflow at 400 per ton turn Setup SW1 5 ON See Fig 55 The airflow selected for low speed cooling will also be the airflow used for continuous fan The continuous fan speed can be further adjusted at the thermostat using the Comfort Fan select function Changing the continuous fan speed at the thermostat DOES NOT change the low speed cooling airflow selected at the control board Adjust Thermostat Heat Anticipator a Mechanical thermostat Set thermostat heat anticipator to match the amp draw of the electrical components in the R W W1 circuit Accurate amp draw readings be ob tained at the wires normally connected to thermostat sub base terminals R and W The thermostat anticipator should NOT be in the circuit while measuring current 1 Set SW1 2 switch on furnace control board to ON 2 Remove thermostat from subbase or from wall 3 Connect an amp meter as shown in Fig 53 across the R and W subbase terminals or R and W wires at wall 4 Record amp draw across terminals when furnace is in low heat and after blower starts 5 Set heat anticipator on thermostat per thermostat instructions and install on subbase or wall 6 Turn SW1 2 switch OFF 7 Install bl
195. urnace is installed in the horizontal right position the factory installed trap will be located at the bottom of the collector box When the furnace is installed in the horizontal left position the factory installed trap will be located at the top of the collector box The trap must be repositioned on the collector box for proper condensate drainage When the furnace is installed as a direct vent furnace a field supplied accessory Horizontal Installation Kit is required for all horizontal installations The kit contains a rubber Casing Grommet designed to seal between the furnace casing and the condensate trap See Fig 17 NOTE The condensate trap extends below the side of the casing in the horizontal position A minimum of 2 in 51 mm of clearance is required between the casing side and the furnace platform for the trap to extend out of the casing in the horizontal position To Relocate the Condensate Trap Remove the knockout in the casing for the Casing Grommet nstall the grommet in the casing Orient the furnace in the desired position Allow for 2 in 51 mm of clearance underneath the furnace for the condensate trap and drain line Fig 10 shows the condensate trap and tubing before and after relocation in the horizontal right position Fig 11 shows the condensate trap and tubing before and after relocation in the horizontal left position Refer to the appropriate figure to begin the trap conversion
196. vent for this appliance shall not terminate a Over public walkways or b Near soffit vents of crawl space vents or other areas where condensate or vapor could create a nuisance 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 conditions which may cause recirculation of the combustion 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 Fig 45 Direct Vent Termination Clearance 55 A11046 59TN6A VENT TERMINAL 9 AIR SUPPLY INLET LLLLLILLLLLKNT Y X DIIS 25 24 65 2 ESS AREA WHERE TERMINAL IS NOT PERMITED Item Clearance Description Canadian Installation 1 U S Installation 2 Clearance above grade veranda porch deck bal A uu 12 in 305 mm 18 in 457 mm above roof surface 12 in 305 mm cony or anticipated snow level 152 mm for appliances lt 10 000 3kW 12 305 mm for appliances gt 10 000 Btuh SkW 4 ft 1 2
197. w 17 Turn on electrical supply Manually close blower door Switch Use a piece of tape to hold switch closed Check for proper rotation and speed changes between heating and cooling by jumpering R to G and R to Y Y2 on furnace control thermostat terminals If outdoor temperature is be low 70 F turn off circuit breaker to outdoor unit before running furnace in the cooling cycle Turn outdoor circuit breaker on after completing cooling cycle See Fig 35 NOTE If R W W1 thermostat terminals are jumpered at the time blower door switch is closed blower will run for 90 sec before beginning a heating cycle a Perform component self test as shown at the bottom ofthe SERVICE label located on the control door b Verify blower is rotating in the correct direction 18 If furnace is operating properly RELEASE BLOWER DOOR SWITCH Remove any jumpers or reconnect any disconnected thermostat leads Replace blower door 19 Turn on gas supply and cycle furnace through one complete heating cycle Verify the furnace temperature rise as shown in Adjustments Section Adjust temperature rise as shown in Adjustments Section Cleaning Burners and Flame Sensor The following items must be performed by a qualified service technician If the burners develop an accumulation of light dirt or dust they may be cleaned by using the following procedure NOTE Use a back up wrench on the gas valve to prevent the valve from rotating on the manifold or damaging th
198. ximum pipe lengh Maintain 12 in 305mm minimum clearance above highest anticipated 12 in 805 mm min from now level or grade overhang or roof whichever is greater Sidewall Termination with Straight Pipe preferred Maintain 12 in 305mm minimum clearance above highest anticipated snow level or grade whichever is greater Side wall termination with 2 elbows preferred A05091 Fig 48 Vent Pipe Termination for Non Direct Vent and Ventilated Combustion Air System 57 59TN6A NOTE This illustration is for reference only Your unit may differ in appearance or may not include all components shown OVERHANG OR ROOF Angle 22 50 Termination Bracket to Required for all 2 pipe Y d 450 bs off wall BRACKET terminatiens Fd Di E COUPLING 12 IN SEPARATION L gt ys BETWEEN BOTTOM A COMBUSTION AIR AND 62 BOTTOM OF VENT 5 2 d MAINTAIN 12 IN M CLEARANCE ABOVE HIGHEST COMBUSTION AIR ANTICIPATED SNOW ELBOW PARALLEL LEVEL OR GRADE TO WALL WHICHEVER IS 12 in GREATER 30 48 cm Above anticipated snow level L10F024 1 L10F022 oue OVERHANG EXHAUST Clearance to overhang per code NN 12 in 304 8mm MIN Ground Level OR Snow Level 11346 Fig 49 Alberta and Saskatchewan Vent Termination 58 Ventilated Combustion Air intake pipe ll Pipe hangar Ventilated Combustion Air 12 805 mm intake termination in

Download Pdf Manuals

Related Search

Related Contents

Anleitung - Slowflyer.ch  AN-702SN_info - 株式会社 エイ・アイ・ディー  STIHL 046  Manual de Instruções Monitor com controlo remoto para  D-Link DSL-502T router    マニュアル  CM4.2 - Bike Components  Weil-McLain 88 Boiler User Manual  Manuals - Newport  

Copyright © All rights reserved. Failed to retrieve file