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Carrier 58CTA/CTX User's Manual

1. 35 Adjustments 35 Check Safety Controls 40 Checklist 4 sek be Y ee racer E Ser See ene 40 SERVICE AND MAINTENANCE PROCEDURES 45 Introduction cere m e ehe 45 Care and Maintenance 46 Sequence of Operation 50 Wiring Diagrams sus s ss sous me hern 53 Troubleshooting 53 EFFICIENCY RATING CERTIFIED ama Ki ISO 9001 2000 CERTIFIED OMI REGISTERED NOTE Read the entire instruction manual before starting the installation Portions of the text and tables are reprinted from NFPA 54 ANSI Z223 1 2006 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 entirety 58CT 733mm 664mm 28 7 8 26 1 8 FLUE COLLAR 641mm 25 1 4 22 96 573mm JUNCTION BOX LOCATION 22mm 7 8 DIA ACCESSORY 1 2 DIA THERMOSTAT WIRE ENTRY 24 7 8 846 632mm 7 8 DIA ACCESSORY N N Af 5 12 140mm 1 11 16 43mm 11 16 17mm 549mm 21 5 8 BOTTOM INLET 24 CASING 610mm NOTES 1 Tw
2. 350702 LON GIG Av 13H HO HOLIMS 34NSS2Hd IV3H HOIH UNDO 3104 ejejos 0 spee 1e1souueu Buum Apc Aiepuoses 3404 40 409949 N3dO SI 3604 39VEIOA AHVANO93S xonis YMS einsseJd eqni X09049 LON GIG HOLIMS 55 yeo 10 uedo xong s und jim 189npu 7 1 IVNDSIS ONIAOHd 3INV TH TVIWWHONS8V OJIM SeD 0 1104 JO S1IMSIN uo Aejas 5 X09949 pue 18mod uj 10004901 SVD epoo sniejs 99 5 Jaye 1959 OUD siduiege pue seb pelle 5 NOLLINSI epoo Bag Jaye 1959 IM uey si pesn ji NOJO yeup y yi 811220 100x501 10104901 poued Buunp suado LAM M H JO LM M H Y 10 Buunp dn si Aejap
3. Conditioner THERMIDISTAT TWO STAGE SINGLE SPEED FURNACE HEAT PUMP RVS COOLING O W2 41 L HEAT STAGE 3 2 NOTE 11 wz FURNACE HI HEAT STAGE 2 W W1 _________ 11 41 1 w2 FURNACE LO EX HEAT COOL STAGE 1 YIY2 _________ mz 1 LT Y COMPRESSOR FAN 6 LL 4 8 24VACHOT R 1 al RU baser 1 1 R DEHUMIDIFY DHUM 24VAC COMM C L 1 E E HUM E DET TT HUMIDIFIER 8 HUMIDIFY HUM I HUM 24 VAC N A OUTDOOR L OUTDOOR 9 SENSOR SENSOR CONNECTION 82 See notes 1 2 4 6 7 9 10 11 and 15 Fig 27 Two Stage Furnace with Single Speed Heat Pump on the page following these figures Dual Fuel 23 THERMIDISTAT TWO STAGE TWO SPEED FURNACE HEAT PUMP RVS COOLING 2 __________________________ W2 HEAT COOL STAGE 1 Y1 W2 ____________ Eee te 1 COMPRESSOR LO FX HEAT STAGE 3 WWI J 4 4 L I w1 FURNACE FX HEAT COOL STAGE 2 viva NOTE 12 yo Y2 COMPRESSOR HI
4. OUTDOOR Ares SENSOR SENSOR CONNECTION 582 Lens pere See notes 2 11 and 12 on the See notes 1 2 3 4 12 13 14 15 and 17 page following these figures on the page following these figures A03182 A03183 Fig 30 Dual Fuel Thermostat with Two Stage Furnace Fig 31 Two Stage Thermostat with Two Stage Furnace and Two Speed Heat Pump and Two Speed Air Conditioner SINGLE STAGE TWO STAGE TWO SPEED THERMOSTAT FURNACE AIR CONDITIONER w2 E NEESER beeko 1 We gt sms 222524 1 2 Lidl sise zd Y2 E G RTE 22 s 99 ee See es wal R DHUM 6 ee sos ncm zl C See notes 1 and 2 on the page following these figures A03184 Fig 32 Single Stage Thermostat with Two Stage Furnace and Two Speed Air Conditioner NOTES For Figures 26 32 1 Heat pump MUST have a high pressure switch for dual fuel applications Refer to outdoor equipment Installation Instructions for additional information and setup procedure Outdoor Air Temperature Sensor must be attached in all dual fuel applications Dip switch No 1 on Thermidistat should be set in OFF position for air conditioner installations This is factory default Dip switch No 1 on Thermidistat should be set in ON position for heat pump installations Dip switch No 2 on Thermidistat should be set in OFF position for single speed compressor operation This is factory default Dip switch
5. WAH IH W NO uni 044409 eu pajeoipui eouenbes 159 jueuoduJoo eui HEIS eui Sow opoo syeedai eu ne ou use Buol pue HOUS epoo 10 jo sniels eui USE Iim 997 no eui UN 0 NIML LSAL Buoys Aq epoo SNIS Y 12981 ULI epoo snjeis e10jeq jeued sseooe JO jou 131 GAY pejois ejdsip 0 prenDejes yesp GAY j2euuooai pue epoo sniels 112981 OL ejqeo BunoeuuooJeiul JO JeJSOWJAY Y99049 Buoj jo 1equunu puooes aui pue uoys jo eu Aq peuiuuejep 14 eu YUM 1equunu epoo SNIS epoo SNIS Buoj pue jo e uy A mo s 44 1461 snes 11 SI Burseud 4940 4 10 49949 peuuiw spun Muejod 1981109 JO 4994 asned e Ajpides Buyung 1461 snes 037 SI LHVLLS 01 eq pue 1exeeig 95019 eoeu
6. peioejes eui 10 suni uone1edo jeuuoN Av HO H3 1HV NO H3MO l8 wayshs oeuo 01 21949 Jo yeay yBiy uiejs s uny pednuequt si 10 ASL L Jamod osje 5 uo sinou Jaye Sepoo 101 2409 SNOIAAYd I A05001 55 58CT Copyright 2008 Carrier Corp 7310 W Morris St Indiana 4 Printed in U S A Edition Date 08 T 1 polis IN 4623 Catalog No 58C 051 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces 58CT 9SI 56
7. AS ORIFICE Fig 54 Orifice Hole A93059 Refer to Table 12 for cubic ft of gas per hr Multiply gas rate cu ft hr by heating value Btuh cu ft to obtain input If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Repeat steps b through e until correct low heat input is achieved Re install low heat regulator seal cap on gas valve 5 Set low heat temperature rise The furnace must operate within the temperature rise ranges specified on the furnace rating plate Do not exceed temperature rise ranges spe cified on unit rating plate for high and low heat Determine the temperature rise as follows NOTE Blower access door must be installed when taking temperature rise reading Leaving blower access door off will result in incorrect temperature measurements WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect 115 v electrical power before changing speed tap a Verify unit is running in low heat per Step 3 Place ther mometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see radiant heat from heat exchangers Radiant heat affects temperature rise readings This practice is particularly important with straight run ducts b When thermometer readings stabilize subtract return air temperature from
8. G ___________ 24VACHOT ___________ 1 R DEHUMIDIFY DAUM ___________ DHUM 24 COMM C _________ HUM Eltern i A 7 HUMIDIFIER HUMIDIFY _____ __ id E 24 VAC B 1 11 OUTDOOR L OUTDOOR SENSOR SENSOR CONNECTION 82 11 DUAL FUEL THERMOSTAT RVS COOLING HEAT STAGE 3 Y1 W2 FURNACE HI HEAT STAGE 2 W W1 FURNACE LO HEAT COOL STAGE 1 COMPRESSOR G 24VACHOT R 24vac COMM NA B RVS SENSING L OUTDOOR 51 SENSOR CONNECTION 52 A03178 Fig 28 Two Stage Furnace with Two Speed Heat Pump Dual Fuel TWO STAGE SINGLE SPEED FURNACE HEAT PUMP 21 NOTET UT we 1 ERROR 11 1 1 1 2 pacts S220 YIY2 os cesses T Y sensuel 28 E R DHUM Com 1 4 um OUTDOOR puis SENSOR See notes 1 2 4 11 14 15 and 16 on the page following these figures A03181 See notes 1 2 3 4 6 8 9 10 12 13 and 15 on the page following these figures Fig 29 Dual Fuel Thermosta
9. 16 C 6 1 8 NR NR 145 196 8 2 4 NR NR 159 213 10 3 0 NR NR 175 231 15 4 6 NR NR NR 283 20 6 1 NR NR NR 333 30 9 1 NR NR NR NR Local 99 Winter Design Temperature 11 F 24 C or lower Not recommended for any vent configuration The 99 6 heating db temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook Climatic Design Information chapter Table 1A United States and 2A Canada or the 2005 ASHRAE Fundamentals handbook Climatic Design Information chapter and the CD ROM in cluded with the 2005 ASHRAE Fundamentals Handbook APPLIANCE APPLICATION REQUIREMENTS Appliance operation has a significant impact on the performance of the venting system If the appliances are sized installed adjusted and operated properly the venting system and or the appliances should not suffer from condensation and corrosion The venting system and all appliances shall be installed in accordance with applicable listings standards and codes The furnace should be sized to provide 10090 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 over sizing of the f
10. 2 Indoor openings shall comply with the Indoor Combus tion Air Method below and Outdoor openings shall be located as required in the Out door Combustion Air Method mentioned previously and Outdoor openings shall be sized as follows a Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Meth od below b Outdoor opening size reduction Factor is 1 minus the Ratio in a above c Minimum size of Outdoor openings shall be the size re quired in Outdoor Combustion Air Method above mul tiplied by reduction Factor in b above The minimum dimension of air openings shall be not less than 3 in 80 mm INSTALLATION UPFLOW INSTALLATION 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 3 4 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 Rotate bottom filler panel downward to release holding tabs Remove bottom closure panel Reinstall bottom filler panel 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 10 NOTE Side return air openings can be used in UPFLOW and most HORIZONTAL configurati
11. c Combining space on different floor levels The volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more per manent openings in doors or floors having free area of at least 2 in 2 1 000 Btuh 4 400 mm kW of total input rating of all gas appliances An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to out doors having free area of at least 1 in 2 4 000 Btuh of total input rating for all gas appliances in the space In spaces that use the Indoor Combustion Air Method in filtration should be adequate to provide air for combus tion permanent ventilation and dilution of flue gases However in buildings with unusually tight construction additional air MUST be provided using the methods de Scribed in the Outdoor Combustion Air Method section Unusually tight construction is defined as Construction with a Walls and ceilings exposed to the outdoors have a con tinuous sealed vapor barrier Openings are gasketed or sealed and b Doors and openable windows are weatherstripped and c Other openings are caulked or sealed These include joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines etc Combination of Indoor and Outdoor Air 1
12. 110 000 55 35484 9 229 86 7 23677 7 178 27 5 17742 6 152 132 000 66 42580 10 254 44 28387 8 203 33 21290 7 178 154 000 77 49677 10 254 51 3 33096 9 229 38 5 24839 8 203 EXAMPLES Determining Free Area FURNACE WATER HEATER TOTAL INPUT 110 000 30 000 140 000 divided by 4 000 35 0 Sq In for each two Vertical Ducts or Openings 66 000 40 000 106 000 divided by 3 000 35 3 Sq In for a Single Duct or Opening 88 000 30 000 118 000 divided by 2 000 59 0 Sq In for each of two Horizontal Ducts 1 SQIN PER 4000 DUCTS TO BTUH OUTDOORS CDN 1 i 1 1 305 12 12 a05mm 1SQIN VENT MAX PER 2000 B E5 THROUGH FE BTUH 5 ROOF 1SQIN oa PER o 4000 BTUH 5 DUCTS TO 258 a OUTDOORS gt gt 5 Le 1SQIN E PER zBoug 4000 ee BTUH rJ 1 SQIN 28 PER 2000 G sue goo 12 405 305mm 12 805mm 1 dz MAX 305mm IRCULATING AIR DUCTS CIRCU G UC DUCT i TO PER 4000 OUTDOORS BTUH Minimum dimensions of 3 in 76 mm Note Use any of the following combinations of openings A amp BC amp DD amp EF amp G A03174 Fig 7 Air for Combustion Ventilation and Dilution for Outdoors The opening shall commence within 12 in 30
13. Inadequate combustion air Supply Flame Roll out Switch open IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for Oxide buildup on flame sensor clean with fine steel wool Proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal Manual valve shut off Control ground continuity Gas valve defective or gas valve turned off Low inlet gas pressure Inadequate flame carryover or rough ignition Defective Hot Surface Ignitor Flame sensor must not be grounded Green Yellow wire MUST be connected to furnace sheet metal LOW HEAT PRESSURE SWITCH OPEN WHILE HIGH HEAT PRESSURE SWITCH IS CLOSED Check for Disconnected or obstructed pressure tubing Mis wired pressure switches Low heat pressure switch stuck open Low inlet gas pressure if LGPS used CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to Software check error PS used Gas valve relay stuck open Flame sense circuit failure Reset power to clear lockout Replace control if status code repeats 327598 101 REV C P A04210 Fig 56 Service Label Step 2 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 anything on near or in contact with the
14. 1640 1570 1465 1345 1225 155 20 Low 1570 1565 1550 1525 1495 1445 1370 1270 1175 1070 060155 Both Sides Or 1 High 2375 2285 2200 2105 1995 1870 1730 1570 Side amp Bottom Med High 2155 2135 2095 2040 1975 1895 1790 1685 1550 1400 1 Side Only High 2260 2180 2085 1975 1865 1740 1605 1455 Med High 2140 2095 2040 1975 1890 1810 1705 1595 1480 1325 filter is required for each return air inlet Airflow performance included 3 4 in 19 mm washable filter media such as contained in factory authorized ac cessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions NOTE For horizontal applications the top most flange may be bent past 90 to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed Downflow Furnaces Connect supply air duct to supply air outlet on furnace Bend flange inward past 90 with wide duct pliers See Fig 14 The supply air duct must be connected to ONLY the furnace supplyoutlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the accessory subbase KGASBO201ALL a factory approved air conditio
15. 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 c Adjust air temperature rise by adjusting blower speed In crease blower speed to reduce temperature rise Decrease blower speed to increase temperature rise For low heat speed selection can be low factory setting med low or med 5 speed blowers only d Remove thermostat jumpers and release Blower Access Door Switch To change motor speed selection for low heat remove blower motor lead from control LO HEAT terminal See Fig 33 Select desired blower motor speed lead from 1 of the other terminals and relocate it to the LO HEAT terminal See Table 13 for lead color identifica tion Reconnect original lead to SPARE terminal f Repeat steps a through e 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 midpoint of rise range or slightly above g When correct low heat input rate and temperature rise is achieved proceed to Step 6 6 Adjust Manifold Pressure to Obtain High Heat Rate Remo
16. 4 Multipoise Orientations LOCATION GENERAL This multipoise furnace is shipped in packaged configuration Some assembly and modifications are required when used in any of the four applications shown in Fig 4 NOTE For high altitude installations the high altitude conversion kit MUST be installed at or above 5500 ft 1676 M above sea level Obtain high altitude conversion kit from your area authorized distributor This furnace must e be installed so the electrical components are protected from water e not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS located close to the chimney or vent and attached to an air distribution system Refer to Air Ducts section e provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustible construction label A WARNING CARBON MONOXIDE POISONING DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and furnace damage AND UNIT 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 and shorten furnace life Air contaminants are found in aerosol sprays detergents blea
17. Blower access 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 3 To Begin Component Self Test Remove blower access door Disconnect the thermostat R lead from furnace control board Manually close blower door switch Short jumper the COM 24v terminal on control to the TEST TWIN 3 16 in 8 mm quick con nect terminal on control until the LED goes out approx imately 2 sec Gas valve and humidifier will not be turned on Remove jumper from terminals See Fig 33 and Table 10 NOTE The furnace control allows all components except the gas valve to be run for short period of time This feature helps diagnose a system problem in case of a component failure Component test feature will not operate if any thermostat signal is present at the control Refer to service label attached to furnace or See Fig 56 Component test sequence is as follows a LED will display previous status code 4 times b Inducer motor starts on high speed and continues to run until Step g of component test sequence Hot surface igniter is energized for 15 sec then off Blower motor operates on LO HEAT speed for 10 sec Blower motor operates on HI HEAT speed for 10 sec Blower motor operates on COOL speed for 10 sec Inducer motor goes to low speed for 10 sec then stops Reconnect R lead
18. ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation serious injury death or property damage Improper installation adjustment alteration service maintenance or use could 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 4 CAUTION FURNACE RELIABILITY HAZARD Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure Application of this furnace should be indoors with special attention given to vent sizing and material gas input rate air temperature rise unit leveling and unit sizing 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 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 ins
19. NOTE If factory location of J Box is acceptable go to next section ELECTRICAL CONNECTION TO J BOX Field Supplied Electrical Box on Furnace J Box Bracket See Fig 26 TE 14 wid 1 dels the J B hall not b NO on Wide casing models the I Box shall not be 1 Remove cover from furnace J Box relocated to other side of furnace casing when the vent pipe is routed within the casing 2 Attach electrical box to furnace J Box bracket with at least two field supplied screws through holes in electrical box into holes in bracket Use blunt nose screws that will not pierce wire insulation 1 Remove and save two screws holding J Box See Fig 24 NOTE Box removed Mom iMg J Box 3 Route furnace power wires through holes in electrical box in order to move the J Box Do NOT remove green ground and J Box bracket and make field wire connections in screw inside J Box The ground screw is not threaded into the electrical box Use best practices NEC in U S and CSA casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J box outboard of the casing C22 1 in Canada for wire bushings strain relief etc 4 Route and secure field ground wire to green ground screw on J Box bracket 2 Cut wire tie on loop in furnace wires attached to J Box 5 Connect line voltage leads as shown in Fig 23 3 Move J Box to desired location 21 58CT 6 Reinstall cover t
20. OPENING D FLOOR OPENING A96283 Fig 11 Floor and Plenum Opening Dimensions 12 FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING DOWNFLOW 7 SUBBASE SHEET METAL PLENUM FLOOR OPENING 22221322 96285 Fig 12 Furnace Plenum and Subbase installed on a Combustible Floor LL CERE NR FURNACE APPROVED COIL ASSEMBLY OR COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR OPENING 22222232 22224222 08556 Fig 13 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor Table 4 Opening dimensions In mm FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B c 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 Downflow applications on combustible flooring KGASB sub 11 13 16 19 13 7 16 20 5 8 376 base required 284 483 841 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR o
21. 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 Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Loosen the thumbscrew from outer door and remove outer door 3 For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door a Disconnect vent connector from furnace vent elbow b Disconnect and remove short piece of vent pipe from within furnace 4 Remove 2 screws from blower access door and remove blower access door 5 Disconnect blower leads from furnace control Record wire color and location for reassembly All other factory wires can be left connected but field thermostat connec tions may need to be disconnected depending on their length and routing 6 Remove 2 screws holding control box to blower shelf 7 Hang control box from front of furnace casing and away from blower compartment 8 Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace 9 Clean blower wheel and motor using a vacuum with soft brush attachment Blower wheel blades may be cleaned with a small paint or flux brush Do not remove or disturb balance weights clips on blower wheel blades 10 Vacuum any loose dust from blower housing wheel and motor 11 If a greasy residue is present on blower
22. 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 Explosure to these materials could lead to corrosion of the heat exchanger 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 or property damage Turn off the gas and electrical supplies to the unit before performing any maintenance or service Follow the operating instructions on the label attached to the furnace A WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Never operate unit without a filter or with filter access door 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 gl
23. 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 See Fig 33 2 Humidifier HUM Connect an accessory 24 VAC 0 5 amp maximum hu midifier if used to the 1 4 in male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip The HUM terminal is energized when gas valve relay GVR is energized See Fig 33 NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation SETUP SWITCHES LOW HEAT ONLY AND BLOWER OFF DELAY NOTE DO NOT connect furnace control HUM terminal to HUM humidifier terminal on Thermidistat Zone Controller or similar device See Thermidistat Zone Controller thermostat or controller manufacturer s instructions for proper connection VENTING The furnace shall be connected to a listed factory built chimney or vent or a clay tile lined masonry or concrete chimney Venting into an unlined masonry chimney or concrete chimney is prohibited When an existing Category I furnace is removed or replaced the original venting system may no longer be sized to properly vent the attached appliances An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent leakage of co
24. 19 Downflow Return Air Configurations and Restrictions RETURN AIR SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS SUPPLY I RETURN AIR 2 3 SIDE RETURN AIR NOT PERMITTED FOR 066 060 22 20 AIR FLOW MODELS 4 HORIZONAL RETURN AIR NOTE RESTRICTION SAME FOR RETURN RESTRICTIONS HORIZONAL LEFT HORIZONTAL RETURN AIR CONFIGURATIONS AND RESTRICTIONS RETURN AIR CONNECTION 3 ONLY DOWNFLOWRETURNAIRCONFIGURATIONSAND RESTRICTIONS AIR FLOW MODELS RETURN AIR CONNECTION 1 ONLY RETURN AIR COMBINATIONS OF 1 2 AND3 AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 2 CONNECTION3 COMBINATIONS ONLY Ol ONLY OF 1 2 AND3 066 060 22 AND YES NO NO 20 MODELS ALL OTHER MODELS YES YES YES Fig 20 Horizontal Return Air Configurations and Restrictions 18 A02075 A02163 A02162 Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S and the CAN CSA B149 1 05 in Canada Table 6 Maximum Capacity of Pipe INTERNAL LENGTH OF PIPE FT M SIZE NA 10 20 30 40 50 IN MM 30 60 1 12 1 152 1 2 12 7 ise 175 120 97 82 78 3 4 19 0 209 360 250 200 170 151 1 25 4 36 6 680 465 375 3
25. 300 4 950 6 600 8 250 9 900 11 550 0 10 6 300 8 400 10 500 6 600 9 900 13 200 16 500 19 800 23 100 0 00 NP NP NP NP NP NP NP NP NP NP Not Permitted Table 3 Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223 1 2006 NFPA 54 2006 9 3 2 2 If lother Iran ACH For other than fan assisted appliances such as a draft hood equipped water heater Volume 2113 other Other ACH 1000 Btu hr A04002 For fan assisted appliances such as this furnace Volume _ 151 rn _ Fan ACH 1000 Btu hr A04003 combined input of all other than fan assisted appliances in Btuh hr combined input of all fan assisted appliances in Btuh hr airchanges 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 2 Adjoining rooms can be considered part of a space if a There are no closeable doors between rooms b Combining spaces on same floor level Each opening shall have free area of at least 1 in 2 1 000 Btuh 2 000 mm 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 8
26. No 2 on Thermidistat should be set in ON position for two speed compressor operation Configuration Option No 10 Dual Fuel Selection must be turned ON in all dual fuel applications NO connection should be made to the furnace HUM terminal when using a Thermidistat Optional connection If wire is connected dip switch SW1 2 on furnace control should be set in ON position to allow Thermidistat Thermostat to control furnace staging Optional connection If wire is connected ACRDJ jumper on furnace control should be removed to allow Thermidistat Thermostat to control outdoor unit staging 12 When using both a two stage furnace and two stage heat pump the furnace must control its own high stage heating operation via furnace control algorithm 13 The RVS Sensing terminal 1 should not be connected This is internally used to sense defrost operation 14 DO NOT SELECT the FURNACE INTERFACE or BALANCE POINT option on the two speed heat pump control board This is controlled internally by the Thermidistat Dual Fuel Thermostat 15 Dip switch D on Dual Fuel Thermostat should be set in OFF position for single speed compressor operation This is factory default 16 Dip switch D on Dual Fuel Thermostat should be set in ON position for two speed compressor operation DA FW D E Eni 24 ACCESSORIES 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used us ing
27. Step 2 General Installation e US Current edition of the NFGC and the NFPA 90B For copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 www NFPA org or for only the NFGC contact the American Gas Association 400 N Capitol Street N W Washington DC 20001 www AGA org CANADA CAN CSA B149 1 05 For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario MOW 1R3 Canada Step Step 3 Combustion and Ventilation Air US Section 9 3 of the NFGC NFPA 54 ANSI Z223 1 2006 Air for Combustion and Ventilation CANADA Part 8 of CAN CSA B149 1 05 Venting Systems and Air Supply for Appliances Step 4 Duct Systems e US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16 Step 5 Acoustical Lining and Fibrous Glass Duct US and CANADA current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts Step 6 Gas Piping and Gas Pipe Pressure Testing US 54 ANSI Z223 1 2006 chapters 5 6 7 and 8 and National Plumbing Codes CANADA CAN CSA B149 1 05 Parts 4 5 and 6 and Appendices A B E and H St
28. U S A and Canada U S A 2001 611 to 3000 914 Canada 2001 611 U S A and Canada 915 to 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to 7000 2133 A08485 41 58CT Table 15 Orifice Size and Manifold Pressures In wc for Gas Input Rate cont TABULATED DATA BASED ON 22 000 BTUH HIGH HEAT 14 500 BTUH LOW HEAT PER BURNER DERATED 494 1000 FT 305M ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE ft m 2134 to 8000 2438 8001 2439 Orifice numbers shown inBOLD are factory installed A08485A 42 Table 16 Orifice Size and Manifold Pressures In wc for Gas Input Rate TABULATED DATA BASED ON 21 000 BTUH HIGH HEAT 14 500 BTUH LOW HEAT PER BURNER DERATED 4 1000 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 U S A and Canada 915 to 4000 1219 4001 1220 to 5000 1524 5001 1525 to 6000 1829 6001 1830 to 7000 2133 A08219 43 58CT Table 16 Orifice Size and Manifold Pressures In wc for Gas Input Rate cont TAB
29. average yearly gas specific gravity from local gas supplier c Find installation altitude in Table 15 or 16 d Find closest natural gas heat value and specific gravity in Table 15 or 16 e Follow heat value and specific gravity lines to point of intersection to find orifice size and low and high heat manifold pressure settings for proper operation f Check and verify burner orifice size in furnace NEVER ASSUME ORIFICE SIZE ALWAYS CHECK AND VERIFY g Replace orifice with correct size if required by Table 15 or 16 Use only factory supplied orifices See EXAMPLE 2 EXAMPLE 2 0 2000 ft 0 610 M altitude For 22 000 Btuh per burner application use Table 15 Heating value 1000 Btuh cu ft Specific gravity 0 62 Therefore Orifice No 43 Manifold pressure 3 7 in wc for high heat 1 6 in wc for low heat Furnace is shipped with No 43 orifices In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate 3 Adjust manifold pressure to obtain low fire input rate See Fig 53 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 A06667 Fig 53 Redundant Automatic Gas Control Valve e Move setup switch LHT SW 1 on furnace control to ON position to lock furnace in
30. blocks bricks or pad 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 Suspended Furnace Support The furnace may be supported under each end with threaded rod angle iron or metal plumber s strap as shown See Fig 15 and 16 Secure angle iron to bottom of furnace as shown Heavy gauge sheet metal straps plumber s straps may be used to suspend the furnace from each bottom corner To prevent screws from pulling out use 2 8 x 3 4 in 19 mm screw into the side and 2 48 x 3 4 in 19 mm screw in the bottom of the furnace casing for each strap See Fig 15 and 16 If the screws are attached to ONLY the furnace sides and not the bottom the straps must be vertical against the furnace sides and not pull away from the furnace sides so that the strap attachment screws are not in tension are loaded in shear for reliable support 11 58CT Platform Furnace Support Construct working platform at location where all required furnace clearances are met See Fig 2 and 17 For furnaces with 1 in 25 mm clearance requirement on side set furnace on non combustible blocks bricks or angle iron For crawlspace inst
31. 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 Sealany unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Code and these instructions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building 4 Close fireplace dampers 5 Turn on clothes dryers and any appliance not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they are operating at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously 7 Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use t
32. included with two stage furnace 1 Turn off electrical supply to furnace before removing filter access door 2 Remove filter cabinet door 3 Slide filter out of cabinet 4 If equipped with permanent washable 3 4 in 19 mm fil ter clean filter by spraying cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oil ing or coating of the filter is not recommended See Table 17 for size information 5 If equipped with factory specified disposable media filter replace only with media filter having the same part num ber and size For expandable replacement media refer to the instructions included with the replacement media If equipped with accessory KGAFRO301ALL external filter rack See Table 17 6 Slide filter into cabinet 7 Replace filter cabinet door 8 Turn on electrical supply to furnace BLOWER MOTOR AND WHEEL 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access 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 NOTE The blower wheel should not be dropped or bent as balance will be affected The following steps should be performed by a qualified service agency To ensure long life and high efficiency clean accumulated dirt and grease from blower wheel and motor annually
33. leaks Use a soap and water solution 19 Check for gas leaks 20 Replace outer access door Step 3 Sequence of Operation NOTE Furnace control must be grounded for proper operation or control will lockout Control is grounded through green wire connected to gas valve and burner bracket screw Using the schematic diagram in Fig 57 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 or W W1 and W2 the control run the blower for the selected blower off delay period two seconds after power is restored and if the thermostat is still calling for gas heating The LED light will flash code 12 during this period after which the LED will be ON continuous as long as no faults are detected After this 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 50 1 Two Stage Heating Adaptive mode with Single Stage Thermostat See Fig 23 or 32 for thermostat connections NOTE The low heat only switch LHT 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 33 When th
34. of Table 9 and 5 The authority having jurisdiction approves If all of these conditions cannot be met an alternative venting design shall be used such as the listed chimney adapter kit with a furnace listed for use with the kit a listed chimney lining system or a Type B common vent Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and or re lining Refer to Fig 34 to perform a chimney inspection If the inspection of a previously used tile lined chimney a Shows signs of vent gas condensation the chimney should be relined in accordance with local codes and the authority having jurisdiction The chimney should be re lined with a listed metal liner Type B vent or a listed chimney adapter kit shall be used to reduce condensation If a condensate drain is required by local code refer to the 54 ANSI Z223 1 2006 Section 12 10 for ad ditional information on condensate drains b Indicates the chimney exceeds the maximum permissible size in the tables the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction A chimney without a clay tile liner which is otherwise in good condition shall be rebuilt to conform to ANSI NFPA 211 or be lined with a UL listed ULC listed in Canada metal liner or UL listed Type B vent Relining with a listed metal liner or Typ
35. pi ce n CAR CAP CNPV WENC ou WTNC ou le carter de serpentin Dans une alc ve on doit maintenir un d gagement l avant de 18 po 450mm La poistion indiqu e conceme le c t d entr e ou de retour quand la foumaise est dans la position horizontale Le contact n est permis qu entre les lignes form es par les intersections du dessus et des deux c t s de la cherrise de la foumaise et les solives montant sous cadre de charpente 335137 101 REV A J A08471 Fig 2 Clearances to Combustibles m MAX80 F 27 C roel my FRONT o mmy mmm RETURN AIR MIN60 F 16 C A06745 Fig 3 Return Air Temperature CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions The installation must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction In the United States and Canada follow all codes and standards for the following Step 1 Safety e US National Fuel Gas Code NFGC 54 2006 51 Z223 1 2006 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CSA B149 1 05 National Standard of Canada Natural Gas and Propane Installation Code CAN CSA B149 1 05
36. rise Decrease blower speed to increase temperature rise For high heat speed selection can be med high med 5 speed blowers only or med low factory setting 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect 115 v electrical power before changing speed tap d To change motor speed selection for high heat remove blower motor lead from control HI HEAT terminal See Fig 33 Select desired blower motor speed lead from 1 of the other terminals and relocate it to the HI HEAT ter minal DO NOT use the low heat tap that was already set See Table 13 for lead color identification Reconnect original lead to SPARE terminal e Repeat steps a thru e f When correct high heat input rate and temperature rise is achieved turn gas valve ON OFF switch to OFF Release Blower Access Door switch ga h Remove manometer or similar device from gas valve i Re install manifold pressure tap plug in gas valve See Fig 54 4 WARNING FIRE HAZARD Failure to reinstall manifold pressure tap plug in gas valve could result in personal injury property damage or death Reinstall manifold pressure tap plug in gas valve to prevent gas leak j Remove thermostat jumper wire from furnace control board k Turn LHT switch OFF 1 Turn gas valve ON OFF switch to ON m Proceed to Step 9 Set Blower Off Delay before in stalling blower acce
37. speed Sim ultaneously the electronic air cleaner EAC 1 terminal is energized and remains energized as long as the BLWM is energized f Switching from Low to High Heat Ifthe furnace con trol CPU switches from low heat to high heat the fur nace 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 solenoid GV Hl is energized The blower motor BLWM will switch to HI HEAT speed five seconds after the fur nace control CPU switches from low heat to high heat g 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 h Blower OFF Delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV M stopping gas flow to the burners and de energiz ing the humidifier terminal HUM The inducer motor IDM will remain energized for a 5 second post purge period The blower motor BLWM and air cleaner termin al EAC 1 will remain energized for 90 120 150 or 180 seconds depending on selection at blower OFF delay switches The furnace control CPU is factory set for a 120 second blower OFF delay 2 Two Stage Thermostat and Two Stage Heating See Fig 31 for thermostat co
38. supply air temperature to determine air temperature rise NOTE If the temperature rise is outside this range first check 37 1 Gas input for low heat operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in wc 58CT Table 12 Gas Rate cu ft hr SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 FOR 1 REVOLUTION 1 Cu Fr 2 Cu Fr 5 Cu REVOLUTION 1 2 Cu FT 5 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 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
39. than 1790 to minimize the potential for condensation in the venting system These furnaces are approved for common venting and multi story venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the CAN CSA B149 1 05 local building codes and furnace and vent manufacturers instructions The following information and warning must be considered in addition to the requirements defined in the NFGC or the CAN CSA B149 1 05 A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Do not bypass the draft safeguard switch as an unsafe condition could exist which must be corrected 1 If a vent common or dedicated becomes blocked the fur nace will be shut off by the draft safeguard switch located on the vent elbow 2 Two stage furnaces require Type B vent connectors out side the casing in all configurations Single wall vent con nector may be used inside the furnace casing with the transition to Type B vent outside the furnace casing Size the connector so that the FAN Min vent connector capa city is equal to or lower than the low fire rate of the fur nace and the FAN Max vent connector capacity is equal to or higher than the furnace high fire rate 3 Do not vent this Category I furnace into a single wall ded icated or common vent The dedicated or common vent is considered to be the vertical portion of the vent system tha
40. the building could cause the furnace to be exposed to halogen compounds causing premature failure of the furnace or venting System due to corrosion Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system Do not use vent dampers on appliances common vented with this furnace ADDITIONAL VENTING REQUIREMENTS A 4 in 102 mm round vent elbow is supplied with the furnace A 5 in or 6 in 127 or 152 mm vent connector may be required for some model furnaces A field supplied 4 in to 5 in 102 to 127 mm or 4 in to 6 in 102 mm to 152 mm sheet metal increaser fitting is required when 5 in or 6 in 127 or 152 mm vent connector is used See Fig 35 47 Venting Orientation for approved vent configurations See Venting Notes after Fig 47 SEE NOTES 1 2 4 7 8 9 on the page following these figures A03208 Fig 35 Upflow Application Vent Elbow Up SEE NOTES 1 2 3 4 7 8 9 on the pages following these figures A03209 Fig 36 Upflow Application Vent Elbow Right 58CT SEE NOTES 1 2 3 4 5 7 8 9 SEE
41. up then Downflow right Fig 40 110 000 036 12 only 5 127 10 3 0 4 in 102 mm inside casing or vent guard Including 4 in 102 mm vent section s NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 32 A04127 Fig 48 Using Tin Snips to Cut Tie Points 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 NOTE Vent connector length for connector sizing starts at furnace vent elbow The 4 in 102 mm vent elbow is shipped for upflow configuration and may be rotated for other positions Remove the 3 screws that secure vent elbow to furnace rotate furnace vent elbow to position desired re install screws The factory supplied vent elbow does NOT count as part of the number of vent connector elbows The vent connector can exit the door through one of 5 locations on the door 1 Attach the single wall vent connector to the furnace vent elbow and fasten the vent connector to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart NOTE An accessory flue extension KGAFEO112UPH is available to extend from the furnace elbow to outside the furnace casing If flue extension is used fasten the flue extensio
42. used when approved by the authority having jurisdiction Select the listed mechanical venter to match the Btuh input of the furnace being vented Follow all manufacturer s installation requirements for venting and termination included with the listed mechanical venter START UP ADJUSTMENT AND SAFETY CHECK Step 1 General 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage This furnace is equipped with manual reset limit switches in the gas control area The switches open and shut off power to the gas valve if a flame roll out or overheating condition occurs in the gas control area DO NOT bypass the Switches Correct problem before resetting the switches 1 Maintain 115 v wiring and ground Improper polarity will result in rapid flashing LED and no furnace operation 2 Make thermostat wire connections at the 24 v terminal block on the furnace control Failure to make proper con nections will result in improper operation See Fig 23 3 Gas supply pressure to the furnace must be greater than 4 5 wc 0 16 psig but not exceed 14 in wc 0 5 psig 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 4 Check all manual reset switch
43. 0 1620 1495 1345 Both 99001 Medium 1845 1815 1770 1720 1655 1580 1500 1395 1270 1090 Med Low 1540 1515 1475 1435 1385 1335 1270 1175 1045 915 Low 1280 1250 1220 1190 115 1105 1035 945 845 745 High 2420 2845 2265 2165 2070 1960 1850 1720 1570 1420 Med High 2160 2110 2045 1960 1885 1790 1695 1570 1445 1305 1Side Only Medium 1850 1815 1765 1710 1635 1560 1480 1380 1250 1110 Med Low 1530 1490 1455 1420 1375 1320 1250 1160 1055 905 Low 1290 1250 1220 1190 115 1110 1040 950 835 740 High 1625 1575 1515 1445 1355 1260 1165 990 785 595 110 12 Bottom Med High 1510 1470 1415 1355 1285 1185 1070 890 725 530 036110 Side s Med Low 1360 1335 1295 1250 1180 1100 985 810 670 475 Low 1195 1180 1155 1115 1065 980 860 740 605 410 High 2055 1990 1910 1815 1695 1575 1425 1230 1090 910 Med High 1750 1725 1670 1605 1515 1400 1255 1120 975 785 un Medium 1545 1525 1490 1445 1355 1260 1135 1020 880 750 Med Low 1300 1290 1275 1235 1165 1085 1005 895 750 620 Low 1050 1045 1015 975 935 880 815 715 610 515 High 2530 2460 2380 2285 2200 2085 1970 1835 1695 1545 Med High 2225 2190 2135 2075 1995 1
44. 0 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 Indoor Combustion Air NFPA 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 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in death and or personal injury Many homes require air to be supplied from outdoors for furnace combustion ventilation and dilution of flue gases The furnace combustion air supply must be provided in accordance with this instruction manual o RCULATING AIR DUCTS VENT THROUGH ROOF 12 MAX 305mm 1 SQIN PER 1000 BTUH IN DOOR ORWALL UNCONFINED INTERIOR SPACE HEATED SPACE 6 MIN 152mm FRONT U 150 1000 BTUH IN DOOR ORWALL OPENINGS SHALL BE AT LEAST3 IN CLEARANCE IN FRONT OF COMBUSTION AIR L 12 MAX 305mm CIRCULATING AIR DUCTS Minimum opening size is 100 sq in 64516 sq mm with minimum dimensions of 3 in 76 mm t Mi
45. 1 497 ueuM poj2euuoo 10 2e saydepy 9 uauM paj2euuoo u0j2e 4 104 6 10 019 420 q 10 99UU09 TYYLNIN 94 ejqeeBueuo1jui 10 s y yms urejuoo Wal 10 pue WM78 1 au papny esnj dwe e sejd y pue 103 pieoq seu S euie j 10 aq jsnui 5141 y pue j2euuoosip ay Jeddoo Ajuo esf S 31ON Od PRINTED CIRCIUT BOARD 9350 N3HW Sd91 LL 31ON NIMLAS3LL 1 mm LOL L9SLZE 319 93933 ONd 46 0134 ANNOYS IN3 AdInO3 ANNOYS HI3Vv3 034 5 0134 1 4 NO YOLONGNOD 2 0131 1 0133 2 OVASLL ONIMIM HIMOd ANOLOWS 31 1OSINO
46. 1120 1075 1020 960 895 815 720 605 455 340 045 08 Bottom or Med High 930 890 850 805 750 680 600 500 8345 195 024045 Side s Med Low 820 785 750 700 650 585 505 400 235 Low 725 690 655 605 555 495 405 305 High 1465 1400 1325 1250 1175 1085 980 860 725 560 Med High 1295 1260 1210 1155 1090 1015 930 830 700 545 E Medium 1150 1120 1085 1040 985 920 835 740 620 510 Med Low 1030 1010 980 945 895 835 765 685 570 345 Low 860 835 810 780 745 700 635 555 445 260 High 1140 1105 1055 1010 955 885 815 715 545 390 070 081 Bottom or Med High 915 885 855 825 785 725 655 530 420 280 024070 Side s Med Low 795 770 740 700 655 600 510 420 325 Low 690 665 630 590 550 475 415 340 245 High 1440 1400 1855 1300 1240 1170 1090 1000 890 745 20 Bones Med High 1180 1165 1150 1125 1085 1030 970 890 785 645 dpi E Medium 1015 1020 1010 990 965 925 875 800 700 560 Med Low 885 885 880 865 845 815 770 700 605 475 Low 695 700 700 690 670 640 600 540 460 345 High 1840 1790 1780 1670 1605 1530 1450 1370 1275 1170 mom Med High 1610 1575 1535 1485 1435 1370 1305
47. 1230 1145 1055 Medium 1460 1430 1400 1360 1315 1260 1205 1130 1055 965 Med Low 1260 1240 1215 1180 1145 110 1040 985 915 835 Low 1065 1040 1015 985 955 915 875 825 765 695 High 1650 1600 1535 1465 1385 1285 1175 1055 895 645 090 14 Bottom or Med High 1515 1485 1440 1880 1300 1220 1115 990 830 600 042090 Side s Med Low 1385 1360 1320 1260 1195 1120 1025 915 710 565 Low 1205 1180 1160 1120 1065 1005 925 810 630 510 Lio 2060 2000 1930 1835 1755 1620 1490 1315 1115 910 T T Meu ign 1710 1695 1665 1585 1480 1390 1245 1110 955 775 spon en Ved HO 1470 1475 1450 1390 1335 1280 1120 1005 855 690 e 1260 1365 1245 1225 1165 1090 995 880 750 600 1080 1025 1020 990 940 890 810 720 615 500 High 2380 2295 2205 2105 2005 1900 1775 1650 1510 1335 Med High 2185 2115 2045 1960 1875 1770 1655 1535 1400 1240 Bottom Only Medium 1905 1865 1815 1740 1670 1590 1490 1390 1245 1110 Med Low 1595 1565 1530 1485 1430 1855 1275 1160 1055 920 Low 1340 1310 1280 1225 1170 1120 1040 955 850 750 High 2485 2415 2330 2230 2185 2030 1920 1790 1645 1485 090 20 BothSideor1 Med High 2175 2130 2070 2000 1930 1840 174
48. 20 285 1 1 4 1 380 315 35 0 1400 950 770 660 580 121 2 1 610 581 40 9 2100 1460 1180 990 900 Cubic ft of natural gas per hr for gas pressures of 0 5 psig 14 in wc or less and a pressure drop of 0 5 in wc based on a 0 60 specific gravity gas Ref Table 6 2 ANSI Z223 2006 54 2006 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 In the state of Massachusetts 1 Gas supply connections MUST be performed by a li censed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 inches 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 6 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 4 WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage If lo
49. 3 1 2 19 5 8 24 1 2 subbase not required 581 483 597 498 Downflow applications on Combustible flooring KGASB sub 22 1 8 19 23 3 4 20 5 8 622 base required 562 483 603 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR Coil Assembly or KCAKC coil box rs i 25 pos KGASB subbase not required UPFLOW DOWNFLOW HORIZONTAL 90 90 so YES YES YES YES EN YES YES MIN NOT NOT NOT RECOMMENDED RECOMMENDED RECOMMENDED Fig 14 Duct Flanges 13 A02329 58CT 8 203 mm MIN FOR DOOR REMOVAL 1 6 mm THREADED ROD 4 REQ SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 8 19 mm SCREWS TYPICAL FOR 2 SUPPORTS 1 25 mm SQUARE 11 4 x 11 4 x 1 4 32 x 32 x 6 mm ANGLE IRON OR UNI STRUT MAY BE USED 2 HEX NUTS 2 WASHERS amp 2 LOCK WASHERS REQ PER ROD OUTER DOOR ASSEMBLY Fig 15 Horizontal Unit Suspension 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH 4 8 x 3 4 19 mm SHEET METAL SCREWS 2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM Fig 16 Horizontal Suspension with Straps 14 A02345 AIR Pi OPENING De METHOD 2 USE 4 8 x 3 4 19 mm SHEET METAL SCREWS FOR EACH STRAP THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SI
50. 5 second prepurge period After the low heat pressure switch re closes the furnace control CPU will begin a 15 second pre purge 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 relay HPSR is de energized to close the NC contact When sufficient pressure is available the high heat pressure switch HPS closes and the high heat gas valve solenoid GV HI is energized The furnace control CPU begins a 15 second 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 furnace 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 second igniter warm up period c Trial for Ignition Sequence When the igniter warm up period is completed the main gas valve relay contacts GVR 1 and 2 close to energize the gas valve solenoid GV M the gas valve opens and 24 vac power is supplied for a field installed humidifier at the HUM terminal 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 ni
51. 508 135 16 048135 21 533 19 3 8 492 19 1 2 495 13 5 16 838 4 102 149 68 20 508 135 22 066135 24 1 2 622 22 7 8 581 23 584 15 1 16 883 4 102 163 74 24 610 155 20 060155 24 1 2 622 22 7 8 581 23 584 15 1 16 883 4 102 170 77 24 610 5 in or 6 in 127 152 mm vent connector may be required in some cases T 135 and 155 size furnaces require 5 in 127 mm or larger vents Use a 4 to 5 or 4 to 6 in 102 to 127 102 to 152 mm vent adapter between furnace and vent connector product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation 1 10 Use only with type of gas approved for this furnace Refer to the furnace rating plate 2 Install this furnace only in a Install this furnace only in a location and position as spe cified in the Location section of these instructions Provide adequate combustion and ventilation air to the furnace space as specified in Air for Combustion and Ventilation section 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 Never test for gas leaks with an open flame Use a com mercially available soap solution made specifically for the detection of leaks to check all connections as specified in the Gas P
52. 58CTA CTX 2 Stage Deluxe Induced Combustion 4 Multipoise Furnace Turn to the Experts Installation Start up Operating and Service and Maintenance Instructions Series 130 D SAFETY CONSIDERATIONS 2 INTRODUCTION RR tm see see s sieste 3 CODES AND STANDARDS 5 Safety MEME 5 General Installation 5 Combustion and Ventilation Air 5 Duct Systems vete e ve tea e e we ose 5 Acoustical Lining and Fibrous Glass Duct 5 Gas Piping and Gas Pipe Pressure Testing 5 Electrical Connections 9 Vening ne te th eek dan e eg vue 5 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE ER beares east Pea eA Hees Sede 5 LOCATION tee expe e PER He e Seg 6 AIR FOR COMBUSTION AND VENTILATION 8 INSTALLATION s ssss 10 UPFLOW INSTALLATION 10 DOWNFLOW INSTALLATION 11 HORIZONTAL INSTALLATION 11 FILTER ARRANGEMENT 15 AIR tete Gp cued nente e impose os 15 GAS PIPING tep een 17 ELECTRICAL CONNECTIONS 21 VENTING em eR EP 26 START UP ADJUSTMENT AND SAFETY CHECK 34 General OR eae eed EENE TERNET PET 34 Start Up Procedures
53. 910 1805 1695 1565 1430 Bottom Only Medium 1895 1885 1865 1820 1770 1700 1610 1520 1410 1290 Med Low 1565 1555 1535 1505 1465 1410 1350 1265 1175 1050 Low 1320 1295 1265 1235 1205 1160 1105 1035 950 870 110 22 Bottom Sides or High 2415 2880 2235 2125 1995 1860 1735 1605 066110 1 Side amp Bottom Med High 2205 2175 2120 2065 1975 1900 1790 1685 1580 1460 High 2485 2430 2360 2270 2175 2070 1950 1825 1685 1535 Med High 2155 2185 2100 2040 1970 1885 1790 1680 1560 1420 1Side Only Medium 1830 1830 1810 1780 1730 1665 1595 1505 1395 1275 Med Low 1520 1505 1490 1470 1430 1385 1330 1250 1165 1055 Low 1275 1260 1240 1210 1180 1185 1090 1025 930 840 filter is required for each return air inlet Airflow performance included 3 4 in 19 mm washable filter media such as contained in factory authorized ac static pressure cessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available externa Indicates unstable operating conditions 16 Table 5 Air Delivery CFM With Filter Cont FURNACE RETURN AIR BREED EXTERNAL STATIC PRESSURE IN WC SIZE INLET 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 H
54. DES BACK OF FURNACE 03176 LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING EQUIPMENT MANUAL SHUT OFF GAS VALVE SEDIMENT TRAP 17 3 4 451mm OVERALL 4 3 4 121mm UNDER DOOR 1 25mm UNDER FURNACE EXTEND OUT 12 305mm FROM FACE OF DOOR A03177 Fig 17 Typical Attic Installation Not all horizontal furnaces are approved for side return air connections See Fig 20 FILTER ARRANGEMENT 4 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Never operate a furnace without a filter or with filter access door removed There are no provisions for an internal filter rack in these furnaces An external filter rack is required This furnace is shipped with a factory supplied Media Filter Cabinet The Media Filter Cabinet uses either a factory supplied standard 3 4 in 19 mm filter or 4 in 102 mm wide Media Filter which can be purchased separately Refer to the instructions supplied with Media Cabinet for assembly and installation options 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 A
55. Disconnect wires to the following components Mark wires to aid in reconnection of be careful when discon necting wires from switches because damage may occur Draft safeguard switch Inducer motor Pressure switches Limit overtemperature switch Gas valve Hot surface igniter Flame sensing electrode mo Flame rollout switches 6 Remove screws that fasten the collector box assembly to the cell panel Be careful not to damage the collector box Inducer assembly and elbow need not be removed from collector box 7 Disconnect gas line from gas manifold 8 Remove the 5 screws that attach the burner assembly to the cell panel The gas valve and individual burners need not be removed from support assembly Remove NOx baffles if installed NOTE Be very careful when removing burner assembly to avoid breaking igniter See Fig 58 and 59 for correct igniter location 9 32 m 7 1 mm 5 167 7 9 mm 05025 Fig 58 Igniter Position Side View 49 58CT 9 Using field provided 25 caliber rifle cleaning brush 36 in 914 mm long 1 4 in 6 mm diameter steel spring cable a variable speed reversible electric drill and vacuum cleaner clean cells as follows a Remove metal screw fitting from wire brush to allow in sertion into cable b Insert the twisted wire end of brush into end of spring c
56. IDE 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 Carbon Monoxide Poisoning Hazard warning in venting section of these instructions to determine if an adequate amount of make up air is available The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1 000 Btuh input rating for all gas appliances installed in the space Spaces having less than 50 cubic feet per 1 000 Btuh require the Outdoor Combustion Air Method Spaces having at least 50 cubic feet per 1 000 Btuh may use the Indoor Combustion Air Standard or Known Air Infiltration Method Outdoor Combustion Air Method 1 Provide the space with sufficient air for proper combus tion ventilation and dilution of flue gases using perman ent horizontal or vertical duct s or opening s directly communicating with the outdoors or spaces that freely communicate with the outdoors 2 Fig 7 illustrates how to provide TWO OUTDOOR OPENINGS one inlet and one outlet combustion and ventilation air opening to the outdoors a One opening MUST commence within 12
57. IRCIUT BOARD YISH 935 1 A 1Y3H 440 tc 06 INHONLI NO x AV 130 340 A TINO MS J3VHO 193135 GaSN 5897 541 31ON 7 ILON 9351 5 NIHM NASA 560 OL SLON INVHOVIO NOLLO3NNOO A07125 Fig 57 Wiring Diagram 47 58CT TABLE 17 FILTER SIZE INFORMATION IN MM FILTER SIZE FURNACE CASING WIDTH SIDE BOTTOM FILTER TYPE RETURN RETURN 16 x25 x 3 4 14 x25 x 3 4 14 1 2 368 406 x635 x 19 856 x635 x 19 Washable 16 25 x 3 4 16 25 x 3 4 17 1 2 445 406 x635 19 406 x635 19 Washable 16325 x 3 4 20x25 x 3 4 21 533 406 x635 x 19 508 x635 19 Washable 16 x25 x 3 4 24 x25 x 3 4 24 610 406 x635 x 19 610 x635 x 19 Washable Recommended Some furnaces may have 2 filters CLEANING AND OR REPLACING AIR FILTER The air filter arrangement will vary depending on the application NOTE If the filter has an airflow direction arrow the arrow must point towards the blower 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 Media cabinet filter procedures NOTE Media Cabinet is
58. Install and connect short piece of vent pipe inside furnace to existing vent b Connect vent connector to vent elbow 21 Turn on gas supply and cycle furnace through one com plete heating and cooling cycle Verify the furnace temper ature rise as shown in Adjustments Section Adjust tem perature rise as shown in Adjustments Section If outdoor temperature is below 70 F 21 C turn off circuit breaker to outdoor unit before running furnace in the cooling cycle Turn outdoor circuit breaker on after completing cooling cycle CLEANING HEAT EXCHANGER The following steps should be performed by a qualified service agency NOTE If the heat exchangers get a heavy accumulation of soot and carbon they should be replaced rather than trying to clean them thoroughly 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 incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger Action must be taken to correct the problem If it becomes necessary to clean the heat exchangers because of dust or corrosion proceed as follows 1 Turn OFF gas and electrical power to furnace 2 Remove outer access door 3 Disconnect vent connector from furnace vent elbow 4 For downflow or horizontal furnace having an internal vent pipe remove internal vent pipe within the casing 5
59. J Box to furnace casing with screws re moved in Step 4 11 Secure field ground wire to J Box green ground screw 12 Complete electrical box wiring and installation Connect line voltage leads as shown in Fig 23 Use best practices NEC in U S and CSA C22 1 in Canada for wire bush ings strain relief etc 13 Reinstall cover to J Box Do not pinch wires between cover and bracket POWER CORD INSTALLATION IN FURNACE J BOX NOTE Power cords must be able to handle the electrical requirements listed in Table 7 Refer to power cord manufacturer s listings 1 Remove cover from J Box 2 Route listed power cord through 7 8 inch 22 mm dia meter hole in J Box 3 Secure power cord to J Box bracket with a strain relief bushing or a connector approved for the type of cord used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 23 6 Reinstall cover to J Box Do not pinch wires between cover and bracket BX CABLE INSTALLATION IN FURNACE J BOX 1 Remove cover from J Box 2 Route BX cable into 7 8 inch 22 mm diameter hole in J Box 3 Secure BX cable to J Box bracket with connectors ap proved for the type of cable used 4 Secure field ground wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 23 6 Reinstall cover to J Box Do not pinch wires between cover and bracket 24 V WIRING Make field 24 v co
60. Jnj 1942914 10 100p pasop Jexeeiq S yams SI 52 036 pue 095 18 1 SI OMS 100p uo snieis 11 SI YMS JOOP S g1 pue 11 AGL 91991 SI ON 3din9 ONILOOHSTTIANOHL LYVLS 1988 A02107A 61 Troubleshooting Guide 2 Speed Fig 54 eoeuun epoJjoeje uoneoo 10sues eurejj pue x99uo JI einsseid ayesado eoe dei uo els JOU Jins M yey uo ejs jou pue 0 9 07 jeord S Juana pue uoneJedo 10 01158 pue uo jeuiuou 907 def 1810 10 ainssaid sef jejui 10 ayenbepeu 10 49949 anea eoe dou UO seb yey YOOUD eaejdeJ HO J suonoeuuoo x
61. NOTES 1 2 4 5 6 7 8 9 10 on the page following on the page following these figures these figures A03207 03210 Fig 39 Downflow Application Vent Elbow Left then Up Fig 37 Downflow Application Vent Elbow Up then Left o on the page following these figures SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures A03212 A03211 Fig 40 Downflow Application Vent Elbow Up then Right Fig 38 Downflow Application Vent Elbow Up 30 1 SEE NOTES 1 2 4 7 8 9 on the page SEE NOTES 1 2 4 5 7 8 9 on the page following these figures following these figures A03213 A03215 Fig 41 Horizontal Left Application Vent Elbow Left Fig 44 Horizontal Left Application Vent Elbow Up fog IE el 7 y X SEE NOTES 1 2 4 5 7 8 9 on the page SEE NOTES 1 2 4 5 7 8 9 on the page following these figures following these figures A03214 A03216 Fig 42 Horizontal Left Applicati
62. NS COMBUSTIBLES This forced air furnace is equipped for use with This furnace is approved for UPFLOW DOWNFLOW and natural gas at altitudes 0 10 000 ft 0 3 050m HORIZONTAL installations An accessory kit supplied by the Cette foumaise est approuv e pour l installation HORIZONTALE manufacturer shall be used to convert to propane et la circulation VERS LE HAUT et VERS LE BAS gas use or may be required for some natural gas applications This furnace is for indoor installation in a building constructed on site This fumace may be installed on combustible flooring in alcove or closet at minimum clearance as indicated by the diagram from combustible material This fumace may be used with a Type B 1 Vent and may be vented in common with other gas fired appliances Clearance arrows do not change with fumace orientation Les fl ches de d gagement ne change avec l orientation de la fournaise TS 5 RE 3 TOP PLENUM DESSUS CHAMBRE D AI Cette fournaise air puls est quip e pour utilisation avec gaz naturel et altitudes comprises entre 0 3 050m 0 10 000 pi Utiliser une trousse de conversion foumie par le fabricant pour passer au gaz propane ou pour certaines installations au gaz naturel Cette foumaise est pr vue pour tre install e dans un b timent construit sur place Cette fournaise peut tre install e sur un plancher combustible dans une alc ve ou dans un garde robe en respecta
63. NV31O 2INOSIO313 O N 1848 13538 011 HOLIMS 33v5 Lived NOILO3NNOO WAHG WNHd ANY 4055390944085 fido YOLOVdVO O N 154 19934 HO1IMS 44 1 IN3A 0342018 SS 8 OLD VAVO LAS ININVNE Id 83MO 18 NM IS 07 1545 HOLOIN 43MO 18 MIS 1045 Av 34 03395 YOLOW 18 1445 Av H8 03385 YOLOW 343MO 18 318VSIO Av 138 ONINOLLIGNOO aly O N 1545 mi 035 N3HW 2235 UE CH 235 ral 1 Ssd qasn NaHW SSAg OVASLL Md 9 uvas 1V3HO1 HO TIHS ANVdOdd SVD Ven LVN INVSIOVIO OU VIWN3HOS N3HM HOLMS 1O3NNOOSIQ 33 388 HOLIMS LOANNOOSIG CTAld OVASLL OL HO 3503 H H GaN 9 a OVASLLO dv 1 Ave 3909 SNIVIS Y Uo 9 LA eM OWA 21 TWHLNAN Z L LOIS 206 NIMI S WM AWE 3504 9 3ION mm OAS 440 081 t NO 23S 1 1 440 081 93 111410 Ivan ya oct O1 1 PRINTED C
64. O 82d 31 NOILONNT 431 ONINNIML 8 1531 ININOdNOS OVAVC ONAS LL HINAOISNVEL 1531 AUOLIVI 6 3O1O3NNOO ISH 2 SOIO3NNOO WAI LINDYID NMOHS LON YOLOINNOD YOLOW WO LINDYID 9 YOLOANNOOD WII 8 ISH 808 LINDYIO YOLOINNOD 89d 1 NIML 1S31 Sd vd ld Ld AAYO TANIA HOIIMS QVO TH3AO YOLOW 13838 O10 V CO N 1595 13534 HOLMS 154 HOLMS 34055384 IV3H MOT O N 1SdS HOLMS 33055384 SVO MOT YAN 3909 501 15 303 34010 CO N 1SdS HOLIMS XOO TH3INI TANWd SSIOOV 83MO 8 1045 Av H8 03395 8OLOIN CO N 1SdS 8OLOIN 31Od Q3QVHS YOLOW CXV 870 NOLLO3NNOO HAHICINNH OvAvz O N 1846 S3lINDI JOVIYNS LOH OVASLL 3 JOVSUNS LOH O N 154 Av 138 HOLMS 38056344 IV3H HOIH O N 164 HOLMS 38055384 IV3H HOIH CO N 1SdQ ATH 3 1 SVO SVO 1N3I AdInO3 Q3TIVISNI ONY 03114405 01314 3OIA3Q 1914431 1 139 V3 YO ISNI Q3TIVISNI 3dAL 3QV 18 JAILOWOLAY ISNI 390319313 ONIAONd WV 1H O N ISdS 13538 MS INOTION NOWINOO NOILO3NNOO YANVITO SINOYLOINS dv O L OVA SLL NOLO3NNOO H
65. PA 54 ANSI Z223 1 2006 or the authority having jurisdiction to determine whether relining is required If relining is required use a properly sized listed metal liner Type B vent or a listed alternative venting design NOTE See the NFPA 54 ANSI Z223 1 2006 13 1 8 and 13 2 20 regarding alternative venting design and the exception which cover installations such as the Chimney Adapter Kits 02014 and KGACAO02015FC which are listed for use with these furnaces 26 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances in the U S A or to the Canadian installation Code CSA B149 1 in Canada Crown condition Missing mortar or brick Rebuild crown Is chimney property lined with clay tile liner Is liner and top seal in good condition Repair liner or top seal or reline chimney as necessary Reline Repair Debris in cleanout Mortar Mortar tile metal vent or tile pie fuel oil residue debris No Remove metal vent or liner Clay tile misalignment missing sections gaps Consult Part B of chimney adapter venting instructions for application suitability Not Suitable Line chimney with property lined with properly sized listed flexib
66. ULATED DATA BASED ON 21 000 BTUH HIGH HEAT 14 500 BTUH LOW HEAT PER BURNER DERATED 4 1000 FT 305 ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE ft m 2134 to 8000 2438 8001 2439 Orifice numbers shown inBOLD are factory installed A08219A 44 SERVICE AND MAINTENANCE PROCEDURES 4 WARNING FIRE PERSONAL INJURY AND UNIT DAMAGE 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 maintenance on this equipment other than those procedures recommended in the User s Manual A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death or property damage Before servicing disconnect all electrical power to furnace Verify proper operation after servicing CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in improper unit operation or failure of unit components Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation CAUTION ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental pollution Remove and recycle all c
67. able and crimp tight with crimping tool or crimp by striking with ball peen hammer TIGHTNESS IS VERY IMPORTANT NOTE The materials needed in item 9 can usually be purchased at local hardware stores 1 Attach variable speed reversible drill to the end of spring cable end opposite brush 2 Insert brush end of cable into the outlet opening of cell and slowly rotate with drill DO NOT force cable Gradually insert cable into upper pass of cell See Fig 60 3 Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning DO NOT pull cable with great force Reverse drill and gradually work cable out 4 Insert brush end of cable in burner inlet opening of cell and proceed to clean 2 lower passes of cell in same manner as upper pass 5 Repeat foregoing procedures until each cell in fur nace has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly 8 Clean flame sensor with fine steel wool 9 Install NOx baffles if removed 10 Reinstall burner assembly Center burners in cell openings 10 Remove old sealant from cell panel and collector box flange 11 Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel NOTE A releasing agent such as cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadeq
68. access panel door switch opens 115 v power to control No component operation can occur Do not bypass or close switch with panel removed See Fig 23 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 A 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 2008 and Canadian Electrical Code CSA C22 1 or local codes to minimize personal injury if an electrical fault should occur This may consist of electrical wire 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 WIRING Verify that the voltage frequency and phase correspond to that specified on unit rating pla
69. 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 draft safeguard switch The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions a Verify vent pipe is cool to the touch b Disconnect power to furnace and remove vent connector from furnace vent elbow c Restore power to furnace and set room thermostat above room temperature d After normal start up allow furnace to operate for 2 minutes then block vent elbow in furnace 8096 of vent area with a piece of flat sheet metal e Furnace should cycle off within 2 minutes If gas does not shut off within 2 minutes determine reason draft safe 40 tion f Remove blockage from furnace vent elbow g Switch will auto reset when it cools h Re install vent connector NOTE Should switch remain open longer than 3 minutes furnace control board will lockout the furnace for 3 hours To reset furnace control board turn thermostat below room temperature or from HEAT to OFF and turn 115 v power OFF then back ON 3 Check Pressure Switch es This control proves operation of the draft inducer blower a Turn
70. allations 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 Roll Out Protection Provide a minimum 17 3 4 in x 22 in 451 x 559 mm piece of sheet metal for flame roll out protection in front of burner area for furnaces closer than 12 inches 305 mm above the combustible deck or suspended furnaces closer than 12 inches 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 17 for proper orientation of roll out shield 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 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel 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 PLENUM
71. cal 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 furnace 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 of furnace A 1 8 in 3 mm NPT plugged tapping accessible for test gauge connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve 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 wc stated on gas control valve See Fig 53 Some installations require gas entry on right side of furnace as viewed in upflow See Fig 21 TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY a JL Y 90 Elbow gt o U To Gas 4 7 2 51mm Nipple mm Nippl Fig 21 Burner and Manifold S
72. ches 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 The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures Commercial buildings Buildings with indoor pools Laundry rooms e Hobby or craft rooms and Chemical storage areas If air is exposed to the following substances it should not be used for combustion air and outdoor air may be required for combustion Permanent wave solutions e Chlorinated waxes and cleaners e Chlorine based swimming pool chemicals e Water softening chemicals e De icing salts or chemicals e Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc e Hydrochloric acid e Cements and glues e 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 and from draft safeguard opening 4 WARNING FIRE INJURY OR DEATH HAZARD Failure to
73. cuit is closed and there is a demand for dehumidification the fur nace blower motor BLWM will continue running at low cool speed same speed as LO HEAT 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 speed from COOL to HI HEAT for a maximum of 10 minutes before reverting back to COOL speed If there is still a demand for dehumidification after 20 minutes the fur 52 nace control CPU will drop the blower speed back to HI HEAT speed This alternating 10 minute cycle will con tinue as long as there is a call for cooling c Cooling off delay When the call for cooling is satis fied and there is a demand for dehumidification the cool ing blower off delay is decreased from 90 seconds to 5 seconds Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on continuous blower speed can be set to LO HEAT HI HEAT or COOL speed Factory default is LO HEAT speed Terminal 1 is energized as long as the blower motor BLWM is energized During a call for heat the blower BLWM will stop during igniter warm up 17 seconds ignition 7 seconds and blower ON delay 45 seconds in low heat and 25 seconds 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 LO HEAT or HI HEAT speed respect
74. d d BRIEFLY remove insulated terminal wire from the draft safeguard DSS switch until LED goes out then recon nect it NOTE If wire to DSS is disconnected longer than 4 sec main blower starts and retrieval request is ignored 2 When above items have been completed the LED flashes status code 4 times Record this status code for further troubleshooting After the LED flashes status code four times BRIEFLY remove wire again from DSS switch un til LED goes out then reconnect it to retrieve previous status code if available Repeat as needed for more previ ous status codes or until Code 11 appears 45 SERVICE If status code recall is needed briefly remove then reconnect one main limit wire to display last stored status code On RED LED boards do not remove power or blower door before initiating status code recall LED CODE STATUS CONTINUOUS OFF Check for 115VAC at L1 and L2 and 24VAC at SEC 1 and SEC 2 CONTINUOUS ON Control has 24 Power RAPID FLASHING Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions 58CT EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES 11 NO PREVIOUS CODE Stored status code is erased automatically after 72 hours On RED LED boards stored status codes can also be erased when power 115 VAC or 24 VAC to control is
75. do nothing to recharge your body with static electricity for example DO NOT move or shuffle your feet do not touch un grounded 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 dis charge your body s electrostatic charge to ground to pro tect the control from damage If the control is to be in stalled in a furnace follow items 1 through 4 before bringing the control or yourself in contact with the fur nace Put all used and new controls into containers before touching ungrounded objects 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage 58CT gt AIRFLOW THE BLOWER IS LOCATED BELOW THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED UPWARD THE BLOWER IS LOCATED T TO THE RIGHT OF THE BURNER SECTION AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT 2 7 lt HORIZONTAL LEFT HORIZONTAL RIGHT Es AIRELOW AIRFLOW DOWNFLOW THE BLOWER IS THE BLOWER IS LOCATED ABOVE THE LOCATED TO THE LEFT BURNER SECTION AND OF THE BURNER SECTION CONDITIONED AIR IS 7 AND CONDITIONED AIR IS DISCHARGED DOWNWARD 20 DISCHARGED THE RIGHT A02097 Fig
76. e B vent is considered to be a vent in a chase If a metal liner or Type B vent is used to line a chimney no other appliance shall be vented into the annular space between the chimney and the metal liner Exterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors ONFPA amp AGA Table 8 Combined Appliance Maximum Input Rating in Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT SQ IN 50 MM FT M 12 19 28 38 7741 12258 18064 24516 6 1 8 74 119 178 257 8 2 4 80 130 193 279 10 3 84 138 207 299 15 4 5 NR 152 233 334 20 6 0 NR NR 250 368 30 9 1 NR NR NR 404 Table 9 Minimum Allowable Input Rating of Space Heat ing Appliance in Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT SQ IN SQ MM FT 12 19 28 38 7741 12258 18064 24516 Local 99 Winter Design Temperature 17 to 26 F 8 to 3 C 6 1 8 0 55 99 141 8 2 4 52 74 111 154 10 3 0 NR 90 125 169 15 4 6 NR NR 167 212 20 6 1 NR NR 212 258 30 9 1 NR NR NR 362 Local 99 Winter Design Temperature 5 to 16 F 15 to 9 C 6 1 8 NR 78 121 166 8 2 4 NR 94 135 182 10 3 0 NR 111 149 198 15 4 6 NR NR 193 247 20 6 1 NR NR NR 293 30 9 1 NR NR NR 377 Local 99 Winter Design Temperature 10 to 4 F 23 to
77. e 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 starts 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 If the 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 1
78. ed operation which selects low cooling or high cooling operation 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 33 When is 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 cool speed same speed as LO HEAT If the furnace control CPU switches from low cooling t
79. en shift to LOW speed for 7 to 15 seconds The hot surface igniter blower motor LO HEAT speed blower motor HI HEAT speed and blower motor COOL speed will be turned ON for 10 15 seconds each Gas Valve and Humidifier will not be turned on When the blower is turned OFF the inducer will be switched to low speed for 10 seconds Short circuit in secondary 32 LOW HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five minutes inducer shuts off for 15 minutes before retry ens during blower on delay eck for Defective inducer motor Low inducer voltage 1 5 Low inlet gas pressure GL period blower will come on for the selected blower off delay Excessive wind Restricted vent Proper vent sizing Defective pressure switch Inadequate combustion air supply Disconnected or obstructed pressure tubing LIMIT CIRCUIT FAULT Indicates a limit draft safeguard flame rollout or blocked vent Switch if used is open 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 and BVSS require manual reset Check for Dirty filter or restricted duct system Defective blower motor or capacitor Proper vent sizing Restricted vent Defective switch or connections Loose blower wheel Excessive wind
80. ep 7 Electrical Connections US National Electrical Code NEC ANSI NFPA 70 2008 CANADA Canadian Electrical Code CSA C22 1 Step 8 Venting US NFGC 54 ANSI Z223 1 2006 chapters 12 and 13 CANADA CAN CSA B149 1 05 Part 8 and Appendix C ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE CAUTION FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electrostatic potential 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch the clean unpainted metal surface of the 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
81. erminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame roll out and or drawing combustion products into the structure The furnace is controlled by a thermostat It may not be hot wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials It also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained between 55 F 13 C and 80 F 27 C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the 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
82. es for continuity 5 Install blower compartment door Door must be in place to operate furnace 6 Setup switch descriptions The 2 stage furnace has DIP Switches used to select thermostat staging and blower off delay timings For switch locations on Furnace control board See Fig 33 and 57 7 Setup switch descriptions See Table 10 34 Table 10 2 Stage Furnace Setup Switch Description SETUP SWITCH NORMAL DESCRIPTION SWITCH NO NAME POSITION OF USE When OFF allows 2 stage operation with a single stage thermostat Turn ON when using 2 stage thermostat to allow Low Heat opera en Adaptive keat Mode one tion when R to W W1 closes and High Heat operation when R to W W1 and W2 close SW 2 Blower OFF delay ON or OFF Control blower OFF conjunction with SW 3 Control blower OFF delay time Used in conjunction with SW 2 SW 3 Blower OFF delay ON or OFF See Table 14 Step 2 Start Up Procedures 4 WARNING FIRE AND EXPLOSION HAZARD Failure to follow this warning could cause personal injury death and or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections 1 Purge gas lines after all connections have been made 2 Check gas lines for leaks 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death
83. 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 inches 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 NFGC or CAN CSA B149 1 05 See Fig 5 18 IN 457 2 mm MINIMUM TO BURNERS A93044 Fig 5 Installation in a Garage 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 6 BACK A02054 Fig 6 Prohibit Installation on Back CAUTION PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may cause premature component failure This gas furnace may be used for construction heat 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 t
84. he flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Natural Gas and Propane Installation Code 9 After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning appliance to their previous conditions of use Vent system or vent connectors may need to be resized Vent systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the NFGC or CAN CSA B149 1 05 GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation requirements including local building codes the National Fuel Gas Code ANSI Z223 1 2006 NFPA 54 2006 NFGC Parts 12 and 13 in the United States or the National Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 05 CAN CSA B149 1 05 Section 8 and Appendix C in Canada the local building codes and furnace and vent manufacturers instructions These furnaces are design certified as Category I furnaces in accordance with ANSI Z21 47 2006 CSA 2 3 2006 and operate with a non positive vent static pressure to minimize the potential for vent gas leakage Category I furnaces operate with a flue loss not less
85. idpoint of the rise range or slightly above Refer to SET TEMPERATURE RISE under START UP ADJUSTMENT and SAFETY CHECK NOTE Refer to Table 13 for motor speed lead relocation if leads were not identified before disconnection 17 Reconnect blower leads to furnace control Refer to fur nace wiring diagram and connect thermostat leads if pre viously disconnected 18 To check blower for proper rotation a Turn on electrical supply b Manually close blower access door switch NOTE If thermostat terminals are jumpered at the time blower access door switch is closed blower will run for 90 sec before beginning a heating or cooling cycle c Perform component self test as shown at the bottom of the SERVICE label located on the front of blower access door d Verify blower is rotating in the correct direction 19 If furnace is operating properly RELEASE BLOWER ACCESS DOOR SWITCH Remove any jumpers or re connect any disconnected thermostat leads Replace blower access door A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access 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 20 Downflow or horizontal furnaces with vent pipe through furnace only a
86. ify correct operation sequence 53 jeisouueu eui eoe dai JO jejsouueui eui 0 16160191 APZWOD eui 12euuo2 101559 1SeJ eq 121 13447 1 eoeuunj ejqneduuoo jou s je1s0uueu 941 m Buisn uaym 0 4 au peydnuejui 10 AG LL paseia osje ued sepoo 5 1 437 Sunoy 22 sepoo sneg xoeuo 0 21949 10 jeou uBiu jeeu wo e urejs s ung eu UJOJJ O 5 101 U09 BU uo jejsouueu 9 10 ZAJA LA ZM EM M 1495944 SI eseuBis Aye 5 pue ZA A LA ZM 01 puodsai seoq L L epoo snieis snoi eJd e SEM paysey SEM JEU sniels 10 uonoes 0 o5 Spuooes OL 10 peeds wo IM Jeonpul au 440 PEUIN SI uSuA UO peuuni eq jou IM pue Sec spuooes 01 JO UNI peeds 1009 pue IH Peeds O7 2010 ISH 941 189 eJnue 10 eu
87. igh 2090 2010 1930 1835 1710 1590 1470 1335 1025 835 135 16 D Med High 1790 1755 1705 1640 1550 1465 1360 1210 945 785 048135 Side s Med Low 1545 1525 1500 1450 1380 1315 1215 1005 855 670 Low 1325 1320 1295 1265 1210 1150 995 865 745 540 High 2485 2400 2310 2215 2110 2000 1880 1725 1535 1355 Bottom Med High 2195 2150 2090 2000 1920 1825 1720 1565 1405 1255 Only Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 Low 1640 1635 1615 1585 1530 1465 1370 1255 1150 1040 High m 2385 2305 2195 2085 1960 1825 1670 1465 135 22 Med High 2180 2145 2060 2010 1945 1865 1765 1660 1515 1325 066135 4 Side amp Bottom Med Low 1880 1850 1820 1780 1715 1635 1540 1415 1290 1160 Low 1640 1635 1615 1585 1530 1465 1370 1255 1150 1040 High 2320 2250 2155 2055 1970 1855 1725 1600 1450 1280 1 Side Only Med High 2125 2065 1995 1910 1815 1710 1610 1490 1340 1175 Med Low 1845 1825 1765 1710 1650 1570 1475 1370 1240 1100 Low 1640 1620 1580 1540 1485 1410 1330 1220 1080 960 High 2465 2430 2375 2305 2230 2110 2000 1865 1725 1545 Bottom Only Med High 2115 2105 2075 2030 1980 1910 1830 1725 1590 1425 Med Low 1800 1790 1770 1735 1695
88. 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 7 and Table 2 c TWO HORIZONTAL DUCTS require 1 in of free area per 2 000 Btuh 1 100 mm2 kW of combined input for all gas appliances in the space per Fig 7 and Table 2 d TWO OPENINGS OR VERTICAL DUCTS require 1 in of free area per 4 000 Btuh 550 mm2 kW for com bined input of all gas appliances in the space per Fig 7 and Table 2 3 ONE OUTDOOR OPENING requires a One square inch of free area per 3 000 Btuh 734 mm2 kW for combined input of all gas appliances in the space per Table 2 and b Not less than the sum of the areas of all vent connectors in the space Table 2 Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS FURNACE 1 SQ IN 2 000 BTUH 1 100 SQ MM KW 1 SQ IN 3 000 BTUH 734 SQ MM KW 1 SQ IN 4 000 BTUH 550 SQ MM KW INPUT Free Area of Opening Round Duct Free Area of Opening Round Duct Free Area of Opening Round Duct BTUH and Duct Dia and Duct Dia and Duct Dia Sq In Sq mm In mm Sq In Sq mm In mm Sq In Sq mm In mm 44 000 22 14194 6 152 14 7 9484 5 127 11 7096 4 102 66 000 33 21290 7 178 22 14193 6 152 16 5 10645 5 127 88 000 44 28387 8 203 29 3 18903 7 178 22 14193 6 152
89. interrupted 12 BLOWER ON AFTER POWER UP 115 VAC or 24 Blower runs for the selected blower off delay time if unit is powered up during a call for heat R W W1 closed R W W1 opens during blower on delay 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if a limit draft safeguard flame rollout or blocked vent switch if used is open longer than 3 minutes Control will auto reset after three hours Refer to 33 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 434 21 GAS HEATING LOCKOUT Control will 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 IS OPEN Check for voltage 24VAC wiring 31 HIGH HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED Control relay may be defective refer to status code 32 COMPONENT TEST To initiate the component test sequence shut OFF the room thermostat or disconnect the thermostat lead Briefly short the TEST TWIN terminal to the Com 24V terminal Status LED will flash last status code and then turn ON the inducer motor The inducer motor will start in HIGH speed and remain on HIGH speed until the end of the test th
90. iping section Always install furnace to operate within the furnace s in tended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in the Start Up Adjustments and Safety Check section See furnace rating plate When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space con taining the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating out side the space containing the furnace See Air Ducts sec tion A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these in structions These Multipoise Gas Fired Furnaces are CSA formerly A G A and C G A design certified for use with natural and propane gases see furnace rating plate and for install ation in alcoves attics basements 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 lis ted accessory gas conversion kit is required to convert fur nace for use with propane gas 11 See Fig 2 for required clearances to combustible construc tion 12 Maintain a 1 i
91. itch to continuous blower speed When the R to W W1 and Y Y2 R to W W1 and Y Y2 and G R to W Wi and Y1 and Y Y2 R to W W1 and Y1 and Y Y2 and G circuits are en ergized the furnace control CPU will switch to or turn on the blower motor BLWM at COOL speed and begin a high heat cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HI HEAT speed When the W W1 input signal disappears the furnace control begins a normal inducer post purge period and the blower switches to COOL speed after a 3 second delay If the R to W W1 and Y Y2 and G or R to W W1 and Y1 and Y Y2 and G signals disappear at the same time the blower motor BLWM will remain on for the se lected blower OFF delay period If the R to W W1 and Y Y2 R to W W1 and Y1 and Y Y2 signals disappear leaving the G signal the blower motor BLWM will remain on for the selected blower OFF delay period then switch to continuous blower speed Step 4 Wiring Diagrams Refer to wiring diagram Fig 57 Step 5 Troubleshooting Refer to the service label See Fig 56 Service Label The Troubleshooting Guide 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 ver
92. ively The blower motor BLWM will revert to continuous blower speed after the heating cycle is completed In high heat the furnace control CPU will hold the blower motor BLWM at HI HEAT speed during the selected blower OFF delay period before reverting to continuous blower speed When the thermostat calls for low cooling the blower motor BLWM will switch to operate at low cool speed same speed as LO HEAT When the thermostat is satis fied the blower motor BLWM will operate an additional 90 seconds on low cool speed before reverting back to continuous blower speed When the thermostat calls for high cooling the blower motor BLWM will operate at COOL speed When the thermostat is satisfied the blower motor BLWM will oper ate an additional 90 seconds on COOL speed before re verting back to continuous blower speed When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM operation Continuous Blower Speed Selection from Thermostat To select different continuous blower speeds from the room thermostat momentarily turn off the FAN switch or push button on the room thermostat for 1 3 seconds after the blower motor BLWM is operating The furnace control CPU will shift the continuous blower speed from the fact ory setting of LO HEAT to HI HEAT speed Momentarily turning off the FAN switch again at the thermostat will shift the continuou
93. l connection as shown FURNACE 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A95236 Fig 23 Field Wiring Diagram 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 NFGC in the United States or CAN CSA B149 1 05 in Canada local and national plumbing and gas codes before the furnace has been connected After all connections have been made purge lines and check for leakage at furnace prior to operating furnace If pressure exceeds 0 5 psig 14 in wc gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test If test pressure is equal to or less than 0 5 psig 14 in wc turn off electric shutoff switch located on furnace gas control valve and accessible manual 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 ELECTRICAL CONNECTIONS WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower
94. le metal sized listed liner or liner or Type B vent per Type B vent NFGC or NSCNGPIC Vent Sizing Tables and liner or d cou vent manufacturer s Installation instructions Condensate drainage at bottom of chimney Not Suitable Consult Chimney Part C of s chimney art t exposed to to be dedicated to outdoors below a single instructions for roof line furnace application suitability Install chimney adapter per instructions Chimney is acceptable for use 03206 Fig 34 Chimney Inspection Chart 27 58CT The Chimney Adapter Kit is a listed alternative venting system for these furnaces See the kit instructions for complete details Canada and U S A This furnace is permitted to be vented into a clay tile lined masonry chimney that is exposed to the outdoors below the roof line provided 1 Vent connector is Type B double wall and 2 This furnace is common vented with at least 1 draft hood equipped appliance and 3 The combined appliance input rating is less than the max imum capacity given in Table 8 and 4 The input rating of each space heating appliance is greater than the minimum input rating given in Table 9 for the local 99 Winter Design Temperature Chimneys having internal areas greater than 38 in 24516 mm require fur nace input ratings greater than the input ratings of these furnaces See footnote at bottom
95. light suggestions which will result in enhanced installation reliability or operation Table 1 Dimensions F A D E C L TOP AND FLUE ABINET PPLY AIR RETURN AIR HIPWT MEDIA FURNACE SIZE WIDTH P WIDTH WIDTH BOTTOM FLUE COLLAR LB KG CABINET IN mm IN mm IN mm IN mm IN mm 045 08 024045 14 3 16 360 12 9 16 319 12 11 16 322 9 5 16 237 4 102 104 47 1 406 045 12 036045 14 3 16 360 12 9 16 319 12 11 16 322 95 16 237 4 102 107 48 6 406 070 08 024070 14 3 16 360 12 9 16 319 12 11 16 322 9 5 16 237 4 102 111 50 6 406 070 12 036070 14 3 16 360 12 9 16 319 12 11 16 322 9 5 16 237 4 102 115 52 6 406 070 16 048070 17 1 2 445 15 7 8 403 16 406 11 9 16 294 4 102 126 57 6 406 090 14 042090 17 1 2 445 15 7 8 403 16 406 11 9 16 294 4 102 127 58 6 406 090 16 048090 21 533 19 3 8 492 19 1 2 495 13 5 16 838 4 102 140 64 5 508 090 20 060090 21 533 19 3 8 492 19 1 2 495 13 5 16 838 4 102 146 66 20 508 110 12 036110 17 1 2 445 15 7 8 403 16 406 11 9 16 294 4 102 135 61 16 406 110 16 048110 21 533 19 3 8 492 19 1 2 495 13 5 16 838 4 102 146 66 20 508 110 22 066110 21 533 19 3 8 492 19 1 2 495 13 5 16 838 4 102 152 69 20
96. livery CFM With Filter See Table 13 for lead color identification Table 13 Speed Selection COLOR SPEED AS SHIPPED White Common BLW Black High COOL Yellow Med High SPARE Oranget Med SPARE Blue Med Low HI HEAT Red Low LO HEAT Continuous blower speed as shipped default t Not all models equipped with 5 speed motors 39 58CT Table 14 2 Stage Furnace Blower OFF delay Setup Switch DESIRED HEATING MODE SETUP SWITCH SETUP SWITCH BLOWER OFF DELAY SEC SW 2 SW 3 90 OFF OFF 120 OFF ON 199 ON OFF 180 ON ON THERMOSTAT SUBBASE guard switch did not function properly and correct condi TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER 10 27 n FROM UNIT 24 V CONTROL TERMINALS EXAMPLE 2 9 AMPS ON AMMETER _ 0 5 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SETTING 96316 Fig 55 Amp Draw Check with Ammeter Step 4 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 es This control shuts off combustion system and energizes air circulating blower motor if furnace overheats By us ing this method to check limit control it can be established that limit is functioning properly and will operate if there is a restricted return
97. low heat operation See Fig 33 and Table 10 f Manually close blower door switch 2 Jumper and W W1 thermostat connections on control to start furnace See Fig 33 h Remove regulator adjustment cap from low heat gas valve pressure regulators See Fig 53 Turn low heat adjusting screw 3 16 in 5 mm or smaller flat tipped screwdriver counterclockwise out to decrease input rate or clockwise in to increase input rate NOTE DO NOT set low heat manifold pressure less than 1 4 in wc or more than 1 7 in wc for natural gas If manifold pressure is outside this range change main burner orifices i Install low heat regulator adjustment cap j Leave manometer or similar device connected and pro ceed to Step 4 NOTE If orifice hole appears damaged or it is suspected to have been re drilled check orifice hole with a numbered drill bit of correct size Never re drill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics 4 Verify natural gas low heat input rate by clocking meter NOTE Gas valve regulator adjustment caps must be in place for proper input to be clocked a Turn off all other gas appliances and pilots served by the meter 36 b Run for 3 minutes in low heat operation c 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 D BURNER
98. ly for the detection of leaks to check all connections 4 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 a gas leak WARNING FIRE OR EXPLOSION HAZARD Failure to protect gas valve inlet from water and debris could result in death personal injury 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 58CT SUPPLY 6 UPFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS AIR FLOW MODELS RETURN AIR RETURN AIR RETURN AIR CONNECTION 1 CONNECTION3 COMBINATIONS ONLY ONLY OF 1 2 AND3 066 060 22 AND YES YES YES 20 MODELS ALLOTHER MODELS YES YES YES gt 4 ET RETURN RETURN AIR AIR UPFLOW RETURN RETURN AIR RESTRICTIONS Fig 18 Upflow Return Air Configurations and Restrictions 1 RETURN AIR RETURN AIR SIDE RETURN NOT PERMITTED FOR ANY MODEL SIDE RETURN NOT PERMITTED FOR ANY MODEL 066 060 22 AND 20 MODELS ALL OTHER MODELS SUPPLY AIR RETURN AIR SAN ES TION 2 Fig
99. merican 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 5 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 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 elbow and 10 ft 3 M of main duct to the first branch take off may require internal acoustical lini
100. n 25 mm clearance from combustible ma terials to supply air ductwork for a distance of 36 inches 914 mm horizontally from the furnace See NFPA 90B or local code for further requirements 13 These furnaces SHALL NOT be installed directly on car peting tile or any other combustible material other than wood flooring In downflow installations factory access ory floor base MUST be used when installed on combust ible materials and wood flooring Special base is not re quired when this furnace is installed on manufacturer s Coil Assembly Part No CAR CAP CNRV CNPV or when Coil Box Part No KCAKC is used See Fig 2 for clearance to combustible construction information INTRODUCTION The Series 130 D 4 way multipoise Category I fan assisted furnace is CSA formerly A G A and C G A design certified A Category I fan assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and or heat exchanger The furnace is factory shipped for use with natural gas This furnace is not approved for installation in mobile homes recreational vehicles or outdoors These furnaces shall not be installed directly on carpeting tile or any other combustible material other than wood flooring For downflow installations a factory accessory floor base must be used when installed on combustible materials and wood flooring This special base is not required
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102. n to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart Fasten the vent connector to the flue extension with at least two field supplied corrosion resistant sheet metal screws located 180 apart 2 Vent the furnace with the appropriate connector as shown in Fig 35 47 3 Orient the door to determine the correct location of the door knockout to be removed 4 Remove the correct U shaped knockout in door NOTE A number of techniques can be used to remove these knockouts as seen in Fig 48 through 52 The knockout in the bottom of the door is unique due to its flanging and is more easily removed by first cutting the two tie points at the edge of the door using aviation type tin snips See Fig 48 A sharp blow to the rounded end of the knockout See Fig 49 will separate more tie points and allow the knockout to be pulled loose See Fig 50 Remove all burrs any sharp edges For the rectangular J box knockout use tin snips along the door edge and use a sharp blow with a hammer to remove the knockout Remove any burrs and sharp edges For the knockouts in the other locations on the door top and sides tin snips can also be used along the door edges however the preferred method is to use a hammer and screwdriver to strike a sharp blow See Fig 51 directly to the knockout tie points or use a hammer in the upper left corner of the desired knockout See Fig 52 Remove an
103. ndensate and combustion products and spillage of combustion products into the living space TWINNING AND OR COMPONENT TEST TERMINAL AIR CONDITIONING RELAY DISABLE JUMPER lV TRANSFORMER 24 VAC CONNECTIONS PL1 LOW VOLTAGE MAIN BLWR 50 lt DLY ok 24 V THERMOSTAT TERMINALS Lo I SA TESTTWIN 2 5 Q 0 5 24 VAC HUMIDIFIER TERMINAL 7L 24 VAC 0 5 5 3 FUSE 290 18 aT To Je LED OPERATION amp 289 ur DIAGNOSTIC LIGHT as p E 115 VAC L2 NEUTRAL CONNECTIONS i HI HEAT gt LO HEAT gt 2 COOL 1 AMP 115 VAC SPARE 1 SPARE2 EACH PRA LES HARNESS CONNECTOR 2 PL3 F 540 LIH HSI HI LO SPARE 1 BLOWER SPEED SPARE 2 COOL SELECTION TERMINALS 115 VAC L1 LINE VOLTAGE CONNECTION PL2 HOT SURFACE IGNITER amp INDUCER MOTOR CONNECTOR EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02017 Fig 33 Furnace Control PSC Blower Motor 25 58CT WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Failure to follow the steps outlined below for
104. nents EAC humidifier etc full load amps t Time delay type is recommended t Length shown is as measured 1 way along wire path between unit and service panel for maximum 296 voltage drop U S Installations Make all electrical connections in accordance 4 Fasten J Box to casing with the two screws removed in with National Electrical Code NEC ANSI NFPA 70 2008 and Step 1 any local codes or ordinances that might apply 5 Route J Box wires within furnace away from sharp edges Canadian Installations Make all electrical connections in rotating parts and hot surfaces accordance with Canadian Electrical Code CSA C22 1 or FACTORY authorities having jurisdiction INSTALLED LOCATION FIRE HAZARD TWO Failure to follow this warning could result in personal ALTERNATE injury death or property damage FIELD s 2 LOCATION Do not connect aluminum wire between disconnect switch 2 and furnace Use only copper wire s Use a separate branch electrical circuit with a properly sized fuse or circuit breaker for this furnace See Table 7 for wire size and fuse specifications A readily accessible means of electrical disconnect must be located within sight of the furnace NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control LED status indicator light will flash A02099 rapidly and furnace will NOT operate Fig 24 Relocating J Box J BOX RELOCATION f ELECTRICAL CONNECTION J BOX
105. ng 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 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 Upflow and Horizontal Furnaces Connect supply air duct to flanges on furnace supply air outlet Bend flange upward to 90 with wide duct pliers See Fig 14 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 15 58CT Table 5 Air Delivery With Filter FURNACE RETURN AIR EXTERNAL STATIC PRESSURE IN WC SIZE INLET SPEED 02 04 05 06 07 09 10 High
106. nimum of 3 in 76 mm when type B1 vent is used A03175 Fig 8 Air for Combustion Ventilation and Dilution from Indoors The Standard Method 1 The space has no less volume than 50 cubic feet per 1 000 Btuh of the maximum input ratings for all gas appliances installed in the space and 2 The air infiltration rate is not known to be less than 0 40 air changes per hour ACH The Known Air Infiltration Rate Method shall be used if the infiltration rate is known to be 1 Less than 0 40 ACH and 2 Equal to or greater than 0 10 ACH Infiltration rates greater than 0 60 ACH shall not be used The minimum required volume of the space varies with the number of ACH and shall be determined per Table 3 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 58CT Table 3 Minimum Space Volumes for 100 Combustion Ventilation and Dilution from Indoors OTHER THAN FAN ASSISTED TOTAL FAN ASSISTED TOTAL 1 000s BTUH GAS INPUT RATE 1 000s BTUH GAS INPUT RATE ACH 30 40 50 44 66 88 110 132 154 Space Volume ft 3 0 60 1 050 1 400 1 750 1 100 1 650 2 200 2 750 3 300 3 850 0 50 1 260 1 680 2 100 1 320 1 980 2 640 3 300 3 960 4 620 0 40 1 575 2 100 2 625 1 650 2 475 3 300 4 125 4 950 5 775 0 30 2 100 2 800 3 500 2 200 3 300 4 400 5 500 6 600 7 700 0 20 3 150 4 200 5 250 3
107. ning 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 4 WARNING FIRE HAZARD 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 Downflow Furnaces The return air duct must be connected to return air opening bottom inlet as shown in Fig 1 DO NOT cut into casing sides left or right Side opening is permitted for only upflow and most horizontal furnaces Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace See Fig 19 Upflow and Horizontal Furnaces The return air duct must be connected to bottom sides left or right or a combination of bottom and side s of main furnace casing as shown in Fig 1 Bypass humidifier may be attached into unused return air side of the furnace casing See Fig 18 and 20 Not all horizontal furnaces are approved for side return air connections See Fig 20 GAS PIPING 17 4 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 specifical
108. nit rating plate For installations above 2000 ft 610 M multiply the in put on the rating plate by the derate multiplier in Table 11 for the correct input rate EXAMPLE 88 000 BTUH INPUT FURNACE INSTALLED AT 4300 FT 1310 M Derate Furnace Input Rate Furnace Input Rate Multiplier at Installation at Sea Level Factor Altitude 88 000 X 0 90 79 200 In Canada The input rating must be reduced by 10 for altitudes of 2 000 ft 610 M to 4 500 ft 1372 M above 35 58CT sea level by an authorized Gas Conversion Station or Dealer To determine correct input rate for altitude see example and use 0 90 as derate multiplier factor 2 Determine the correct orifice and manifold pressure adjust ment All models in all positions except Low NOx models in downflow and horizontal positions use Table 15 22 000 BTUH per burner Table 11 Altitude Derate Multiplier for U S A ALTITUDE PERCENT DERATE MULTIPLIER FT M OF DERATE FACTOR 0 61 0 5 s oe I eu deeem mum I Emm 2 ho ios I s 306 36 40 0 62 Derate multiplier factors are based on midpoint altitude for altitude range Low NOx models in downflow or horizontal positions MUST use Table 16 21 000 BTUH per burner See input listed on rating plate a Obtain average yearly gas heat value at installed altitude from local gas supplier b Obtain
109. nnections NOTE In this mode the LHT 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 W1 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 W1 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 58CT 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 pres sure switch relay HPSR is de energized to close the NC contact When sufficient 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 switch to HI HEAT speed five seconds after the R to W2 circuit closes b Switching from High to Low Heat If the thermostat R to W2 circuit opens and the R to W1 circuit remains closed the furnace control CPU will switch the inducer mot
110. nnections at the 24 v terminal strip See Fig 33 Connect terminal Y Y2 as shown in Fig 26 32 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24 v circuit contains an automotive type 3 amp fuse located on the 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 22 THERMIDISTAT HEAT STAGE 2 COOL STAGE 1 1 2 HEAT STAGE 1 COOL STAGE 2 2 FAN G 24 VAC HOT R DEHUMIDIFY DHUM 24 VAC COMM C HUMIDIFY HUM NA B OUTDOOR 81 SENSOR CONNECTION 52 11 PM FURNACE TWO SPEED AIR CONDITIONER 1 2 COM EL HUM HUMIDIFIER 24 VAC OUTDOOR SENSOR Fig 26 Two Stage Furnace with Two Speed Air See notes 2 5 8 10 11 and 12 on the page following these figures
111. nt le minimum d espace libre des mat riaux combustibles tel qu indiqu sur le diagramme Cette fournaise peut tre utilis e avec un Clearance in inches D gagement po Vent Clearance to combustibles For Single Wall vents 6 inches 6 po For Type B 1 vent type 1 inch 1 po he D gagement de l vent avec combustibles conduit d vacuation de Type B 1 ou connect e Pour conduit d vacuation paroi simple 6 po 6 inches au conduit ommun d autres appareils gaz Pour conduit d vacuation de Type B 1 1 po 1 inch MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DOWNFLOW POSITIONS Installation on non combustible floors only For Installation on combustible flooring only when installed on special base Part No KGASBO201ALL 011018 Coil Assembly Part No CAR CAP CNPV WENC or WTNC 18 inches front clearance required for alcove Indicates supply or retum sides when fumace is in the horizontal position Line contact only permissible between lines formed by intersections of the Top and two Sides of the fumace jacket and building joists studs or framing DEGAGEMENT MINIMUM EN POUCES AVEC ELEMENTS DE CONSTRUCTION COMBUSTIBLES POUR LA POSITION COURANT DESCENDANT T Pour l installation sur plancher non combustible seulement Pour l installation sur un plancher combustible seulement quand on utilise la base sp ciale pi ce KGASBO201ALL ou NAHA01101SB l ensemble serpentin
112. o 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 switch the furnace blower motor BLWM to COOL speed NOTE When transitioning from low cooling to high cooling the outdoor unit compressor will shut down for 1 minute while the BLWM continues to run at low cool speed same speed as LO HEAT until the outdoor unit compressor comes back on at high speed The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM is operating When the thermostat is satisfied the R to G and 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 seconds Jumper Y1 to DHUM to reduce the cooling off delay to 5 seconds See Fig 34 c Two Stage Thermostat and Two Speed Cooling See Fig 31 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 33 The thermostat closes the R to G and Y1 circuits for low cooling or closes the R to G and Y1 and Y2 circuits for high cooling The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and Y1 circuit starts the furnace blower motor BLWM on low co
113. o J Box Do not pinch wires between cover and bracket Electrical Box on Furnace Casing Side See Fig 25 A 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 A03221 Fig 25 Field Supplied Electrical Box on Furnace Casing 1 Select and remove a hole knockout in the casing where the electrical box is to be installed NOTE Check that duct on side of furnace will not interfere with installed electrical box 2 Remove the desired electrical box hole knockout and posi tion the hole in the electrical box over the hole in the fur nace casing 3 Fasten the electrical box to casing by driving two field supplied screws from inside electrical box into casing steel 4 Remove and save two screws holding J Box See Fig 24 5 Pull furnace power wires out of 1 2 inch 12 mm diamet er hole in J Box Do not loosen wires from strain relief wire tie on outside of J Box 6 Route furnace power wires through holes in casing and electrical box and into electrical box 7 Pull field power wires into electrical box 8 Remove cover from furnace J Box 9 Route field ground wire through holes in electrical box and casing and into furnace J Box 10 Reattach furnace
114. o additional 7 8 in 22 mm diameter holes are located in the top plate lt gt 2 7 16 62mm Teher ssl AIRFLOW 33mm 19 13 16 13 16 11 8 483mm 21mm 21mm 41316 29mm OUTLET 1 2 DIA K O THERMOSTAT WIRE ENTRY 13mm 1146 7 34 997 8 9 16 1 3 4 DIA RIGHT HAND 17 197 244 225 44 11 1 2 292 7 8 DIA K O WIRE ENTRY ALTERNATE 2mm JUNCTION BOX N LOCATIONS TYP VENT OUTLET 5 PLACES TYP 7 8 DIA ACCESSORY 22mm 140mm 11 16 3 3 47 17mm 95mm A04037 2 Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations for equivalent diameters a For 800 CFM 16 in 406 mm round or 14 1 2 x 12 in 368 x 305 mm rectangle b For 1200 20 in 508 mm round or 14 1 2 x 19 1 2 in 368 x 495 mm rectangle c For 1600 CFM 22 in 559 mm round or 14 1 2 x 22 1 16 in 368 x 560mm rectangle d For airflow requirements above 1800 CFM see Air Delivery table in Product Data literature for specific use of single side inlets The use of both side inlets a combination of 1 side and the bottom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM Fig 1 Dimensional Drawing SAFETY CONSIDERATIONS WARNING FIRE EXPLOSION
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116. 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 ig niter 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 imme diately e Determine reason pressure switch did not function prop erly and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace outer door and turn on 115 v power h Blower will run for 90 seconds before beginning the call for heat again i Furnace should ignite normally Step 5 Checklist 1 Put away tools and instruments Clean up debris 2 Verify that switches for LHT and OFF DELAY are blower OFF DELAY are selected as desired 3 Verify that blower and burner access doors are properly in stalled 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer fs in structions 6 Review User s Guide with owner 7 Attach literature packet to furnace Table 15 Orifice Size and Manifold Pressures In wc for Gas Input Rate TABULATED DATA BASED ON 22 000 BTUH HIGH HEAT 14 500 BTUH LOW HEAT PER BURNER DERATED 4 1000 FT 305M ABOVE SEA LEVEL ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE ft m
117. oil Box Part No KCAKC 1 Determine application being installed from Table 4 2 Construct hole in floor per Table 4 and Fig 11 3 Construct plenum to dimensions specified in Table 4 and Fig 11 4 If downflow subbase KGASB is used install as shown in Fig 12 If Coil Assembly Part No CNPV CNRV CAP CAR or Coil Box Part No is used install as shown in Fig 13 NOTE It is recommended that the perforated supply air duct flanges be completely folded over or 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 14 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 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws HORIZONTAL INSTALLATION The furnace can be installed horizontally in an attic or crawl space 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
118. ol speed same speed as LO HEAT 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 on COOL speed The electronic air cleaner terminal EAC 1 is energized with 115 vac whenever the blower motor BLWM 18 operating When the thermostat is satisfied the R to G and Y1 Or R to G and Y1 and Y2 circuits are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 seconds Jumper Y1 to DHUM to reduce the cooling off delay to 5 seconds See Fig 33 4 Thermidistat Mode See Fig 26 28 for Thermidistat connections The dehu midification output DHUM on the Thermidistat should be connected to the furnace control thermostat terminal DHUM When there is a dehumidify demand the DHUM input is activated which means 24 vac signal is removed from the DHUM input terminal In other words the DHUM input logic is reversed The DHUM input is turned ON when no dehumidify demand exists Once 24 vac is detected by the furnace control on the DHUM input the furnace control operates in Thermidistat mode If the DHUM input is low for more than 48 hours the furnace control reverts back to non Thermidistat mode The cooling operation described in item 3 above also ap plies to operation with a Thermidistat The exceptions are listed below a Low cooling When the R to G and Y1 cir
119. omponents or materials i e oil refrigerant control board etc before unit final disposal Step 1 Introduction 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 4 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 The electrical ground and polarity for 115 v wiring must be properly maintained Refer to Fig 23 for field wiring information and to Fig 57 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 31 Any shorts of the 24 v wiring during installation service or maintenance will cause this f
120. on Vent Elbow Right Fig 45 Horizontal Left Application Vent Elbow Right then Up aL SEE NOTES 1 2 4 7 8 9 on the page following these figures SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03218 A03219 Fig 43 Horizontal Right Application Vent Elbow Right Fig 46 Horizontal Right Application Vent Elbow Left then Up 31 58CT SEE NOTES 1 2 4 5 7 8 9 A02068 Fig 47 Horizontal Right Application Vent Elbow Left NOTES Venting Notes for Fig 35 47 1 2 10 For common vent vent connector sizing and vent material United States use the NFGC Canada use the 5 8149 1 05 Immediately increase to 5 in or 6 in 127 or 152 mm vent connector outside furnace casing when 5 in 127 mm vent connector is required refer to Note 1 above Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace except when KGAVGO101DFG Downflow Vent Guard Kit is used in the downflow position Type B vent where required refer to Note 1 above Four in 102 mm single 26 ga min vent must be used inside furnace casing and when the KGAVGO101DFG Downflow Vent Guard Kit is used external to the furnace Accessory Downflow Vent Guard Kit KGAVGO101DFG required in downflow installations with lower vent configuration Chimne
121. ons Do not use side return air openings in DOWNFLOW configuration e BOTTOM CLOSURE BOTTOM FILLER PANEL PANEL A02098 Fig 9 Removing Bottom Closure Panel Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 10 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 See Fig 10 2 For each leg install nut on bolt and then install bolt and nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if desired 4 Adjust outside nut to provide desired height and tighten inside nut to secure arrangement 5 Reinstall bottom closure panel if removed 5 48 8mm n 44mm SN A89014 Fig 10 Leveling Legs DOWNFLOW INSTALLATION NOTE For downflow applications this furnace is approved for use on combustible flooring when any one of the following 3 accessories are used Special Base KGASB Cased Coil Assembly Part No CNPV CNRV CAP and CAR C
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123. or IDM speed from high to low The high heat pres sure switch relay HPSR is energized to open the NC con tact and de energize the high heat gas valve solenoid GV HI When the inducer motor IDM reduces pressure sufficiently the high heat pressure switch HPS will open The gas valve solenoid GV M will remain ener gized as long as the low heat pressure switch LPS re mains closed The blower motor BLWM will switch to LO HEAT speed five seconds after the 10 2 circuit opens 3 Cooling Mode The thermostat calls for cooling a Single Speed Cooling See Fig 27 for thermostat connections The thermostat closes the R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G and Y Y2 circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal 1 is energized with 115 vac when theblower 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 on the COOL speed for an additional 90 seconds Jumper Y Y2 to DHUM to reduce the cooling off delay to 5 seconds See Fig 24 b Single Stage Thermostat and Two Speed Cooling Adaptive Mode See Fig 32 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 con troll
124. oves 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 heat ing and cooling season Clean as necessary 3 Check electrical connections for tightness and controls for proper operation each heating season Service as neces sary 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 5 Inspect the vent pipe vent system before each heating sea son for rust corrosion 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 humidifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the ac cessory instructions 46 40 spuooes 06 duind 10 SI NNHQ spuooes 081 OSL 02 06 suonoejes seb Aejap yo samog spuooes z duind jeeu 10 Buijooo spuoses jeeu wo seb spuooes cz jeeu uBiu seb Aejap Jaye jasel o ne 99143 joHuo9 5 6 INOJ Jaye 1n220 3n0320 UOI I jou
125. peat steps b through e until correct high heat input is achieved Re install high heat regulator seal cap on gas valve 8 Set high heat temperature rise Jumper R to W W1 and W2 to check high gas heat tem perature rise Do not exceed temperature rise ranges spe cified on furnace rating plate for high heat The furnace must operate within the temperature rise ranges specified on the furnace rating plate Determine the air temperature rise as follows NOTE Blower access door must be installed when taking temperature rise reading Leaving blower access door off will result in incorrect temperature measurements a Verify the furnace is operating in high heat per Step 6 Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see radiant heat from heat exchangers Radiant heat affects temperature rise readings This practice is particularly im portant with straight run ducts b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE If the temperature rise is outside this range first check 1 Gas input for low and high heat operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in we 4 Dirty filter c Adjust air temperature rise by adjusting blower speed In crease blower speed to reduce temperature
126. r CAP Coil Assembly or KCAKC coil box 23 i 45 Eo KGASB 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 1 2 subbase not required 403 483 419 498 Downflow applications on combustible flooring KGASB sub 15 1 8 19 16 3 4 20 5 8 445 base required 384 483 425 600 Downflow Applications on Combustible Flooring with CNPV 15 1 2 19 16 1 2 20 CAR Coil Assembly box 394 483 419 508 KGASB subbase not required Upflow Applications on Combustible or Noncombustible Floor 19 1 2 21 5 8 20 1 8 22 1 4 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 Downflow applications on combustible flooring KGASB sub 18 5 8 19 20 1 4 20 5 8 533 base required 473 483 514 600 Downflow Applications on Combustible Flooring with CNPV 19 19 20 20 CNRV CAR or Coil Assembly or KCAKC coil box 483 483 508 508 KGASB 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 22 718 19 2
127. s blower speed from HI HEAT to COOL Repeating the procedure will shift the continuous blower speed from COOL to LO HEAT speed The selec tion can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption NOTE 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 6 Heat Pump See Fig 27 through 30 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 When the R to W W1 and Y1 or R to W W1 and Y1 and G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at low cool speed same speed as LO HEAT and begin a low heat cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at LO HEAT speed When the W W1 input signal disappears the furnace control begins a normal in ducer post purge period and the blower remains running at LO HEAT speed If the R to W W1 and Y1 and G signals disappear at the same time the blower motor BLWM will remain on for the selected blower OFF delay period If the R to W W1 and Y1 signals disappear leaving the G signal the blower motor BLWM will remain on for the selected blower OFF delay period then sw
128. ss door 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 midpoint of rise range or slightly above 9 Set Blower Off Delay a Remove Blower Access Door if installed b Turn Dip switch 2 and 3 ON or OFF for desired blower off delay See Table 14 and Fig 34 10 Set 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 can beobtained at the wires normally connected to thermostat subbase terminals R and W The thermostat anticipator should NOT be in the circuit while measuring current 1 Set LHT switch on furnace control board to ON 2 Remove thermostat from sub base or from wall 3 Connect an amp meter as shown in Fig 55 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 in structions and install on subbase or wall 6 Turn LHT switch OFF 7 Install blower access door b Electronic thermostat Set cycle rate for 3 cycles per hr 11 Set airflow CFM for cooling Select the desired blower motor speed lead for cooling air flow See Table 5 Air De
129. t terminates outdoors 4 Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure 5 In the US Do not vent this appliance with any solid fuel burning appliance In Canada Check with the authority having jurisdiction for approval on use with solid fuel burning appliance 6 Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed mechanical venter See the SIDEWALL VENTING section 7 Do not vent this appliance into an unlined masonry chim ney Refer to Chimney Inspection Chart Fig 34 MASONRY CHIMNEY REQUIREMENTS NOTE These furnaces are CSA design certified for use in exterior tile lined masonry chimneys with a factory accessory Chimney Adapter Kit Refer to the furnace rating plate for correct kit usage The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit number marked on the furnace rating plate If a clay tile lined masonry chimney is being used and it is exposed to the outdoors below the roof line relining might be required Chimneys shall conform to the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 2006 in the United States and to a Provincial or Territorial Building Code in Canada in its absence the National Building Code of Canada and must be in good condition U S A Refer to Sections 13 1 8 and 13 2 20 of the NF
130. t with Two Stage Furnace and Single Speed Heat Pump 58CT DUAL FUEL TWO STAGE TWO SPEED TWO STAGE TWO STAGE TWO SPEED THERMOSTAT FURNACE HEATPUME THERMOSTAT FURNACE AIR CONDITIONER RVS COOLING 2 J_ E w2 NOTE11 Two W2 L YT lisses 217 20177 Y1 HEAT COOL STAGE 1 Y1 w2 4 1 4 5 41 L COMPRESSOR LO HEAT STAGE 3 W W111___________ ww1l l 21 7 1 FURNACE HEAT COOL STAGE 2 viva NOTE 12 __ ________ 41 Y2 v2 NOTE12 Y2 COMPRESSOR HI 8 6 G 24VACHOT R 1 1 21 R Ro Bxz22oeseeeesd Ress za R DHUM FA 24 COMM C Lj 4 41 DHUM B HUM C ll LaL _1 RVSSENSING L OUTDOOR
131. taller service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing Follow all safety codes Wear safety glasses protective clothing and work gloves Have a fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions include in literature and attached to the unit Consult local building codes the current editions of the National Fuel Gas Code NFGC NFPA 54 ANSI Z223 1 and the National Electrical Code NEC NFPA 70 In Canada refer to the current editions of the National Standards of Canada CAN CSA B149 1 and 2 Natural Gas and Propane Installation Codes and Canadian Electrical Code CSA C22 1 Recognize safety information This is the safety alert symbol A When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage NOTE is used to high
132. te 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 7 for equipment electrical specifications 20 Table 7 Electrical Data OPERATING VOLTAGE MAXIMUM MAXIMUM HERE RANGE iens FURNACE UNIT WIRE FUSE OR EM PHASE _ AMPS SIZE AMPACITY LENGTH CKTBKR GAUGE MAX MIN FT AMPSt 115 60 1 127 104 5 3 045 08 024045 7 42 49 14 9 15 14 115 60 1 127 104 7 1 045 12 036045 9 67 38 11 5 15 14 115 60 1 127 104 5 2 070 08 024070 7 22 51 15 5 15 14 115 60 1 127 104 7 3 070 12 036070 9 90 87 11 2 15 14 115 60 1 127 104 10 1 070 16 048070 13 42 27 8 2 15 14 115 60 1 127 104 8 2 090 14 042090 10 84 34 10 3 15 14 115 60 1 127 104 9 9 090 16 048090 13 0 28 8 5 15 14 115 60 1 127 104 12 9 090 20 060090 16 70 34 10 3 20 12 115 60 1 127 104 8 2 110 12 036110 10 76 34 10 3 15 14 115 60 1 127 104 10 1 110 16 048110 13 19 28 8 5 15 14 115 60 1 127 104 13 7 110 22 066110 17 60 32 9 7 20 12 115 60 1 127 104 10 2 135 16 048135 13 28 27 8 2 15 14 115 60 1 127 104 14 5 135 22 066135 18 61 30 9 1 20 12 115 60 1 127 104 15 0 155 20 060155 19 34 29 8 8 20 12 Permissible limits of the voltage range at which the unit operates satisfactorily Unit ampacity 125 of largest operating component s full load amps plus 100 of all other potential operating compo
133. temperature rise and venting according to these installation instructions LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with or on the downstream side of the unit to avoid condensation in the heat exchangers When installed parallel with the furnace dampers or other flow control must prevent chilled air from entering the furnace If the dampers are manually operated they must be 58CT equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with U S installations Section 9 3 of the NFPA 54 A ANSI Z223 1 2006 Air for Combustion and Ventilation and applicable provisions of the local building codes Canadian installations Part 8 of the CAN CSA B149 1 05 Venting Systems and Air Supply for Appliances and all authorities having jurisdiction 4 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 MONOX
134. ter lighting this appliance V rifier tous les l ments gaz pour rechercher les fuites apr s avoir allum cet appareil INSTALLATION 1 This fumace must be installed in accordance with the manufacturer s instructions and local codes In the absence of local codes follow the National Fuel Gas Code ANSI Z223 1 54 or CSA B 149 1 Gas Installation Code Ce foumaise air chaud doit amp tre install conform ment aux instructions du fabricant et aux codes locaux En l absence de ces demiers la norme ANSI Z223 1 NFPA54 intitul e National Fuel Gas Code ou les code d installation CSAB149 1 2 This fumace must be installed so there are provisions for combustion and ventilation air See manufacturer s installation information provided with this appliance Ce foumaise air chaud doit tre install de mani re ce qu ilyait ait suffisamment d air de ventilation et combustion Consulter les instructions d installation du fabricant foumies avec cet appareil OPERATION This furnace is equipped with manual reset limit switch es in bumer compartment to protect against overheat conditions that can result from inadequate combustion air supply or blocked vent conditions 1 Do not bypass limit switches 2 limit opens call a quallified serviceman to correct the condition and reset limit switch INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIO
135. ter will remain energized until the flame is sensed orun til the 2 sec flame proving period begins If the furnace control CPU selects high heat operation the high heat gas valve solenoid GV HI is also energized 51 d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the inducer motor IDM switches to low speed unless running at high speed 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 seconds the control CPU will close the gas valve GV M and the control CPU will repeat the ignition sequence for up to three more Trials For Ignition before going to Ig nition Lockout Lockout will be reset automatically after three hours by momentarily interrupting 115 vac power to the furnace or by interrupting 24 vac power at SECI or SEC2 to the furnace control CPU not at W W1 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 e Blower ON Delay If the burner flame is proven the blower ON delay for low heat and high heat are as fol lows Low Heat 45 seconds after the gas valve GV M is en ergized the blower motor BLWM is energized at LO HEAT speed High Heat 25 seconds after the gas valve GV M is en ergized the BLWM is energized at HI HEAT
136. to furnace control board remove tape from blower door switch and re install blower door 4 Operate furnace per instruction on inner door 5 Verify furnace shut down by lowering thermostat setting below room temperature 6 Verify furnace restarts by raising thermostat setting above room temperature Step 3 Adjustments A WARNING FIRE HAZARD Failure to follow this warning could result in injury death and or property damage DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess over fire and heat exchanger failures CAUTION FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life DO NOT re drill 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 49 Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft 610 M Furnace input rate must be within 2 of furnace rating plate input For altitudes above 5500 ft 1676 M a field supplied high altitude pressure switch 18 required 1 Determine the correct gas input rate In the U S The input rating for altitudes above 2 000 ft 610 M must be reduced by 4 for each 1 000 ft 305 M above sea level For installations below 2000 ft 610 M refer to the u
137. treet Elbow Gas Valve A08551 Install a sediment trap in riser leading to furnace as shown in Fig 22 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 manifold and exterior manual equipment gas shutoff valve GAS TE sine SUPPLY 71 MANUAL e SHUTOFF VALVE ac REQUIRED SEDIMENT UNION 02035 Fig 22 Typical Gas Pipe Arrangement 19 58CT FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING NOTES 1 STAGE FIVE QOO 06 THERMOSTAT WIRE a rt FUSED DISCONNECT l THREE WIRE e e HEATING b 8 208 230 OR ONLY 460 VOLT tene e 2 t 29 i oop ener 208 230 GND Gee ONE L J ee RTE 115 VOLT FIELD JUNCTION MM PHASE SUPPLIED BOX H dle t 9 ND FUSED CONTROL CONDENSING DISCONNECT 4 UNIT 24 VOLT TERMINAL NOTES 1 Connect Y Y2 terminal as shown for proper operation BLOCK 2 Some thermostats require a C termina
138. uate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 12 Apply new sealant to flange of collector box and attach to cell panel using existing screws making sure all screws are secure 13 Reconnect wires to the following components Use con nection diagram on wiring label if wires were not marked for reconnection locations Draft safeguard switch Inducer motor Pressure switches Limit overtemperature switch Gas valve Hot surface igniter Flame sensing electrode Bm Flame rollout switches 14 Reinstall internal vent pipe if applicable 15 Reinstall vent connector on furnace vent elbow Securely fasten vent connector to vent elbow with 2 field supplied corrosion resistant sheet metal screws located 180 apart A05026 T A91252 Fig 60 Cleaning Heat Exchanger Cell 16 Replace blower access door only if it was removed 17 Set thermostat above room temperature and check furnace for proper operation 18 Verify blower airflow and speed changes between heating and cooling A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never use a match or other open flame to check for gas
139. urnace could cause the furnace and or vent to fail prematurely When a metal vent or metal liner is used the vent must be in good condition and be installed in accordance with the vent manufacturer s instructions To prevent condensation in the furnace and vent system the following precautions must be observed 1 The return air temperature must be at least 60 F 15 C db except for brief periods of time during warm up from setback at no lower than 55 F 13 C db or during initial start up from a standby condition 28 2 Adjust the gas input rate per the installation instructions Low gas input rate causes low vent gas temperatures caus ing condensation and corrosion in the furnace and or vent ing system Derating is permitted only for altitudes above 2000 ft 3 Adjust the air temperature rise to the midpoint of the rise range or slightly above Low air temperature rise can cause low vent gas temperature and potential for condensation problems 4 Set the thermostat heat anticipator or cycle rate to reduce short cycling Air for combustion must not be contaminated by halogen compounds which include chlorides fluorides bromides and iodides These compounds are found in many common home products such as detergent paint glue aerosol spray bleach cleaning solvent salt and air freshener and can cause corrosion of furnaces and vents Avoid using such products in the combustion air supply Furnace use during construction of
140. use 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 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 It can be viewed through the sight glass in blower access door The furnace control LED is either ON continuously rapid flashing 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 blower access door or Fig 56 and the troubleshooting guide which can be obtained from your distributor See Fig 61 for a brief Troubleshooting guide For Controls with an Amber LED The stored status codes will NOT be erased from the control memory if 115 or 24 v power is interrupted The control will store up to five 5 status codes 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 Remove outer access door c Look into blower access door sight glass for current LED status Removing blower access door will open blower access door switch and terminate 115 v power to control so that status code is not displaye
141. ve high fire regulator adjustment cap from gas valve pressure regulator Manually close blower access door switch c Jumper R W W1 and W2 thermostat connections on NOTE control to run furnace in high heat See Fig 33 d Turn high heat adjusting screw 3 16 in 5 mm or smaller flat tipped screwdriver counterclockwise out to decrease input rate or clockwise in to increase rate Re install high fire adjustment caps Leave manifold or similar device connected and proceed to Step 7 DO NOT set high heat manifold pressure less than 3 2 in wc or more than 3 8 in wc for natural gas If manifold pressure is outside this range change main burner orifices 7 Verify natural gas high heat input rate by clocking meter NOTE Gas valve regulator adjustment caps must be in place for proper input to be clocked a Turn off all other gas appliances and pilots served by the meter Run for 3 minutes in high heat operation c Measure time in sec for gas meter to complete 1 revolu 38 tion and note reading Refer to Table 12 for cubic ft of gas per hr Multiply gas rate cu ft hr by heating value Btuh cu ft to obtain input NOTE Using the 2 cu ft or 5 cu ft gas meter dial provides greater accuracy in verifying gas input rate If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Re
142. wheel remove wheel from the blower housing and wash it with an appro priate degreaser To remove wheel NOTE Before disassembly mark blower mounting arms motor and blower housing so motor and each arm is positioned at the same location during reassembly a Disconnect capacitor wires if equipped and ground wire attached to blower housing b Remove screws securing cutoff plate and remove cutoff plate from housing c Loosen set screw holding blower wheel on motor shaft 160 20 in Ib when reassembling d Remove bolts holding motor to blower housing and slide motor out of wheel 40 10 in Ib when reassembling e Remove blower wheel from housing f Clean wheel and housing 12 Reassemble motor and blower by reversing steps 116 through 11a Be sure to reattach ground wire to the blower housing 48 13 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 neces sary 14 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 15 Reinstall blower assembly in furnace 16 Reinstall control box assembly in furnace CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in shortened heat exchanger life Heating fan speed s MUST be adjusted to provide proper air temperature rise as specified on the rating plate Recommended operation is at the m
143. when this furnace is installed on the manufacturer s coil assembly or when the manufacturer s coil box is used See Fig 2 for clearance to combustible material information This furnace is designed for minimum continuous return air temperature of 60 F 16 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 For accessory installation details instruction literature refer to the applicable NOTE Remove all shipping brackets and materials before operating the furnace 58CT Improper adjustment alteration service maintenance or installation can cause serious injury or death Read and follow instructions and precautions in User s Information Manual provided with this furnace Installation and service must be performed by a qualified service agency or the gas supplier Une r glage une modification un reparation un enretien ou une installation incorrect puet entrainer des blessures graves ou la mort Suivre les instructions et les consignes qui figurent dans la notice d utilisation qui accompagne ce g n rateur d air chaud L installation et l entretien doivent tre effectur s par un r parateur qualifi ou par le fournisseur de gaz Check entire gas assembly for leaks af
144. y Adapter Kit may be required for exterior masonry chimney applications Refer to Chimney Adapter Kit KGACA02014FC or KGACA02015FC for sizing and complete application details Secure vent connector to furnace elbow with 2 corrosion resistant sheet metal screws spaced approximately 180 apart Secure all other single wall vent connector joints with 3 corrosion resistant screws spaced approximately 120 apart Secure Type B vent connectors per vent connector manufacturer s recommendations The total height of the vent and connector shall be at least seven feet 2 M for the 154 000 Btuh gas input rate model when installed in a downflow applica tion with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward See Fig 40 Caution For the following applications use the minimum vertical heights as specified below For all other applications follow exclusively the National Fuel Gas Code FURNACE VENT FURNACE DIAMETER Hone ORIENTATION ORIENTATION INPUT BTUH HR IN mm FT M 154 000 Downflow EE pr then 132 000 5 127 12 86 BUS 110 000 036 12 only Vent elbow right 154 000 Horizontal Left then up Fig 42 132 000 5 127 7 65 Vent Elbow up Fig 154 000 Horizontal Left 43 132 000 5 127 7 65 Horizontal Left exc 154 000 5 127 7 65 Vent elbow up then Downflow left Fig 37 110 000 036 12 only 5 127 10 3 0 Vent elbow
145. y burrs and sharp edges NOTE If a knockout does not come out after two sharp blows pull and snip as needed to remove the knockout Additional blows may cause damage to the door 04128 Fig 49 Rounded End of Knockout 33 58CT A04129 Fig 50 Knockout Pulled Loose A04130 Fig 51 Hammer and Screwdriver Used for Knockout A04131 Fig 52 Remove Knockout with Hammer CAUTION BURN HAZARD Failure to follow this caution may cause personal injury Hot vent pipe is within reach of small children when installed in downflow position See the following instruction An accessory Vent Guard Kit KGAVG0101DFG is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing door Refer to the Vent Guard Kit Instructions for complete details The horizontal portion of the venting system shall slope upwards not less than 1 4 in per linear ft 6 mm 3 M from the furnace to the vent and shall be rigidly supported every 5 ft 1 5 M or less with metal hangers or straps to ensure there is no movement after installation SIDEWALL VENTING This furnace is not approved for direct sidewall horizontal venting In the U S Per section 10 3 4 of the NFPA 54 ANSI Z223 1 2006 any listed mechanical venter may be used when approved by the authority having jurisdiction In Canada Per section 8 24 2 of the CAN CSA B149 1 05 any listed mechanical venter may be

Carrier 58CTA/CTX User's Manual

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