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  9. Carrier 58MSA040-08 Instructions and recipes

Carrier 58MSA040-08 Instructions and recipes

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88MSA
4-Way MuMtipoise Fixed-Capacity
Condensing Gas Furnace
\isit_ v_w carrier.corn
Installation, Start-Up, and Operating
For Sizes 040--120 Series t50
HEATUNG & COOUNG
I mlCI[NCY
A93040
NOTE: Read the entire instl_action manual be%re starting the
installation
This symbol -->indicates a change since the last issue,
Index Page
DIMENSIONAL DRAWING 3
SAFETY CONSIDERATIONS 2
(learances to ( ombustibles 4
CODES AND STANDARDS ........................................................ 5
ELE< TROSTATIC DIS<HARGE (ESD) PRE(AUTIONS ........ 5
INTRODU< TION .......................................................................... 5
APPLICATIONS ..................................... 6
General ........................................... 6
[pflow Applications ............................... 6
Downflow Applications ............................. 8
Horizontal Lek (Supply-Air Dischmge) Applications ....... 9
Horizontal Right {Supply-Air Discharge) Applications ..... 11
LO< ATION ........................................ 13
Gene*al .......................................... 13
Furnace Location Relative to ( ooling Equipment ......... I4
Hazardous Locations .............................. 14
AIR FOR COMBUSTION AND VENTILATION .......... 14
INSTALLATION ........................................ 18
Leveling Legs (If"Desired) .............................. 18
Installation in Upflow and Downflow Applications ......... 18
Installation In Horizontal Applications .................. 18
Air Ducts ....................................... !8
General ........................................ 18
Ductwork Acoustical Treatment .................... 20
Supply Air Connections ......................... 20
Return Air Connections .......................... 20
Filter Arrangement ................................ 20
Bottom Closure Panel ............................ 21
Gas Piping ....................................... 22
Electrical ( onnections ............................. 23
115-v Wiring ................................... 23
24-v Wiring .................................... 24
Accessories .................................. 24
Venting ............................................ 27
Removal of Existing Furnaces from
( ommon Vent Systems .......................... 27
Combustion-Air and Vent Piping ................... 28
Vent Te*mination .............................. 35
Multiventing ................................. 35
As an FNFR(JY ST4Rx¢
Pa_ner Carrier Corpora-
tion has determined that
this pro_tct meets the EN'-
FRGY S fARaV g/iidelines
_r energy efflc{ency
I$O 9001:2000
@
AIRFLOW
42>
r
¢ _ HORLIZOTNTA_ _ _ HO _II_C_NTALN'NI 0
AIRFLOW AIRFLOW
©
AIRFLOW A93041
Fig. 1--NuRipoise Orientations
Condensate Drain .................................................................... 35
General ....................................... 35
Application ....................................... 35
Condensate Drain Protection ...................... 36
START°UP, ADJL STMENTS AND SAFETY (HECK ....... 37
General .......................................... 37
Prime ( ondensate Trap With Warm .................... 37
Purge Gas Lines ................................... 38
Sequence of Operation ............................. 38
Heating Mode ................................. 38
Cooling Mode ................................ 38
Continuous Blowe* Mode ........................ 38
Heat Pump Mode .............................. 39
Component Test ............................... 39
Adjustments....................................... 39
Set Gas Input Rate .............................. 39
Set Temperature Rise ................................ 44
Blower Off"Delay (Heat Mode) .................... 44
Set Thermostat Heat Anticipator .................... 45
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 101 Catalog No 535-80154 Printed in U.S.A. Form 58MSA-11SI Pg 1 2-05 Replaces: 58MSA-10SI
Check Safhty Controls 45
Check Prima_ Limit Control 45
Check Pressure Switch 45
CHECKLIST ...................................... 45
SAFETY CONSIDERATIONS
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of fml_ace may re=
quire excessive servicing o1" cause premature component
failm'e
Application of this fm'nace should be indoors with special
attention given to vent sizing and material, gas input rate, air
temperature rise, unit leveling, and unit sizing.
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in electrical shock,
firQ personal ir!inry, or death,
Improper installation, adjustment, alteration, service, mainte°
nance, or use can cause carbon monoxide poisoning, explo=
sion, fire, electrical shock, or other conditions which may
cause personal Jr!ire'y.,-or property damage. Consult a qualified
installer, smwice agency, local gas supplier, or your distribu-
tor or branch fbr information or assistance. The qualified
installer or agency must use only [itctory=authorized and
listed kits or accessories when modi_)ing this product.
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified
persomiel should instMl, repair, or service heating equipment.
Untrained personnel can perform basic maintenance fimctions
such as cleaning and replacing air filters All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in literature, on tags, and
on labels attached to or shipped with unit and other safety
precautions that may apply
These instructions cover the minimum requirements and confoml
to existing national standards and safkty codes In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing resider>
tial construction practices. We require these instrnctions as a
minimum ibr a saf_ installation
Wear safety glasses and work gloves. Have a fire extinguisher
available during start=up and adjustment procedures and service
calls,
CUT HAZARD
Failure to %tlow this caution may result in personal injury.
Sheet metal parts may have sharp edges or bun's Use care and
wear appropriate protective clothing and gloves when ban=
dling parts.
Recognize safety information. This is the safety=alert symbol Z_
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
--€
--€
--€
--€
--€
-->
Understand these signal words DANGER, WARNING, and (AU°
TION These words are used with the safkty=alert symbol. DAN-
GER 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 ma? result in minor personal
injury or product and property damage NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
The 58MSA Muhipoise Condensing Gas-Fired Furnaces are CSA
(fbm_erly AGA and (GA) design-certified for natural and propane
gases (see ftmmce rating plate) and fbr installation in alcoves,
attics, basements, closets, utility rooms, erawlspaces, and garages.
The fi/rnace is factory=shipped fbr use with natural gas. A CSA
listed gas conversion kit is required to convert furnace for use with
propane gas.
See Fig. 3 for required clearances to combustibles.
Maintain a l-in. clearance fiom combustible materials to supply air
ductwork for a distance of 36 inches horizontally fiom the fimaace.
See NFPA 90B or local code fbr further requirements.
These furnaces SHALL NOT be installed directly on carpeting,
tile, or any other combustible material other than wood flooring. In
downflow installations, factory accessow floor base MUST be
used when installed on combustible materials and wood flooring.
Special base is not required when this Nmace is installed on
manufacturer's (:oil Assembly Part No. CD5 or CK5, or when Coil
Box Part No. KCAKC is used. The design of this fi/rnace line is
NOT CSA (formerly AGA and CGA) designocertified fbr instal-
lation in recreation vehicles, manufi_ctured mobile homes, or
outdoors.
This furnace is designed for continuous return-air mininmm
temperature of 60_>F db or intermittent operation down to 55°F db
such as when used with a night setback thermometer. Return-air
temperature must not exceed 80°F db. Failure to follow these
return-air limits may affect reliability of heat exchangers, motors,
and controls. (See Fig. 4.)
These Nrnaces are shipped with the drain and pressure robes
connected for UPFLOW applications. Minor modifications are
required when used in DOWNFLOW, HORIZONTAL RIGHT, or
HORIZONTAL LEFT (supply=air discharge direction) applica-
tions as shown in Fig. 1. See details in Applications section.
Install this Nmace only in a location and position as specified in
LOCATION and INSTALLATION sections of these instnlctions.
Combustion products must be discharged outdoors. Connect this
furnace to an approved vent system only, as specified in the
Combustion Air and Vent piping sections of d_ese instructions.
Never test for gas leaks with an open flame. Use a commercially
available soap solution made specifically for detection of leaks to
check all connections as specified in the GAS PIPING section of
these instructions.
Always install the furnace to operate within the fitrnace's intended
rise range with a duct system which has an external static pressure
within the allowable range as specified in the SET TEMPERA-
TURE RISE section of these instructions.
When a Nrnace is installed so that supply ducts carry air circulated
by tl_e fi/rnace to areas outside the space containing the f:umace,
the return air shall also be handled by ducts sealed to the Nrnace
casing and terminating outside the space containing the fhrnace.
22 _"_
T
I4 _" SIDE INLET
TYP
S{OEiNLET
26 _,e"TVp
HORIZONTAL LEFT)
POWER CONN
ACCESSORY [ J
POWERENTRY 2]
_ CONDENSATE
DRAINTRAP
LODATION
(ALTERNATE
UPFLOW) 24
17 :,i_"
9/6" !
TiP
CONDENSATE
DRAIN LO CATION
(UPFLOW)
P
©
A_RFLOW
OaT TYP
t
{DOWNFLOW&
HORIZONTALRIGHT)
ORALTERNATE
gqN DIAGAS CONN
1
30 _;"
DRA_N LOCATION
(UPFLO\M)
DIMPLE LOCATORS
FOR HORIZONTAL
HANGING
i
i
i
i
i
qN DIA
THERMOSTAT ENTRY
2qN VENT CONN
SIDE iNLET
BOTTOM iNLET
UNIT SIZE
040-08
040-t2
080-08
080-t2
080-t6
080-t2
080-t6
080_20
100-16
100-20
120_20
NOTES: 1. Minimum return-air openings at furnace, based on metal duct if flex duct is used,
see flex duct manufacturer's recommendations for equivalent diameters
2 Minimum return-air opening at furnace:
a, For 800 CFM-16-in, round or 14/_ x 12-in rectangle
b For 1200 CFM-20qn, round or 14'h x 19 Lqn, rectangle
c, For 1600 CFM-22qn, round or 14/;, x 23 L-in, rectangle
d For airflow requirements above 1800 CFM see Air Delivery table in Product Data
literature for specific use of single side inlets The use of both side inlets a
combination of 1 side and the bottom, or the bottom only will ensure adequate
return air openings for airflow requirements above 1800 CFM at 0_5 WC ESP
A
17-I/2
17-I/2
17-I/2
17-I/2
17-I/2
17-I/2
17-I/2
21
21
21
24-I/2
Dimensions (In.)
D
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
15-7/8
19-3/8
19-3/8
19-3/8
22-7/8
E
16
16
16
16
16
16
16
19-1/2
19-1/2
19-1/2
23
A02149
Fig. 2--Dimensional Drawing
--->A gas-fired fire, ace %1"installation in a residential garage must be
installed as specified in the Hazardous Locations section of these
insm/etions,
--> The [:urnaee is not to be used %r tempora Uheating of buildings or
structures under construction unless the furnace installation and
operation complies with the first CAUTION in the LOCATION
section of these instructions,
These fi.u'naces are shipped with the %llowing materials to assist in
proper furnace installation, These materials are shipped in the main
blower compartment,
Installer Packet includes:
Installation, Startup, and Operating instructions
Service and Maintenance instructions
User's Information Manual
Warranty Certificate
Loose Parts Bag includes: Quantity
Pressure tube extension 1
Collector Box or condensate trap extension tube 1
Inducer housing drain tube 1
1/2-in CPVC street elbow 2
Drain tube coupling 1
Drain tube coupiing grommet 1
Vent and combustion-air pipe support 2
Condensate trap hole filler plug 3
Vent and combustion-air intake hole filler ptug 2
Combustion-air pipe perforated disk assembly 1
Vent Pipe Extension 1"
* ONLY supplied with some furnaces.
e This forced air lurnace is equipped for use with natural gas at altitudes 0 -10.000 ff (0 -3,050m), except 140 size _rnaces are only approved for altitudes 0 -7.000 ft.
(0 -2,135m).
¢ An accessory kit, supptied by tbe manufacturer, shall be used to convert to propene gas use or rr_ay be required for some natural gas apptications.
o This furnace is for indoor installation in a building constructed on site. This furnace may be ins"tailed in a manufactiJred (mobile) home when stated on rating plate and
using factory authorked kit..
This furnace may be tilstalled on combustible floodng in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below.
® This furnace requires a special venting system Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC.
PVC-DW%L CPVC. or ABS-DWV pipe, and must not be vented in common with other gas-tired apptiances. Construction tbrough which vent/air intake pipes may be
installed is maximum 24 inches (600 ram), minimum 3/4 inches (19 ram) thickness (including roofing materials)
e Cetta fournalse &air puls6 est 6quip6e peur utitisation avec gaz naturel et altitudes compdees entre 0 - 3.050m (0 - 10,000 pi),except6 queles fournaises de 140 taille
sont pour altitudes comprises entre 0 - 2,135m 0 - 7,000pi).
® Ut set une trousse de cenvers on. fourn e par e fabr can, pour passer au gaz propane ou pour certaines installations au gaz natureL
o Cetta fournaise a air puls6 es"t pour installation a Fint6rieur darts un bNiment construit sur place. Cetta fournalse a air pulse peut 6tre install6e dens une maison
pr6fabdqu6e (maison mobile) si prescht par la plaque signN6tique et si r on utitise une trousse specifi6e par le labdcant.
e C'etta fournaise peut _tre instati6e sur un plancher combustible darts un enfoncement ou un placard en observant les D_gagement Minimum En Pouces Ave¢
Elements De Construction Combustibles,
® Cetta fournaise n6cessite un systeme d'evaoJation special La m6thede d'installation et la tiste des pieces n6cessaires figurent dens les instructions d'instatiation. Cetle
fournalse doit s'u!itiser avec la tuyautede des nomendatures 40 PVC. PVC-DWV, CPVC, oN ABS-DVW et elle ne peut pas 6tre ventil6e conjointment avec d'autres
appereils a gaz. Epalsseur de la construction au travers de laquetie il est pcesible de laire passer les tuyaux d'a6ration (admlssion/6vacuation): 24 po ('600 ram)
maximum. 3/4 po (19ram) minimum (y cornprls la toiture)
For uptiow and downtiow applications, furnace mu_t be installed level, or pitched within 1/2" of level For a MIN 1/4" TO 1/2" MAX
horizontal apptication, the furnace must be pitched minimum 1/4" to maximum of 1/2" forward for proper
draina:je. See Installation Manual for IMPORTANT unit supped details on horizontal apptications,
Pour des appticatises de flux ascendent et descendant. _ fournaise ddt 8tre install6e de niveau ou indti%,e
pes plus de 1/2" du niveau. Pour une apptication hodzontale, la fournalse doit g,tre inciinde entre minimum
1/4" et maximum 1/2" du nNeau pour le drainage appropd6. En _ d'instatiation en position beCEontale.
consulter les renseignements tMPORTANTS sur le support dens le manuel d'instatiation. HORIZON TAL
NtNINUN iNCHESCLEARANCE TO CONBUSTtBLE CONSTRUCTION
ALL POSITIONS:
Minimum front clearance for service 24 inches (610mm),
? ? 140 size furnaces require 1 inch back clearance to combustible materials,
DOWNFLOW POSITIONS:
t For ir_stallation on cembustible floors only when installed on special base No, KGASB0201ALL,
Coil Assembly Part No, CD5 or CKS, or Coil Casing, Part No, KCAKC,
HORIZONTAL POSITIONS:
Line contact is permissible only between lines formed by intersections of top and two sides of
furnace jacket, and building joists, studs, or framing,
§ Clearance shown is for air inlet and air outlet ends.
O 120 and 140 size furnaces require 1 inch bottom clearance to combustible materials,
DEGAGEMENTMINIMUM EN POUCESAVEC _LEMENTS DE CONSTRUCTIONCOMBUSTIBLES
POUR TOUS LES POSITIONS:
Degagen_ent avant minimum de 610mm (24 po ) pour l'entretien,
tt Pourlesfoumaissede140taille,1po(25mm)degagen-entdesn_t@iauxcombustiblseest
requis au-arriere.
POUR LA POSITION COURANT DESCENDANT:
1 Pour Iinstallation sur le plancher combustible seulement quand on utilise la base speciale, piece
n ° KGASB0201ALL, I'sesemble serpentin, piece n° CD5 ou CKS, ou le carter de serpentin,
piece n° KCAKC.
POUR LA POSITION HORIZONTALE:
Le contact n'est pem?is qdentre les ligses forages par les intersections du dessus et des
deuxoStes de la chemise de la foumaise et des selives, des n_ntan% ou de la charpente du
b4,timent,
§ La distance indiquee cenceme I'extr@mit6 du tuyau d'arrivde d'air et Fextremite du tuyau de sortie
d'air,
Pour Ise foumaises de 120 et 140 taille 1 po (25ram) d&Jagement des mat@iaux combusitbles
est requis au<l_'ssous.
TNs furnace is approved for UPFLOW, DOWNFLOW aed
HORIZONTAL instNlations,
Cette toumaise est approuv¢e pour Iinstallaflon HORIZONTALE
e! la circulaJion d'air VERS LE HAUT et VERS LE BAS
Cleat_nce arrows
do not change with ne change pas avec
furnace onentation I'odentation de la
gen@aIeur d'air cbaud.
Vent clearance to
combustibles 0",
Clearance in inches 0 (po) Ocgagement
Degagetnent (po), d'@vent avec combustibles
3280_201 REV, B LITTOP
Fig. 3--Clearances to Combustibles
4
J
A04110
"} MAX 80°F
FRONT
RETURN
AHR MHN60°F
A05004
--9 Fig. 4_Retum-Air Temperature
For accessory installation details, refer to accesse D' installation
instructions
--@ ,
CODES AND STANDARDS
Follow all national and local codes and standards in addition to
these instructions° The installation must comply with regulations
of the serving gas supplier, local building, heating, plumbing, and
other codes. In absence of local codes, the installation must
comply with the national codes listed below and all authorities
having jurisdiction.
In the United States and Canada, follow all codes and standards for
the _bllowing:
Step l--Safety
* US: National Fuel Gas (ode (NFGC) NFPA 54-2002/ANSI
Z223.1 °2002 arid the Installation Standards, Warm Air Heating
and Air (onditioning Systems ANSI NFPA 90B
* CANADA: National Standard of Canada, Natnral Gas and
Propane Installation Code (NS(NGPIC) CSA BI49J-00.
Step 2--General Installation
*US: NFG( and the NFPA 90B. For copies, contact the National
Fire Protection Association Inc, BatteD-march Pad< Quincy,
MA 02269; or for only the NFG( contact the American Gas
Association, 400 N. Capitol, N.W., Washington DC 20001
A manu_hctured (Mobile) home installation must con_brrn with
the Mam!/actured h2)me d'onstl'z¢ctior_ as_d &{fi.-t3' Sta,c/ard
Tide 24 (iFR, Part 3230, or when this standard is not
applicable, the Standard _br _l,Ian@tctz¢red Hnme l_Tst_d]ation
(.hIclmt/act_lred D))me Sites, ('omm_¢nitie.s, and Set-L_.s),
AXIST/A'C_' A225. l, an&or (14A',( %-l-Z240, liD" Serie.s 3/obiIe
Hom_,s'
* CANADA: NSCNGPI& For a copy, contact Standard Sales,
CSA International, 178 Rexdale Boulevard, Etobicoke
(Toronto), Ontario, M9W IR3, Canada.
Step a--Combustion and Ventilation Air
* US: Section 8.3 of the NFGC, Air for (ombnstion arid
Ventilation
* CANADA: Part 7 of d-ieNSCNGPIC, Venting Systems and Air
Supply _k}r Appliances
Step 4--Duct Systems
* US and (ANADA: Air (onditioning (ontractors Association
(AC(A) Manual D, Sheet Metal and Air Conditioning (7on-
tlactors National Association (SMACNA), or American Soci-
ety of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE) 2001 Fundamentals Handbook Chapter 34.
Step 5--Acoustical Lining and Fibrous Glass Duct
* US and (ANADA: current edition of SMACNA, NFPA 90B as
tested by UL Standard 181 for (;lass I Rigid Air Ducts
Step g--Gas Piping and Gas Pipe Pressure Testing
*US: NFG( chapters 2, 3, 4_ and 9 and national phn'nbing codes
In the state of Massachusetts:
This product must be installed by a licensed plumber or gas
fitter.
When flexible connectors are used, the maxinmm length shall
not exceed 36 inches.
When lever type gas shutof_is are used they shall not exceed 36
inches.
CANADA: NSCNGPIC Parts 3, 4, 5, A, B, E, and H.
Step 7--Emectrical Connections
* US: National Electrical (ode (NE() ANSIiNFPA 70°2002
CANADA: (anadian Electrical (ode CSA C22.1
ELECTROSTATIC DISCHARGE {ESD) PRECAUTIONS
[NIT DAMAGE HAZARD
Faihn'e to follow this caution may result in damage to unit
components.
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing to
protect d_e t:umace electronic control. Precautions will pre-
vent electrostatic discharges fiom personnel and hand tools
which are held during the proce&re. These precautions will
help to avoid exposing the control to electrostatic discharge
by putting d_e [:urnace, the control, and the person at the same
electrostatic potential.
1. Disconnect all power to the furnace. Multiple disconnects may
be required. DO NOT TOU(H THE CONTROL OR ANY
WIRE CONNE(TED TO THE ( ONTROL PRIOR TO DIS-
(HARGING YOUR BODY'S ELECTROSTATI( CHARGE
TO GROUND.
2 Firefly touch a clean, unpainted, metal surface of the fmTlace
chassis which is close to the control. Tools held in a person's
hand during grounding will be satisfactorily discharged.
3. After touching the chassis you may proceed to service the
control or connecting wires as tong as you do nothing that
recharges your body with static electricity (fbr example; DO
NOT move or shuffle your feet, DO NOT touch ungrounded
objects, etc)
4 If you touch ungronnded objects (recharge your bo@ with
static electricity), firmly touch the unpainted metal surfi_ce of
the furnace again be_bre touching control or wires.
5. Use this procedure for installed and urdnstalled (ungrounded)
_i/rnaces
6. Befbre removing a new control fiom its container, discharge
your body's electrostatic charge to ground to protect dae
control from damage. If d_e control is to be installed in a
ii/mace, _bllow items 1 through 5 be_bre bringing the control
or yourself into contact with the furnace. Put all used and new
controls into containers be_bre touching ungrounded objects.
7. An ESD service kit (available ti'om commercial sources) may
also be used to prevent ESD damage.
INTRODUCTION
The model 58MSA 4-way multipoise, Gas-Fired, Category IV,
condensing furnaces are available in model sizes ranging in gas
input rates of 40,000 to 120,000 Bmh.
__D FURNACE
OOR
TRAP (INSIDE_ X[
TU% OOSO ETRAP
DRAIN TUBE LOCATION
UPFLOW APPLICATIONS
FIELD--
DRAIN
CONN
/-- CONDENSATE
/TRA uRNAOE7
JS'DV
Y,--? /o
£_2% ......
26_/4 1_/2
SIDE VIEW FRONT VIEW
DOWNFLOW AND ALTERNATE
EXTERNAL UPFLOW APPLICATIONS
_1 FURNACE
OOR
FIELD --
DRAIN
CONN
-- FURNACE
SIDE
¾
END VIEW FRONT VIEW
HORIZONTAL
APPLICATIONS
s'-°7'-%:°:U7
(OPTIONAL) /
Z W, ET,E
GUIDES
(WHEN USED)
71/8
l
COD
COLLECTOR BOX TO
TRAP RELIEF PORT
_OD
INDUCER HOUSING
DRAIN CONNECTION
'_OD
COLLECTOR BOX
DRAIN CONNECTION
SCREW HOLE FOR
UPFLOW OR DOWN-
FLOW APPLICATIONS
(OPTIONAL)
YnlN. PVC OR CPVC
FRONT VIEW SIDE VIEW
A93026
Fig. 8--Condensate Trap
MINOR PROPERTY DAMAGE
Failure to follow this caution may result in minor property
damage,
Local codes may reqnire a drain pan under entire _rnace and
condensate trap when a condensing furnace is used in an attic
application or over a finished ceiling.
APPLiCATiONS
Step l--General
Some assembly and modifications are required for fire, aces
installed in any of the 4 applications shown in Fig. 1. All &ain and
pressure robes are connected as shown in Fig 6 See appropriate
application instructions _br these procedures
Step 2--Upflow Applications
An upflow t'tmlace application is where fm'nace blower is located
below combustion and controls section of ffimace, and conditioned
air is discharged upwards
( ONDENSATE TRAP LO(ATION (FACTORY-SHIPPED
ORIENTATK)N)
The condensate tlap is _hctory installed in the blower shell:"and
fhctory connected for UPFLOW applications. A factory-supplied
tube is used to extend the condensate trap drain connection to the
desired furnace side %r field drain attachment See Condensate
Trap Tubing (FactoQ--Shipped Orientation) section *%r drain tube
extension details. (See Fig. 6.)
CONDENSATE TRAP TL BING (FACTORY-SHIPPED
ORIENTATION)
NOTE: See Fig. 6 or robe routing label on main furnace door to
confirm tocation of these tubes
l. ( ollector Box Drain, Inducer Housing Drain, Retief Port, and
Pressure Switch Tubes
These tubes are fhcto W attached to the condensate trap and
pressure switch ready _;oruse in UPFLOW applications. These
robes can be identified by their connection location and also
by a color label on each robe. These robes are identified as
£_llows: collector box &ain robe (blue label), inducer housing
&ain robe (violet label or molded), relief port robe (green
label), and pressure switch robe (pink label).
2. (ondensate Trap Drain Tube
The condensate trap drain connection must be extended for
field attachment by doing the *%llowing:
a. Detemine location of field drain connection. (See Fig. 2or
6.)
NOTE: If internal filter is used, drain robe should be located to
opposite side of casing from remm duct attachment to assist in
filter removal.
PLUG
CAP
COLLECTOR
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR
TUBE (PINK)
COLLECTOR BOX --_
TUBE (GREEN)
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
DRAIN TUBE (BLUE)
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
FIELD-INSTALLED
FACTORY-SUPPLiED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED
V_-IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
A94163
Fig. 6--Factory-SNpped Upflow Tube Configuration
(Shown With Blower Access Panel Removed}
b. Remove and discard casing drain hole plug button from
desired side.
c Install &ain tube coupling grommet (factor-supplied in
loose parts bag) in selected casing hole.
& Slide drain robe coupling di_ctok_'°supplied in loose parts
bag) through grommet ensuring tong end of coupling fi_ces
blower.
e. Cement 2 factory°supplied 1i2qn. stleet CPVC elbows to
the rigid drain tube connection on the condensate trap. (See
Fig. 6.) These elbows must be cemented together and
cemented to condensate trap drain connection.
NOTE: Failure to use CPV( elbows may allow &ain to kink and
prevent draining.
t_ Connect larger diameter drain tube and clamp (factory°
supplied in loose parts bag) to condensate trap and clamp
securely.
g. Route robe to coupling and cut to appropriate length.
h. Attach robe to coupling and clamp securely.
(ONDENSATE TRAP LOCATION (ALTERNATE UPFLOW
ORIENTATION)
An alternate location fbr the condensate tlap is the left-hand side
of casing. (See Fig 2and 7)
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE)
TRAP
HOUSING
DRAIN TUBE
(VIOLET)
O O
A94164
Fig. 7--Alternate Upflow Tube Configuration and
Trap Location
--9
NOTE: If the alternate tef_-hand side of casing location is used_
the factory-connected drain and relief port robes must he discon-
nected and modified for attachment See Condensate Trap Tubing
(Alternate Upflow Orientation) section for tubing attachment
To relocate condensate trap to the te_t-hand side, perfbrm the
following:
1 Remove 3 tubes connected to condensate t_ap.
2 Remove trap from blower shelf by gently pushing tabs inward
and rotating trap.
3. Install casing hole filler cap (_i_ctory=supplied in loose parts
bag) into blower shelf hole where trap was removed.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning eoutd result in personal inju W
or death,
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated.
4 Install condensate trap into left=hand side casing hole by
inserting tube cormection stubs through casing hole and
rotating until tabs snap into locking position.
5. Fill unused condensate tlap casing holes with plastic filler
caps (bactory=supplied in loose parts bag).
CONDENSATETRAPTUBING(ALTERNATEt PFL()W
ORIENTATION)
NOTE:SeeFig.7orroberoutinglabelonmainfhrnacedoorto
confirmlocationoftheserobes
1.(ollectorBoxDrainTube
(onnectcollectorboxdrainrobe(bluelabel)tocondensate
t_ap.
NOTE:On17-1/2-in.widetk_rnacesONLY,cuttubebetween
corrugatedsectionstopreventkinksfloraoccurring.
2.InducerHousingDrainTube
a.RemoveanddiscardLOWER(molded)inducerhousing
&Bintubewhichwaspreviouslyconnectedtocondensate
t_ap.
b.[seinducerhousing&Binextensiontube(violetlabeland
fhctow-suppliedinloosepartsbag)toconnectLOWER
inducerhousing&Binconnectiontothecondensatetrap
c.Determineappropriatelength,cut,andconnectrobe
d.Clamprobetopreventanycondensateleakage.
3.ReliefPortTube
a.(onnectreliefporttube(greenlabel)tocondensatetrap.
b.Usesmallerdiametertube(fitctory=suppliedinlooseparts
bag)toextendthistubeifrequired.
c.Determineappropriatelength,cut,andconnectrobe.
(ONDENSATETRAPFIELDDRAINATTACHMENT
Referto CondensateDrainsectionforrecommendationsand
procedures.
PRESStRESWIT(HTtBING
TheLOWER collector box pressure tube (pink 1abel) is facto W
connected to the pressure switch and should not require any
modificatiom
COLLECTOR
DRAIN TUBE (BLUE)
TUBE (GREEN)
EXTENSION TUBE
TUBE (PINK)
COLLECTOR
DRAIN TUBE (BLUE
& WHITE STRIPED)
EXTENSION TUBE
TRAP ©
INDUCER HOUSING
DRAIN TUBE(VIOLET)
Fig. 8--Downflow Tube Configuration
(Left-Hand Trap Installation)
A94165
NOTE: See Fig 6 or 7 or robe routing label on main furnace door
to check fbr proper connections.
UPPER COLLECTOR BOX AND INDUCER HOUSIN'G
(UNUSED) DRAIN" CONNE(TIONS
tipper (ollector Box Drain Connection
Attached to the tIPPER collector box drain connection is a
factory-installed corrugated, plugged tube (blue and white striped
label). This tube is plugged to prevent condensate leakage in this
application. Ensure this robe is plugged.
NOTE: See Fig. 6 or 7 or tube routing label on main furnace door
to check fbr proper connections.
tipper Inducer Housing Drain (onnection
Attached to the tIPPER (unused) inducer housing &Bin connection
is a cap and clamp. This cap is used to prevent condensate leakage
in this application Ensure this connection is capped.
NOTE: See Fig. 6 or 7 or tube routing label on main fhrnace door
to check fbr proper connections.
CONDENSATE TRAP FREEZE PROTECTION
RefBr to (ondensate Drain Protection section for recommenda-
tions and procedures.
Step 3--Oownflow Applications
A downflow ftn'nace application is where fitmace blower is located
above combustion and controls section of furnace, and conditioned
air is discharged downwards.
CONDENSATE TRAP LOCATION
The condensate trap must be removed from the fhctow-installed
blowe* shelf'location and relocated in selected application location
as shown in Fig 2, 8, or 9.
O O
©
LDRAIN TUBE "_
COUPLING
PLUG
CAP
_ COLLECTOR BOX
DRAIN TUBE (BLUE)
_ COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
EXTENSION TUBE
INDUCER HOUSING
D RAIN TUBE
(VIOLET)
CONDENSATE
TRAP
_'- COLLECTOR BOX
EXTENSION
DRAIN TUBE
Fig. 9--Oownflow Tube Configuration
(Right-Hand Trap Insta{lation)
A94166
-->
To relocate condensate trap fi'om the blower shelf to desired
location, perfbrm the following:
1. Remove 3 tubes connected to condensate t_ap
2. Remove trap from blower shelf by gently pushing tabs inward
and rotating t_ap.
3. Install casing hole filler cap (*hctow-supplied in loose parts
bag) into blower shelf hole where trap was removed.
CARBON MONOXIDE POISONING HAZARD
Failure to fbllow this warning could result in personal in}ury
or death.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated.
4. Install condensate trap into desired casing hole by inserting
tube connection stubs through casing hole and rotating until
tabs snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (*i_ctory=supplied in loose parts bag)
CONDENSATE TRAP TUBING
NOTE: See Fig 8 or 9 or robe routing label on main furnace door
to check fbr proper connections.
1. Collector Box Drain Tube
a Remove fimtory=installed plug fi'om LOWER collector box
drain robe (blue and white striped label).
b. Install removed clamp and plug into [PPER collector box
&ain robe (blue label) which was connected to condensate
tlap.
c. Connect LOWER collector box drain connection to con=
densate trap.
(1.) Condensate Trap Located on Left Side of Casing
Ca3 Connect LOWER collector box &ain robe (blue
and white striped label) to condensate tlap. Tube
does not need to be cut.
(b.) Clamp tube to prevent any condensate leakage.
(2.) Condensate Trap Located on Right Side of Casing
Ca3 Install drain robe coupling (fhctow-supplied in
loose parts bag) into collector box drain robe
(blue and white striped label) which was previ=
ously plugged.
(b.) Connect larger diameter &ain robe (_tctory°
supplied in loose parts bag) to &ain tube cou°
piing, extending collector box drain robe for
connection to condensate trap.
(c.) Route extended collector box drain robe between
gas valve and inlet housing as shown in Fig. 9.
(d.) Determine appropriate length and cut.
(e.) Connect to condensate trap.
(f.) Clamp robe to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a Remove fhctoEyoinstalled cap and clamp from LOWER
inducer housing drain connection.
b. Remove and discard UPPER (molded) inducer housing
&ain robe which was previously connected to condensate
t_ap.
c Install cap and clamp on UPPER inducer housing &ain
connection where molded &ain robe was removed.
d. l_se inducer housing &ain robe (violet label and factoQ-
supplied in loose parts bag) to connect LOWER inducer
housing drain connection to the condensate trap.
e. Connect inducer housing drain connection to condensate
trap.
(10 Condensate Trap Located on Left Side of Casing
Ca,) Determine appropriate length and cut,
(b.) Connect tube to condensate trap.
(c.) Clamp robe to prevent any condensate teakage
(20 Condensate Trap Located on Right Side of Casing
Ca.) Route inducer housing drain tube (violet 1abel)
between gas valve and inlet housing behind col-
lector box drain tube
(b) Determine appropriate length and cut
(c.) Connect robe to condensate trap.
(d) Clamp robe to prevent any condensate teakage.
3 Relief Port Tube
Refkr to Pressure Switch Tubing section fbr connection
procedure
CONDENSATE TRAP FIELD DRAIN ATTACHMENT
Refer to Condensate Drain section fbr recommendations and
procedures,
PRESSURE SWITCH TUBING
One collector box pressure tube (pink label) is factory connected to
the pressure switch fbr use when furnace is installed in UPFLOW
applications. This robe MUST be disconnected and used for the
condensate trap relief port robe. The other collector box pressure
robe (green label) which was f_ctory connected to the condensate
trap relief port connection MUST be connected to the pressure
switch in DOVv_TLOW or HORIZONTAL RIGHT applications.
NOTE: See Fig. 8 or 9 or robe routing label on main fhrnace door
to check fbr proper connections
Relocate robes as described below.
1. Disconnect collector box pressure robe (pink label) attached to
pressure switch
2. Use smaller diameter robe (factor-supplied in loose parts
bag) to extend collector box pressure tube (green label) which
was previously connected to condensate t_ap relief port
connection.
3. Connect collector box pressure robe (green label) to pressure
switch connection labeled "collector box."
4. Use remaining smaller diameter robe (factmT-supplied in
loose parts bag) to extend collector box pressure robe (pink
label) which was previously connected to pressure switch.
5. Route this extended tube (pink label) to condensate trap relief
port connection.
6. Determine appropriate length, cut, and connect robe.
7. Clamp robe to relief port connection.
CONDENSATE TRAP FREEZE PROTECTION
Refer to Condensate Drain Protection section for recommenda-
tions and procedures
Step 4--Horizontal Left (Supply-Air Discharge)
Applications
A horizontal left fhrnace application is where fhrnace blower is
located to the right of combustion and controls section of' furnace,
and conditioned air is discharged to the left.
PLUG
AUXILIARY 'U" BOX COLLECTOR BOX
DRAIN TUBE
(BLUE AND WHITE STRIPED)
O
o
CONDENSATE
TRAP COLLECTOR BOX
TUBE (GREEN)
BOX EXTENSION
DRAtNTUBE
COLLECTOR BOX
EXTENSION TUBE
HOUSING
DRAIN TUBE (VIOLET)
BOX
DRAIN TUBE (BLUE)
DRAIN TUBE COUPLING
COLLECTOR BOX TUBE (PINK)
RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR
040,060, AND 080 HEATING INPUT FURNACES
Fig. 10--Horizontal Left Tube Configuration A00215
CONDENSATE TRAP LOCATION
The condensate tlap must be removed from the factor-installed
blower shelf location and relocated in selected application location
as shown in Fig. 2or 10.
To relocate condensate trap from the blower shelf to desired
location, perform the Ibllowing:
1. Remove 3 robes connected to condensate trap.
2. Remove tlap flora blower shelf by gently pushing tabs inward
and rotating trap.
3. Install casing hole filler cap (factov-supplied in loose parts
bag) into blower shelf hole where tlap was removed.
-9 CARBON MONOXIDE POISONING HAZARD
Failure to _bllow this warning could result in personal injury
or death.
Casing hole filler cap must be installed in blower shelf hole
when condensate trap is relocated.
4. Install condensate trap into casing hole by inserting tube
connection stubs through casing hole and rotating until tabs
snap into locking position.
5. Fill unused condensate trap casing holes with plastic filler
caps (fi_ctory=supplied in loose parts bag)
CONDENSATE TRAP TUBING
NOTE: See Fig. 10 or tube routing label on main fl/rnace door to
check for proper connections.
10
1. Collector Box Drain Tube
a Install &ain tube coupling (factory-supplied in loose parts
bag) into collector box drain tube (blue label) which was
previously connected to condensate trap
b. Connect large diameter drain robe and clamp (factory-
supplied in loose parts bag) to drain robe coupling, extend-
ing collector box &ain robe
c Route extended robe (blue label) to condensate trap and cut
to appropriate length
d. (lamp robe to prevent any condensate leakage.
2. Inducer Housing Drain Tube
a. Remove and discard LOWER (molded) inducer housing
drain robe which was previously connected to condensate
trap.
b. Use inducer housing &ain extension robe (violet label and
factoryosupplied in loose parts bag) to connect LOWER
inducer housing &ain connection to the condensate trap.
c. Detem_ine appropriate length, cuL and connect robe.
d. (lamp robe to prevent any condensate leakage.
3. Relief Port Tube
a. Use smaller diameter robe (factov-supplied in loose parts
bag) to extend collector box tube (green label) which was
previously connected to the condensate trap.
b. Route extended collector box pressure robe to relief port
connection on the condensate trap.
c. Detem_ine appropriate length, cuL and connect robe.
d. (lamp robe to prevent any condensate leakage.