Carrier 58tua Instructions and recipes

58TUA

2–Speed, 2–Stage

Induced-Combustion Gas Furnace

Installation, Start-Up, and Operating Instructions

Size 040–135, Series 130

NOTE: Read the entire instruction manual before starting the

installation.

This symbol →indicates a change since the last issue.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS.....................................................1

INTRODUCTION..........................................................................1

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........3

LOCATION....................................................................................4

General......................................................................................4

Location Relative to Cooling Equipment ................................4

Hazardous Locations.................................................................4

AIR FOR COMBUSTION AND VENTILATION......................4

Unconfined Space.....................................................................5

Confined Space.........................................................................5

INSTALLATION...........................................................................6

Air Ducts...................................................................................6

General Requirements .........................................................6

Ductwork Acoustical Treatment .........................................6

Supply Air Connections......................................................7

Return Air Connections.......................................................7

Filter Arrangement....................................................................7

Leveling Legs (If Required).....................................................8

Gas Piping.................................................................................8

Electrical Connections..............................................................9

115-v Wiring........................................................................9

24-v Wiring..........................................................................9

Accessories ..........................................................................9

Venting......................................................................................9

START-UP, ADJUSTMENT AND SAFETY CHECK...............9

General......................................................................................9

Sequence of Operation............................................................10

Start-up Procedures.................................................................15

Adjustments.............................................................................15

Check Safety Controls............................................................21

Checklist..................................................................................22

SAFETY CONSIDERATIONS

Installation and servicing of heating equipment can be hazardous

due to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions

such as cleaning and replacing air filters. All other operations must

be performed by trained service personnel. When working on

heating equipment, observe precautions in the literature, on tags,

and on labels attached to or shipped with the unit and other safety

precautions that may apply.

Follow all safety codes. In the United States, follow all safety

codes including the National Fuel Gas Code (NFGC) NFPA

54-1999/ANSI Z223.1-1999 and the Installation Standards, Warm

Air Heating and Air Conditioning Systems (NFPA 90B)

ANSI/NFPA 90B. In Canada, refer to the current edition of the

CAN/CGA-B149.1- and .2-M00 National Standard of Canada,

Natural Gas and Propane Installation Codes (NSCNGPIC). Wear

safety glasses and work gloves. Have a fire extinguisher available

during start-up and adjustment procedures and service calls.

Recognize safety information. This is the safety-alert symbol .

When you see this symbol on the furnace and in instructions or

manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION,

and NOTE. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in

severe personal injury or death. WARNING signifies hazards

which could result in personal injury or death. CAUTION is used

to identify unsafe practices which would result in minor personal

injury or product and property damage. NOTE is used to highlight

suggestions which will result in enhanced installation, reliability,

or operation.

These instructions cover minimum requirements and conform to

existing national standards and safety codes. In some instances,

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing residen-

tial construction practices. We require these instructions as a

minimum for a safe installation.

INTRODUCTION

The model 58TUA Series 130 furnace is available in sizes 40,000

through 133,000 Btuh input capacities.

The design of the upflow gas-fired furnace is CSA (A.G.A. and

C.G.A.) design-certified for use with natural and propane gases

and for installation on combustible wood flooring, in alcoves,

attics, basements, closets, or utility rooms. The design of this

furnace line is not CSA (A.G.A. and C.G.A.) design-certified for

installation in mobile homes, recreation vehicles, or outdoors.

Before installing the furnace in the United States, refer to the

current edition of the NFGC/NFPA 54/Z223.1 and the NFPA 90B.

For further information, the NFGC/NFPA 54/Z223.1 and NFPA

90B are available from National Fire Protection Association Inc.,

REGISTERED QUALITY SYSTEM

EFFICIENCY

RATING

CERTIFIED

Visit www.carrier.com

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4

Tab 6a 8a PC 101 Catalog No. 535–80044 Printed in U.S.A. Form 58TUA-8SI Pg 1 9-01 Replaces: 58TUA-7SI

Batterymarch Park, Quincy, MA 02269; or American Gas Asso-

ciation, 1515 Wilson Boulevard, Arlington, VA 22209.

Before installing the furnace in Canada, refer to the current edition

of the NSCNGPIC. Contact Standard Sales CSA International

Approval Services of Canada, 178 Rexdale Boulevard, Etobicoke,

(Toronto) Ontario, Canada M9W 1R3.

Canadian installations must be made in accordance with NSCNG-

PIC and all authorities having jurisdiction.

Installation must comply with regulations of serving gas supplier

and local building, heating, plumbing or other codes in effect in the

area in which installation is made. In absence of local codes,

installation must conform with NFGC.

These instructions cover minimum requirements for a safe instal-

lation and conform to existing national standards and safety codes.

In some instances, these instructions exceed certain local codes

and ordinances, especially those that may not have kept pace with

changing residential construction practices. We require these

instructions as a minimum for a safe installation.

Application of this furnace should be indoors with special

attention given to vent sizing and material, gas input rate, air

temperature rise, and unit sizing. Improper installation or

misapplication of the furnace can require excessive servicing

or cause premature component failure.

To aid in installation, troubleshooting, and service, a status code

label is located on the blower compartment door. This label

explains how to use the LED status indicator on the furnace control

which is viewed through the sight glass on the door.

Fig. 1—Dimensional Drawing

Table 1—Dimensions (IN.)

UNIT SIZE A D E FLUE COLLAR SHIP. WT

040-12 14-3/16 12-9/16 12-11/16 4 124

060-08 14-3/16 12-9/16 12-11/16 4 132

060-12 14-3/16 12-9/16 12-11/16 4 134

080-14 17-1/2 15-7/8 16 4 150

080-16 21 19-3/8 19-1/2 4 154

100-12 17-1/2 15-7/8 16 4 160

100-16 21 19-3/8 19-1/2 4 166

100-20 24-1/2 22-7/8 23 4 184

120-16 21 19-3/8 19-1/2 5* 178

120-20 24-1/2 22-7/8 23 5* 194

135-20 24-1/2 22-7/8 23 5* 204

* Oval collar

A00210

D13⁄16″

E11⁄16″

11⁄16″

28 1⁄2″

39 7⁄8″

24 5⁄16″

11⁄16″3″

2 1⁄16″

1″

12 5⁄16″

5 3⁄8″

5 13⁄16″

2 3⁄8″

AIR INLET

7⁄8-IN. DIA HOLE

POWER ENTRY

7⁄8-IN. DIA

ACCESSORY

1 3⁄4-IN.DIA HOLE

GAS ENTRY

1⁄2-IN. DIA HOLE

THERMOSTAT

WIRE ENTRY

SIDE INLET

VENT CONN

1. Two additional 7⁄8-in. dia holes are located in the top plate.

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

see flex duct manufacturer's recommendations for equivalent diameters.

a. For 800 CFM–16-in. round or 141⁄2x 12-in. rectangle.

b. For 1200 CFM–20-in. round or 141⁄2x 191⁄2-in. rectangle.

c. For 1600 CFM–22-in. round or 141⁄2x 231⁄4-in. rectangle.

d. For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific

use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the

bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

NOTES:

5 3⁄8″

5 13⁄16″

2 3⁄8″

2 11⁄16″

1″

2 1⁄16″19″

13⁄16″

7⁄8-IN. DIA

POWER ENTRY

AIRFLOW

OUTLET

1 1⁄2-IN.DIA

R.H. GAS ENTRY

7⁄8-IN. DIA ACCESSORY

1⁄2-IN. DIA THERMOSTAT

WIRE ENTRY

SIDE INLET 141⁄2″

1″

231⁄4″

SIDE RETURN

DUCT LOCATION

11⁄4″

TYP 1″

5⁄8″

TYP

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 injury or property damage. Consult a qualified

installer, service agency, local gas supplier, or your distribu-

tor or branch for information or assistance. The qualified

installer or agency must use only factory-authorized and

listed kits or accessories when modifying this product. A

failure to follow this warning can cause electrical shock, fire,

personal injury, or death.

For high-altitude installations, the high-altitude conversion kit

MUST be installed at or above 5500 ft above sea level. Obtain

high-altitude conversion kit from your area authorized distributor.

For accessory installation details, refer to applicable installation

literature.

NOTE: Remove all shipping brackets and materials before oper-

ating furnace.

NOTE: These furnaces are designed for a minimum continuous

return-air temperature of 60°F or intermittent operation down to

55°F such as when used with a night setback thermostat. Return-air

temperature must not exceed a maximum of 85°F. Failure to

follow these return-air temperature limits may affect reliability of

heat exchangers, motors, and controls (See Fig. 3.)

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing to

protect the furnace electronic control. Precautions will pre-

vent electrostatic discharges from personnel and hand tools

which are held during the procedure. These precautions will

help to avoid exposing the control to electrostatic discharge

by putting the furnace, the control, and the person at the same

electrostatic potential.

1. Disconnect all power to the furnace. DO NOT TOUCH THE

CONTROL OR ANY WIRE CONNECTED TO THE CON-

TROL PRIOR TO DISCHARGING YOUR BODY’S ELEC-

TROSTATIC CHARGE TO GROUND.

Fig. 2—Clearances to Combustibles

A98122

320325-101 REV. H

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

his forced air furn

nace is equipped for use with

atural gasat altitudes 0 - 10,000 ft (0-3,050m).

n accessory kit, supplied by the m

anufacturer,

all be used to convert to propane gas use or

y be required for some natural gas applications.

his

furnace is for indoor installation in

uilding constructed on site.

his f

urnace may be install

led on combustible

oor

ring in alcove or closet at minimum clearance

mcombustible material.

his furnace ma

y be used with a Type B-1 Vent

nd may be vented in common with other gas-fired

pliances.

Clearance in inches.

1" #

30"

MIN

SIDE

FRONT

BCK

SERVIE

FRONT

SIE

FRNACE

TOP / PLENUM

For furnaces wider than 14.25 inches

(362mm) may be 0 inches.

For single wall vent type 6 inches.

For Type B-1 vent type 3 inches.

Vent Clearance to combustibles:

For Single Wall vents 6 inches (6 po).

For Type B-1 vent type 1 inch (1 po).

This furnace is approved for UPFLOW installations only.

BOTTOM

DESSOUS

Fig. 3—Return-Air Temperature

A99075

FRONT

RETURN

AIR

MAX 85°F MIN 55°F

°F°F

2. Firmly touch a clean, unpainted, metal surface of the furnace

chassis which is close to the control. Tools held in a person’s

hand during grounding will be satisfactorily discharged.

3. After touching the chassis you may proceed to service the

control or connecting wires as long as you do nothing that

recharges your body with static electricity (for example; DO

NOT move or shuffle your feet, DO NOT touch ungrounded

objects, etc.).

4. If you touch ungrounded objects (recharge your body with

static electricity), firmly touch furnace again before touching

control or wires.

5. Use this procedure for installed and uninstalled (ungrounded)

furnaces.

6. Before removing a new control from its container, discharge

your body’s electrostatic charge to ground to protect the

control from damage. If the control is to be installed in a

furnace, follow items 1 through 5 before bringing the control

or yourself into contact with the furnace. Put all used AND

new controls into containers before touching ungrounded

objects.

7. An ESD service kit (available from commercial sources) may

also be used to prevent ESD damage.

LOCATION

Step 1—General

Do not use this furnace during construction when adhesives,

sealers, and/or new carpets are being installed and curing. If

the furnace is required during construction, use clean outside

air for combustion and ventilation. Compounds of chlorine

and fluorine, when burned in combustion air, form acids

which will cause corrosion of the heat exchangers and metal

vent system. Some of these compounds are released from

paneling and dry wall adhesives, paints, thinners, masonry

cleaning materials, and many other solvents commonly used

in the construction process. Excessive exposure to contami-

nated combustion air will result in safety and performance

related problems.

Do not install furnace in a corrosive or contaminated atmo-

sphere. Make sure all combustion and circulating air require-

ments are met in addition to all local codes and ordinances.

This furnace must be installed so the electrical components are

protected from water.

Locate furnace as near the center of the air distribution system and

chimney or vent as possible. The furnace should be installed as

level as possible. When a furnace is installed so that supply ducts

carry air to areas outside the space containing the furnace, return

air must also be handled by a duct(s) sealed to the furnace casing

and terminating outside the space containing the furnace.

Provide ample space for servicing and cleaning. Always comply

with the minimum fire protection clearances shown on furnace

clearance-to-combustible construction label. This furnace shall not

be installed directly on carpeting, tile, or any combustible material

other than wood flooring.

Step 2—Location Relative to Cooling Equipment

The cooling coil must be installed parallel with or on downstream

side of furnace to avoid condensation in heat exchangers. When

installed parallel with a furnace, dampers or other means used to

control flow of air must prevent chilled air from entering furnace.

If dampers are manually operated, they must be equipped with

means to prevent operation of either unit unless damper is in

full-heat or full-cool position.

Step 3—Hazardous Locations

When furnace is installed in a residential garage, it must be

installed so that burners and ignition sources are located a

minimum of 18 in. above floor. The furnace must be located

or protected to avoid physical damage by vehicles. When

furnace is installed in a public garage, airplane hangar, or

other building having a hazardous atmosphere, unit must be

installed in accordance with requirements of National Fire

Protection Association, Inc. (See Fig. 4.)

AIR FOR COMBUSTION AND VENTILATION

Provisions for adequate combustion and ventilation air must be

provided in accordance with Section 5.3, Air for Combustion and

Ventilation, of the NFGC or applicable provisions of the local

building codes.

Canadian installations must be in accordance with NSCNGPIC

and all authorities having jurisdiction.

Air for combustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and

iodide. These elements are found in aerosol sprays, deter-

gents, bleaches, cleaning solvents, salts, air fresheners, and

other household products.

All fuel-burning equipment must be supplied with air for combus-

tion of fuel. Sufficient air MUST be provided to ensure there will

not be a negative pressure in the equipment room or space. In

addition, a positive seal MUST be made between furnace cabinet

and return-air duct to prevent pulling air from burner area and draft

safeguard opening into the circulating air.

Fig. 4—Installation in a Garage

A93044

18-IN. MINIMUM

TO BURNERS

The operation of exhaust fans, kitchen ventilation fans,

clothes dryers, or fireplaces could create a NEGATIVE AIR

PRESSURE CONDITION at the furnace. Make-up air MUST

BE PROVIDED for these devices, in addition to that required

by the furnace.

Combustion and ventilation air requirements are determined by

whether the furnace is located in a CONFINED or UNCONFINED

space.

Step 1—Unconfined Space

An unconfined space has volume of at least 50 cu ft for each 1000

Btuh of total input for all appliances (such as furnaces, clothes

dryers, water heaters, etc.) in the space.

For Example:

If the unconfined space is of unusually tight construction, air for

combustion and ventilation MUST come from either the outdoors

or spaces freely communicating with the outdoors. Combustion

and ventilation openings must be sized the same as for a confined

space as defined below. Return air must not be taken from the

room unless an equal or greater amount of air is supplied to the

room.

Step 2—Confined Space

A confined space is defined as a space whose volume is less than

50 cu ft per 1000 Btuh of total input ratings of all appliances

installed in that space. A confined space MUST have provisions

for supplying air for combustion, ventilation, and dilution of flue

gases using 1 of the following methods. (See Fig. 5 and Table 2.)

NOTE: In determining free area of an opening, the blocking

effect of louvers, grilles, and screens must be considered. If free

area of louver or grille design is unknown, assume that wood

louvers have a 20 percent free area and metal louvers or grilles

have a 60 percent free area. Screens, when used, must not be

smaller than 1/4-in. mesh. Louvers and grilles must be constructed

so they cannot be closed.

The size of the openings depends upon whether air comes from

outside of the structure or an unconfined space inside the structure.

1. All air from inside the structure requires 2 openings (for

structures not unusually tight):

a. Each opening MUST have at least 1 sq in. of free area per

1000 Btuh of total input for all equipment within the

confined space, but not less than 100 sq in. per opening.

(See Fig. 5 and Table 2.) The minimum dimension of air

openings shall not be less than 3 in.

b. If building is constructed unusually tight, a permanent

opening directly communicating with the outdoors shall be

provided. (See item 2 below.)

c. If furnace is installed to obtain a return-air directly from

hallway or space adjacent to furnace, all air for combustion

must come from outdoors.

2. Air from outside the structure requires 1 of the following

methods:

Table 2—Free Area of Combustion Air Opening*

58TUA

FURNACE

HIGH-FIRE

INPUT

(BTUH)

AIR FROM

UNCONFINED SPACE OUTDOOR AIR THROUGH

VERTICAL DUCTS OUTDOOR AIR THROUGH

HORIZONTAL DUCTS OUTDOOR AIR THROUGH

SINGLE DUCT

Free Area

of Opening

(Sq In.)

Free Area of

Opening and Duct

(Sq In.)

Round

Pipe

(In. Dia)

Free Area of

Opening and Duct

(Sq In.)

Round

Pipe

(In. Dia)

Free Area of

Opening and Duct

(Sq In.)

Round

Pipe

(In. Dia)

40,000 100 10.0 4 20.0 6 13.4 5

60,000 100 15.0 5 30.0 7 20.0 6

80,000 100 20.0 6 40.0 8 26.7 6

100,000 100 25.0 6 50.0 8 33.4 7

120,000 120 30.0 7 60.0 9 40.0 8

133,000 133 33.3 7 66.5 10 44.4 8

58TUA FURNACE HIGH-FIRE

INPUT BTUH MINIMUM SQ FT WITH

7-1/2 FT CEILING

40,000 267

60,000 400

80,000 534

100,000 667

120,000 800

133,000 887

Fig. 5—Confined Space: Air for Combustion and

Ventilation from an Unconfined Space

A89012

SUPPLY

AIR

6″MIN

(FRONT) †

RETURN AIR

VENT THROUGH ROOF

1 SQ IN.

PER 1000

BTUH*IN DOOR

OR WALL

12″MAX

1 SQ IN.

PER 1000

BTUH*IN DOOR

OR WALL

12″MAX

INTERIOR

HEATED

SPACE

* Minimum opening size is 100 sq in. with

minimum dimensions of 3 in.

†Minimum of 3 in. when type-B1 vent is used.

UNCONFINED

SPACE

CONFINED

SPACE

a. If combustion air is taken from outdoors through 2 vertical

ducts, the openings and ducts MUST have at least 1 sq in.

of free area per 4000 Btuh of total input for all equipment

within the confined space. (See Fig. 6 and Table 2.)

b. If combustion air is taken from outdoors through 2 hori-

zontal ducts, the openings and ducts MUST have at least 1

sq in. of free area per 2000 Btuh of total input for all

equipment within the confined space. (See Fig. 6 and Table

2.)

c. If combustion air is taken from outdoors through a single

opening or duct (horizontal or vertical) commencing within

12 in. of the top of the confined space, opening and duct

MUST have at least 1 sq in. of free area per 3000 Btuh of

the total input for all equipment within the confined space

and not less than the sum of the areas of all vent connectors

in the confined space. (See Fig. 6 and Table 2.) Equipment

clearances to the structure shall be at least 1 in. from the

sides and back and 6 in. from the front of the appliances.

When ducts are used, they must be of the same cross-sectional area

as the free area of the openings to which they connect. The

minimum dimension of ducts must not be less than 3 in. (See Fig.

6.)

Do not install furnace on its back. Safety control operation

will be adversely affected. Never connect return-air ducts to

back of furnace. Failure to follow this warning could result in

fire, personal injury, or death. (See Fig. 7.)

INSTALLATION

Step 1—Air Ducts

GENERAL REQUIREMENTS

The duct system should be designed and sized according to

accepted national standards such as those published by: Air

Conditioning Contractors Association (ACCA), Sheet Metal and

Air Conditioning Contractors National Association (SMACNA) or

American Society of Heating, Refrigerating and Air Conditioning

Engineers (ASHRAE) or consult factory The Air Systems Design

Guidelines reference tables available from your local distributor.

The duct system should be sized to handle the required system

design airflow CFM at the design external static pressure.

When a furnace is installed so that the supply ducts carry air to

areas outside the space containing the furnace, the return air must

also be handled by a duct(s) sealed to the furnace casing and

terminating outside the space containing the furnace.

Secure ductwork with proper fasteners for type of ductwork used.

Seal supply- and return-duct connections to furnace with code

approved tape or duct sealer.

Flexible connections should be used between ductwork and

furnace to prevent transmission of vibration. Ductwork passing

through unconditioned space should be insulated to enhance

system performance. When air conditioning is used, a vapor

barrier is recommended.

Maintain a 1-in. clearance from combustible materials to supply air

ductwork for a distance of 36 in. horizontally from the furnace. See

NFPA 90B or local code for further requirements.

DUCTWORK ACOUSTICAL TREATMENT

Metal duct systems that do not have a 90 degree elbow and 10 ft

of main duct to the first branch take-off may require internal

acoustical lining. As an alternative, fibrous ductwork may be used

if constructed and installed in accordance with the latest edition of

SMACNA construction standard on fibrous glass ducts. Both

acoustical lining and fibrous ductwork shall comply with NFPA

90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Fig. 6—Confined Space: Air for Combustion and

Ventilation from Outdoors

A89013

1 SQ IN.

PER

4000

BTUH*

DUCTS

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

SUPPLY

AIR

VENT

THROUGH

ROOF

1 SQ IN.

PER 4000

BTUH*

DUCT

OUTDOORS

RETURN AIR

1 SQ IN.

PER 2000

BTUH*

1 SQ IN.

PER 2000

BTUH*

DUCTS

OUTDOORS

12″MAX

12″MAX 12″MAX

Use any of the following

combinations of openings:

A & B C & D D & E F & G

NOTE:

*Minimum dimensions of 3 in.

CONFINED

SPACE

12″

MAX

12″

MAX

OUTDOORS

1 SQ IN.

PER

4000

BTUH*

Fig. 7—Prohibit Installation on Back

A93043

FRONT

BACK

FRONT

SUPPLY AIR CONNECTIONS

Upflow Furnaces

Connect supply-air duct to 3/4-in. flange on furnace supply-air

outlet. The supply-air duct attachment must ONLY be connected

to furnace supply-/outlet-air duct flanges or air conditioning coil

casing (when used). DO NOT cut main furnace casing to attach

supply side air duct, humidifier, or other accessories. All accesso-

ries MUST be connected external to furnace main casing.

RETURN AIR CONNECTIONS

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.

Upflow Furnaces

The return-air duct must be connected to bottom, sides (left or

right), or a combination of bottom and side(s) of main furnace

casing as shown in Fig. 1. Bypass humidifier may be attached into

unused side return air portion of the furnace casing. DO NOT

connect any portion of return-air duct to back of furnace casing.

Step 2—Filter Arrangement

The air filter arrangement will vary due to application and filter

type. The filter may be installed in an external Filter/Media cabinet

(if provided) or the furnace blower compartment. Factory supplied

washable filters are shipped in the blower compartment.

If a factory-supplied external Filter/Media cabinet is provided,

instructions for its application, assembly, and installation are

packaged with the cabinet. The Filter/Media cabinet can be used

with the factory- supplied washable filter or a factory-specified

high-efficiency disposable filter (see cabinet instructions).

If installing the filter in the furnace blower compartment, deter-

mine location for the filter and relocate filter retaining wire if

necessary. See Fig. 8 for side return application and Fig. 9 for

bottom return application. See Table 3 to determine correct filter

size for desired filter location. Table 3 indicates filter size,

location, and quantity shipped with the furnace.

For bottom air-return applications, filter may need to be cut to fit

some furnace casing widths. A bottom closure panel is factory

installed in the bottom of the furnace. When bottom return inlet is

desired, remove and discard the bottom closure panel. Two sets of

hardware are needed for furnaces in 24-1/2-in. wide casings using

2 filters for bottom return. All hardware is provided for filter

installation.

NOTE: Furnaces with a 17-1/2-in. wide casing require an addi-

tional procedure when locating the filter for bottom return-air

application. Field fabricate a sheet metal filler strip1X3X24-1/2

in. and install it along side of the filter as shown in Fig. 9. Drive

Fig. 8—Side Filter Arrangement

(Control Removed for Clarity)

A93045

FILTER

RETAINER

WASHABLE

FILTER

Fig. 9—Bottom Filter Arrangement

(Control Removed for Clarity)

A00290

WASHABLE

FILTER

SUPPORT

FILTER

RETAINER

171⁄2-IN.WIDE

CASINGS ONLY:

INSTALL FIELD-SUPPLIED

FILTER FILLER STRIP

UNDER FILTER.

1″

24 1/2″

3″

21-IN.WIDE

CASINGS ONLY:

SUPPORT RODS (3)

EXTEND 1/4" ON EACH

SIDE OF FILTER AND

REST ON CASING FLANGE

Table 3—Filter Information (IN.)

FURNACE

CASING WIDTH FILTER SIZE* FILTER

TYPE

Side Return Bottom Return

14-3/16 (1)16X25X1†(1) 14 X 25 X 1 Cleanable

17-1/2 (1)16X25X1†(1)16X25X1†Cleanable

21 (1)16X25X1 (1)20X25X1†Cleanable

24-1/2 (1or2)16X25X1 (1)24X25X1†Cleanable

* Filters may be field modified by cutting filter material and support rods (3) in

filters. Alternate sizes can be ordered from your distributor or dealer.

†Factory provided with furnace.

2 screws through the casing side and into the filler strip to secure

it in place. Filter should rest on the top of the filler strip when

installed.

Never operate unit without a filter or with filter access door

removed. Failure to follow this warning can cause fire,

personal injury, or death.

Step 3—Leveling Legs (If Required)

When furnace is used with side inlet(s) and leveling legs are

required, refer to Fig. 10 and install field-supplied, corrosion-

resistant 5/16-in. machine bolts and nuts.

NOTE: The length of the bolt should not exceed 1-1/2 in.

1. Lay furnace on its back. Locate and drill 5/16-in. diameter

hole in each bottom corner of furnace as shown in Fig. 10.

2. Install nut on bolt and install bolt with nut in hole. (Install flat

washer if desired.)

3. Install another nut on other side of furnace base. (Install flat

washer if desired.)

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

nut to secure arrangement.

Step 4—Gas Piping

Gas piping must be installed in accordance with national and local

codes. Refer to the NFGC. Canadian installations must be installed

in accordance with NSCNGPIC and all authorities having juris-

diction.

The gas supply line should be a separate line running directly from

gas meter to furnace, if possible. Refer to Table 4 for recom-

mended gas pipe size. Risers must be used to connect furnace to

gas meter.

If a flexible connector is required or allowed by the authority

having jurisdiction, black iron pipe shall be installed at the

gas valve and extend a minimum of 2 in. outside the furnace

casing.

Piping should be pressure tested in accordance with local and

national plumbing and gas codes before furnace has been attached.

If test pressure exceeds 0.5 psig (14-in. wc), the gas supply pipe

must be disconnected from the furnace and capped before pressure

test. If test pressure is equal to or less than 0.5 psig (14-in. wc),

turn OFF electric shutoff switch before test. (See Fig. 10.) It is

recommended that the ground joint union be loosened before

pressure testing. After all connections have been made, purge lines

and check for leakage with regulated gas supply pressure.

Install a sediment trap in riser leading to furnace. The trap can be

installed by connecting a tee to riser leading from the furnace.

Connect a capped nipple into lower end of the tee. The capped

nipple should extend below level of gas controls. (See Fig. 11.)

Apply joint compound (pipe dope) sparingly and only to male

threads of each joint. The compound must be resistant to action of

propane gas.

Install an accessible manual shutoff valve upstream of furnace gas

controls and within 72 in. of furnace. A 1/8-in. NPT plugged

tapping is provided on the gas valve for test gage connection.

Installation of an additional 1/8-in. NPT plugged tapping, acces-

sible for test gage connection, installed immediately upstream of

gas supply connection to furnace and downstream of manual

shutoff valve, is not required. Place ground joint union between

gas control manifold and manual shutoff valve.

Use the proper length of pipes to avoid stress on the gas

control manifold. A failure to follow this warning can cause

a gas leak resulting in a fire, explosion, personal injury, or

death.

Use a backup wrench at the furnace gas control when

connecting the gas pipe to the furnace to avoid damaging gas

controls or manifold.

Fig. 10—Leveling Leg Installation

A89014

1 3⁄4″

5⁄16″

Table 4—Maximum Capacity of Gas Pipe*

NOMINAL

IRON PIPE

SIZE (IN.)

INTERNAL

DIAMETER

(IN.)

LENGTH OF PIPE (FT)

10 20 30 40 50

1/2 0.622 175 120 97 82 73

3/4 0.824 360 250 200 170 151

11.049 680 465 375 320 285

1-1/4 1.380 1400 950 770 660 580

1-1/2 1.610 2100 1460 1180 990 900

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a

supply line pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas).

Ref: Table 10-2, NFPA 54–1999.

Never purge a line into a combustion chamber. Never use

matches, candles, flame, or other sources of ignition for the

purpose of checking leakage. Use a soap-and-water solution

to check for leakage. A failure to follow this warning can

cause a fire, explosion, personal injury, or death.

Step 5—Electrical Connections

115-V WIRING

Refer to the unit rating plate or Table 5 for equipment electrical

requirements. The control system requires an earth ground for

proper operation.

Do not connect aluminum wire between disconnect switch

and furnace. Use only copper wire.

Make all electrical connections in accordance with the National

Electrical Code (NEC) ANSI/NFPA 70-1999 and local codes or

ordinances that apply. For Canadian installations, all electrical

connections must be made in accordance with CSA C22.1 Cana-

dian Electrical Code, or authorities having jurisdiction.

The cabinet MUST have an uninterrupted or unbroken ground

according to NEC ANSI/NFPA 70-1999 and Canadian Elec-

trical Code, CSA C22.1 or local codes to minimize personal

injury if an electrical fault should occur. This may consist of

electrical wire or conduit approved for electrical ground when

installed in accordance with existing electrical codes. Do not

use gas piping as an electrical ground. Failure to follow this

warning could result in electrical shock, fire, or death.

The junction box can be moved to left-hand side of furnace when

a left-hand side power supply is desired. Remove 2 screws holding

the junction box. Mount junction box on left-hand side of furnace.

Holes have been provided in casing. When moved, tuck wiring

harness behind clip provided to keep extra wire lengths out of the

way.

NOTE: Proper polarity must be maintained for 115-v wiring. If

polarity is incorrect, the furnace control status LED will flash

rapidly and prevent heating operation.

24-V WIRING

Refer to ESD Precautions Procedure before proceeding with 24-v

connections.

Make field 24-v connections at 24-v terminal block. (See Fig. 14.)

Connect terminal Y/Y2 as shown in Fig. 12 or 13 for proper

cooling operation. Use only AWG No. 18 or larger, color-coded

copper thermostat wire.

The 24-v circuit contains an automotive-type, 3-amp fuse located

on main control. Any 24-v electrical shorts during installation,

service, or maintenance could cause this fuse to blow. If fuse

replacement is required, use ONLY a 3-amp fuse. The control will

flash code 24 when fuse needs replacement.

ACCESSORIES

1. Electronic air cleaner (EAC)

A terminal block (EAC-1 and EAC-2 ) is provided for EAC

connection. (See Fig. 14.) The terminals are energized with

115v, 1-amp maximum during blower motor operation.

2. Humidifier (HUM)

Screw terminals (HUM and COM) are provided for 24-v

humidifier connection. The terminals are energized with 24v,

0.5-amp maximum when the gas valve is energized.

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 connec-

tion. A failure to follow this warning could result in fire.

NOTE: A field-supplied, 115-v controlled relay connected to

EAC terminals may be added, if humidifier operation is desired

during blower operation.

Step 6—Venting

Refer to the enclosed Installation Instructions, (Vent Tables For 1-

and 2-Stage Category I Fan-Assisted Furnaces) for quick, easy

reference, and national or local installation code such as National

Fuel Gas Code NFPA 54-1999/ANSI Z223.1-1999 in the United

States, or the National Standard of Canada Natural and Propane

Installation Codes CAN/CGA- B149.1- and .2-M00 in Canada, for

proper vent sizing and installation requirements.

After fully assembling the vent connector to the furnace flue collar,

securely fasten the vent connector to the collar with 2 field-

supplied, corrosion-resistant, sheet metal screws located 180

degrees apart and midway up the collar.

The horizontal portion of the venting system shall maintain a

minimum of 1/4-in. upward slope per linear ft, and it shall be

rigidly supported every 5 ft or less with hangers or straps to ensure

that there will be no movement after installation.

START-UP, ADJUSTMENT AND SAFETY CHECK

Step 1—General

The furnace must have a 115-v power supply properly connected

and grounded. Correct polarity must be maintained to enable gas

heating operation.

The gas service pressure must not exceed 0.5 psig (14-in. wc), and

no less than 0.16 psig (4.5-in. wc).

Thermostat wire connections at R and W/W1 are the minimum

required for gas heating operation. W2 must be connected for

Fig. 11—Typical Gas Pipe Arrangement

A89417

GAS

SUPPLY

MANUAL

SHUTOFF

VALVE

(REQUIRED)

SEDIMENT

TRAP

UNION

2-stage heating thermostats. COM, Y/Y2, and G are required for

cooling, heat pumps, and some clock thermostats. These must be

made at the 24-v terminal block on the control. (See Fig. 14.)

This furnace can be installed with either a single-stage heating or

a 2-stage heating thermostat.

For single-stage thermostats, connect thermostat W to W/W1 at

furnace control terminal block. (See Fig. 12.) For single-stage

thermostats, the control will determine, based on length of previ-

ous heating on and off cycles, when to operate in low- and

high-gas heat for optimum comfort. Setup switch-2 (SW-2) must

be in the factory-shipped OFF position. See Fig. 15 and Tables 6

and 7 for setup switch information.

If a 2-stage heating thermostat is to be used, move SW-2 to ON

position at end of furnace installation. This overrides built-in

control process for selecting high and low fire and allows the

2-stage thermostat to select gas heating modes. The W2 from

thermostat must be connected to W2 on control terminal block.

(See Fig. 13.)

This furnace is equipped with a manual reset limit switch in

the gas control area. The switch will open and shut off power

to the gas valve if a flame rollout or overheating condition

occurs in the gas control area. DO NOT bypass the switch.

Correct inadequate combustion-air supply, component fail-

ure, or restricted flue gas passageway before resetting the

switch.

Before operating furnace, check each manual reset switch for

continuity. If necessary, press and release button to reset switch.

Step 2—Sequence of Operation

Using schematic diagram in Fig. 16, follow the sequence of

operation through the different modes. Read and follow diagram

very carefully.

NOTE: If power interruption occurs during ″call for heat″(W/W1

or W/W1 and W2) and if the thermostat is still calling for gas

Table 5—Electrical Data

UNIT SIZE VOLTS—

HERTZ—

PHASE

OPERATING

VOLTAGE RANGE MAX

UNIT

AMPS

MIN

WIRE

GAGE

MAX WIRE

LENGTH (FT)‡MAX FUSE OR

CKT BKR AMPS†

Max* Min*

040-12 115—60—1 127 104 11.4 14 32 15

060-08 115—60—1 127 104 8.2 14 45 15

060-12 115—60—1 127 104 10.6 14 34 15

080-12 115—60—1 127 104 11.7 14 31 15

080-16 115—60—1 127 104 13.4 14 27 15

100-12 115—60—1 127 104 10.5 14 35 15

100-16 115—60—1 127 104 13.2 14 28 15

100-20 115—60—1 127 104 17.7 12 32 20

120-16 115—60—1 127 104 13.2 14 28 15

120-20 115—60—1 127 104 18.2 12 31 20

135-20 115—60—1 127 104 17.4 12 33 20

* Permissible limits of the voltage range at which the unit will operate satisfactorily.

†Time-delay fuse is recommended.

‡Length shown is as measured along wire path between unit and service panel for maximum 2 percent voltage drop.

Fig. 12—Heating and Cooling Application Wiring Diagram 1–Stage Thermostat and Condensing Unit

A99071

115-V FUSED

DISCONNECT

SWITCH

(WHEN REQUIRED)

JUNCTION

BOX CONTROL

BOX

24-V

TERMINAL

BLOCK

TWO-WIRE

HEATING-

ONLY

FIVE

WIRE

1-STAGE THERMOSTAT TERMINALS

FIELD-SUPPLIED

FUSED DISCONNECT

CONDENSING

UNIT

FURNACE

COM

WYRG

GND GND

FIELD 24-V WIRING

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

FACTORY 24-V WIRING

FACTORY 115-V WIRING

208/230- OR

460-V

THREE

PHASE

208/230-V

SINGLE

PHASE

WHT

BLK

WHT

BLK

W/W1

Y/Y2

NOTES: 1. Connect Y-terminal as shown for proper operation.

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

3. If any of the original wire, as supplied, must be replaced,

use same type or equivalent wire.

heating, the control will start a 90-sec blower only on period 2 sec

after power is restored. The red LED will flash code 12 during

90-sec period, after which the LED will be on continuously as long

as no faults are detected. After 90-sec period, furnace will respond

to the thermostat normally.

The blower door must be installed for power to be conducted

through blower door interlock switch ILK to furnace control CPU,

transformer TRAN, inducer motor IDM, blower motor BLWM,

hot surface ignitor HSI, and gas valve GV.

1. Adaptive Heating Mode—Single-Stage Thermostat with

2-Stage Heating

(See Fig. 12 for thermostat connections.)

NOTE: With high-heat-only switch SW-1 off, low-heat-only

switch SW-2 selects either the low-heat-only operation mode when

on (see item 2 below), or adaptive heating mode when off in

response to a call for heat. (See Fig. 14.) When high-heat-only

switch (SW-1) is in ON position, it always causes high-gas-heat

operation when R-W/W1 circuit is closed, regardless of setting of

low-heat-only switch (SW-2).

This furnace can operate as a 2-stage furnace with a single-stage

thermostat because furnace control CPU includes a programmed

adaptive sequence of controlled operation, which selects low-gas-

heat or high-gas-heat operation. This selection is based upon the

stored history of the length of previous gas heating on/off periods

of the single-stage thermostat.

The furnace will start up in either low- or high-gas heat. If the

furnace starts up in low-gas heat, the control CPU determines the

low-gas heat on time (from 0 to 16 minutes) which is permitted

before switching to high-gas heat.

If power is interrupted, the stored history is erased. When this

happens, the control CPU selects low-gas heat for up to 16 minutes

and then switches to high-gas heat, as long as the thermostat

continues to call for heat. Subsequent selection is based on stored

history of thermostat cycle times.

Fig. 13—Heating and Cooling Application Wiring Diagram 2-Stage Thermostat and Condensing Unit

A99072

115-V FUSED

DISCONNECT

SWITCH

(WHEN REQUIRED)

JUNCTION

BOX CONTROL

BOX

24-V

TERMINAL

BLOCK

THREE-WIRE

HEATING-

ONLY

SEVEN

WIRE

2-STAGE THERMOSTAT TERMINALS

FIELD-SUPPLIED

FUSED DISCONNECT

2-SPEED

CONDENSING

UNIT

FURNACE

W2 Y2 G Y1 C

GND GND

FIELD 24-V WIRING

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

FACTORY 24-V WIRING

FACTORY 115-V WIRING

208/230- OR

460-V

THREE

PHASE

208/230-V

SINGLE

PHASE

WHT

BLK

WHT

BLK

W1 R

COM

W/W1

Y/Y2

NOTES: 1. Connect Y-terminal as shown for proper operation.

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

3. If any of the original wire, as supplied, must be replaced,

use same type or equivalent wire.

Table 6—Setup Switch Description

SETUP

SWITCH NO. NORMAL

POSITION DESCRIPTION

OF USE

SW-1

Only High-Gas Heat OFF (Staged Gas Heat) Turn switch on to obtain only high-gas-heat operation on

any call for heat regardless of whether R-W/W1, or

R-W/W1, -W2 is closed. SW-1 overrides SW-2.

SW-2

Low-Gas Heat (Adaptive Mode) OFF (Single-Stage Thermostat)

Turn switch off for installations with single-stage thermo-

stats; control selects low-gas-heat or high-gas-heat opera-

tion based on previous cycles. Turn switch on for installa-

tions with 2-stage thermostats to permit only low-gas-heat

operation in response to closing R-W/W1. High-gas heat is

supplied only when R to W/W1 and W2 are closed.

SW-3 and SW4 ON, OFF Switches control gas heating mode blower-off delay. (See

Table 8.)

Table 7—Blower-Off Delay Setup

Switch (SW) Position

DESIRED HEATING

MODE BLOWER-OFF

DELAY (SEC)

SETUP SWITCH

SW-3 SW-4

90 OFF OFF

135 OFF ON

180 ON OFF

225 ON ON

When wall thermostat ″calls for heat″, R-W/W1 circuit closes. The

furnace control performs a self check, verifies the low-heat and

high-heat pressure switch contacts LPS and HPS are open, and

starts inducer motor IDM in low speed or high speed as appropri-

ate.

a. Inducer prepurge period—As inducer motor IDM comes up

to low speed or high speed, the low-heat pressure switch

contacts LPS (or LPS and HPS) close to begin a 15 sec

prepurge period.

b. Ignitor warm-up—At end of prepurge period, the hot

surface ignitor HSI is energized for a 17-sec ignitor

warm-up period.

c. Trial-for-ignition sequence—When ignitor warm-up period

is completed, the main gas valve relay contacts MGVR-1

and -2 close to energize the low-heat gas valve solenoid

GV. The gas valve opens, and 24-v power is supplied for a

field-installed humidifier at terminals HUM and COM. The

low-heat gas valve solenoid GV permits gas flow to the

burners where it is ignited. After 5 sec, the ignitor HSI is

de-energized, and a 2-sec flame-proving period begins.

If high-heat gas valve solenoid GV is also energized after

normally closed high-heat pressure switch relay HPSR

closes and after inducer motor IDM goes to high speed and

provides sufficient pressure to close high-heat pressure

switch HPS. HPSR is open while furnace is powered in

standby mode. If high-heat pressure switch HPS fails to

close and low-heat pressure switch LPS closes, furnace

operates at low-heat gas flow rate until high-heat pressure

switch closes.

d. Flame-proving—When burner flame is proved at flame-

proving sensor electrode FSE, the control CPU begins

blower on delay period and continues to hold gas valve GV

open. If burner flame is not proved within 2 sec, the control

CPU closes gas valve GV, and the control CPU repeats the

ignition sequence for up to 3 more trials-for-ignition before

going to ignition lockout. LOCKOUT IS RESET AUTO-

MATICALLY after 3 hr, or by momentarily interrupting

115-v power to furnace, or by interrupting 24-v power at

SEC1 or SEC2 to the control CPU (not at W/W1, G, R,

etc.). Opening thermostat R-W circuit will not reset an

ignition lockout.

If flame is proved when flame should not be present, the

control CPU locks out of gas heating mode and operates

inducer motor IDM on high speed until flame is no longer

proved.

e. Blower on delay—If burner flame is proven, 45 sec after

gas valve GV is opened the blower motor BLWM is

energized on the appropriate heating speed, low-gas-heat or

high-gas-heat speed. Simultaneously, the EAC terminals

EAC-1 and EAC-2 are energized with 115v and remain

energized as long as blower motor BLWM is energized.

f. Switching from low- to high-gas heat—If furnace control

CPU switches from low-gas heat to high-gas heat, the

control CPU switches inducer motor IDM speed from low

to high. The high-heat pressure switch relay HPSR closes.

When inducer motor IDM provides sufficient pressure to

close the high-heat pressure switch HPS, the high-heat gas

valve solenoid GV is energized. The blower motor BLWM

switches speed for high-gas heat 5 sec after the control CPU

switches from low-gas heat to high-gas heat.

g. Switching from high- to low-gas heat—The control CPU

will not switch from high-gas heat to low-gas heat while

the thermostat R to W circuit is closed when a single-stage

thermostat is used.

h. Blower off delay—When thermostat is satisfied, the R-W

circuit is opened, de-energizing gas valve GV, stopping gas

flow to burners, and de-energizing humidifier terminals

HUM and COM. The inducer motor IDM remains energized

for a 5 sec post-purge period. The blower motor BLWM

and EAC terminals EAC-1 and EAC-2 remain energized

for 90, 135, 180, or 225 sec (depending on selection at

blower off delay switches SW-3 and SW-4). The furnace

control CPU is factory set for a 135-sec blower off delay.

2. Non-Adaptive Heating Mode—Two-Stage Thermostat and

2-Stage Heating

(See Fig. 13 for thermostat connections).

NOTE: The low-heat-only switch SW-2 in ON position selects

low-heat-only operation mode in response to closing the thermo-

stat R-W1 circuit. When high-heat-only switch SW-1 is in OFF

position, closing the thermostat R to W1 and W2 circuits is

Fig. 14—Control Center

A01370

123

456

78 9

PR2

COM

PR1

HI-COOL

HI-GAS

-HEAT

LO-GAS

-HEAT

PARK

FU1

SEC-1

SEC-2

123

456

789

10 11 12

M S

TWIN

TEST

LED

GRY/Y2W/W1COM

24 V

OFF

1234

FURNACE AND

BLOWER OFF DELAY

SETUP SWITCHES

24-VOLT

THERMOSTAT

TERMINALS

EAC - ELECTRONIC

AIR CLEANER

(115-VAC 1 AMP MAX) 3-AMP

FUSE

LED -

DIAGNOSTIC

LIGHT

TWIN / TEST

TERMINAL

HUM -

HUMIDIFIER

(24-VAC 0.5

AMP MAX)

HUM

Fig. 15—Setup Switches on Control Center

(Factory Settings)

A96402

BLOWER-

OFF

DELAY

LOW

HEAT

(ADAPTIVE

ALGORITHM)

HIGH

HEAT

ONLY

43 2 OFF

→

→Fig. 16—Wiring Diagram A01365

LEGEND

ALS1 AUXILIARY LIMIT SWITCH, OVERTEMP. MANUAL RESET, SPST (N.C.)

ALS2 AUXILIARY LIMIT SWITCH, OVERTEMP. AUTO RESET, SPST (N.C.)

BHI / LOR BLOWERMOTOR SPEED CHANGE RELAY, SPDT

BHT / CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT

BLWM BLOWER MOTOR, 4 or 5 -SPEED, PERMANENT-SPLIT-CAPACITOR

BLWR BLOWER MOTOR RELAY, SPST (N.O.)

CAP CAPACITOR

CPU MICROPROCESSOR AND CIRCUITRY

DSS DRAFT SAFEGUARD SWITCH (N.C.)

EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC, 1 AMP MAX.)

EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)

FRS1 FLAMEROLLOUT SWITCH OVERTEMP. MANUAL RESET, SPST (N.C.)

FRS2 FLAMEROLLOUT SWITCH OVERTEMP. MANUAL RESET, SPST (N.C.)

FSE FLAME-PROVING SENSOR ELECTRODE

FU1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED

FU2 FUSE, FIELD INSTALLED

GV GAS VALVE, REDUNDANT LOW-HEAT OPERATORS, 2-STAGE

HPS HIGH-HEAT PRESSURE SWITCH, SPST (N.O.)

HPSR HIGH-HEAT PRESSURE SWITCH RELAY, SPST (N.C.)

HSI HOT-SURFACE IGNITER (115 VAC)

HSIR HOT-SURFACE IGNITOR RELAY, SPST (N.O.)

HUM 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)

IDM INDUCED DRAFT MOTOR, 2-SPEED, SHADED-POLE

IDR INDUCER MOTOR RELAY, SPST (N.O.)

IHI / LOR INDUCER MOTOR SPEED CHANGE RELAY, SPDT

ILK BLOWER DOORINTERLOCK SWITCH, SPST (N.O.)

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STATUS CODES

LGPS LOW GAS-PRESSURE SWITCH, SPST (N.O.)

LPS LOW-HEAT PRESSURE SWITCH, SPST (N.O.)

LS LIMIT SWITCH, OVERTEMPERATURE-AUTO RESET, SPST (N.C.)

MGVR MAIN GAS VALVE RELAY, DPST (N.O.)

1 = VALVE

2 = HUMIDIFIER

PL1 12-CIRCUIT CONNECTOR

PL2 9-CIRCUIT CONNECTOR

PL3 3-CIRCUIT IDM CONNECTOR

PL6 2-CIRCUIT HSI CONNECTOR

SW1 HIGH-HEAT-ONLY SWITCH, SPST (MANUAL)

SW2 LOW-HEAT-ONLY SWITCH, SPST (MANUAL)

SW3 & 4 BLOWER-OFF DELAY SETTING SWITCHES,

SPST (MANUAL)

TJ TWINNING JUMPER, SPDT FOR MAIN OR

SECONDARY STATUS (MANUAL CHANGE OVER)

TRAN TRANSFORMER-115VAC/24VAC

TWIN/TEST 1-CIRCUIT TWINNING BUSSCONNECTOR,

ALSO STATUS CODE RECALL

JUNCTION

TERMINAL

CONTROL TERMINAL

FACTORY POWER WIRING (115VAC)

FACTORY CONTROL WIRING (24VAC)

FIELD POWER WIRING (115VAC)

FIELD CONTROL WIRING (24VAC)

CONDUCTOR ON CONTROL

FIELD WIRING SCREW TERMINAL

FIELD GROUND

EQUIPMENT GROUND

FIELD SPLICE

PLUG RECEPTACLE

NOTES:

1. Use only copper wire between the disconnect switch and

the unit.

2. If any of the original wire, as supplied, must be replaced,

use the same or equivalent type wire.

3. Inducer (IDM) and blower (BLWM) motors contain

internal auto-reset thermal overload switches.

4. Blower motor speed selections are for average

conditions. See Installation Instructions for details on

optimum speed selection.

5. Replace only with a 3-AMP fuse.

6. Auxiliary limit switches (ALS1 & 2) used on some

horizontal and some downflow models.

7. This wire must be connected to furnace sheet metal for

control to prove flame.

8. Factory connected when LGPS not used.

RED

LS FRS2

FRS1

(WHEN USED) ALS1

DSS

ORN

LGPS

YEL

NOTE #8

LPS

NOTE #8

(WHEN USED)

NOTE #6

ALS2

SWITCH

HEAT

SET-UP

SWITCH

NORM

HI HT

LO HT

OFF

BLOWER-

OFF DELAY

(SEC.) SWITCH

90 SEC

135 SEC

180 SEC

225 SEC

OFF

2-STAGE

FURNACE

CONTROL

FACTORY

SETTINGS

1234

OFF

321

BLU

BLOWER-OFF DELAY

LOW-HEAT ONLY

HIGH-HEAT ONLY

W2 Com

24V W/W1 Y/Y2 R G HUM LED S

TWIN

TEST

12 11 10

WHT

321

987

FSE

HPS HI

IDM

HSI

ILK JB

PL6

123

PL3

PL2

PR1 PR2

L1 L2

COMMON

HI-COOL

HI-GAS

HEAT EAC-2

EAC-1

LO-GAS

HEAT

SPARE

SEC1

FU1

SEC2

NOTE #4

BLWM

BRN BRN

CAP

TRAN

FUSED DISCONNECT

SWITCH (WHEN REQ’D)

NOTE #1

BLK

WHT

GND

L2 FU2

CONNECTION DIAGRAM

L1 BLWR

TO 115VAC FIELD

DISCONNECT SWITCH NOTE #1

LO-GAS-HEAT

HI-GAS-HEAT

SPARE

NOTE #4

COMMON

HSIR EAC-1 EAC-2

31HSI

PL2

PR2

115VAC

PR1

TRAN

24VAC

IDR

ILK

IDM

BLWM

BHI / LOR

BHT / CLR

CAP

BRN

PL6

IHI / LOR

SEC1

FU1

NOTE #5

COM

HPSR 1

N/A

HI-COOL

PL3

SEC2

ALS1

DSS

ALS2

FRS1

(WHEN USED)

FRS2

N/A

MGVR-2

NOTE #8 LPS

(WHEN USED)

TWIN

TEST S

W/W1

HUM

TWINNING

JUMPER

Y/Y2

MGVR-1

NOTE #8

HPS

8N/A

N/A

FSE

NOTE#7

PL1

CPU

LGPS

SW1

ORN

SW4

SW3

SW2

9. Symbols are an electrical representation only.

10. BLOWER-ON DELAY: Gas heating 45 seconds,

Cooling/Heat Pump 2 seconds.

11. Cooling/Heat Pump BLOWER-OFF DELAY is 90

seconds.

12. IGNITION-LOCKOUT will occur after four

consecutive unsuccessful trials-for-ignition.

Control will automatically reset after threehours.

13. Control must be grounded at pin 10 of 12-pin

connector.

14. NA - Not Applicable

15. Spare terminal and wire not available on some

applications. Insulate connector if not available.

RED

MED LO BLU

COM WHT

BLK

HI YELMED HI MED

COM

HIMED

MED LO LO

NOTE #15

ORN

SPARE MED HI

SPARE

BLU

NOTE #15

324459-101 REV. D

WHT

BLK

BLU

BRN

GRY

BRN

GRY

WHT

RED

WHT

BLK

RED

BLK

YEL

BRN

GRY

BLU

ORN

RED RED

RED

WHT

BLK

BLK BLK

BLK

WHT

BLU

RED

(NATURAL GAS & PROPANE)SCHEMATIC DIAGRAM

EQUIPMENT

GROUND

GRN/YEL

GRN/YEL GRN/YEL

required for high-gas-heat operation. When high-heat-only switch

SW-1 is on, it always causes high-gas-heat operation when R-W1

circuit is closed, regardless of the setting of the low-heat-only

switch SW-2 and regardless of whether R-W2 circuit is closed or

open.

When the wall thermostat ″calls for heat″, R-W/W1 circuit closes

for low-gas heat or R to W1-and-W2 circuits close for high-gas

heat. The furnace control performs a self check, verifies low-heat

and high-heat pressure switch contacts LPS and HPS are open, and

starts inducer motor IDM in low speed or high speed as appropri-

ate.

The start-up and shutdown functions and delays described in item

1 above apply to 2-stage heating mode as well, except for

switching from low- to high-gas heat and vice versa.

a. Switching from low- to high-gas heat—If thermostat

R-W/W1 circuit for low-gas heat is closed and R-W2

circuit for high-gas- heat closes, the control CPU switches

the inducer motor IDM speed from low to high. The

high-heat pressure switch relay HPSR closes. When in-

ducer motor IDM provides sufficient pressure to close

high-heat pressure switch HPS, the high-heat gas valve

solenoid GV is energized. The blower motor BLWM

switches speed for high-gas heat 5 sec after R-W2 circuit

closes.

b. Switching from high- to low-gas heat—If thermostat R-W2

circuit for high-gas heat opens and R to W/W1 circuit for

low-gas heat remains closed, the control CPU will switch

inducer motor IDM speed from high to low. The high-heat

pressure switch relay HPSR will open to de-energize

high-heat gas valve solenoid GV. When inducer motor

IDM reduces pressure sufficiently, the high-heat pressure

switch HPS will open. The low-heat gas valve solenoid GV

remains energized as long as low-heat pressure switch LPS

remains closed. The blower motor BLWM switches speed

for low-gas heat 5 sec after R-W2 circuit opens.

3. Cooling Mode

a. Single-Speed Cooling Outdoor Unit

(See Fig. 12 for thermostat connections.)

(1.) The thermostat closes R to G-and-Y circuits. The R-Y

circuit starts the outdoor unit, and R to G-and-Y

circuits start the furnace blower motor BLWM on

high-cool speed.

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when blower motor BLWM is operating.

(3.) When thermostat is satisfied, the R to G-and-Y circuits

are opened. The outdoor unit stops, and furnace

blower motor BLWM continues operating on high-

cool speed for an additional 90 sec.

b. Two-Speed Cooling Outdoor Unit

(See Fig. 13 for thermostat connections.)

(1.) The thermostat closes R to G-and-Y1 circuits for low

cooling or closes R to G-and-Y1-and-Y/Y2 circuits for

high cooling. The R to Y1 circuits start the outdoor

unit on low-cooling speed, and the R-G circuit starts

furnace blower motor BLWM on low-cooling speed

(same speed as for low-gas heat). The R to Y1-and-Y2

circuits start the outdoor unit on high-cooling speed,

and the R to G-and-Y2 circuits start furnace blower

motor BLWM on high-cooling speed.

NOTE: Y1 is found in the outdoor unit. The furnace control CPU

controls blower motor BLWM speed by sensing only G for

low-cooling speed and Y/Y2 for high-cooling speed.

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when blower motor BLWM is operating on

either cooling speed.

(3.) When thermostat is satisfied, the R to G-and-Y1 or R

to G-and-Y1-and-Y/Y2 circuits open. The outdoor

unit stops, and furnace blower continues operating on

cooling speed for an additional 90 sec.

4. Continuous Blower Mode

a. When R to G circuit is closed by thermostat, the blower

motor BLWM operates on low-gas heat speed (identical to

low-cool speed). Terminals EAC-1 and EAC-2 are ener-

gized with 115v as long as blower motor BLWM is

energized.

b. During a ″call for heat,″the blower motor BLWM stops

during ignitor warm-up (17 sec), ignition (7 sec), and

blower on delay (45 sec), allowing furnace heat exchangers

to heat up quickly.

c. The blower motor BLWM reverts to continuous blower

speed after the heating cycle is completed. In high-gas heat,

the furnace control CPU holds the blower motor BLWM at

high-gas-heat speed during the selected blower off delay

period before reverting to continuous blower speed.

(1.) When thermostat ″calls for low-cooling,″the blower

motor BLWM continues to operate on low-cool speed.

When thermostat is satisfied, the blower motor

BLWM continues on continuous blower speed.

(2.) When thermostat ″calls for high-cooling,″the blower

motor BLWM operates on high-cool speed. When the

thermostat is satisfied, the blower motor BLWM

operates an additional 2 sec on high-cool speed before

reverting back to continuous blower speed.

(3.) When R-G circuit is opened, the blower motor BLWM

continues operating for an additional 90 sec if no other

function requires blower motor BLWM operation.

5. Heat Pump Mode

NOTE: An accessory interface kit, Thermidistat control or Dual

Fuel thermostat are required with single-speed heat pumps. See

interface kit Installation Instructions for single-speed heat pump

thermostat and interface connections. No interface kit is needed for

2-speed heat pumps. See 2-speed heat pump Installation Instruc-

tions for thermostat connections.

a. Single-Speed Heat Pump Cooling

(1.) The thermostat and interface kit close the R to

G-and-Y/Y2 circuit to start the furnace blower motor

BLWM on high-cooling speed. The Y/Y2 input to the

furnace control is necessary to provide adequate cool-

ing airflow.

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when the blower motor BLWM is operat-

ing.

(3.) When thermostat is satisfied, furnace blower motor

BLWM continues operating on high-cool speed for an

additional 90 sec.

b. Two-Speed Heat Pump Cooling

(1.) The thermostat R to G circuits start the furnace blower

motor BLWM on low-cool speed. The thermostat R to

G-and-Y/Y2 circuits start the furnace blower motor

BLWM on high-cool speed.

NOTE: The furnace control CPU controls blower motor BLWM

speed by sensing only G for low-cool speed and Y2 for high-cool

speed.

→

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when the blower motor BLWM is operating

on either cooling speed.

(3.) When thermostat is satisfied, the furnace blower

motor BLWM continues operating on cooling speed

for an additional 90 sec.

c. Single-Speed Heat Pump Heating

(1.) The thermostat and accessory interface kit R to G-

and-Y/Y2 circuits start the furnace blower motor

BLWM on heat pump high-heat speed (identical to

high-cool speed).

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when the blower motor BLWM is operat-

ing.

(3.) When thermostat is satisfied, the furnace blower motor

BLWM continues operating on heat pump high-heat

speed for an additional 90 sec.

d. Two-Speed Heat Pump Heating

(1.) The thermostat closes R-G circuit for low heat and

starts furnace blower motor BLWM on heat pump

low-heat speed (identical to low-cooling speed). Clos-

ing R-Y/Y2 circuit to furnace provides blower motor

BLWM heat pump high-heat speed.

NOTE: The furnace control CPU controls blower motor BLWM

speed by sensing only G (for heat pump low-heat speed) and Y2

(for heat pump high-heat speed).

(2.) The EAC terminals EAC-1 and EAC-2 are energized

with 115v when the blower motor BLWM is operating

on either heating speed.

(3.) When thermostat is satisfied, the furnace blower

motor BLWM continues operating on heating speed

for an additional 90 sec.

(4.) Opening only R-Y/Y2 circuit reduces blower motor

BLWM speed to heat pump low-heat speed.

6. Defrost

a. When furnace control R to W/W1-and-Y/Y2 circuits are

closed, furnace control CPU continues blower motor

BLWM operation at heat pump heating speed until the end

of the prepurge period, then shuts off until the end of the

HSI ignitor-on period (22 sec).

b. When installed with a heat pump, the furnace control CPU

automatically holds blower off time to 22 sec during HSI

ignitor on period. After 17 sec of HSI ignitor-on period, a

trial for ignition sequence occurs as described above for

gas heating. After flame is proved and without a blower on

delay, the blower motor BLWM will operate on high-gas-

heat speed during defrost. For both single-speed and

2-speed heat pumps, defrost mode is in high-gas heat only.

c. When furnace control R-W/W1 circuit is opened, the

furnace control CPU begins the normal inducer post purge

period and the blower motor BLWM remains on for the

blower off delay period. If R-G circuit remains closed,

blower motor BLWM reverts to continuous operation.

Step 3—Start-up Procedures

1. Component test—The furnace features a component test

system to help diagnose a system problem in the case of a

component failure. To initiate the component test procedure,

ensure that there are no thermostat inputs to the control and all

time delays have expired. Short the TWIN/TEST terminal to

ground or COM for 1 to 4 sec. (See Fig. 14.)

NOTE: The component test feature will not operate if the control

is receiving any thermostat signals or until all time delays have

expired.

The component test sequence is as follows:

a. The furnace control checks itself, operates the inducer

motor on low speed for 7 sec and on high speed for 7 sec,

then stops.

b. The hot surface ignitor is energized for 15 sec, then

de-energized.

c. The blower motor operates on low-gas-heat/heat pump

low-heat/low-cool/continuous fan speed for 7 sec, then

stops.

d. The blower motor operates on high-gas heat for 7 sec, then

stops.

e. The blower motor operates on heat pump high-heat/high-

cool speed for 7 sec, then stops.

The gas valve and humidifier terminal HUM are not energized for

safety reasons.

NOTE: The EAC terminals are energized when the blower is

energized.

2. After all connections have been made, purge gas lines and

check for leaks.

Never purge a line into a combustion chamber. Never use

matches, candles, flame, or other sources of ignition for the

purpose of checking leakage. Use a soap-and-water solution

to check for leakage. A failure to follow this warning can

cause a fire, explosion, personal injury, or death.

3. To operate furnace, follow procedures on operating instruc-

tions label attached to furnace.

4. With furnace operating, set thermostat below room tempera-

ture and observe that furnace goes off. Set thermostat above

room temperature and observe that furnace restarts.

Step 4—Adjustments

1. Set gas input rate.

Furnace gas input rate on rating plate is for installations at

altitudes up to 2000 ft.

In the U.S.A., input rating for altitudes above 2000 ft must be

reduced by 4 percent for each 1000 ft above sea level.

In Canada, input rating must be derated by 10 percent for

altitudes of 2000 ft to 4500 ft above sea level.

Furnace input rate must be within ±2 percent of input on

furnace rating plate.

2. Determine natural gas orifice size and manifold pressure for

correct input.

a. Obtain yearly heat value average (at installed altitude) from

local gas supplier.

b. Obtain yearly specific gravity average from local gas

supplier.

c. Verify furnace model. Table 9 can only be used for model

58TUA Furnaces.

d. Find installation altitude in Table 9.

NOTE: For Canada altitudes of 2000 to 4500 ft, use U.S.A.

altitudes of 2001 to 3000 ft in Table 9.

e. Find closest natural gas heat value and specific gravity in

Table 9.

f. 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.

EXAMPLE: (0–2000 ft altitude)

Heating value = 1075 Btu/cu ft

Specific gravity = 0.62

Therefore: Orifice No. 45

Manifold pressure 3.6-in. wc for high heat

* Furnace is shipped with No. 45 orifices. In this example,

all main burner orifices are the correct size and do not need

to be changed to obtain proper input rate.

g. Check and verify burner orifice size in furnace. NEVER

ASSUME ORIFICE SIZE; ALWAYS CHECK AND

VERIFY.

3. Adjust manifold pressure to obtain input rate.

a. Remove caps that conceal adjustment screws for low- and

high-heat gas valve regulators. (See Fig. 18.)

b. Move setup switch SW-2 on control center to ON position.

(See Fig. 15.) This keeps furnace locked in low-heat

operation.

c. Jumper R and W/W1 thermostat connections on control

center to start furnace.

d. Turn low-heat adjusting screw (5/64 hex Allen wrench)

counterclockwise (out) to decrease input rate or clockwise

(in) to increase input rate.

NOTE: DO NOT set low-heat manifold pressure less than 1.3-in.

wc or more than 1.7-in. wc for natural gas. If manifold pressure is

outside this range, change main burner orifices.

DO NOT bottom out gas valve regulator adjusting screw.

This can result in unregulated manifold pressure and result in

excess overfire and heat exchanger failures.

NOTE: If orifice hole appears damaged or it is suspected to have

been redrilled, check orifice hole with a numbered drill bit of

correct size. Never redrill an orifice. A burr-free and squarely

aligned orifice hole is essential for proper flame characteristics.

DO NOT redrill 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 burners and heat exchangers, causing fail-

ures. (See Fig. 17.)

e. Move setup switch SW-2 to OFF position after completing

low-heat adjustment.

f. Jumper R and W2 thermostat connections on control center.

(See Fig. 14.) This keeps furnace locked in high-heat

operation.

g. Turn high-heat adjusting screw (5/64 hex Allen wrench)

counterclockwise (out) to decrease input rate or clockwise

(in) to increase rate.

NOTE: 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.

h. When correct input is obtained, replace caps that conceal

gas valve regulator adjustment screws. Main burner flame

should be clear blue, almost transparent. (See Fig. 19.)

i. Remove jumper R to W2.

4. Verify natural gas input rate by clocking gas meter.

a. Calculate high-altitude adjustment (if required).

UNITED STATES

At altitudes above 2000 ft, this furnace has been approved

for a 4 percent derate for each 1000 ft above sea level. See

Table 8 for derate multiplier factor and example.

CANADA

At installation altitudes from 2000 to 4500 ft, this furnace

must be derated 10 percent by an authorized Gas Conver-

sion Station or Dealer. To determine correct input rate for

altitude, see example above and use 0.82 as derate multi-

plier factor.

b. Check that gas valve adjustment caps are in place for

proper input to be clocked.

c. Obtain yearly heat value average for local gas supply.

NOTE: Be sure heating value of gas used for calculations is

correct for your altitude. Consult local gas utility for altitude

adjustment of gas heating value.

d. Check and verify orifice size in furnace. NEVER AS-

SUME THE ORIFICE SIZE. ALWAYS CHECK AND

VERIFY.

e. Turn off all other gas appliances and pilots.

f. Move setup switch SW-2 to ON position. (See Fig. 15.)

This keeps furnace locked in low-heat operation.

g. Jumper R to W/W1.

h. Let furnace run for 3 minutes in low-heat operation.

i. Measure time (in sec) for gas meter to complete 1 revolu-

tion. Note reading.

j. Refer to Table 10 for cubic ft of gas per hr.

k. Multiply gas rate cu ft/hr by heating value (Btu/cu ft).

l. Move setup switch SW-2 to OFF position and jumper R and

W2 thermostat connections. (See Fig. 15.) This keeps

furnace locked in high-heat operation. Repeat items h

through k for high-heat operation.

Table 8—Altitude Derate Multiplier for U.S.A.

ALTITUDE

(FT) PERCENT OF

DERATE DERATE MULTIPLIER

FACTOR FOR U.S.A.*

0—2000 0 1.00

2001—3000 8—12 0.90

3001—4000 12—16 0.86

4001—5000 16—20 0.82

5001—6000 20—24 0.78

6001—7000 24—28 0.74

7001—8000 28—32 0.70

8001—9000 32—36 0.66

9001—10,000 36—40 0.62

* Derate multiplier factor is based on midpoint altitude for altitude range.

Table 9—Model 58TUA Orifice Size and Manifold Pressure for Correct Input

(Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner

Derated 4 Percent for Each 1000 Ft Above Sea Level)*

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. and Canada

2000

850 43 3.7/1.5 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 42 3.4/1.4

875 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4

900 44 3.7/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6

925 44 3.5/1.5 44 3.7/1.6 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5

950 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.7/1.6 44 3.8/1.6

975 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

1000 45 3.7/1.6 45 3.8/1.6 44 3.2/1.4 44 3.4/1.4 44 3.5/1.5

1025 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4

1050 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6

1075 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5

1100 47 3.6/1.5 47 3.71.6 45 3.2/1.4 45 3.4/1.4 45 3.5/1.5

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. and Canada

Altitudes

2001

3000

Canada

Altitudes

2000

4500

775 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5 43 3.7/1.6 43 3.8/1.6

800 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5

825 44 3.4/1.4 44 3.5/1.5 44 3.7/1.5 44 3.8/1.6 43 3.4/1.4

850 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.6/1.5 44 3.7/1.5

875 45 3.7/1.6 45 3.8/1.6 44 32/1.4 44 3.4/1.4 44 3.5/1.5

900 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4

925 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6

950 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.6/1.5

975 47 3.5/1.5 47 3.6/1.5 47 3.2/1.3 45 3.3/1.4 45 3.4/1.4

1000 48 3.8/1.6 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4

1025 48 3.6/1.5 48 3.8/1.6 48 3.4/1.4 47 3.5/1.5 47 3.6/1.5

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. Only

3001

4000

750 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4 43 3.5/1.5 43 3.6/1.5

775 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.8/1.6 43 3.4/1.4

800 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

825 45 3.6/1.5 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4

850 45 3.4/1.4 45 3.5/1.5 45 3.7/1.5 45 3.8/1.6 44 3.2/1.4

875 45 3.1/1.4 45 3.3/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6

900 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5

925 47 3.4/1.5 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4

950 48 3.7/1.6 48 3.8/1.6 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6

975 48 3.5/1.5 48 3.7/1.5 48 3.8/1.6 47 3.4/1.4 47 3.5/1.5

1000 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6

* Orifice numbers 45 are factory installed.

Table 9—Model 58TUA Orifice Size and Manifold Pressure for Correct Input—Continued

(Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner

Derated 4 Percent for Each 1000 Ft Above Sea Level)*

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. Only

4001

5000

725 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5 44 3.8/1.6 42 3.4/1.4

750 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 42 3.6/1.5

775 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4 43 3.4/1.4

800 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 43 3.2/1.3

825 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 44 3.6/1.5

850 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 44 3.4/1.4

875 47 3.8/1.6 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 44 3.2/1.4

900 48 3.6/1.5 48 3.8/1.6 47 3.4/1.4 47 3.5/1.5 45 3.6/1.5

925 48 3.4/1.5 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6 45 3.4/1.5

950 48 3.8/1.6 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5 45 3.7/1.6

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. Only

5001

6000

700 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

725 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4

750 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6

775 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5

800 47 3.5/1.5 47 3.6/1.5 45 3.2/1.3 45 3.3/1.4 45 3.4/1.4

825 48 3.8/1.6 47 3.4/1.4 47 3.5/1.5 47 3.7/1.5 45 3.2/1.3

850 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6 47 3.4/1.5 47 3.5/1.5

875 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6

900 49 3.7/1.6 49 3.8/1.6 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5

925 49 3.5/1.5 49 3.6/1.5 49 3.8/1.6 48 3.3/1.4 48 3.4/1.4

950 49 3.3/1.4 49 3.5/1.5 49 3.6/1.5 49 3.7/1.6 49 3.8/1.6

975 50 3.7/1.6 49 3.3/1.4 49 3.4/1.4 49 3.5/1.5 49 3.6/1.5

1000 50 3.6/1.5 50 3.7/1.6 50 3.8/1.6 49 3.3/1.4 49 3.4/1.4

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. Only

6001

7000

650 44 3.2/1.4 44 3.3/1.4 44 3.4/1.4 44 3.5/1.5 44 3.6/1.5

675 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6 44 3.3/1.4 44 3.4/1.4

700 45 3.3/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6

725 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4/1.5 45 3.5/1.5

750 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4

775 48 3.7/1.6 48 3.8/1.6 47 3.5/1.5 47 3.6/1.5 47 3.7/1.6

800 48 3.5/1.5 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6 47 3.5/1.5

825 49 3.8/1.6 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5 48 3.7/1.6

850 49 3.6/1.5 49 3.7/1.6 48 3.3/1.4 48 3.4/1.4 48 3.5/1.5

875 49 3.4/1.4 49 3.5/1.5 49 3.6/1.5 49 3.8/1.6 48 3.3/1.4

* Orifice numbers 45 are factory installed

Table 9—Model 58TUA Orifice Size and Manifold Pressure for Correct Input—Continued

(Tabulated Data Based on 20,000 Btuh High Heat/13,000 Btuh Low Heat per Burner

Derated 4 Percent for Each 1000 Ft Above Sea Level)*

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. Only

7001

8000

625 45 3.6/1.5 45 3.7/1.6 44 3.2/1.3 44 3.3/1.4 44 3.4/1.4

650 45 3.3/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.6

675 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4/1.4 45 3.5/1.5

700 47 3.4/1.5 47 3.5/1.5 47 3.7/1.5 45 3.2/1.3 45 3.3/1.4

725 48 3.6/1.6 48 3.8/1.6 47 3.4/1.4 47 3.5/1.5 47 3.6/1.5

750 48 3.4/1.5 48 3.5/1.5 48 3.6/1.5 48 3.8/1.6 47 3.4/1.4

775 49 3.7/1.4 48 3.3/1.4 48 3.4/1.4 48 3.5/1.5 48 3.6/1.5

800 49 3.5/1.5 49 3.6/1.5 49 3.8/1.6 48 3.3/1.4 48 3.4/1.4

825 49 3.3/1.4 49 3.4/1.4 49 3.5/1.5 49 3.6/1.5 49 3.8/1.6

850 50 3.7/1.6 50 3.8/1.6 49 3.3/1.4 49 3.4/1.4 49 3.5/1.5

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. Only

8001

9000

600 45 3.4/1.4 45 3.5/1.5 45 3.6/1.5 45 3.7/1.6 45 3.8/1.5

625 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4/1.4 45 3.5/1.4

650 47 3.4/1.4 47 3.5/1.5 47 3.6/1.5 45 3.2/1.3 45 3.3/1.5

675 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6 47 3.5/1.5 47 3.6/1.6

700 48 3.3/1.4 48 3.5/1.5 48 3.6/1.5 48 3.7/1.6 48 3.8/1.5

725 49 3.7/1.5 49 3.8/1.6 48 3.3/1.4 48 3.4/1.5 48 3.5/1.6

750 49 3.4/1.4 49 3.5/1.5 49 3.7/1.5 49 3.8/1.6 48 3.3/1.5

775 50 3.8/1.6 49 3.3/1.4 49 3.4/1.4 49 3.5/1.5 49 3.6/1.4

800 50 3.6/1.5 50 3.7/1.6 50 3.8/1.6 49 3.3/1.4 49 3.4/1.5

ALTITUDE

RANGE

(FT)

AVG GAS

HEAT VALUE

(BTU/CU FT)

SPECIFIC GRAVITY OF NATURAL GAS

0.58 0.60 0.62 0.64 0.66

Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low Orifice

No. Manifold

Pressure

High/Low

U.S.A. Only

9001

10,000

575 47 3.7/1.6 45 3.2/1.4 45 3.3/1.4 45 3.4 45 3.5/1.5

600 47 3.4/1.4 47 3.5/1.5 47 3.6/1.5 47 3.7 45 3.2/1.4

625 48 3.6/1.5 48 3.7/1.6 48 3.8/1.6 47 3.5 47 3.6/1.5

650 48 3.3/1.4 48 3.4/1.4 48 3.5/1.5 48 3.6 48 3.7/1.6

675 49 3.6/1.5 49 3.7/1.6 49 3.8/1.6 48 3.4 48 3.5/1.5

700 49 3.3/1.4 49 3.4/1.5 49 3.6/1.5 49 3.7 49 3.8/1.6

725 50 3.7/1.6 50 3.8/1.6 49 3.3/1.4 49 3.4 49 3.5/1.5

750 50 3.4/1.5 50 3.6/1.5 50 3.7/1.6 50 3.8 49 3.3/1.4

775 51 3.8/1.6 50 3.3/1.4 50 3.4/1.5 50 3.5 50 3.7/1.5

EXAMPLE: (High-heat operation at 0–2000 ft altitude)

Furnace input from rating plate is 85,000 Btuh

Btu heating input = Btu/cu ft X cu ft/hr

Heating value of gas = 1050 Btu/cu ft

Time for 1 revolution of 2-cu ft dial = 92 sec

Gas rate = 80 cu ft/hr (from Table 10) Btu heating input =

1050 X 80 = 84,000 Btuh. In this example, the orifice size

and manifold pressure adjustment is within ±2 percent of

the furnace input rate.

NOTE: Measured gas inputs (high heat and low heat) must be

within ±2 percent of that stated on furnace rating plate when

installed at sea level or derated per that stated above when installed

at higher altitudes.

m. Remove jumper across R, W/W1, and W2 thermostat

connections to terminate call for heat.

5. Set temperature rise.

Place SW-2 in ON position. Jumper R to W/W1 and W2 to

check high-gas-heat temperature rise. To check low-gas-heat

temperature rise, remove jumper to W2. Determine air tem-

perature rise for both high and low fire. Do not exceed

temperature rise ranges specified on unit rating plate for high

and low fire.

a. Place duct thermometers in return and supply ducts as near

furnace as possible. Be sure thermometers do not see heat

exchangers so that radiant heat will not affect thermometer

readings. This is particularly important with straight run

ducts.

b. When thermometer readings stabilize, subtract return-air

temperature from supply-air temperature to determine tem-

perature rise.

NOTE: If the temperature rise is outside this range, first check:

(1.) Gas input for low- and high-fire operation.

(2.) Derate for altitude if applicable.

(3.) Return and supply ducts for excessive restrictions

causing static pressures greater than 0.50-in. wc.

c. Adjust air temperature rise by adjusting blower speed.

Increase blower speed to reduce temperature rise. Decrease

blower speed to increase temperature rise. For high fire,

speed selection can be med-high, med (5-speed blowers

only), or med-low (factory setting). For low fire, speed

selection can be low (factory setting), med-low, or med

(5-speed blowers only).

Disconnect the electrical power before changing the speed tap

(or removing motor lead cap, if used, on 5-speed motors). A

failure to follow this warning can cause personal injury.

NOTE: For units with 5-speed motors, make sure the unused

speed tap is either capped or placed on SPARE terminal on control

board before power is restored.

d. To change motor speed selection for high heat, remove

blower motor lead from control HIGH-GAS-HEAT termi-

nal. (See Fig. 13 and 15.) Select desired blower motor

Fig. 17—Burner Orifice

A93059

BURNER

ORIFICE

EXAMPLE:

85,000 Btuh furnace installed at 4300 ft.

Furnace Input

Rate at

Sea Level XDerate

Multiplier

Factor =Furnace Input Rate

at Installation

Altitude

85,000 X 0.82 = 69,700

Table 10—Gas Rate (CU FT/HR)

SECONDS

FOR 1

REVOLUTION

SIZE OF TEST DIAL SECONDS

FOR 1

REVOLUTION

SIZE OF TEST DIAL

Cu Ft 2

Cu Ft 5

Cu Ft 1

Cu Ft 2

Cu Ft 5

Cu Ft

10 360 720 1800 50 72 144 360

11 327 655 1636 51 71 141 355

12 300 600 1500 52 69 138 346

13 277 555 1385 53 68 136 340

14 257 514 1286 54 67 133 333

15 240 480 1200 55 65 131 327

16 225 450 1125 56 64 129 321

17 212 424 1059 57 63 126 316

18 200 400 1000 58 62 124 310

19 189 379 947 59 61 122 305

20 180 360 900 60 60 120 300

21 171 343 857 62 58 116 290

22 164 327 818 64 56 112 281

23 157 313 783 66 54 109 273

24 150 300 750 68 53 106 265

25 144 288 720 70 51 103 257

26 138 277 692 72 50 100 250

27 133 267 667 74 48 97 243

28 129 257 643 76 47 95 237

29 124 248 621 78 46 92 231

30 120 240 600 80 45 90 225

31 116 232 581 82 44 88 220

32 113 225 563 84 43 86 214

33 109 218 545 86 42 84 209

34 106 212 529 88 41 82 205

35 103 206 514 90 40 80 200

36 100 200 500 92 39 78 196

37 97 195 486 94 38 76 192

38 95 189 474 96 38 75 188

39 92 185 462 98 37 74 184

40 90 180 450 100 36 72 180

41 88 176 439 102 35 71 178

42 86 172 429 104 35 69 173

43 84 167 419 106 34 68 170

44 82 164 409 108 33 67 167

45 80 160 400 110 33 65 164

46 78 157 391 112 32 64 161

47 76 153 383 116 31 62 155

48 75 150 375 120 30 60 150

49 73 147 367

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