59MN7A Modulating 4---Way Multipoise Gas Furnace Series 200 Installation, Start---up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the installation. SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS . . . 4 ACCESSORIES .
Required Notice for Massachusetts Installations 59MN7A IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA--54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: a.
! WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation, personal injury, death, or property damage. Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage.
59MN7A INTRODUCTION The 4--way multipoise Category IV condensing furnace is CSA design--certified for both direct--vent (2-pipe) and ventilated combustion air venting installations. (See Fig. 2.) The furnace is factory--shipped for use with natural gas. The furnace can be converted in the field for use with propane gas when a factory-supplied conversion kit is used. Refer to the furnace rating plate for conversion kit information.
ACCESSORIES See Product Data Sheet for a list of accessories for this product LOCATION ! CAUTION wood flooring (refer to SAFETY CONSIDERATIONS). S be located close to the chimney or vent and attached to an air distribution system. Refer to Air Ducts section. S be provided ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown in Table 2 or on the furnace clearance to combustible construction label.
! WARNING ! WARNING FIRE, INJURY OR DEATH HAZARD FIRE HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. Failure to follow this warning could result in personal injury, death and/or property damage. When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 in. (457 mm) above the floor. The furnace must be located or protected to avoid damage by vehicles.
59MN7A A11588 Fig.
THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. 59MN7A THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS LOCATED TO THE LEFT OF THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED TO THE RIGHT. THE BLOWER IS LOCATED ABOVE THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED DOWNWARD A02097 Fig. 2 -- Multipoise Orientations 80 / 27˚C 60 / 16˚C SUPPLY AIR A10490 Fig.
Introduction Direct Vent (2-- pipe) Applications When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required. However, other gas appliances installed in the space with the furnace may require outside air for combustion. Follow the guidelines below to insure that other gas appliances have sufficient air for combustion.
Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) FURNACE INPUT (BTUH) SINGLE DUCT OR OPENING (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) Free Area of Opening and Duct Sq. In (Sq. mm) Round Duct In. (mm) Dia 20 (12904) 30 (19355) TWO OPENINGS OR VERTICAL DUCTS (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW) Free Area of OpenRound Duct ing and Duct In. (mm) Dia. Sq. In (mm) Free Area of Opening and Duct Sq. In (Sq.
! CAUTION FROZEN AND BURST WATER PIPE HAZARD Failure to protect against the risk of freezing may result in property damage. Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper operation or damage to equipment. If furnace environment has the potential of freezing, the drain trap and drain line must be protected. The use of electric heat tape or RV antifreeze is recommended for these installations.
Vent Pipe Clamp Condensate Trap Relief Port Collector Box Plugs Vent Elbow Clamp Vent Elbow Collector Box Plug 59MN7A Condensate Trap Relief Port Pressure Switch Port Condensate Trap Outlet A11306 Fig.
Remove pressure switch tube from pressure switch port. Remove relief tube from relief port on condensate trap. Loosen clamp on inlet to vent elbow. Remove middle and bottom plugs. DO NOT DISCARD. 7 Install plugs on open ports on collector box. Attach condensate trap with screw to collector box. Connect relief tube to port on collector box. 9 Trim excess tube. Connect pressure switch tube to port on collector box. Connect relief tube to relief port on condensate trap.
Remove plug from collector box. DO NOT DISCARD. 59MN7A If alternate vent position is required, loosen clamp on inlet of vent elbow. Remove trap from collector box. Unconverted Factory Trap Configuration As Viewed in the Horizontal Right Orientation Slide relief tube in stand-offs to adjust length. Attach condensate trap to collector box with screw. Vent elbow shown in alternate orientation. Tighten clamp on inlet to vent elbow 15 lb.-in. Install plug in open port on collector box.
Remove trap from collector box. If alternate vent position is required, loosen clamp on vent elbow inlet. Remove relief tube from relief port on condensate trap. 59MN7A Remove pressure switch tube from port on collector box. Remove relief tube from port on collector box. Remove middle and right plug from collector box. DO NOT DISCARD Unconverted Factory Trap Configuration As Viewed in the Horizontal Left Orientation Install plugs in open ports on collector box.
CONDENSATE DRAIN CONNECTION ! CAUTION FROZEN AND BURST WATER PIPE HAZARD Failure to protect against the risk of freezing may result in property damage. Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper operation or damage to equipment. If furnace environment has the potential of freezing, the drain trap and drain line must be protected. The use of electric heat tape or RV antifreeze is recommended for these installations.
13. Secure the rubber elbow to the drain trap and the Z-pipe with spring clamps. 14. Secure the grommet to the Z-pipe with the spring clamp. The remaining drain line can be constructed from field supplied 1/2--in. CPVC or 3/4--in. PVC pipe, in compliance with local building codes. A factory-supplied 1/2--in. CPVC to 3/4--in. PVC adapter is supplied in the loose parts bag for use as required. 15. Install the adapter or connect the 1/2--in.
INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAP PULL DRAIN STUB THROUGH CASING NOTE: Trap grommet is required only for direct-vent applications. Remove knockout. Install grommet before relocating condensate trap. 59MN7A OPEN SPRING CLAMP INSERT FACTORYïSUPPLIED 1/2ïIN. CPVC TO 3/4ïIN. PVC ADAPTER OR 1/2ïIN. CPVC PIPE *CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN TUBE A11342A A11582 Fig. 13 -- Formed Tube Grommet Fig. 15 -- Horizontal Drain Trap Grommet A11581 Fig.
NOTE: This furnace is certified to leak 2% or less of nominal air conditioning CFM delivered when pressurized to 1--inch water column with all present air inlets, air outlets, and plumbing and electrical ports sealed, including bottom closure in upflow and horizontal applications. Upflow Installation NOTE: The furnace must be pitched as shown in Fig. 22 for proper condensate drainage.
Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. (See Fig. 24.) Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove and discard this panel when bottom return air is used in downflow applications. To remove bottom closure panel, perform the following: 1. Tilt or raise furnace and remove 4 screws holding bottom plate. (See Fig. 21.) 2. Remove bottom plate. 3. Remove bottom closure panel.
For downflow applications, the Media Cabinet (or field supplied accessory air cleaner) must only be connected to the bottom opening on the furnace. See Fig. 17 and 24. For horizontal applications, the Media Cabinet (or field supplied accessory air cleaner) for all models can be connected to the bottom opening on the furnace. For side return use in the horizontal position, refer to Fig. 25. If both side and bottom openings are used in Fig. 25, each opening used will require a filter.
21-in. Furnace 14-3/16 and 17-1/2-in. Furnace 4-in. Block Off Plate 4-Ton or less, AC capacity airflow 1/2-in. Screws 20-in. Media Cabinet 59MN7A 16-in. Media Cabinet Media Cabinet Installation Side Return Media Cabinet Installation Option for 4-Ton or Less A/C Capacity 21- or 24-1/2-in. Furnace 21-in. Furnace up to 5-Ton AC Capacity Up to 5-Ton AC capacity airflow 24-1/2-in. Furnace up to 4-Ton AC Capacity 20- or 24-in. Media Cabinet 45° Bottom Return Plenum Transition 20- or 24-in.
FURNACE (OR COIL CASING WHEN USED) FURNACE APPROVED COIL ASSEMBLY OR COIL BOX COMBUSTIBLE FLOORING COMBUSTIBLE FLOORING A PLENUM OPENING D DOWNFLOW SUBBASE FLOOR OPENING SHEET METAL PLENUM SHEET METAL PLENUM FLOOR OPENING C FLOOR OPENING A10491 Fig. 18 -- Installation on Combustible Flooring Table 6 – Opening Dimensions -- In. (mm) FURNACE CASING WIDTH IN.
UPFLOW PERFORATED DISCHARGE DUCT FLANGE DOWNFLOW HORIZONTAL 90° 90° YES YES YES 120° MIN YES 120° MIN YES 120° MIN NO NO 59MN7A YES NO A10493 Fig. 19 -- Duct Flanges 5/ 16″ (8mm) (8mm) 5/ 16″ 1 3/4″ (44mm) 1 3/4″ (44mm) (8mm) 5/16″ BOTTOM CLOSURE PANEL (8mm) 5/ 16″ (44mm) 1 3/ 4″ 3/ (44mm) 1 4″ BOTTOM PLATE A89014 A11092 Fig. 20 -- Leveling Legs Fig. 21 -- Removing Bottom Closure Panel LEVEL 0-IN. (0 MM) TO 1/2-IN. (13 MM) MAX MIN 1/4-IN. (6 MM) TO 1/2-IN.
A11036 A11037 Fig. 23 -- Upflow Return Air Configurations and Restrictions Fig. 24 -- Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig. 25 -- Horizontal Return Air Configurations and Restrictions 25 59MN7A ANY COMBINATION OF 1, 2, OR 3 PERMITTED.
COMBUSTION - AIR PIPE (SEE VENTING SECTION) 30 IN. (762 mm) MIN. WORK AREA 59MN7A 2-IN. (51 mm) ROLLOUT PROTECTION REQUIRED Install 12” x 22” (305 x 559 mm) sheet metal in front of burner compartment area. A11154 Fig. 26 -- Working Platform for Attic Installation NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling. COMBUSTION-AIR PIPE (SEE VENTING SECTION) 2-IN. (51 mm) A11155 Fig.
General Requirements The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor.
Table 7 – Cooling4 and Heating Air Delivery -- CFM (Bottom Return5 With Filter) Unit Size (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2) Clg/CF Switch Settings External Static Pressure (ESP) SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.
Unit Size Clg/CF Switch Settings SWx-3 SWx-2 SWx-1 0.1 0.2 0.3 External Static Pressure (ESP) 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1035 1025 1005 875 860 845 1045 1035 1025 1005 1255 1250 1235 1220 1185 1260 1255 1250 1235 1220 1185 1255 1260 1255 1250 1235 1220 1185 1450 1415 1375 1335 1300 1265 1225 1190 1485 1450 1415 1375 1335 1300 1265 1225 1190 755 745 755 755 765 620 625 630 0.1 0.2 0.
Table 7 -- Cooling4 and Heating Air Delivery -- CFM (Bottom Return5 With Filter) (Continued) Unit Size 0.1 0.2 0.3 External Static Pressure (ESP) 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1805 1780 1770 1080 1065 1070 1295 1300 1290 1285 1485 1480 1485 1475 1460 1840 1835 1825 1805 1780 1770 2135 2140 2130 2115 2100 2070 2015 2175 2170 2160 2150 2135 2120 2065 2020 1575 1595 1595 1600 1605 1600 1600 1590 1575 950 955 965 975 970 755 745 750 0.1 0.2 0.
GAS PIPING WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could result in personal injury, death, and/or property damage. FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance.
Table 8 – Maximum Capacity of Pipe NOMINAL IRON PIPE SIZE IN. (MM) 1/2 (13) 3/4 (19) 1 ( 25) 1-1/4 (32) 1-1/2 (39) Field--supplied wiring shall conform with the limitations of 63_F (33_C) rise. LENGTH OF PIPE --- FT (M) 10 (3.0) 20 (6.0) 30 (9.1) 40 (12.1) 50 (15.2) 175 360 680 1400 2100 120 250 465 950 1460 97 200 375 770 1180 82 170 320 660 990 73 151 285 580 900 ! ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury, death, or property damage.
J--Box Installation WARNING FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death, or property damage. If field--supplied manual disconnect switch is to be mounted on furnace casing side, select a location where a drill or fastener cannot damage electrical or gas components. The J-Box is used when field line voltage electrical connections are made to the furnace wiring harness inside the furnace casing.
59MN7A 2. Humidifier (HUM) The HUM terminal is a 24 VAC output, energized when the blower is operating during a call for heat. Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the ¼--in. male quick--connect HUM terminal and COM--24V screw terminal on the control board thermostat strip. NOTE: If the humidifier has its own 24 VAC power supply, an isolation relay may be required.
GROUND NEUTRAL 59MN7A LINE VOLTAGE J BOX LOCATIONS J−BOX MOUNTING SCREWS J−BOX MOUNTING BRACKET GROUND SCREW ELECTRIC DISCONNECT SWITCH J−BOX COVER COPPER WIRE ONLY ALUMINUM WIRE A11156 A11146 Fig. 30 -- Installing J--Box (When Used) (Appearance May Vary) Fig.
To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip A11157 59MN7A Fig.
COMMUNICATION CONNECTOR MODEL PLUG CONNECTOR CONTINUOUS FAN (CF) AIRFLOW SETUP SWITCHES OUTDOOR AIR TEMP CONNECTOR SW4 SETUP SWITCHES PL8 - MODULATING GAS VALVE CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFFDELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES ACRDJ – AIR CONDITIONING RELAY DISABLE JUMPER 24-V THERMOSTAT TERMINALS FLASH UPGRADE CONNECTOR (FACTORY ONLY) STATUS AND COMM LED LIGHTS PL3 – ECM BLOWER HARNESS CONNECTOR 3-AMP FUSE TRANSFORMER 24-VAC CONNECTIONS 115-VAC (L2) NEUTRAL CONNECTION
THERMOSTAT THERMOSTAT D 59MN7A D 11, and 16 15, and 16 Modulating and 2-Stage Furnace with Single-Speed Heat Pump Modulating and 2-Stage Furnace with Single-Speed Air Conditioner THERMOSTAT THERMOSTAT D D 15, and 16 12 and 16 Modulating and 2-Stage Furnace with Two-Speed Air Conditioner Modulating and 2-Stage Furnace with Two-Speed Heat Pump A11274 Fig.
1. Heat pump MUST have a high pressure switch for dual fuel applications. 2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure. 3. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two speed heat pump control. Heat pumps with date code 1601E and later do not have or require a “ZONE” selection. 4. Outdoor Air Temperature - sensor must be attached in all dual fuel applications. 5.
VENTING Furnace is set in place in the required orientation. 59MN7A Special Venting Requirements for Installations in Canada Les autorité es ayant juridiction (inspecteurs de gas, inspecteurs en bâtiments, département des incendies, etc) devraient être consultées avant l’installation afin de déterminer si un permis est requis. ! Installation in Canada must conform to the requirements of CAN/CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC S636.
Materials U.S.A. Combustion air and vent pipe, fittings, primers, and solvents must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards. See Table 11 for approved materials for use in the U.S.A. Canada Special Venting Requirements for Installations in Canada Installation in Canada must conform to the requirements of CAN/CSA B149 code. Vent systems must be composed of pipe, fittings, cements, and primers listed to ULC S636.
59MN7A (1.2 M) of unobstructed distance to the property line of the adjacent lot, no type of vent termination is permitted for appliances with inputs greater than 35,000 btuh. There are no additional restrictions on unobstructed distances greater than 8 ft. (2.4 M). All single, two-pipe and concentric vents may be used, providing all other Code and manufacturer’s requirements in these instructions are adhered to.
Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter ! WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death. To route the vent pipe and combustion air pipe through the furnace, the manufacturer supplied kit must be used. Failure to properly seal the blower compartment from the furnace vestibule could result in the circulation of carbon monoxide throughout the structure.
14. Complete the vent and combustion air pipe as shown in “Install the Vent and Combustion Air Pipe” Installing the Vent Termination 59MN7A Roof Terminations A roof termination of any type will require a 4-in. (102 mm) flashing for a 2 inch (51 mm) concentric vent or a 5--in. diameter (127 mm) flashing for a 3-inch (76 mm) concentric vent kit. For two-pipe or single pipe vent systems, a flashing for each pipe of the required diameter will be necessary.
Table 11 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A.
Table 12 – Maximum Allowable Exposed Vent Lengths Insulation Table -- Ft. / M Maximum Length of Uninsulated and Insulated Vent Pipe-Ft (M) Modulating Furnace High Heat Input Winter Design Temp ° F (° C) 20 (-10) 0 (-20) 60000 -20 (-30) -40 (-40) 59MN7A 20 (-10) 0 (-20) 60600 -20 (-30) -40 (-40) 20 (-10) 0 (-20) 80000 -20 (-30) -40 (-40) 20 (-10) 0 (-20) 100000 -20 (-30) -40 (-40) 20 (-10) 0 (-20) 120000 -20 (-30) -40 (-40) Pipe Length in Ft. & M No Insulation 3/8-in. (9.5 mm) 1/2-in. (12.
NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 14 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 13 – Maximum Equivalent Vent Length -- Ft. (M) 0 to 4500 Ft.
Example A direct--vent 60,000 Btuh furnace installed at 2100 ft. (640 m) with 2--in.(51 mm) Vent piping. Venting system includes, FOR EACH PIPE, (3) 90_ long radius elbows, (2) 45_ long radius elbows and a concentric vent kit. Maximum Equivalent Vent Length Deduct (3) 90 long radius Deduct (2) 45 long radius No deduction for Concentric Vent Kit Maximum Vent Length 3 2 x x = = = = = 3 ft. 1.5 ft. 0 ft. 127 ft. - 9 ft. - 3 ft. - 0 ft. 115 ft.
Attach gaskets to vent pipe and combustion air adapters. A11314 Fig. 36 -- Vent Coupling and Adapter with Gaskets VENT ELBOW CLAMP TORQUE 15 LB-IN. INDUCER OUTLET VENT PIPE CLAMP TORQUE 15 LB-IN. MODULATING INDUCER ASSEMBLY VENT ELBOW A11286 Fig.
7 6 4 5 1 Any other unused knockout may be used for combustion air connection. Rotate vent elbow to required position. 3 2 & 5 Rotate vent elbow to required position. A11309 6 7 6 Any other unused knockout may be used for combustion air connection. 1 2 5 3 4 5 A11308 3 7 59MN7A 2 5 1 Any other unused knockout may be used for combustion air connection. 4 5 A11310 1 Attach vent pipe adapter with gasket to furnace casing. 2 Align notches in rubber coupling over standoffs on adapter.
3 Rotate vent elbow to required position. 2 5 4 1 Rotate vent elbow to required position. 5 4 5 1 2 5 3 Any other unused knockout may be used for combustion air connection. 6 6 A11311 7 A11312 59MN7A 7 A11313 Downflow Vertical Requires Accessory Internal Vent Kit. See Product Data for current kit number. 1 Attach vent pipe adapter with gasket to furnace casing. 2 Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.
59MN7A HORIZONTAL LEFT VERTICAL VENT CONFIGURATION HORIZONTAL LEFT LEFT VENT CONFIGURATION HORIZONTAL LEFT RIGHT VENT CONFIGURATION* *Requires Accessory Internal Vent Kit See Product Data for Current Kit Number 1 Attach vent pipe adapter with gasket to furnace casing. 2 Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. 3 Slide vent pipe through adapter and coupling into vent elbow. 4 Insert vent pipe into vent elbow. 5 Torque all clamps 15 lb.-in.
59MN7A HORIZONTAL RIGHT VERTICAL VENT CONFIGURATION HORIZONTAL RIGHT LEFT VENT CONFIGURATION* *Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT RIGHT VENT CONFIGURATION 1 Attach vent pipe adapter with gasket to furnace casing. 2 Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. 3 Slide vent pipe through adapter and coupling into vent elbow. 4 Insert vent pipe into vent elbow. 5 Torque all clamps 15 lb.-in.
ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND-OFF ON ADAPTER. TORQUE LOWER CLAMP 15 LB-IN. WHEN REMAINING VENT PIPE IS INSTALLED, TORQUE UPPER CLAMP TO 15 LB-IN. 59MN7A VENT PIPE ADAPTER WITH GASKET INSTALLED ON FURNACE VENT PIPE IS CUT FLUSH WITH TOP OF ADAPTER. VENT PIPE FLUSH WITH ADAPTER VENT PIPE FLUSH SHOWING COUPLING A11339 Fig. 42 -- Vent Pipe Flush with Adaptor Point elbow down towards back of furnace 12” MINIMUM 256.
V 59MN7A V Item A Clearance Description Clearance above grade, veranda, porch, deck, balcony or anticipated snow level B Clearance to a window or door that may be opened C Clearance to a permanently closed window Vertical clearance to a ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the centerline of the terminal D E F G H Clearance to an unventilated soffit Clearance to an outside corner Clearance to an inside corner Clearance to each side of the
59MN7A Item A Clearance Description Clearance above grade, veranda, porch, deck, balcony or anticipated snow level B Clearance to a window or door that may be opened C Clearance to a permanently closed window Vertical clearance to a ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the centerline of the terminal D E F G H Clearance to an unventilated soffit Clearance to an outside corner Clearance to an inside corner Clearance to each side of the center
Roof Te rmination (Preferred) At least 36 in. (914mm) Concentric Vent and Combustion Air Roof Termination (preferred) A Ve r tical separation between combustion air and vent 8 3/4 in. (222mm)f or 3 in. (76mm)ki t 6 3/4 in. (172mm)for 2 in. (51mm) ki t 18 in. maximum (457mm) A At least 36 in. (914mm) Maintain 12 in. (305mm)min. clearance above highest anticipated snow level Maximum of 24 in.(614mm) above roof Maintain 12 in. (305mm) min.
NOTE: This illustration is for reference only. Your unit may differ in appearance or may not include all components shown. OVERHANG OR ROOF VENT Angle 22.5 o to 45 o off wall BRACKET 59MN7A COUPLING 12 IN. SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT COMBUSTION-AIR (ELBOW PARALLEL TO WALL) MAINTAIN 12 IN. CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE, WHICHEVER IS GREATER. L10F022 EXHAUST OVERHANG Clearance to overhang per code 12 in. (304.8mm) MIN.
Ventilated Combustion Air intake pipe Pipe hangar 59MN7A 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE highest level of insulation ATTIC A10497 Fig.
START--UP, ADJUSTMENT, AND SAFETY CHECK General 59MN7A 1. Furnace must have a 115-v power supply properly connected and grounded. NOTE: Proper polarity must be maintained for 115-v wiring. Control status indicator light flashes rapidly and furnace does not operate if polarity is incorrect. 2. Thermostat wire connections at terminals R, W/W1, G, Y/Y2, etc. must be made at 24-v terminal block on furnace control. See communicating wall control instructions for proper wiring of communicating controls. 3.
If not previously done, purge the lines after all connections have been made and check for leaks. ! WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.
59MN7A 1. Make sure the gas supply is turned off to the furnace and at the electric switch on the gas valve. 2. Remove the 1/8 inch NPT plug from the outlet pressure tap on the gas valve. 3. Connect a manometer to the outlet pressure tap on gas valve. 4. Turn on furnace power supply. 5. Turn gas supply manual shutoff valve to ON position. 6. Turn furnace gas valve switch to ON position. 7. Jumper the R to W/W1 and W2 thermostat connections at the furnace control board. 8.
! WARNING FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Reinstall manifold pressure tap plug in gas valve to prevent gas leak. ! Adjust Blower Off Delay (Heat Mode) a. Remove blower door if installed. b. Turn Dip switch SW--7 or SW--8 ON or OFF for desired blower off delay. (See Table 17 and Fig. 34 , 54 and 63.
(6.) Turn SW1--2 switch OFF. (7.) Install blower door. b. Electronic thermostat: Set cycle rate for 3 cycles per hr. MODULATING ON/OFF Switch Min/Max Heat Adust (Under Cap) 59MN7A Check Safety Controls The flame sensor, gas valve, and pressure switch were all checked in the Start--up procedure section as part of normal operation. 1. Check Main Limit Switch This control shuts off combustion system and energizes air-circulating blower motor, if furnace overheats.
59MN7A 338307-201 Rev. F A11594 Fig.
59MN7A A11623 Fig.
Furnace Setup Switch Description SWITCH NAME NORMAL POSITION SW1-1 Status Code Recovery OFF SW1-2 Minimum Heat Only (Adaptive Heat Mode when SW1-2 and SW4-2 are OFF) OFF SW1-3 Min/Int Heat Rise Adjustment OFF SW1-4 Comfort/Efficiency Adjustment ON SW1-5 CFM per ton adjust OFF SW1-6 Component Self Test OFF SW1-7 & SW1-8 Blower OFF delay ON or OFF SW4-2 Intermendiate Heat Only (Adaptive Heat Mode when both SW1-2 and SW4-2 are OFF) OFF DESCRIPTION OF USE Turn ON to retrieve up to 7 st
Table 17 – Blower Off Delay Setup Switch Table 16 – Altitude Derate Multiplier for U.S.A.* ALTITUDE FT. M 0–2000 2001–3000 3001–4000 4001–5000 5001–6000 6001–7000 7001–8000 8001–9000 9001–10,000 0---610 610---914 914---1219 1219---1524 1524---1829 1829---2134 2134---2438 2438---2743 2743---3048 PERCENT OF DERATE 0 4--- 6 6--- 8 8--- 10 10--- 12 12--- 14 14--- 16 16--- 18 18--- 20 DERATE MULTIPLIER FACTOR* 1.00 0.95 0.93 0.91 0.89 0.87 0.85 0.83 0.81 DESIRED HEATING MODE BLOWER OFF DELAY (SEC.
Table 19 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate To Be Used with Modulating Furnaces Except 59MN7A060V21--20 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) AVG. GAS RANGE HEAT VALUE AT ALTITUDE U.S.A. and Canada ft (m) U.S.A. and Canada U.S.A. Only U.S.A. Only U.S.A. Only 0.60 0.62 0.
Table 19 -- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) To Be Used with Modulating Furnaces Except 59MN7A060V21--20 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG. GAS RANGE HEAT VALUE AT ALTITUDE U.S.A. Only U.S.A. Only 59MN7A U.S.A. Only ft (m) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.
Table 20 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate To Be Used with Modulating Furnaces 59MN7A060V21--20 Only (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) AVG. GAS RANGE HEAT VALUE AT ALTITUDE U.S.A. Only U.S.A. Only U.S.A. Only U.S.A. Only U.S.A. and Canada U.S.A. and Canada ft (m) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.
Table 20 -- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) To Be Used with Modulating Furnaces 59MN7A060V21--20 Only (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE AVG. GAS RANGE HEAT VALUE AT ALTITUDE U.S.A. Only U.S.A. Only 59MN7A U.S.A. Only ft (m) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.
! Electrical Controls and Wiring ! WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. FIRE, INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. The ability to properly perform maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment.
2. 3. 4. 5. 6. 7. Turn Setup Switch, SW1--1 “ON.” Manually close blower door switch. Control will flash up to 7 Status Codes. The last Status Code, or 8th Code, will be Code 11. Turn SW1--1 “OFF.” A continuously--lit Amber LED will appear and indicates proper operation. 8. Release blower door switch, install blower door and refer to the SERVICE label on the control door for more information.
Cleaning and/or Replacing Air Filter The air filter type may vary depending on the application or orientation. The filter is external to the furnace casing. There are no provisions for an internal filter with this furnace. See “Filter Arrangement” under the “Installation” section of this manual. ! WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury, death and/or property damage.
15. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected. NOTE: Be sure to attach ground wire and reconnect blower harness plugs to blower motor. ! WARNING ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death. 59MN7A Blower door switch opens 115--v power to control. No component operation can occur unless switch is closed.
Failure to follow this warning could result in personal injury, death, and/or property damage. Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. 14. Check for gas leaks with a commercially available soap solution made specifically for the detection of leaks. 15.
10. Turn power on at external disconnect, fuse or circuit breaker. 11. Run the furnace through two complete heating cycles to check for proper operation 12. Install control door when complete. 59MN7A Checking Heat Pad Operation (If Applicable) In applications where the ambient temperature around the furnace is 32_F or lower, freeze protection measures are required. If this application is where heat tape has been applied, check to ensure it will operate when low temperatures are present.
! CAUTION UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the furnace and other property damage. 1. Obtain propylene glycol (RV/swimming pool antifreeze or equivalent). 2. Turn off gas and electrical supplies to your furnace. 3. Remove furnace control door. 4. Remove the top unused rubber plug from the port on the collector box opposite the condensate trap. See Fig. 57. 5. Connect a field supplied 3/8--in. (9.5--mm) ID tube to the open port on the collector box 6.
GROMMET MOTOR SHAFT FLAT MOTOR ARM SCREW SET SCREW MOTOR WHEEL HUB SEE DETAIL A 59MN7A SCREW LOCATION BLO HSG ASSY BRACKET BRACKET ENGAGEMENT DETAIL A CUTOFF, BLOWER WHEEL, BLOWER BLOWER HSG ASSY BRACKET CAPACITOR OR POWER CHOKE (WHEN USED) MOTOR, BLOWER SCREW (GND) A11584 Fig.
IGNITER BURNER SUPT. ASSY BRACKET, IGNITER 59MN7A BURNER ASSY FLAME ROLLOUT SWITCH FLAME SENSOR (BELOW BURNER) A11403 Fig.
Fig. 62 -- Troubleshooting Guide A11290A 82 Go to section below for the status code that was flashed. Determine status code.
A11290B 83 24 SECONDARY VOLTAGE FUSE IS OPEN Check for: - Short circuit in secondary voltage (24V) wiring including thermostat leads. Disconnect thermostat leads to isolate short circuit. 23 PRESSURE SWITCH DID NOT OPEN – Check for: - Obstructed pressure tube. - Pressure switch stuck closed. 22 ABNORMAL FLAME-PROVING SIGNAL Flame is proved while gas valve is deenergized. Inducer will run until fault is cleared. Check for: - Stuck open or leaky gas valve.
A11290C 84 42 INDUCER MOTOR FAULT – Indicates the inducer motor has not started within 20 seconds after a call for heat, the inducer motor RPM is outside its valid range of operation, or the inducer RPM signal was lost for 5 seconds during operation. Check for: - Proper vent sizing. - Failed inducer motor. - Restricted combustion air supply. - Improper motor wiring.
! CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in intermittent unit operation. Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw. Using the schematic diagram (See Fig. 63), follow the sequence of operation through the different modes.
59MN7A CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to Ignition-Lockout. Lockout will be reset automatically after three hours, or by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W/W1, G, R, etc.).
Two-Stage Thermostat and Two-Stage Intermediate/ Maximum Heating See Fig. 34 and 35 for thermostat connections NOTE: In this mode the intermediate-heat only switch SW4-2 must be ON to select the intermediate-heat only operation mode in response to closing the thermostat R to W1 circuit. Closing the thermostat R to W1-and-W2 circuits always causes maximum-heat operation, regardless of the setting of the intermediate-heat only switch.
59MN7A DHUM. When there is a dehumidify demand, the DHUM input is activated, which means 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. Once 24 vac is detected by the furnace control, dehumidification capability is activated. If the DHUM input is removed for more than 48 hours, the furnace control reverts back to non-dehumidification mode.
59MN7A 338307-201 Rev. F A11595 Fig.
PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Blower door Bottom plate Control door Door knob assembly Top filler plate Burner Flame sensor Gas valve Hot surface igniter Manifold Orifice 59MN7A Electrical Group 3--Amp fuse Circuit board Control box Door switch Junction box Limit switch(es) Transformer Heat Exchanger Group Blower Group Inducer Group Blower housing Blower motor Blower wheel Capacitor (when used) Capacitor strap (when used) Cut--off plate Power choke (where used)
