Transcript
Installation Instructions Twinning Kit for HSI Single-and 2-Speed Upflow Condensing and Non-Condensing Gas Furnaces
KGATW0501HSI
NOTE: Read the entire instruction manual before starting the installation. This symbol → indicates a change since the last issue. TABLE OF CONTENTS Safety Considerations ....................................................................................................................................................................................................2 Introduction ....................................................................................................................................................................................................................2 Description and Usage...................................................................................................................................................................................................2 Electrostatic Discharge (ESD) Precautions...................................................................................................................................................................3 SECTION I: MODELS 58PAV, 58WAV, 383KAV, 395CAV, 480BAV, GB1AAV, AND PG8UAA UPFLOW SINGLE-SPEED NONCONDENSING HSI FURNACES................................................................................................................................................................................3 Install Furnaces.........................................................................................................................................................................................................3 Connect Electrical Components—Heating ..............................................................................................................................................................4 Connect Electrical Components-Cooling.................................................................................................................................................................8 Venting......................................................................................................................................................................................................................8 Gas Supply Piping....................................................................................................................................................................................................8 Electrical Supply Connections .................................................................................................................................................................................8 Start-Up and Adjustment........................................................................................................................................................................................10 Sequence of Operation ...........................................................................................................................................................................................10 SECTION II: MODELS 58TUA, 58UXT, 330AAV, AND 330JAV UPFLOW 2–SPEED NON-CONDENSING HSI FURNACES.................11 Install Furnaces.......................................................................................................................................................................................................11 Connect Electrical Components—Heating ............................................................................................................................................................11 Connect Electrical Components—Cooling ............................................................................................................................................................15 Venting....................................................................................................................................................................................................................16 Gas Supply Piping..................................................................................................................................................................................................16 Electrical Supply Connections ...............................................................................................................................................................................16 Start-Up and Adjustment........................................................................................................................................................................................17 Sequence of Operation ...........................................................................................................................................................................................18 SECTION III: MODELS 58MCA, 58MXA, 340MAV, 350MAV, 490AAV, AND PG9MAA UPFLOW SINGLE-SPEED CONDENSING HSI FURNACES.................................................................................................................................................................................................................18 Install Furnaces.......................................................................................................................................................................................................18 Connect Electrical Components—Heating ............................................................................................................................................................22 Connect Electrical Components—Cooling ............................................................................................................................................................26 Venting....................................................................................................................................................................................................................26 Gas Supply Piping..................................................................................................................................................................................................26 Condensate Drain Connections (Furnaces After Serial No. 2894A00001)..........................................................................................................26 Electrical Supply Connections ...............................................................................................................................................................................26 Start-Up and Adjustment........................................................................................................................................................................................28 Sequence of Operation ...........................................................................................................................................................................................28 → SECTION IV: MODELS 58MTA AND 352MAV UPFLOW 2-SPEED CONDENSING HSI FURNACES........................................................28 Install Furnaces.......................................................................................................................................................................................................28 Connect Electrical Components—Heating ............................................................................................................................................................33 Connect Electrical Components—Cooling ............................................................................................................................................................34 Venting....................................................................................................................................................................................................................34 Gas Supply Piping..................................................................................................................................................................................................34 Condensate Drain Connections ..............................................................................................................................................................................34 Electrical Supply Connections ...............................................................................................................................................................................34 Start-Up and Adjustment........................................................................................................................................................................................35 Sequence of Operation ...........................................................................................................................................................................................35 ......................................................................................................................................................................................................................................36 ......................................................................................................................................................................................................................................36 ......................................................................................................................................................................................................................................36 Form:
AG-GATW-11
Cancels:
AG-GATW-10
Printed in U.S.A.
6-01
Catalog No.
63GA-TW4
......................................................................................................................................................................................................................................36 SAFETY CONSIDERATIONS Installing and servicing of heating equipment can be hazardous due to gas and electrical components. Only trained personnel should install or service heating equipment. Untrained personnel can perform basic maintenance such as cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on heating equipment, observe precautions in the literature, on tags, and on labels attached to the unit. Follow all safety codes. Wear safety glasses and work gloves. Have a fire extinguisher available. . When you see this symbol on the furnace and in instructions or manuals, be Recognize safety information. This is the safety-alert symbol alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies a hazard which could result in personal injury or death. CAUTION is used to identify 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. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
INTRODUCTION IMPORTANT: Only the furnace sizes listed in Tables 2, 3, 4, and 5 can be twinned. Both furnaces must have the same product number, including heating and cooling sizes, to achieve correct operation. → This furnace twinning kit P/N KGATW0501HSI permits connection of 2 upflow, single-speed, non-condensing furnaces (See Fig. 1 and 2); 2 upflow, 2-speed, non-condensing furnaces (See Fig. 1 and 12); 2 upflow, single-speed, condensing furnaces (See Fig. 17 and 18) or 2 upflow, 2-speed, condensing furnaces (See Fig. 18 and 30) to operate as a single unit on the same duct work. The kit is applicable only to upflow furnaces listed in Tables 2, 3, 4, and 5. A single non-condensing furnace shall NOT be twinned with a single condensing furnace or with a non-condensing furnace with a different number of speeds. Variable-speed furnaces shall not be twinned. DESCRIPTION AND USAGE
→ This twinning kit is designed for use in 2 upflow, single-speed, non-condensing, hot surface ignition (HSI) furnaces as shown in Table 2; 2 upflow, 2-speed, non-condensing, HSI furnaces as shown in Table 3; 2 upflow, single-speed, condensing HSI furnaces as shown in Table 4; 2 upflow, 2-speed, condensing HSI furnaces as shown in Table 5. Refer to the appropriate section for your furnaces. SECTION I: Models 58PAV, 58WAV, 383KAV, 395CAV, 480BAV, GB1AAV, and PG8UAA Upflow Single-Speed Non-Condensing HSI Furnaces • Single-Stage Heat with Single-Stage Gas-Heat Thermostat • Two-Stage Heat with 2-Stage Gas-Heat Thermostat SECTION II: Models 58TUA, 58UXT, 330AAV, and 330JAV Upflow 2-Speed Non-Condensing HSI Furnaces • Two-Stage Heat with Single-Stage Gas-Heat Thermostat • Two-Stage Heat with 2-Stage Gas-Heat Thermostat SECTION III: Models 58MCA, 58MSA, 58MXA, 340MAV, 345MAV, 350MAV, 490AAV, and PG9MAA Upflow Single-Speed Condensing HSI Furnaces • Single-Stage Heat with Single-Stage Gas-Heat Thermostat
→ SECTION IV: Models 58MTA and 352MAV Upflow 2-Speed Condensing HSI Furnaces
• Two-Stage Heat with Single-Stage Gas-Heat Thermostat • Two-Stage Heat with 2-Stage Gas-Heat Thermostat The furnaces must be installed to ensure sufficient return air. A combination of 1 full side and bottom inlet plenum or bottom only inlet plenum shall be used for return air to each furnace. The preferred method is to have all return air brought into the bottom of the furnaces through a common bottom plenum. The bottom return-air plenum shall be at least as high as the width of the furnace bottom return-air opening. When there are height limitations, the bottom return-air plenum height can be reduced to 8 in. minimum if 1 entire side return-air opening of each furnace is used in conjunction with the bottom return opening. Rear inlet plenums shall not be used. (See Fig. 2, 12, 17, or 30.) WARNING: Do not remove the center return-air partitions between the furnaces. Failure to follow this warning could result in improper auxiliary limit operation, fire, personal injury, or death. Staged heating operation is permitted only with this twinning kit. With the 2-speed, non-condensing furnaces, low-gas heat in both furnaces is used for first-stage heat, and high-gas heat in both furnaces is used for second-stage heat. With the single-speed, non-condensing, and condensing furnaces, the left-hand furnace is used for first-stage heat, and both furnaces are used for second-stage heat. This kit ensures both furnace blowers operate simultaneously so air flows through the duct work rather than recirculating in a loop between the furnaces. NOTE: As a result of staged heating with single-speed furnaces, the air temperature distribution in the supply plenum may be uneven when only 1 furnace is heating. NOTE: Refer to the Installation, Start-Up, and Operating Instructions supplied with each furnace for information on venting, clearances, start-up, maintenance, and other information not covered in this publication. —2—
See Table 1 for kit contents. Table 1—Kit Contents DESCRIPTION Foam Strip Relay and Harness Assembly (TKR) Wiring Label Schematic Diagram (Single-Speed NonCondensing) Wiring Label Connection Diagram (Single-Speed NonCondensing) Wiring Label Schematic Diagram (2-Speed Non-Condensing) Wiring Label Connection Diagram (2-Speed NonCondensing) Wiring Label Schematic Diagram (Single-Speed Condensing) Wiring Label Connection Diagram (Single-Speed Condensing) Wiring Label-Schematic Diagram (2-Speed Condensing) Wiring Label-Connection Diagram (2-Speed Condensing) Auxiliary Limit Switch Harness-Master Furnace (ALS-M) Auxiliary Door Switch/Limit Switch Harness Slave Furnace (ALS-S/ILK-1) No. 6 X 3/4-in. LG Sheet Metal Screw 1/4-in. Quick-Connect Wire Terminal Wire Tie Snap Bushing Strain Relief Bushing Installation Instructions
PART NO. 313596-201 320770-301
QUANTITY 4 1
322867-101
1
322866-101
1
322032-401
1
322031-401
1
322865-101
1
322864-101
1
326684-201 326685-201 320773-701
1 1 1
320777-701
1
AL76AZ128 HY60AM065 HY76TB125 HY93NH070 HW60ZW250 AG-GATW-11
7 1 2 2 2 1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS CAUTION: Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic 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 CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND. 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. SECTION I: MODELS 58PAV, 58WAV, 383KAV, 395CAV, 480BAV, GB1AAV, AND PG8UAA UPFLOW SINGLE-SPEED NON-CONDENSING HSI FURNACES NOTE: The furnace installed on the left-hand (LH) side will be referred to as the LH furnace, and the furnace installed on the right-hand (RH) side as the RH furnace throughout these instructions. PROCEDURE 1—INSTALL FURNACES Refer to Fig. 1 and 2 for appearance and dimensional drawing of twinned furnaces and their connection locations. 1. Select 2 identical heating and airflow furnaces. (See Table 2.) 2. Remove bottom closure panels from both furnaces. (See Fig. 3.) a. Remove 2 screws from bottom front panel. b. Rotate front panel downward to remove. c. Remove bottom closure panel and discard. d. Reinstall bottom front panel. 3. If return air is to enter 1 side of each furnace, cut open 1 entire return-air opening in appropriate side of each furnace. (See Fig. 2.) —3—
JUNCTION BOX
JUNCTION BOX
AUXILIARY BLOWER DOOR SWITCH
BLOWER DOOR SWITCH
BLOWER DOOR SWITCH TKR RELAY
10″
TWIN/ TEST CONNECTION
AUXILIARY LIMIT SWITCHES A95227
Fig. 1—Twinning Kit Installed on Non-Condensing Furnaces 4. Apply 2 factory-supplied foam strips to mating side of each furnace. Locate strips equal distance from top and bottom as shown in Fig. 4. 5. Remove gas hole closure from RH furnace only and power hole closure from LH furnace only as indicated in Fig. 2. 6. Remove 7/8-in. diameter accessory hole closures from mating sides of furnaces. (See Fig. 4.) 7. Position furnaces against each other on return-air plenum. Adjust and shim each furnace to align 7/8-in. diameter holes in both furnaces. 8. Drill two 1/8-in. holes, approximately 1 in. below discharge flange, from inside top of discharge opening and through both furnaces. (See Fig. 5.) 9. Drive 1 factory-supplied No. 6 X 3/4-in. LG screw through each hole and tighten until furnaces are secure and foam strips have sealed gap between furnaces. 10. Insert 1 snap bushing through each adjoining accessory hole of each furnace. 11. Remove 7/8-in. diameter knockout from blower shelf of LH furnace near front right corner. 12. Insert 1 strain relief bushing through blower shelf hole. 13. Connect return- and supply-air ducts to furnaces. Seal duct connections to prevent air leakage. 14. Move 115-v junction box JB in LH furnace from right-hand side to left-hand side. For models produced before January 1995, blower door switch ILK in LH furnace must also be moved from right-hand side to left-hand side. WARNING: DO NOT use the back of the furnace for return-air duct connections as limit cycling will occur. A failure to follow this warning can cause a fire, personal injury, or death. PROCEDURE 2—CONNECT ELECTRICAL COMPONENTS—HEATING WARNING: Make no connections between the R 24-vac connector in 1 furnace and the R 24-vac connector in other furnace. Failure to follow this warning can cause a fire, personal injury, or death. See electrostatic discharge precaution on page 2. 1. Remove control doors and blower access doors from both furnaces. 2. Install twinning kit relay (TKR) and harness assembly. The twinning kit can be used for single-stage or 2-stage heating operation. —4—
AIRFLOW
AI
MASTER OR LH FURNACE 28
A 13⁄16″
1⁄2″
F D
2 1⁄16″
1″ 7⁄8-
IN. DIA HOLE POWER ENTRY 7⁄8-IN. DIA HOLE CLOSURE ACCESSORY
FLUE COLLARS
D
7⁄8-IN.
DIA CLOSURE ENTRY 1 1⁄2-IN. D CLOSUR R.H. GA
5 3⁄8″ 12 5⁄16″
13⁄16″
5 13⁄16″
2 11⁄16″
1 3⁄4-IN. DIA HOLE GAS ENTRY
39 7⁄8″
HOLE THERMOSTAT WIRE ENTRY
7⁄8-IN. DIA CLOSURE 1⁄2-IN. DIA CLOSURE WIRE ENT
2 3⁄8″
2 3⁄8″
1⁄2-IN.DIA
SIDE INLET 14 1⁄2″
1
3⁄4″ 11⁄16″
23 1⁄4″
24 5⁄16″ BOTTOM INLET
3″
11⁄16″
E
E
INLET
INLET
11⁄16″
A93532
Fig. 2—Dimensional Drawing for Twinned Single-Speed Non-Condensing Furnaces Table 2—58PAV, 58WAV, 383KAV, 395CAV, 480BAV, GB1AAV, and PG8UAA Single-Speed Non-Condensing Furnace Dimensions (In.) INPUT HEATING SIZE (BTUH) 88,000 110,000 110,000 132,000 132,000 154,000
NOMINAL COOLING SIZE (BTUH) 48,000 48,000 60,000 48,000 60,000 60,000
A
D
E
F
42-5/16 42-5/16 49-5/16 42-5/16 49-5/16 49-5/16
19-3/8 19-3/8 22-7/8 19-3/8 22-7/8 22-7/8
19-1/2 19-1/2 23 19-1/2 23 23
40-11/16 40-11/16 47-11/16 40-11/16 47-11/16 47-11/16
This kit applies to the above furnaces with the date codes of 1594 and later.
Single-Stage Heat with Single-Stage Gas-Heat Thermostat (Field Supplied) NOTE: This application allows both furnaces to operate as 1 furnace in gas heat mode as determined by single-stage thermostat operation. Both furnaces operate in heating mode simultaneously. See furnace Installation, Start-Up, and Operating Instructions for further details on this heating mode. a. Secure relay of TKR assembly to LH furnace control mounting bracket using 2 factory-supplied No. 6 X 3/4-in. LG screws. See Fig. 6 for location of holes to be drilled. NOTE: See Fig. 7. b. Connect TKR white wire labeled W from TKR to LH furnace control thermostat connection W. c. Connect TKR black wire labeled C from TKR to LH furnace control thermostat connection COM 24V. d. Connect TKR yellow wire labeled TEST/TWIN (loose wire end near TKR relay) to LH furnace control TEST/TWIN terminal. e. Route remaining 4 loose TKR wires through: (1.) Strain relief bushing previously installed in 7/8-in. hole in right-hand side of blower shelf. (2.) Gas control compartment of LH furnace. (3.) Snap bushings previously installed between furnaces. (See Fig. 4.) f. Connect TKR red wire labeled R-SLAVE from TKR to RH furnace control thermostat connection R. g. Connect TKR white wire labeled W-SLAVE from TKR to RH furnace control thermostat connection W. h. Connect TKR black wire labeled C-SLAVE from TKR to RH furnace control thermostat connection Com 24V. —5—
O
1″
5 3⁄8″ 5
SLAVE OR 2 1⁄16″
13⁄16″
BOTTOM CLOSURE PANEL FRONT FILLER PANEL A93047
Fig. 3—Removing Bottom Closure Panel
11 3⁄16″
REMOVE 7⁄8-IN. DIA ACCESSORY HOLE CLOSURE FOAM STRIPS
RH FURNACE
Fig. 5—Attaching Furnaces Together
Fig. 4—Location of Foam Strips
A91166
A93533
i. Connect TKR yellow wire labeled TEST SLAVE from LH furnace control TEST terminal to RH furnace control TEST terminal. Two-Stage Heat with 2-Stage Gas-Heat Thermostat (Field Supplied) NOTE: ALL thermostat connections are to be made to LH furnace control ONLY. (See Fig. 7.) NOTE: This application allows only the LH furnace to operate for first-stage heat mode or both furnaces to operate for second-stage heat mode as determined by a 2-stage thermostat. See furnace Installation, Start-Up, and Operating Instructions for further details on this heating mode. To operate furnaces in 2-stage heating mode when a 2-stage thermostat controls the staging, install TKR as described above then modify TKR wiring as follows: a. Disconnect TKR white wire labeled W from the LH furnace control thermostat connection W. b. Cut off terminal of TKR white wire labeled W and strip 1/4 in. c. Connect 2-stage thermostat W2 connection to TKR white wire labeled W. CAUTION: Supply-air temperature will be uneven left-to-right when only master system is operating. NOTE: ALL other 2-stage thermostat connections are to be made to LH furnace control ONLY. (See Fig. 8.) 3. Install LH furnace auxiliary limit switch harness ALS-M. NOTE: LH furnace ALS-M assembly DOES NOT include door switch. a. Drill 1/8-in. hole in blower housing 10 in. below blower shelf. (See Fig. 1.) b. Position ALS-M so reset button faces front of furnace. c. Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. d. Disconnect red transformer wire from LH furnace control SEC-1 connection. e. Cut off the 3/16-in. quick-connect terminal from red transformer wire. —6—
TKR RELAY
CONTROL MOUNTING BRACKET
1⁄4″
1 1⁄2″ 1 3
2 4
W2
ON OFF
COM 24 V
1 2 3 4
W/W1 Y/Y2 R G HUM 1
LED
TWIN TEST
MASTER SLAVE 1 2
1
5
4
8
7
3 6 9
10 11
12 SEC-1
PR1 2 5 8
3 6 9
L2
PR2
COM
EAC-2
PARK
EAC-1
7
FU1 3
4
L1
HI-COOL
HI-GAS -HEAT
LO-GAS -HEAT
1
SEC-2
CONTROL
A93535
Fig. 6—Twinning Kit Relay Mounted on Control Mounting Bracket for LH Furnace (Two-Stage Control Shown)
f. Strip the red wire 1/8 in. and secure the factory-supplied 1/4-in. quick-connect terminal. g. Connect red transformer wire connector to ALS-M wire connector PL7 labeled TRANS ASSY. h. Connect ALS-M wire connector labeled DOOR SWITCH or SEC 1 to LH furnace control SEC-1 terminal. i. Route 2-wire ALS-M connector PL6 through: (1.) Strain relief bushing previously installed in 7/8-in. hole in right-hand side of blower shelf. (2.) Gas control compartment of LH furnace. (3.) Snap bushings previously installed between furnaces into gas control compartment of RH furnace. 4. Install RH furnace auxiliary door switch and auxiliary limit switch harness ALS-S/ILK-1. NOTE: RH furnace auxiliary limit switch harness assembly ALS-S/ILK-1 has door switch included. a. Drill 1/8-in. hole in blower housing 10 in. below blower shelf. (See Fig. 1.) b. Position ALS-S with terminals facing front of furnace. c. Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. d. Relocate RH furnace junction box JB from left side to right side as shown in Fig. 1 if JB is not at right-hand side of RH furnace. For models produced before January 1995, blower door switch ILK must also be moved when JB changes location. e. Position auxiliary door switch ILK-1 on left-hand side of RH furnace. f. Secure auxiliary door switch ILK-1 using factory-supplied No. 6 X 3/4-in. LG screw. g. Route 2-wire harness connector PL6 of ALS-S/ILK-1 assembly up through snap bushing in 7/8-in. hole in left side of blower shelf and into gas control compartment. h. Connect RH ALS-S connector PL6 to LH ALS-M connector PL6 that was routed through furnace casings. 5. Select identical blower motor speed taps at control center motor connectors in both furnaces. CAUTION: Failure to select identical blower speed taps in both furnaces can result in overheating of furnace components and possible loss of furnace operation and damage to the furnaces. 6. Dress wires to ensure they do not contact sharp or moving parts nor interfere with blower operation, removal of filters, or operation of switches. 7. Make all thermostat connections to LH furnace only. —7—
SINGLE-STAGE INDOOR THERMOSTAT NOTES: 1. TRANSFORMER = 115 VAC PRIMARY/24 VAC SECONDARY/40 VA. 2. RELAYS = 24 VAC COILS/PILOT DUTY/NORMALLY OPEN.
W R G C Y
LEFT HAND FURNACE (MASTER) Y
COIL
C
G
R
W
TWIN TEST
RELAY 1
RIGHT HAND FURNACE (SLAVE) Y
C
G
R
W
TWIN TEST
YEL BLK
BLK RED 4
WHT
(FIELD SUPPLIED) NOTE 2
2
WHT
TKR 24 VAC TRANS (FIELD SUPPLIED) 115 VAC
NOTE 1
C
Y
OUTDOOR UNIT NO. 1
C
Y
OUTDOOR UNIT NO. 2 A97116
Fig. 7—Twinning 2 Single-Speed Outdoor Units with 2 Single-Speed Furnaces with a Single-Stage Thermostat PROCEDURE 3—CONNECT ELECTRICAL COMPONENTS-COOLING WARNING: Make no connections between the R 24-vac connector in 1 furnace and the R 24-vac connector in other furnace. Failure to follow this warning can cause a fire, personal injury, or death. When installing twinned outdoor units with twinned gas furnaces, it is necessary to use a field-supplied 24-vac pilot-duty relay and a field-supplied 24/115-vac transformer as shown in Fig. 7 or 8 to prevent overloading furnace 24/115-vac transformer. PROCEDURE 4—VENTING Refer to Installation, Start-Up, and Operating Instructions supplied with each furnace for venting information. CAUTION: When common-venting twinned, Category I (negative-pressure venting), non-condensing furnaces, excessive condensate may occur as a result of oversized vent systems. Dedicated vents and/or proper vent sizing per the furnace Installation, Start-Up, and Operating Instructions will reduce the potential for condensation. PROCEDURE 5—GAS SUPPLY PIPING NOTE: All gas connections must be made through exposed outer side of each furnace. Do not common connect any connection other than supplyand return-air ducts. Furnaces are recommended to be provided with a single shutoff valve. However, individual shutoff valves may be required by local codes or jurisdictions. Refer to Installation, Start-Up, and Operating Instructions provided with each furnace for additional gas supply information. PROCEDURE 6—ELECTRICAL SUPPLY CONNECTIONS NOTE: All electrical power connections must be made through exposed outer side of each furnace. Do not common connect any connection other than supply- and return-air ducts. —8—
TWO-STAGE INDOOR THERMOSTAT W2 W/W1 NOTES: 1. FOR TWO-STAGE COOLING, USE RELAY 1 AND 2 (FIELD SUPPLIED) AS SHOWN. 2. TRANSFORMER = 115 VAC PRIMARY/24 VAC SECONDARY/40 VA. 3. RELAYS = 24 VAC COILS/PILOT DUTY/NORMALLY OPEN. 4. FOR A DUAL-CIRCUITED SINGLE EVAPORATOR COIL THAT COVERS BOTH FURNACE AIR OUTLETS, INTERCHANGE THE THERMOSTAT CONNECTIONS AT Y1 AND Y/Y2 FOR STAGED BLOWER OPERATION.
R G C Y1 Y/Y2
NOTE 1
LEFT HAND FURNACE (MASTER) COIL
COIL
RELAY 2
RELAY 1
Y
C
G
R
W
TWIN TEST
NOTE 1
RIGHT HAND FURNACE (SLAVE) Y
C
G
R
W
TWIN TEST
YEL BLK
BLK
(FIELD SUPPLIED) NOTE 3
RED
4 TKR
WHT 2
WHT
24 VAC TRANS (FIELD SUPPLIED) C
115 VAC NOTE 2
Y
OUTDOOR UNIT NO. 2
C
Y
OUTDOOR UNIT NO. 1 A97117
Fig. 8—Twinning 2 Single-Speed Outdoor Units with 2 Single-Speed Furnaces with a 2-Stage Thermostat 1. Each furnace shall be connected to its own 115-vac power supply. The twinning kit installation interconnects the furnaces, allowing them to operate as a single furnace. The L1 (black) connection to each furnace must be connected to circuit breakers connected to the same service panel 115-vac phase leg. On single-phase (residential) systems, each furnace circuit breaker should be located directly across from each other in service panel, or each furnace circuit breaker should be located on the same side of service panel, but must skip 1 space to be connected to the same leg of the 1-phase power supply. On 3-phase (commercial) systems, each furnace circuit breaker should be located directly across from each other in service panel, or each furnace circuit breaker should be located on the same side of service panel, but must skip 2 spaces to be connected to the same leg of the 3-phase power supply. The proper 115-vac phasing of furnace connections permits 24-vac transformer phasing as described below. 2. Phasing of the connected 24-vac transformer secondary circuits can be determined with the LED status of both furnaces. See furnace Installation, Start-Up, and Operating Instructions and status code labels on blower doors. The furnaces’ transformers’ black leads should be connected to PR1 connectors and white leads to PR2 connectors on controls. If 1 or both LEDs are rapidly flashing, disconnect lead at TEST/TWIN terminal of LH furnace and observe LED at each furnace. IF: a. Both LEDs are on continuously: System phasing is okay. b. One or both LEDs are rapidly flashing: (1.) Line voltage polarity is reversed —9—
BLOWER OFF DELAY SWITCH OR JUMPER WIRE
G
24-VAC THERMOSTAT LEAD TERMINALS
R Y
TEST/TWIN
W Com 24V HUM
SEC-1
LED OPERATION & DIAGNOSTIC LIGHT
24-VAC TRANSFORMER SEC-2
3-AMP FUSE
SPARE 1
COOL HEAT
BLOWER SPEED SELECTION TERMINALS SPARE 2
115-VAC (L1) POWER SUPPLY
115-VAC (L2) NEUTRAL CONNECTION A95228
Fig. 9—Single-Stage Furnace Control (2.) Reverse SEC-1 and SEC-2 in furnace with rapid flashing LED. c. One LED is off, 1 LED is on continuously: (1.) The 24-vac circuit is inoperative on furnace with LED light off. (2.) Check transformers, auxiliary limits, and door switches in both furnaces and correct problem. 3. Reconnect lead at TWIN/TEST terminal of LH furnace and observe LED at each furnace. The LEDs will glow steady for proper phasing. PROCEDURE 7—START-UP AND ADJUSTMENT Refer to Installation, Start-Up, and Operating Instructions supplied with furnaces for detailed information. 1. Shut off all power and gas to both furnaces. 2. Position blower off delay switches on controls in BOTH furnaces to SAME desired gas heat blower off delay. (See Fig. 9.) See furnace Installation, Start-Up, and Operating Instructions for further details. If 1 furnace control has blower off delay switches and the other has a fixed jumper wire which sets blower off delay at 135 sec, the control with selectable switches MUST be set for 135 sec off delay. 3. Attach twinning connection diagram label over existing wiring label on inside of LH furnace blower door. 4. Attach twinning schematic diagram label over existing wiring label on inside of RH furnace blower door. 5. Turn on power and gas to both furnaces. 6. Reinstall blower access doors on both furnaces. 7. Operate furnaces through 2 cycles in each mode to confirm correct operation by operating only thermostat. a. Single-stage gas heating thermostat R-to-W for gas heat. First stage of a 2-stage thermostat causes LH furnace to operate in gas-heat mode. b. First and second stage of 2-stage heating thermostat R-to-W/W1-and-W2 causes both furnaces to operate in gas-heat mode. c. Thermostat R-to-G for continuous fan or low-cooling blower. d. Cooling thermostat R-to-G-and-Y for single-speed cooling blower. 8. Reinstall control doors on both furnaces. 9. Instruct user in operation of furnace and thermostat. PROCEDURE 8—SEQUENCE OF OPERATION See Fig. 10 and 11 for single-speed non-condensing furnace twinning connection and schematic wiring diagrams while reviewing the sequence of operation. —10—
Twinning operation is controlled by LH furnace. The TWIN/TEST and COM 24 connection wires ensure the 2 furnaces coordinate their blower operation. When either furnace requires blower operation, both furnaces operate their blowers at the same speed. Both furnaces operate simultaneously in the same mode: heat, cool, or continuous fan. Exceptions can occur if a safety switch on either furnace is activated (such as pressure switch, flame roll-out switch, main limit switch, draft safeguard switch, twinning kit auxiliary limit switch, or flame-proving sensor). In such a case, the other furnace continues to operate unless open switch is the flame roll-out, main limit, or twinning kit auxiliary limit switch, in which case both furnaces respond. Before performing component test, disconnect TKR yellow wire labeled TEST from LH furnace control TEST/TWIN terminal. After removing yellow wire, component test can be initiated on each furnace individually as stated in Installation, Start-Up, and Operating Instructions. Single-Stage Heat with Single-Stage Gas-Heat Thermostat See Section I, Procedure 2 for furnace and kit components used. 1. Single-stage thermostat causes both furnaces to operate in heating mode. 2. Operation in ALL modes is the same for twinned furnaces as for an individual furnace. See furnace Installation, Start-Up, and Operating Instructions for more information on sequence of operation. Two-Stage Heat with 2-Stage Gas-Heat Thermostat See Section I, Procedure 2 for furnace and kit components used. 1. The 2-stage thermostat causes the furnaces to operate in first-stage heat (LH furnace operates in heat while RH furnace blower operates but RH furnace is not heating) or causes the furnaces to operate in second-stage heat (both furnaces operate in heat), depending on whether 1 or 2 thermostat stages are calling for heat. 2. Operation in ALL modes is the same for twinned furnaces as for an individual furnace. See furnace Installation, Start-Up, and Operating Instructions for more information on sequence of operation. SECTION II: MODELS 58TUA, 58UXT, 330AAV, AND 330JAV UPFLOW 2–SPEED NON-CONDENSING HSI FURNACES PROCEDURE 1—INSTALL FURNACES NOTE: Multipoise units must be installed in UPFLOW configuration. Refer to Fig. 1 and 12 for appearance and dimensional drawing of twinned furnaces and their connection locations. 1. Select 2 identical heating and airflow furnaces. (See Table 3.) 2. Remove bottom closure panels from both furnaces. (See Fig. 3.) a. Remove 2 screws from bottom front panel. b. Rotate front panel downward to remove. c. Remove bottom closure panel and discard. d. Reinstall bottom front panel. 3. If return air is to enter 1 side of each furnace, cut open 1 entire return-air opening in appropriate side of each furnace. (See Fig. 12.) 4. Apply 2 factory-supplied foam strips to mating side of each furnace. Locate strips equal distance from top and bottom as shown in Fig. 4. 5. Remove gas and power hole closures from RH furnace only as indicated in Fig. 12. 6. Remove 7/8-in. diameter accessory hole closures from mating sides of furnaces. (See Fig. 4.) 7. Position furnaces against each other on return-air plenum. Adjust and shim each furnace to align 7/8-in. diameter holes in both furnaces. 8. Drill two 1/8-in. holes, approximately 1 in. below discharge flange, from inside top of discharge opening and through both furnaces. (See Fig. 5.) 9. Drive 1 factory-supplied No. 6 X 3/4-in. LG screw through each hole and tighten until furnaces are secure and foam strips have sealed gap between furnaces. 10. Insert 1 snap bushing through each adjoining accessory hole of each furnace. 11. Remove 7/8-in. diameter knockout from blower shelf of LH furnace near front right corner. 12. Insert 1 strain relief bushing through blower shelf hole. 13. Connect return- and supply-air ducts to furnaces. Seal duct connections to prevent air leakage. 14. Move 115-v junction box JB in LH furnace from right-hand side to left-hand side. For models produced before January 1995, blower door switch ILK in LH furnace must also be moved from right-hand side to left-hand side. WARNING: DO NOT use the back of the furnace for return-air duct connections as limit cycling will occur. A failure to follow this warning can cause a fire, personal injury, or death. PROCEDURE 2—CONNECT ELECTRICAL COMPONENTS—HEATING WARNING: Make no connections between the R 24-vac connector in 1 furnace and the R 24-vac connector in other furnace. Failure to follow this warning can cause a fire, personal injury, or death. See electrostatic discharge precaution on page 2. 1. Remove control and blower access doors from both furnaces. —11—
WHT BLK
DSS
4
PRS
NOTE #15
LGPS NOTE #15
TEST/TWIN
ORN
ORN
90 SEC 180 SEC PL1
225 SEC
BLU
NOTE #5
COOL SPARE-1
PL3 PR2
1 2 3
SEC-1
EAC-2
RED
BRN OL
HSIR
YEL (MED-HI) START
NOTE #7
IDR
TRAN
L2 BRN
WHT
PL3
PL2
BLWM
RED (LO)
120 VAC L1
1 2
PR1
2
PL5
WHT
IDM
WHT BLK
1
PR2 C OM
EAC-2
IDM BLK
GRN ILK
WHT
2
BLK
HSI
BLK
FU2 HSI
GRN
LEGEND
GV GVR HI/LO HSI HSIR HUM IDM IDR ILK ILK-1 JB LED LGPS LS OL
HEAT SPARE-2 EAC-1
WHT
BLK
BLK
FUSED DISCONNECT SWITCH (WHEN REQ’D) NOTE #4
BLK
BLK
BLK
BLK
WHT
JB
WHT BLK
ALS-M ALS-S BLWR BLWM CAP DSS EAC-1 EAC-2 FL FRS FSE FU1 FU2
COOL SPARE-1
WHT
WHT
1
1 2 3
24 VAC-3A FUSE
WHT (COM) BLK
PL5
BLOWER SPEED SELECT
BLWR
BLU (MED-LO)
C OM
SEC-2
HI/LO RELAY FU1
GRN HEAT SPARE-2 EAC-1
3 2 1 6 5 4 9 8 7 WHT
225 SEC
SLAVE OR RH FURNACE
BLK
L2
NOTE #3
RE
GVR
WHT
BLOWER SPEED SELECT
L PL1
180 SEC 2-C
NOTE #8 1 1 PL6 ORN ORN ILK-1 ALS-S BLU ORN 2 2 BLU NOTE #8 RED PL7 ALS-M WHT (COM)
BLK (HI)
LED
135 SEC
GV FRS1
(WHEN USED)
BLK YEL
TEST/TWIN
BLU
SEC-2
24 VAC-3A FU1 FUSE
1 2
FSE
G R Y W OM 24V HUM
90 SEC
3-P
FL
RED
HI/LO RELAY
PL2
1-M
BLOWER OFF DELAY SELECTION CHART
3 BLK
GRN SEC-1
BLWR
120 VAC L1 PR1
WHT
BLU
CAP
IDR
LS
1.0 AMP
HSIR
3 2 1 6 5 4 9 8 7
GVR MASTER OR LH FURNACE
FRS2
RED
NOTE #12 (NOT ON ALL MODELS)
BLK 1
BLOWER SW1 OFF DELAY SW2 C
PCB
TKR
135 SEC
NOTE #8
2
WHT
YEL (WHEN USED)
LED
WHT
RED
YEL
RED
NOTE #12 (NOT ON ALL MODELS) BLOWER OFF DELAY SELECTION CHART
WHT
PCB
G R Y W C OM 24V HUM
1.0 AMP
NOTES #9 AND #14 BLOWER SW1 OFF DELAY SW2
MASTER AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) PCB SLAVE AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) BLOWER MOTOR RELAY, SPST-(N.O.) PL1 BLOWER MOTOR, 3- OR 4-SPEED, PERMANENT-SPLIT-CAPACITOR PL2 CAPACITOR DRAFT SAFEGUARD SWITCH, AUTO-RESET, SPST-(N.C.) PL3 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.) PL5 ELECTRONIC AIR CLEANER CONNECTION (COMMON) PL6 FUSIBLE LINK FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.) PL7 FLAME-PROVING SENSOR ELECTRODE PRS FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED FUSE OR CIRCUIT-BREAKER CURRENT-INTERRUPT DEVICE TEST / TWIN (FIELD INSTALLED & SUPPLIED) TKR GAS VALVE-REDUNDANT OPERATORS GAS VALVE RELAY, DPST-(N.O.) TRAN BLOWER MOTOR SPEED CHANGE RELAY, SPDT HOT SURFACE IGNITER (115 VAC) HOT SURFACE IGNITER RELAY, SPST-(N.O.) 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.) INDUCED DRAFT MOTOR, SHADED-POLE INDUCER MOTOR RELAY, SPST-(N.O.) BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) SLAVE AUX. BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) JUNCTION BOX LIGHT-EMITTING DIODE FOR STATUS CODES LOW GAS-PRESSURE SWITCH, SPST (N.O.) LIMIT SWITCH, AUTO RESET, SPST(N.C.) AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SWITCH, SPST-(N.C.)
PRINTED CIRCUIT BOARD 9-CIRCUIT CONNECTOR 2-CIRCUIT CONNECTOR 3-CIRCUIT IDM CONNECTOR 2-CIRCUIT HSI CONNECTOR 2-CIRCUIT TWINNING KIT CONNECTOR
JUNCTION UNMARKED TERMINAL PCB CONTROL TERMINAL FACTORY WIRING (115VAC) FACTORY WIRING (24VAC)
1-CIRCUIT TWINNING KIT IN-LINE SPLICE PRESSURE SWITCH, SPST-(N.O.)
FIELD WIRING (115VAC)
COMPONENT TEST & TWIN TERMINAL
FIELD ACCESSORY WIRING (24VAC)
TWINNING KIT RELAY, SPST-(N.O.) TRANSFORMER-115VAC / 24VAC
—12—
FIELD WIRING TERMINAL, NOTE #14 FIELD GROUND EQUIPMENT GROUND FIELD SPLICE PLUG RECEPTACLE WIRES PASSING THROUGH HOLES IN
322866-101 REV. B
CASINGS FROM LH TO RH FURNACE.
NOTES:
1. If any of the for 105°C o 2. Inducer (ID auto-reset 3. Blower mo installation 4. Use only co furnace. 5. This wire m prove flame 6. Replace on 7. Yellow lead 8. Passes thr slave furna 9. Make therm 10. Make no th 11. Blower-on 2 seconds. 12. Blower-off (135 secon 90 seconds 13. Ignition-loc trials-for-ig 14. Some mod 15. Factory Co
SCHEMATIC DIAGRAM (NATURAL GAS & PROPANE) TO 115VAC FIELD DISCONNECT
MASTER OR LH FURNACE
TO 115VAC FIELD DISCONNECT NOTE #4 L2 L1
EQUIPMENT GROUND
ILK
EQUIPMENT GROUND
ILK BLWM
LO SPARE-1 MED LO HEAT MED HI NOTE #7 HI/LO SPARE-2 OL HI COOL
L1
MAKE THERMOSTAT CONNECTIONS TO ONLY THE LH FURNACE
BLWR
COM HSIR
L2
START
L1 MAKE NO THERMOSTAT CONNECTIONS TO RH FURNACE
BRN CAP GRN NOTE #3
2
PL5
COM
PASSES THROUGH HOLES IN CASINGS
IDR PR1
PR2
115VAC
1
2
PL2
PL5
HS
2
IDR PR2
115VAC
PR1
3
TRAN
1
1 IDM
ALS-M PL7
COM
EAC-2
HSI
2
PL3
1 3
TRAN
PL3
RED 24VAC
ORN
24VAC 2
YEL
TEST/TWIN
FU
FRS1
SEC-2
LS
W WHT
BLK 3
NOTE #13 (WHEN USED) PRS PL1 DSS
4 BLWR IDR
HI/LO GVR
RED
WHT
4
CPU
GVR-1
Y
G
2
W
8
HSIR
BLWR
HI/LO
IDR
3
GV GVR-1
CPU NOTE #5
Y
5
6 NOT USED
24V
9
NOT USED
6
COM 24V BLK
NOTE #12
9 PL6
ORN
ALS-S ORN
NOT
ILK-1
BLU
NOTE #8
2
LEGEND MASTER AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) SLAVE AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) BLOWER MOTOR RELAY, SPST-(N.O.) BLOWER MOTOR, 3- OR 4-SPEED, PERMANENT-SPLIT-CAPACITOR CAPACITOR MICROPROCESSOR AND CIRCUITRY DRAFT SAFEGUARD SWITCH, AUTO-RESET, SPST-(N.C.) ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.) ELECTRONIC AIR CLEANER CONNECTION (COMMON) FUSIBLE LINK FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.) FLAME-PROVING SENSOR ELECTRODE FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
ORN
NOT
BLU
1 BLU
ALS-M ALS-S BLWR BLWM CAP CPU DSS EAC-1 EAC-2 FL FRS FSE FU
2 8
G
5
COM
PL1
GVR
FSE
BL K
NO
4
WHT
2-C 1-M
LS
1
NOTE #13
3 3-P
2
RED
BLK
TKR
7
R LGPS
WHT
GVR-2
HUM
FL
(WHEN USED)
R
FRS1
SEC-2
SEC-1 NOTE #12
1
NOT U
NOTE #6
FRS2
7
HUM
1
FU
TEST/TWIN
GVR-2
HSIR
2
YEL
NOT USED
NOTE #6 SEC-1
OL
HI
EAC-1 HSIR
PL2
RED
HI/LO SPARE-2 COOL
BLWR
EAC-2 1
LO MED LO MED HI NOTE #7
SPARE-1 HEAT
BRN
COM
EAC-1
1
BLU
SLAV
NOTE #4
L2
L1
GV GVR HI/LO HSI HSIR HUM IDM IDR ILK ILK-1
GAS VALVE-REDUNDANT OPERATORS GAS VALVE RELAY, DPST-(N.O.) -1 = VALVE -2 = HUMIDIFIER BLOWER MOTOR SPEED CHANGE RELAY, SPDT HOT SURFACE IGNITER (115 VAC) HOT SURFACE IGNITER RELAY, SPST-(N.O.) 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.) INDUCED DRAFT MOTOR, SHADED-POLE INDUCER MOTOR RELAY, SPST-(N.O.) BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) SLAVE AUX. BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.)
—13—
LED LGPS LS OL PCB PL1 PL2 PL3 PL5 PL6
LIGHT-EMITTING DIODE LOW GAS-PRESSURE S LIMIT SWITCH, AUTO RE AUTO-RESET INTERNAL TEMP. SW., SPST (N.C.) PRINTED CIRCUIT BOAR 9-CIRCUIT CONNECTOR 2-CIRCUIT CONNECTOR 3-CIRCUIT IDM CONNEC 2-CIRCUIT HSI CONNEC 2-CIRCUIT TWINNING KI
AIRFLOW
AIRFL
MASTER OR LH FURNACE 28
A 13⁄16″
1⁄2″
F D
2 1⁄16″ 1″
7⁄8-
IN. DIA HOLE POWER ENTRY 7⁄8-IN. DIA HOLE CLOSURE ACCESSORY
FLUE COLLARS
D
7⁄8-IN.
DIA HO CLOSURE, PO ENTRY 1 1⁄2-IN. DIA CLOSURE R.H. GAS E
5 3⁄8″ 12 5⁄16″
13⁄16″
5 13⁄16″
2 11⁄16″
1 3⁄4-IN. DIA HOLE GAS ENTRY
39 7⁄8″
HOLE THERMOSTAT WIRE ENTRY
7⁄8-IN. DIA HO CLOSURE, AC 1⁄2-IN. DIA HO CLOSURE, TH WIRE ENTRY
2 3⁄8″
2 3⁄8″
1⁄2-IN.DIA
SIDE INLET 14 1⁄2″
1
3⁄4″ 11⁄16″
23 1⁄4″
24 5⁄16″ BOTTOM INLET
3″
11⁄16″
E
E
INLET
INLET
11⁄16″
A93532
Fig. 12—Dimensional Drawing for Twinned 2–Speed Non-Condensing Furnaces Table 3—58TUA, 330AAV, and 330JAV 2-Speed Non-Condensing Furnace Dimensions (In.) INPUT HEATING SIZE (BTUH) 80,000 100,000 100,000 120,000 120,000 130,000
NOMINAL COOLING SIZE (BTUH) 48,000 48,000 60,000 48,000 60,000 60,000
A
D
E
F
42-5/16 42-5/16 49-5/16 42-5/16 49-5/16 49-5/16
19-3/8 19-3/8 22-7/8 19-3/8 22-7/8 22-7/8
19-1/2 19-1/2 23 19-1/2 23 23
40-11/16 40-11/16 47-11/16 40-11/16 47-11/16 47-11/16
2. Determine desired furnace control operation and see appropriate section for use and application of twinning kit relay and harness assembly (TKR). Two-Stage Heat with Single-Stage Gas-Heat Thermostat (Field-Supplied) NOTE: This application allows both furnaces to operate in either high- or low-gas-heat as determined by adaptive mode of both furnace controls. See furnace Installation, Start-Up, and Operating Instructions for further details on this heating mode. a. Remove black and yellow wires from wire-tied TKR harness assembly for later use. b. Discard relay, red wire, and both white wires from TKR harness assembly. c. Use field-supplied electrical tape to insulate black wire’s 1/4-in. quick-connect terminal labeled 3. d. Connect black wire terminal labeled C to LH furnace control thermostat connection COM 24. e. Connect yellow wire terminal labeled TEST to LH furnace control TWIN/TEST terminal. f. Route black and yellow wire loose ends through snap bushings previously installed between furnaces. (See Fig. 4.) g. Connect black wire terminal labeled C-SLAVE to RH furnace control thermostat connection COM 24. h. Connect yellow wire terminal labeled TEST SLAVE to RH furnace control TWIN/TEST terminal. i. Connect yellow wire terminal labeled TEST SLAVE to RH furnace control TWIN/TEST terminal. Two-Stage Heat with 2-Stage Gas-Heat Thermostat (Field Supplied) NOTE: This attachment allows both furnaces to operate in either high- or low-gas heat as determined by thermostat’s 2-stage operation. See furnace Installation, Start-Up, and Operating Instructions for further details on this heating mode. a. Secure relay of TKR assembly to LH furnace control mounting bracket using 2 factory-supplied No. 6 X 3/4-in. LG screws. See Fig. 6 for location of holes to be drilled. —14—
OUT
1″
5 3⁄8″ 5
SLAVE OR R 2 1⁄16″ 19
13⁄16″
b. Connect TKR white wire labeled W from TKR to LH furnace control thermostat connection W/W1. c. Connect TKR black wire labeled C from TKR to LH furnace control thermostat connection COM 24. d. Connect TKR yellow wire labeled TEST (loose wire end near TKR) to LH furnace control TWIN/TEST terminal. e. Route remaining 4 loose TKR wires through: (1.) Strain relief bushing previously installed in 7/8-in. hole in right side of blower shelf. (2.) Gas control compartment of LH furnace. (3.) Snap bushings previously installed between furnaces. (See Fig. 4.) f. Connect TKR red wire labeled R-SLAVE from TKR to RH furnace control thermostat connection R. g. Connect TKR white wire labeled W-SLAVE from TKR to RH furnace control thermostat connection W/W1. h. Connect TKR black wire labeled C-SLAVE from TKR to RH furnace control thermostat connection COM 24V. i. Connect TKR yellow wire labeled TEST SLAVE from LH furnace control TWIN/TEST terminal to RH furnace control TWIN/TEST terminal. j. Proceed to item 3 to complete electrical connections. 3. Install LH furnace auxiliary limit switch harness ALS-M. NOTE: LH furnace ALS-M assembly DOES NOT include door switch. a. Drill 1/8-in. hole in blower housing 10 in. below blower shelf. (See Fig. 1.) b. Position ALS-M so reset button faces front of furnace. c. Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. d. Disconnect red transformer wire from LH furnace control SEC-1 connection. e. Cut off the 3/16-in. quick-connect terminal from red transformer wire. f. Strip red wire 1/8 in. and secure factory-supplied 1/4-in. quick-connect terminal. g. Connect red transformer wire connector to ALS-M wire connector labeled TRANS ASSY. h. Connect ALS-M wire connector labeled DOOR SWITCH or SEC 1 to LH furnace control SEC-1 terminal. i. Route 2-wire ALS-M connector PL8 through: (1.) Strain relief bushing previously installed in 7/8-in. hole in right side of blower shelf. (2.) Gas control compartment of LH furnace. (3.) Snap bushings previously installed between furnaces into gas control compartment of RH furnace. 4. Install RH furnace auxiliary door switch and auxiliary limit switch harness ALS-S/ILK-1. NOTE: RH furnace auxiliary limit switch harness assembly ALS-S/ILK-1 has door switch included. a. Drill 1/8-in. hole in blower housing 10 in. below blower shelf. (See Fig. 1.) b. Position ALS-S so terminals face front of furnace. c. Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. d. Relocate RH furnace junction box JB from left side to right side as shown in Fig. 1 if JB is not at right-hand side of RH furnace. For models produced before January 1995, blower door switch ILK must also be moved when JB changes location. e. Position auxiliary door switch ILK-1 on left side of RH furnace. f. Secure auxiliary door switch ILK-1 using factory-supplied No. 6 X 3/4-in. LG screw. g. Route 2-wire harness connector PL8 of ALS-S/ILK-1 assembly up through snap bushing in 7/8-in. hole in left side of blower shelf and into gas control compartment. h. Connect RH ALS-S connector PL8 to LH ALS-M connector PL8 that was routed through furnace casings. 5. Select identical blower speed taps at blower motor connectors in both furnaces. CAUTION: Failure to select identical blower speed taps in both furnaces can result in overheating of furnace components and possible loss of furnace operation and damage to the furnaces. 6. Dress wires to ensure they do not contact sharp or moving parts nor interfere with blower operation, removal of filters, or operation of switches. 7. Make all thermostat connections to LH furnace only. PROCEDURE 3—CONNECT ELECTRICAL COMPONENTS—COOLING WARNING: Make no connections between the R 24-vac connector in 1 furnace and the R 24-vac connector in other furnace. Failure to follow this warning can cause a fire, personal injury, or death. When installing single- and 2-stage twinned outdoor units with twinned gas furnaces, it is necessary to use a field-supplied 24-vac pilot relay and a field-supplied 24/115-vac transformer as shown in Fig. 13 to prevent overloading furnace 24/115-vac transformer. —15—
INDOOR THERMOSTAT W2
NOTES:1. TWO-SPEED FURNACES CAN BE USED WITH SINGLE-SPEED OUTDOOR UNITS. 2. TRANSFORMER = 115 VAC PRIMARY/24 VAC SECONDARY/40 VA. 3. RELAYS = 24 VAC COILS/PILOT DUTY/NORMALLY OPEN. 4. FOR 2-STAGE COOLING, USE RELAY 1 AND 2 (FIELD-SUPPLIED) AS SHOWN. 5. USE THIS WIRE ONLY FOR SINGLE-STAGE HEAT THERMOSTAT OPERATION IN ADAPTIVE HEATING MODE: HIGH-HEAT-ONLY SWITCH SW-1 IS OFF, AND LOW-HEAT-ONLY SWITCH SW-2 IS ON IN BOTH FURNACES. 6. USE THIS WIRE/TKR ONLY FOR 2-STAGE HEAT THERMOSTAT OPERATION IN NON-ADAPTIVE HEATING MODE: HIGH-HEAT-ONLY SWITCH SW-1 IS OFF, AND LOW-HEAT-ONLY SWITCH SW-2 IS OFF IN BOTH FURNACES. 7. TWINNING JUMPERS TJ SHALL BE SET IN THE APPROPRIATE POSITIONS (MASTER AND SLAVE) IN ACCORDANCE WITH THE START-UP AND ADJUSTMENT PROCEDURE.
NOTE 6
W/W1 R G C Y/Y2 NOTE 4
Y1
Y/Y2
COIL
COIL
RELAY
RELAY
NOTE 4
LEFT HAND FURNACE (MASTER) Y/Y2
C
G
NOTE 4
(FIELD SUPPLIED) NOTE 3
W/W1
BLK C NOTE 5
C
W2
TWIN TEST
Y/Y2
TEST
C
G
R
C-SLAVE
W/W1
R-SLAVE
24 VAC
C
Y1
TWIN TEST
YEL
TEST-SLAVE
NOTES 5 & 6 1
4
3 2 TKR NOTE 6
RED
NOTE 6
WHT
NOTE 6
USE ONLY TWINNING KIT PARTS
NOTE 4
BLK NOTE 6
W2
W-SLAVE
BLK
W NOTE 6 WHT
TRANS (FIELD SUPPLIED) NOTE 2 115 VAC
R
RIGHT HAND FURNACE (SLAVE)
NOTE 4
Y1
C
Y/Y2
Y1
Y/Y2
OUTDOOR UNIT NO. 2
OUTDOOR UNIT NO. 1
A98225
Fig. 13—Twinning 2 Outdoor Units with Two 2-Speed Furnaces with 1 Thermostat PROCEDURE 4—VENTING Refer to the Installation, Start-Up, and Operating Instructions supplied with each furnace for venting information. CAUTION: When common-venting twinned, Category I (negative pressure venting), non-condensing furnaces, excessive condensate may occur as a result of oversized vent systems. Dedicated vents and/or proper vent sizing per the furnace Installation, Start-Up, and Operating Instructions will reduce the potential for condensation. PROCEDURE 5—GAS SUPPLY PIPING NOTE: All gas connections must be made through exposed outer side of each furnace. Do not common connect any connection other than supplyand return-air ducts. Furnaces are recommended to be provided with a single shutoff valve. However, individual shutoff valves may be required by local codes or jurisdictions. Refer to Installation, Start-Up, and Operating Instructions provided with each furnace for additional gas supply information. PROCEDURE 6—ELECTRICAL SUPPLY CONNECTIONS NOTE: All electrical power connections must be made through exposed outer side of each furnace. Do not common connect any connection other than supply- and return-air ducts. 1. Each furnace shall be connected to its own 115-vac power supply. The twinning kit installation interconnects the furnaces, allowing them to operate as a single furnace. The L1 (black) connection to each furnace must be connected to circuit breakers connected to the same service panel 115-vac phase leg. On single-phase (residential) systems, each furnace circuit breaker should be located directly across from each other in service panel, or each furnace circuit breaker should be located on the same side of service panel, but must skip 1 space to be connected to the same leg of the 1-phase power supply. —16—
5
3
6
9
2
8
4
7
1
SET-UP SWITCHES SW4 SW3 SW2 SW1 ON OFF
PR2 PR1 L1
L2
COM HI-COOL EAC-2
HI-GAS -HEAT LO-GAS -HEAT
9
12
6
10 11
3
5
8
2
7
TWIN/TEST CONNECTOR
4
MASTER SLAVE 1
1
1
THERMOSTAT CONNECTIONS
EAC-1 PARK
SEC-1 FU1 3
MASTER
SEC-2
TWINNING JUMPER TJ
LED
SLAVE A93534
Fig. 14—Two-Stage Furnace Control On 3-phase (commercial) systems, each furnace circuit breaker should be located directly across from each other in service panel, or each furnace circuit breaker should be located on the same side of service panel, but must skip 2 spaces to be connected to the same leg of the 3-phase power supply. The proper 115-vac phasing of furnace connections permits 24-vac transformer phasing as described below. 2. Phasing of the connected 24-vac transformer secondary circuits can be determined with the LED status of both furnaces. See furnace Installation, Start-Up and Operating Instructions and status code labels on blower doors. The furnaces’ transformers’ black leads should be connected to PR1 connectors and white leads to PR2 connectors on controls. If 1 or both LEDs are rapidly flashing, disconnect lead at TEST/TWIN terminal of LH furnace and observe LED at each furnace. IF: a. Both LEDs are on continuously: System phasing is okay. b. One or both LEDs are rapidly flashing: (1.) Line voltage polarity is reversed. (2.) Reverse SEC-1 and SEC-2 in furnace with rapid flashing LED. c. One LED is off, 1 LED is on continuously: (1.) The 24-vac circuit is inoperative on furnace with LED light off. (2.) Check transformers, auxiliary limits, and door switches in both furnaces and correct problem. 3. Reconnect lead at TWIN/TEST terminal of LH furnace and observe LED at each furnace. The LEDs will glow steady for proper phasing. PROCEDURE 7—START-UP AND ADJUSTMENT Refer to Installation, Start-Up, and Operating Instructions supplied with furnace for detailed information. 1. Shut off all power and gas to both furnaces. 2. Position TWINNING JUMPERS TJ on furnace controls. (See Fig. 14.) a. The LH furnace control TWINNING JUMPER TJ MUST remain in the MASTER position. b. The RH furnace control TWINNING JUMPER TJ MUST be moved to the SLAVE position. 3. Determine desired furnace control operation and position set-up switches on furnace control. (See Fig. 14.) Two-Stage Heat with Single-Stage Gas-Heat Thermostat a. Position SW1 switch on controls in BOTH furnaces to OFF. b. Position SW2 switch on controls in BOTH furnaces to OFF. c. Position SW3 and SW4 switches on control in BOTH furnaces to desired gas-heat blower off delay. (See furnace Installation, Start-Up, and Operating Instructions for further details.) Two-Stage Heat with 2-Stage Gas-Heat Thermostat a. Position SW1 switch on controls in BOTH furnaces to OFF. b. Position SW2 switch on controls in BOTH furnaces to ON. c. Position SW3 and SW4 switches on controls in BOTH furnaces to desired gas-heat blower off delay. (See furnace Installation, Start-Up, and Operating Instructions for further details.) 4. Attach twinning connection diagram label over existing wiring label on inside of LH furnace blower door. —17—
5. Attach twinning schematic diagram label over existing wiring label on inside of RH furnace blower door. 6. Turn on power and gas to both furnaces. 7. Reinstall blower access doors on both furnaces. 8. Determine furnace model. Using appropriate section below, operate furnaces through 2 cycles in each mode to confirm correct operation by operating only the thermostat. a. Single- or 2-stage gas heating thermostat R-to-W/W1 for low-gas heat. Single-stage thermostat with adaptive heating mode causes furnace to operate in low-gas-heat mode for up to 16 minutes, and then furnace automatically switches to high-gas heat. First stage of a 2-stage thermostat without adaptive heating mode causes furnace to operate in low-gas-heat mode indefinitely. b. First- and second-stage of 2-stage heating thermostat R-to-W/W1-and-W2 for high-gas-heat. c. Thermostat R-to-G for continuous fan or 2-speed cooling low-cool blower. d. Cooling thermostat R-to-G-and-Y/Y2 for single-speed cooling blower or for 2-speed cooling high-cool blower. 9. Reinstall control doors on both furnaces.Reinstall control doors on both furnaces. 10. Instruct user in operation of furnaces and thermostat. PROCEDURE 8—SEQUENCE OF OPERATION See Fig. 15 and 16 for 2-speed non-condensing furnace twinning connection and schematic wiring diagrams while reviewing sequence of operation. Twinning operation is controlled by LH or MASTER furnace. The TWIN/TEST and COM 24V connection wires ensure the 2 furnaces coordinate their blower operation. When either furnace requires blower operation, both furnaces operate their blowers at the same speed (the highest speed required by either furnace). Both furnaces operate simultaneously in the same mode: low-gas heat, high-gas heat, low-cool, high-cool, or continuous fan. Exceptions can occur if a safety device on either furnace is activated (such as low-gas-heat or high-gas-heat pressure switch, flame roll-out switch, limit switch, draft safeguard switch, twinning kit auxiliary limit switch, or flame-proving sensor). In such a case, the other furnace continues to operate unless the safety device is the flame roll-out, limit, or twinning kit auxiliary limit switch, in which case both furnaces respond. Two-Stage Heat with Single-Stage Gas-Heat Thermostat See Section II, Procedure 2 for furnace and kit components used. NOTE: Set-up switches SW1 and SW2 in BOTH furnaces are in OFF position. 1. LH furnace control determines whether furnaces are both operating in low-gas heat or high-gas heat, depending on the control’s adaptive gas heating mode when the R-to-W/W1 circuit is closed in LH furnace. 2. Operation in all modes is the same for twinned furnaces as for an individual furnace. See furnace Installation, Start-Up, and Operating Instructions for more information on sequence of operation. Two-Stage Heat with 2-Stage Gas-Heat Thermostat See Section II, Procedure 2 for furnace and kit components used. NOTE: Set-up switches SW1 in BOTH furnaces are in OFF position, and set-up switches SW2 in BOTH furnaces are in ON position. 1. The 2-stage thermostat (NOT furnace control’s adaptive gas heating mode) determines whether furnaces are both operating in low-gas heat or high-gas heat, depending on whether 1 or both thermostat stages (W/W1 or W/W1-and-W2) are calling for heat. 2. Operation in all modes is the same for twinned furnaces as for an individual furnace. See furnace Installation, Start-Up, and Operating Instructions for more information on sequence of operation. SECTION III: MODELS 58MCA, 58MXA, 340MAV, 350MAV, 490AAV, AND PG9MAA UPFLOW SINGLE-SPEED CONDENSING HSI FURNACES PROCEDURE 1—INSTALL FURNACES NOTE: Multipoise units must be installed in UPFLOW configuration. Refer to Fig. 17 and 18 for appearance and dimensional drawing of twinned furnaces and their connection locations. 1. Select 2 identical heating and airflow furnaces. (See Table 4.) 2. Remove bottom closure panels from both furnaces. (See Fig. 3.) a. Remove 2 screws from front filler panel. b. Rotate front filler panel downward to remove. c. Remove bottom closure panel and discard. d. Reinstall front filler panel. 3. Apply 2 factory-supplied foam strips to mating side of each furnace. Locate strips equal distance from top and bottom as shown in Fig. 19. 4. Position furnaces against each other on return-air plenum. On furnaces AFTER Serial No. 2894A00001, adjust and shim each furnace to align unused condensate drain line holes in lower section of both furnaces holes which will be used for wire routing between furnaces. (See Fig. 19.) 5. Drill two 1/8-in. holes, approximately 1 in. below discharge air flange, from inside top of discharge opening and through both furnaces. (See Fig. 20.) 6. Drive 1 factory-supplied No. 6 X 3/4-in. LG screw through each hole and tighten until furnaces are secure and foam strips have sealed gap between furnaces. —18—
FURNACE CONNECTION DIAG BLK
HPS
BRN
BRN
ILK RED
WHT
GRY GRN
BLK
RED FACTORY SETTINGS
8 7 9
COM HI MED-HI MED-LO LO NOTE #4
EAC-2
PARK SEC1
1
BRN
WHT BLK YEL BLU RED
* PASSES THROUGH HOLES IN CASINGS
TRAN
RED
BLWM
BRN
R W2 COM W/W1 Y/Y2 24V
CAP
BLK
BLU
FU1
BLOWER-OFF BLOWER-OF LOW-HEAT O HIGH-HEAT O
WHT RED
BLU
WHT
L1 COMMON
SEC2
S
YEL
WHT
SW 1 2 3 4 ON OFF
BLK 1 2 MAKE THERMOSTAT CONNECTIONS TO ONLY THE LEFT HAND FURNACE.
LED
PL3
PR2 L2
HI-COOL HI-GAS HEAT
12 11 10
G HUM
FU2
FURNACE CONTROL CPU
P1 LO-GAS HEAT EAC-1
3 2
SW 1 2 3 4 ON OFF
RED
R W2 COM W/W1 Y/Y2 24V
GRN
BLK
3
BRN
PR1
M
WHT
GRN
BLK
ORN
TWIN TEST TJ
3
L2
WHT
PL2
FACTORY SETTINGS WHT BLK
2
FUSED DISCONNECT SWITCH (WHEN REQ’D) NOTE #1 BLK
RED
FURNACE CONTROL CPU
RED
1
WHT
BLK
2
ORN
YEL
BLOWER-OFF DELAY BLOWER-OFF DELAY LOW-HEAT ONLY HIGH-HEAT ONLY
WHT
BLK
GRY
WHT
L1
DSS
*
JB
ORN
FSE
NOTE #7
(WHEN USED)
YEL
RED
GRN
1
FRS1 (WHEN USED)
C NOTE #6 GRN
GRN
IDM
HSI
FRS2 RED
GV M
BLU
PL6
LS
TKR
HI P
LGPS FRS1 (WHEN USED)
RED
RED
GRY
YEL
ORN
RED
RED
WHT
NOTE #7
2 WHT
BLK
LPS
1
BLU
FRS2 RED
WHT
LS
4
ORN
BLK
3
RED
MASTER OR LH FURNACE
KEEP TWINNING JUMPER IN "MASTER" POSITION ON MASTER FURNACE.
PL9 ALS-M RED ORN
PL8 BLU 2 2 BLU
G
MAKE NO THERMO CONNECTIONS TO RIGHT HAND FURN ILK-1
ALS-S ORN
ORN 1 1 ORN
LEGEND JUNCTION
ALS-M
MASTER AUX. LIMIT SWITCH, OVERTEMP. - MANUAL RESET, SPST (N.C.)
ILK
BLOWER DOOR INTERLOCK SWITCH, SPST (N.O.)
ALS-S
SLAVE AUX. LIMIT SWITCH, OVERTEMP. - MANUAL RESET, SPST (N.C.)
JB
JUNCTION BOX
BLWM
BLOWER MOTOR, 4 SPEED, PERMANENT-SPLIT-CAPACITOR
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.)
PL1
12-CIRCUIT CONNECTOR
FACTORY CONTROL WIRI
PL2
9-CIRCUIT CONNECTOR
FIELD POWER WIRING (11
TERMINAL CONTROL TERMINAL
CAP
CAPACITOR
CPU
MICROPROCESSOR AND CIRCUITRY
DSS
DRAFT SAFEGUARD SWITCH, SPST (N.C.)
EAC-1
ELECTRONIC AIR CLEANER CONNECTION (115 VAC, 1 AMP MAX.)
EAC-2
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
PL3
3-CIRCUIT IDM CONNECTOR
FRS1
FLAME ROLLOUT SWITCH OVERTEMP.-MANUAL RESET, SPST (N.C.)
PL6
2-CIRCUIT HSI CONNECTOR
FIELD ACCESSORY WIRIN
FRS2
FLAME ROLLOUT SWITCH OVERTEMP.-MANUAL RESET, SPST (N.C.)
PL8
2-CIRCUIT TWINNING CONNECTOR
FIELD WIRING SCREW TE
FSE
FLAME-PROVING SENSOR ELECTRODE
PL9
1-CIRCUIT TWINNING CONNECTOR
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)
HUM
24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
IDM
INDUCED DRAFT MOTOR, 2-SPEED, SHADED-POLE
ILK-1
SLAVE AUX. BLOWER DOOR INTERLOCK SWITCH, SPST (N.O.)
* SW1 * SW2 * SW3 & 4 TJ
HIGH-HEAT-ONLY SWITCH, SPST (MANUAL) LOW-HEAT-ONLY SWITCH, SPST (MANUAL) BLOWER-OFF DELAY SETTING SWITCHES, SPST (MANUAL) TWINNING JUMPER, SPDT FOR MASTER OR SLAVE STATUS-(MANUAL-CHANGE-OVER)
TKR
TWINNING KIT RELAY, SPST (N.O.)
TRAN
TRANSFORMER-115VAC / 24VAC
TWIN / TEST
—19—
1-CIRCUIT TWINNING BUSS CONNECTOR, ALSO COMPONENT TEST
FACTORY POWER WIRING
FIELD GROUND EQUIPMENT GROUND FIELD SPLICE PLUG RECEPTACLE
TO 115VAC FIELD DISCONNECT SWITCH
MASTER OR LH FURNACE
NOTE #1
ILK BHI/LOR
LO
LO-GAS HEAT HI-GAS HEAT
BLWR
MAKE THERMOSTAT CONNECTIONS TO ONLY THE LEFT HAND FURNACE
BLW BLWM BRN
COM NOTE #4
COMMON HSIR
PL6
1
HSI
LO 4
IDR
PL3
7
HI
3
COM
I
TRAN SEC-2
RED
FU
N/A 5 6 N/A
SEC-1
12 N/A 2 MGVR-2
R
W/W1
MASTER
SW1
FRS2 LS
FRS1 (WHEN USED)
HUM
3
TWINNING JUMPER TJ
6
DSS
5
(WHEN USED) LGPS
YEL
SLAVE
LPS
MGVR-1
M
10
G ALS-M
C NOTE #6
P HI
W2
GV
COM SW4 SW3 SW2
BLK
MASTER AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) SLAVE AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) BLOWER MOTOR SPEED CHANGE RELAY, SPDT BLOWER MOTOR SPEED CHANGE RELAY, SPDT BLOWER MOTOR, 4-SPEED, PERMANENT-SPLIT-CAPACITOR BLOWER MOTOR RELAY, SPST-(N.O.) CAPACITOR MICROPROCESSOR AND CIRCUITRY DRAFT SAFEGUARD SWITCH, SPST (N.C.) ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.) ELECTRONIC AIR CLEANER CONNECTION (COMMON) FLAME ROLLOUT SWITCH OVERTEMP. -MANUAL RESET, SPST-(N.C.) FLAME ROLLOUT SWITCH OVERTEMP. -MANUAL RESET, SPST-(N.C.) FLAME-PROVING SENSOR ELECTRODE FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED GAS VALVE-REDUNDANT LOW-HEAT OPERATORS, 2-STAGE HIGH-HEAT PRESSURE SWITCH, SPST-(N.O.) HIGH-HEAT PRESSURE SWITCH RELAY, SPST-(N.C.) HOT SURFACE IGINITER (115 VAC) HOT SURFACE IGNITER RELAY, SPST-(N.O.) 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
G
BLK
FSE BLK 3 WHT 1
TKR
RED 4 2
BLK
WHT
ORN BLU
LEGEND ALS-M ALS-S BHI/LOR BHT/CLR BLWM BLWR CAP CPU DSS EAC-1 EAC-2 FRS1 FRS2 FSE FU GV HPS HPSR HSI HSIR HUM
Y/Y2
PASSES THROUGH HOLES IN CASINGS
7 8 N\A 11 N/A
IDM IDR IHI/LOR ILK ILK-1 JB LED LGPS LPS LS MGVR
* * *
INDUCED DRAFT MOTOR, 2-SPEED, SHADED-POLE INDUCER MOTOR RELAY, SPST-(N.O.) TJ INDUCER MOTOR SPEED CHANGE RELAY, SPDT BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) SLAVE AUX. BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) TKR JUNCTION BOX TRAN LIGHT-EMITTING DIODE FOR STATUS CODES LOW GAS PRESSURE SWITCH, SPST-(N.O.) TWIN / TEST LOW-HEAT PRESSURE SWITCH, SPST-(N.O.) LIMIT SWITCH, OVERTEMPERTURE-AUTO RESET, SPST(N.C.) 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 PL8 2-CIRCUIT TWINNING CONNECTOR PL9 1-CIRCUIT TWINNING CONNECTOR SW1 HIGH-HEAT-ONLY SWITCH, SPST-(MANUAL) SW2 LOW-HEAT-ONLY SWITCH, SPST-(MANUAL) SW3 & 4 BLOWER-OFF DELAY SETTING SWITCHES, SPST-(MANUAL)
—20—
MASTER
SW1
HPS
1
Y/Y2
W/W1
WHT
NOTE #7
NOTE #7 4
BLU
TWIN TEST
PL1
CPU
W2
R
RED
9
TWIN / TEST SLAVE
NO
2
NOTE #5
HUM
MOVE TWINNING JUMPER TO "SLAVE" POSITION ON SLAVE FURNACE.
1 HPSR
PL9
ORN
RED
IDM
PR2
115VAC
24VAC
WHT
2 1
8 PR1
H
2
9 IHI / LOR
YEL
MAKE NO THERMOSTAT CONNECTIONS TO RIGHT HAND FURNACE
PL2 3
KEEP TWINNING JUMPER IN "MASTER" POSITION ON MASTER FURNACE.
L1
HI
EAC-2
EAC-1
MED-LO MED-HI
PARK HI-COOL
ILK
L2
BRN CAP
BHT/CLR L1
TO 115VA
FURNACE SCHEMATIC DIAGRAM
EQUIPMENT GROUND
1
COM
PL8 ORN BLU
ORN
2
TWINNING JUMPER, SPDT FOR MASTER OR S STATUS-(MANUAL CHANGE-OVER) TWINNING KIT RELAY, SPST-(N.O.) TRANSFORMER-115VAC / 24VAC 1-CIRCUIT TWINNING BUSS CONNECTOR, ALS COMPONENT TEST JUNCTION TERMINAL CONTROL TERMINAL FACTORY POWER WIRING (115VAC) FACTORY CONTROL WIRING (24VAC) FIELD ACCESSORY WIRING (24VAC) CONDUCTOR ON PCB FIELD WIRING SCREW TERMINAL FIELD GROUND
26 15/16″ 26 1/4 TYP
A
24 1/2″ 22 1/4″
AIRFLOW
AIRFLOW 13/16″
2-IN. COMBUSTIONAIR CONN
F D OUTLET
D OUTLET
13/16″
7/8-IN.
DIA POWER CONN
1
/2-IN. GAS CONN
2-IN. VENT CONN 33 1/4″ TYP
32 5/8″ TYP 13/16″ 30 TYP 29 5/8″ TYP 27 5/8″
1/2-IN.
DIA THERMOSTAT ENTRY 22 11/16″
14 1/2″
7
/8-IN. DIA ACCESSORY POWER ENTRY
30 1/2″
27 1/2″ TYP
CONDENSATE DRAIN TRAP LOCATION (USED FOR LH FURNACES BEFORE SERIAL NO. 2894A00001)
24 1/2″ 17 5/16″
18 1/4″
3/8″
SIDE INLET
11/4″ 1"
23 1/4″ SIDE INLET
9 TYP
CONDENSATE DRAIN LOCATION (USED FOR LH FURNACES AFTER SERIAL NO. 2894A00001)
26 15/16″ TYP
11/16″
INLET
INLET
E
E
11/16″
CONDENSATE DRAIN TRAP LOCATION (USED FOR RH FURNACES BEFORE SERIAL NO. 2894A00001)
—21—
CONDENSAT DRAIN LOCA (USED FOR R SERIAL NO. 2
Table 4—58MCA, 58MSA, 58MXA, 340MAV, 345MAV, 350MAV, 490AAV, and PG9MAA Single-Speed Condensing Furnace Dimensions (In.) INPUT HEATING SIZE (BTUH) 60,000 80,000 80,000 100,000 100,000 120,000
NOMINAL COOLING SIZE
A
D
E
F
48,000 48,000 60,000 48,000 60,000 60,000
35 35 42 42 42 49
15-7/8 15-7/8 19-3/8 19-3/8 19-3/8 22-7/8
16 16 19-1/2 19-1/2 19-1/2 23
33-3/8 33-3/8 40-3/8 40-3/8 40-3/8 47-3/8
POWER JUNCTION BOX RELOCATED HERE
AUXILIARY LIMIT DOOR SWITCH (ILK-I)
8″ TYP
SLAVE 24-V TRANSFORMER SLAVE BLOWER ACCESS PANEL DOOR SWITCH
MASTER AUXILIARY LIMIT SWITCH (ALS-M)
SLAVE AUXILIARY LIMIT SWITCH (ALS-S)
TWINNING KIT RELAY (TKR) MASTER BLOWER ACCESS PANEL DOOR SWITCH
UNUSED CONDENSATE DRAIN LINE HOLES WITH SNAP BUSHING INSTALLED
MASTER 24-V TRANSFORMER
→
A94261
Fig. 18—Twinning Kit Installed on Single-Speed and 2-Speed Condensing Furnaces (AFTER Serial No. 2894A00001)—Single-Speed Shown 7. On furnaces AFTER Serial No. 2894A00001, insert 1 snap bushing through each adjoining unused condensate drain line hole of each furnace. (See Fig. 17 and 18.) 8. Connect return- and supply-air ducts to furnaces. Seal duct connections to prevent air leakage. 9. 115-V junction boxes JB must be located on right side of right-hand furnace and left side of left-hand furnace. Relocate as necessary. (See Fig. 18.) WARNING: DO NOT use the back of the furnace for return-air duct connections as limit cycling will occur. A failure to follow this warning can cause a fire, personal injury, or death. PROCEDURE 2—CONNECT ELECTRICAL COMPONENTS—HEATING WARNING: Make no connections between the R 24-vac connector in 1 furnace and the R 24-vac connector in other furnace. Failure to follow this warning can cause a fire, personal injury, or death. See electrostatic discharge precaution on page 2. 1. Remove blower access doors from both furnaces. 2. Install twinning kit relay (TKR) and harness (furnaces AFTER Serial No. 2894A00001). The twinning kit can be used for single-stage or 2-stage heating operation. —22—
7⁄8-IN. DIA POWER CONNECTION HOLE (USED ON FURNACES BEFORE SERIAL NO. 2894A00001)
FOAM STRIPS
UNUSED CONDENSATE DRAIN HOLE (USED ON FURNACES AFTER SERIAL NO. 2894A00001) A93538
Fig. 19—Location of Foam Strips and Hole to be Used for Twinning Kit Wire Routing SCREW DISCHARGE OPENINGS TOGETHER
A93539
Fig. 20—Attaching Furnaces Together Single-Stage Heat with Single-Stage Gas-Heat Thermostat (Field Supplied) NOTE: This application of TKR allows both furnaces to operate in heating mode simultaneously. See furnace Installation, Start-Up, and Operating Instructions for further details on this heating mode. a. Mount TKR assembly to underside of LH furnace control enclosure using 1 No. 6 sheet metal screw (field supplied). Screw hole is located to left of door switch near front edge of control. (See Fig. 21.)
→
NOTE: See Fig. 7. b. Route 3 loose wires (black, yellow, and white) from TKR assembly wire harness through T-STAT/HUM hole adjacent to door switch. (See Fig. 21.) NOTE: Cut wire tie near TKR to provide appropriate length of wires for connection. c. Connect TKR white wire labeled W from TKR to LH furnace control thermostat connection W. d. Connect TKR black wire labeled C from TKR to LH furnace control thermostat connection COM 24V. e. Connect TKR yellow wire labeled TEST to LH furnace control TEST/TWIN terminal. f. Refer to Fig. 17, 18, and 21 and route remaining 4 loose TKR wires through the following: (1.) Snap bushing previously installed between furnaces in unused condensate drain holes. (2.) RH furnace thermostat cable hole T-STAT/HUM in control box. g. Connect TKR red wire labeled R-SLAVE from TKR to RH furnace control thermostat connection R. h. Connect TKR white wire labeled W-SLAVE from TKR to RH furnace control thermostat connection W. i. Connect TKR black wire labeled C-SLAVE from TKR to RH furnace control thermostat connection COM 24V. j. Connect TKR yellow wire labeled TEST SLAVE from LH furnace control TEST/TWIN terminal to RH furnace control TEST/TWIN terminal.
→
NOTE: All field thermostat connections are to be made to LH furnace control ONLY. k. Proceed to item 3 “Install LH furnace auxiliary limit switch harness ALS-M” to complete electrical connections. Two-Stage Heat with 2-Stage Gas-Heat Thermostat (Field Supplied) —23—
CONTROL CENTER
TKR RELAY
BLOWER ACCESS PANEL DOOR SWITCH TKR HARNESS WIRES ROUTED THROUGH THERMOSTAT CABLE HOLE
TKR HARNESS WIRES TO RH FURNACE
A94245
Fig. 21—Twinning Kit Relay Mounted on Control Mounting Bracket for LH Furnace (AFTER Serial No. 2894A00001) NOTE: This modification allows LH furnace only to operate in heating mode for first-stage heat or both furnaces to operate in heating mode for second-stage heat as determined by a 2-stage thermostat. See furnace Installation, Start-Up, and Operating Instructions for further details on this heating mode. To operate furnaces in 2-stage heating mode when a 2-stage thermostat controls the staging, install TKR as described above, then modify TKR wiring as follows: CAUTION: Supply-air temperature will be uneven left-to-right when only master system is operating. NOTE: See Fig. 8. a. Disconnect TKR white wire labeled W from LH furnace control thermostat connection W. b. Cut terminal off TKR white wire labeled W and strip 1/4 in. c. Connect 2-stage thermostat W2 connection to TKR white wire labeled W.
→
NOTE: ALL other 2-stage thermostat connections are to be made to LH furnace control center ONLY. d. Proceed to item 3 “Install LH furnace auxiliary limit switch harness ALSM” to complete electrical connections. 3. Install LH furnace auxiliary limit switch harness ALS-M. For Series A/100 and B/111 of Models 58MCA, 58MXA, 340MAV, 350MAV, and 490AAV furnaces, follow the procedure below: NOTE: LH furnace ALS-M assembly DOES NOT include door switch. a. Drill 1/8-in. hole in blower housing 8 in. below blower shelf as shown in Fig. 18. b. Position ALS-M so reset button faces front of furnace. c. Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. d. Disconnect red transformer wire from LH furnace door switch. e. Connect removed red transformer wire to ALS-M wire connector labeled TRANS ASSY. f. Connect ALS-M connector labeled DOOR SWITCH or SEC 1 to LH furnace door switch, where red wire was removed. g. Route 2-wire ALS-M connector from LH furnace to RH furnace (furnaces AFTER Serial No. 2894A00001). Refer to Fig. 18 and route wires through unused condensate drain line hole with snap bushing. For Series C/121 and D/131 of Models 58MCA, 58MXA, 340MAV, 350MAV, and 490AAV and Series A/101 and B/111 of Models 58MSA, 345MAV, and PG9MAA furnaces, follow the procedure below: —24—
AUXILIARY LIMIT DOOR SWITCH AND BRACKET AS SUPPLIED
NOTCHED CORNER
BRACKET REVERSED
AUXILIARY LIMIT DOOR SWITCH A93540
Fig. 22—Reversing Auxiliary Limit Door Switch Bracket NOTE: LH furnace ALS-M assembly DOES NOT include door switch. a. Drill 1/8-in. hole in blower housing 8 in. below blower shelf as shown in Fig. 18. b. Position ALS-M so reset button faces front of furnace. c. Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. d. Disconnect red transformer wire from SEC-1 connection. e. Cut off 3/16-in. quick-connect terminal from red transformer wire. f. Strip red wire 1/8 in. and secure factory-supplied 1/4-in. quick-connect terminal. g. Connect removed red transformer wire to ALS-M wire connector labeled TRANS ASSY. h. Connect ALS-M connector labeled DOOR SWITCH or SEC 1 to LH furnace control SEC-1 terminal. Cut wire tie and route wire through T-STAT/HUM hole in control box to control board. i. Route 2-wire ALS-M connector from LH furnace to RH furnace through unused condensate drain line hole with snap bushing. 4. Install RH furnace (SLAVE) auxiliary door switch and harness (ALS-S/ILK-1). NOTE: RH furnace ALS-S assembly HAS door switch included. a. Install auxiliary limit switch (ALS-S). (1.) Drill 1/8-in. hole in blower housing 8 in. below blower shelf as shown in Fig. 18. (2.) Position ALS-S so terminals face front of furnace. (3.) Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. b. Install auxiliary door switch (ILK-1). (1.) Remove wires from ALS-S door switch (ILK-1). (2.) Reverse bracket on ALS-S door switch (ILK-1). (See Fig. 22.) NOTE: It is easier to remove switch from bracket by pushing the switch away from flexible catch side and rotating the flexible side through the bracket first. Door switch will only fit in bracket 1 way. Pivot side of switch will be located toward notched opening of bracket. (3.) Reconnect wires to ALS-S door switch (ILK-1). (4.) Drill 7/32-in. hole in left side of RH furnace blower shelf for mounting door switch as shown in Fig. 18. (5.) Secure ALS-S door switch (ILK-1) using factory-supplied No. 6 X 3/4-in. LG screw. c. Connect RH furnace 2-wire ALS-S connector PL6 to LH furnace 2-wire ALS-M connector PL6 that was routed through furnace casings. 5. Select identical blower speed taps at blower motor connections on control center in both furnaces. CAUTION: Failure to select identical blower speed taps in both furnaces can result in overheating of furnace components and possible loss of furnace operation and damage to the furnace. 6. Dress wires to ensure they do not contact sharp edges or moving parts, nor interfere with blower operation, removal of filters, or operation of switches. 7. Make all thermostat connections to the LH furnace only. —25—
A
A96128
Fig. 23—Rooftop Termination (Dimension “A” is Touching or 2-in. Maximum Separation) PROCEDURE 3—CONNECT ELECTRICAL COMPONENTS—COOLING WARNING: Make no connections between the R 24-vac connector in 1 furnace and the R 24-vac connector in other furnace. Failure to follow this warning can cause a fire, personal injury, or death. When installing twinned outdoor units with twinned gas furnaces, it is necessary to use a field-supplied 24-vac pilot-duty relay and a field-supplied 24/115-vac transformer as shown in Fig. 7 or 8 to prevent overloading furnace 24/115-vac transformer. PROCEDURE 4—VENTING Refer to Installation, Start-Up, and Operating Instructions supplied with each furnace for venting information. Each furnace must always be individually vented. Do not common-vent or breach-vent condensing furnaces. For direct-vent installations, refer to Fig. 23, 24, 25, 26, or 27 for proper termination. It is important that vent terminations be made as shown to avoid recirculation of flue gases.
VENT VENT
A
COMBUSTION AIR
A93056
Fig. 24—Concentric Vent and Combustion-Air Roof Termination (Dimension “A” is Touching or 2-in. Maximum Separation) PROCEDURE 5—GAS SUPPLY PIPING NOTE: All gas connections must be made through exposed outer side of each furnace. Do not common connect any connection other than supplyand return-air ducts. Furnaces are recommended to be provided with a single shutoff valve. However, individual shutoff valves may be required by local codes or jurisdictions. Refer to Installation, Start-Up, and Operating Instructions provided with each furnace for additional gas supply information. PROCEDURE 6—CONDENSATE DRAIN CONNECTIONS (FURNACES AFTER SERIAL NO. 2894A00001) The condensate trap is factory installed in blower shelf and factory connected for UPFLOW applications. Install condensate trap extension drain such that field drain connection are on the left side for LH (MASTER) furnace and on right side for RH (SLAVE) furnace. (See Fig. 18.) See furnace Installation, Start-Up, and Operating Instructions for details on attaching field drain. PROCEDURE 7—ELECTRICAL SUPPLY CONNECTIONS NOTE: All electrical power connections must be made through exposed outer side of each furnace. Do not common connect any connection other than supply- and return-air ducts. 1. Each furnace shall be connected to its own 115-vac power supply. The twinning kit installation interconnects the furnaces, allowing them to operate as a single furnace. The L1 (black) connection to each furnace must be connected to circuit breakers connected to the same service panel 115-vac phase leg. On single-phase (residential) systems, each furnace circuit breaker should be located directly across from each other in service panel, or each furnace circuit breaker should be located on the same side of service panel, but must skip 1 space to be connected to the same leg of the —26—
VENT
COMBUSTION AIR COMBUSTION AIR
A A96129
Fig. 26—Sidewall Termination of 12 in. or Less (Dimension “A” is Touching or 2-in. Maximum Separation)
1″ MAXIMUM (TYP) COMBUSTION AIR VENT
A VENT
A93057
Fig. 25—Concentric Vent and Combustion-Air Side Termination (Dimension “A” is Touching or 2-in. Maximum Separation)
VENT
COMBUSTION AIR COMBUSTION AIR
A A96130
Fig. 27—Sidewall Termination of More Than 12 in. (Dimension “A” is Touching or 2-in. Maximum Separation)
1-phase power supply. —27—
On 3-phase (commercial) systems, each furnace circuit breaker should be located directly across from each other in service panel, or each furnace circuit breaker should be located on the same side of service panel, but must skip 2 spaces to be connected to the same leg of the 3-phase power supply. The proper 115-vac phasing of furnace connections permits 24-vac transformer phasing as described below. 2. Phasing of the connected 24-vac transformer secondary circuits can be determined with the LED status of both furnaces. See furnace Installation, Start-Up, and Operating Instructions and status code label on blower access panel or main furnace door. The furnaces’ transformers’ black leads should be connected to PR1 connectors and white leads to PR2 connectors on controls. If 1 or both LEDs are rapidly flashing, disconnect lead at TEST/TWIN terminal of LH furnace and observe LED at each furnace. IF: a. Both LEDs are on continuously: System phasing is okay. b. One or both LEDs are rapidly flashing: (1.) Line voltage polarity is reversed. (2.) Reverse SEC-1 and SEC-2 in furnace with rapid flashing LED. c. One LED is off, 1 LED is on continuously: (1.) The 24-vac circuit is inoperative on furnace with LED light off. (2.) Check transformers, auxiliary limits, and door switches in both furnaces and correct problem. 3. Reconnect lead at TWIN/TEST terminal of LH furnace and observe LED at each furnace. The LEDs will glow steady for proper phasing. PROCEDURE 8—START-UP AND ADJUSTMENT NOTE: Refer to Installation, Start-Up, and Operating Instructions supplied with furnace for detailed information. 1. Shut off all power and gas to both furnaces. 2. Position blower off delay switches on controls in BOTH furnaces to the SAME desired blower off delay in heating. See furnace Installation, Start-Up, and Operating Instruction for further details. If 1 furnace control has blower off delay switches and the other has a fixed jumper wire which sets blower off delay at 135 sec, the control with selectable switches MUST be set for 135 sec off delay. 3. Attach twinning connection diagram label over existing wiring label of LH furnace (located on inside of blower access panel or main furnace door). 4. Attach twinning schematic diagram label over existing wiring label of RH furnace (located on inside of blower access panel or main furnace door). 5. Turn on power and gas to furnaces. 6. Operate furnaces through 2 heating cycles to ensure proper operation. 7. Reinstall all furnace access doors. PROCEDURE 9—SEQUENCE OF OPERATION See Fig. 28 and 29 for condensing furnace twinning connection and schematic wiring diagrams while reviewing sequence of operation. Twinning operation is controlled by LH or MASTER furnace. The TEST/TWIN connection wire ensures the 2 furnaces coordinate their blower operation. When either furnace requires blower operation, both furnace blowers operate at same speed. Both furnaces operate simultaneously in the same mode: heat, cool, or continuous fan. Exceptions can occur if a safety switch on either furnace is opened by a problem (such as pressure switch, flame roll-out switch, main limit switch, twinning kit auxiliary limit switch, or flame-proving sensor). In such a case, the other furnace continues to operate unless open switch is the flame roll-out, main limit, or twinning kit auxiliary limit switch, in which case both furnaces respond. Before performing component test, disconnect TKR yellow wire labeled TEST from LH furnace control center TEST/TWIN terminal. After removing yellow wire, component test can be initiated on each furnace individually as stated in Installation, Start-Up, and Operating Instructions. Single-Stage Heat with Single-Stage Gas-Heat Thermostat See Section III, Procedure 2 for furnace and kit components used. 1. LH (MASTER) furnace control center determines if both furnaces are operating in heating mode. 2. Operation in ALL modes is the same for twinned furnaces as for an individual furnace. See furnace Installation, Start-Up, and Operating Instructions for more information on the sequence of operation. Two-Stage Heat with 2-Stage Gas-Heat Thermostat See Section III, Procedure 2 for furnace and kit components used. 1. The 2-stage thermostat determines if furnaces are operating in first-stage heat (LH furnace operates in heat while RH furnace blower operates but RH furnace is not heating) or if furnaces are operating in second-stage heat (both furnaces operate in heat), depending on how many thermostat stages are calling for heat. 2. Operation in all modes is the same for twinned furnaces as for an individual furnace. See furnace Installation, Start-Up, and Operating Instructions for more information on sequence of operation.
→
SECTION IV: MODELS 58MTA AND 352MAV UPFLOW 2-SPEED CONDENSING HSI FURNACES PROCEDURE 1—INSTALL FURNACES NOTE: Multipoise units must be installed in UPFLOW configuration. Refer to Fig. 30 and 18 for appearance and dimensional drawing of twinned furnaces and their connection locations. 1. Select 2 identical heating and airflow furnaces. (See Table 5.) —28—
NOTES #9 & #15
TEST/TWIN
LGPS (WHEN USED)
NOTE #16
135 SEC 180 SEC PL1
225 SEC
3 2 1
GVR
SEC-2
BLU
NOTE #14
24 VAC-3A FUSE
COOL SPARE-1
1.0 AMP
PR2
1 2 3
EAC-2
OL YEL (MED-HI) START
NOTE #7
HSIR
IDR
PL3
PL2
120 VAC L1 PR1
HSI
BLK
M AUX
ILK
IDM
OL
ALS-M ALS-S BLWR BLWM CAP EAC-1 EAC-2 FRS FSE FU1 FU2 GV GVR HI/LO HSI HSIR HUM IDM IDR ILK ILK-1 JB LED LGPS LS OL
HEAT SPARE-2 EAC-1 EAC-2
C OM
BLK
BLK
GRN
MASTER AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) SLAVE AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) BLOWER MOTOR RELAY, SPST-(N.O.) BLOWER MOTOR,3- OR 4-SPEED, PERMANENT-SPLIT-CAPACITOR CAPACITOR ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.) ELECTRONIC AIR CLEANER CONNECTION (COMMON) FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.) FLAME-PROVING SENSOR ELECTRODE FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED FUSE OR CIRCUIT-BREAKER CURRENT-INTERRUPT DEVICE (FIELD INSTALLED & SUPPLIED) GAS VALVE-REDUNDANT OPERATORS GAS VALVE RELAY, DPST-(N.O.) BLOWER MOTOR SPEED CHANGE RELAY, SPDT HOT SURFACE IGNITER (115 VAC) HOT SURFACE IGNITER RELAY, SPST-(N.O.) 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.) INDUCED DRAFT MOTOR INDUCER MOTOR RELAY, SPST-(N.O.) BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) SLAVE AUX. BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) JUNCTION BOX LIGHT-EMITTING DIODE FOR STATUS CODES LOW GAS-PRESSURE SWITCH, SPST (N.O.) LIMIT SWITCH, AUTO RESET, SPST(N.C.) AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW., SPST (N.C.)
PCB PL1 PL2 PL3 PL4 PL5 PL6 PL7 PRS TEST / TWIN TKR TRAN
BLK
CAP -2
BLK
1 2 3 PL4 PL5
1
NOTE #14
LEGEND
WHT
WHT
FUSED DISCONNECT SWITCH (WHEN REQ’D) NOTE #4 WHT
BLK
BRN
BRN WHT
JB
BLK
CAP -2
1 2 3 PL4
GRN
COOL SPARE-1
PR2
1 2 3
1 2
N
24 VAC-3A FUSE
WHT (COM)
BLK
BLK
BLK
BLK
WHT 2
BLOWER SPEED SELECT
BLWR
WHT
1
RE
L2
BRN
SEC-2
HI/LO RELAY
BLK
PL5
SEC-1
TRAN
BLWM
RED (LO)
6 5 4 9 8 7
FU1
BRN
BLU (MED-LO)
C OM WHT
1 2
SLAVE OR RH FURNACE
NOTE #8
3 2 1
WHT
GVR
ORN ALS-S ORN
GRN
NOTE #3
PL3
PL2
BLK (HI)
PL1
225 SEC
NOTE #5
PL7 WHT (COM)
RED
ALS-M
LED
180 SEC
WHT
BLOWER SPEED SELECT
BLWR
NOTE #8 1 1 ORN ILK-1 BLU 2 2 BLU PL6
ILK
RED
HEAT SPARE-2 L2 EAC-1 120 VAC L1 PR1
2
CAP -1
IDR
GV FSE
RED
SEC-1
90 SEC
FRS
RED
HI/LO RELAY
BL YE
TEST/TWIN
135 SEC
GRN
FU1
HSIR
LS WHT
6 5 4 9 8 7
WHT
BLOWER OFF DELAY SELECTION CHART
3 BLK
3
G R Y W SW1 C OM 24V HUM
SW2
BLOWER OFF DELAY
NOTE #12 (NOT ON ALL MODELS)
BLK 1
BLU 1
RED
RED
NOTE #8
PCB
WHT
YEL
LED
2 TKR
ORN
90 SEC
MASTER OR LH FURNACE
4
1.0 AMP
NOTE #16 PRS
WHT
RED
YEL
RED
BLK
GRN WHT WHT
BLOWER OFF DELAY SELECTION CHART
G R Y W SW1 C OM 24V HUM
BLU
NOTE #12 (NOT ON ALL MODELS)
WHT
SW2
BLK
PCB
BLOWER OFF DELAY
2
GRN HSI
AUX
BLK
FIELD GROUND
UNMARKED TERMINAL EQUIPMENT GROUND PCB TERMINAL FACTORY WIRING (115VAC)
FIELD SPLICE
FACTORY WIRING (24VAC) FIELD WIRING (115VAC) FIELD ACCESSORY WIRING (24VAC)
OL
IDM
NOTES:
PRINTED CIRCUIT BOARD 9-CIRCUIT CONNECTOR 2-CIRCUIT CONNECTOR 3-CIRCUIT IDM CONNECTOR 3-CIRCUIT IDM EXTENSION CONNECTOR 2-CIRCUIT HSI CONNECTOR 2-CIRCUIT TWINNING KIT CONNECTOR 1-CIRCUIT TWINNING KIT IN-LINE SPLICE PRESSURE SWITCH, SPST-(N.O.) COMPONENT TEST & TWIN TERMINAL TWINNING KIT RELAY, SPST-(N.O.) TRANSFORMER-115VAC / 24VAC
JUNCTION
—29—
M
FU2
GRN
FIELD WIRING TERMINAL
BRN
BRN WHT
PLUG RECEPTACLE
WIRES PASSING THROUGH HOLES IN CASINGS FROM LH TO RH FURNACE
1. If any of the origi the same type. 2. Inducer (IDM) an thermal overload 3. Blower motor spe instructions for de 4. Use only copper junction box (JB) 5. This wire must be prove flame. 6. Replace only with 7. Yellow lead (MED 8. Passes through h slave furnace blo 9. Make thermostat 10. Make no thermos 11. Blower-on delay, 2 seconds. 12. Blower-off delay, only on some mo 13. Ignition-lockout w trials-for-ignition. 14. Factory installed L1 or the SEC-1 15. Some models ma 16. Factory connecte
TO 115VAC FIELD DISCONNECT NOTE #4 L1
EQUIPMENT GROUND
ILK NOTE #12
L1
HI/LO SPARE-2 COOL
BLWR
ALS-M
PR1
RED ORN NOTE #12 YEL TEST/TWIN
1
2
2
PL5
PR2
115VAC TRAN
ILK
HSI
1
1
3
3 PL3
GVR-2
WHT WHT
BLK
NOTE #14
BLWR IDR
PL1
GVR
3-P
RED
WHT
CPU
GVR-1
Y
G
RED
2
SEC-1
8
7 1 LGPS
(
W NOTE #14
4 HSIR
BLWR
HI/LO
IDR
PL1
GVR
PRS
N
3
GV
3-P GVR-1
CPU NOTE #5
2 1-M
Y
8
G
5
5
6
6
COM 24V
FRS
SEC-2
GVR-2
FSE
BL K
C
2
R
D RE
BRN PL4
NOTE #6
FU
2-C 1-M
3
2
NOTE #14
3
TKR
1
3 PL3
PRS
BLK
1
24VAC
T WH
HI/LO
PR2
115VAC TRAN
NOTE #13 HUM
4 HSIR
PR1
LS
(WHEN USED)
HSI
2 M
YEL
LGPS
PL5
IDR
ILK
1
1
2
PL2
NOTE #12
7
W
NOTE #3
1
CAP -2
FRS
SEC-2
COM
EAC-2
BRN
2
R
4
COM
STAR OL
HI
EAC-1
TEST/TWIN
HUM
2
AUX
BRN PL4
2
SEC-1
HI/LO SPARE-2 COOL
BLWR
PASSES THROUGH HOLES IN CASINGS
NOTE #6
NOTE #13
3
L1
IDM OL
24VAC
RED FU
MAKE NO THERMOSTAT CONNECTIONS TO RH FURNACE
BLW
LO MED LO MED HI NOTE #7
SPARE-1
HSIR
M
PL7
EQUIPMENT GROUND
ILK NOTE #12
EAC-2
IDR
RED
1
BRN CAP-1 GRN
COM
1
SLAVE OR R
HEAT START
NOTE #3
PL2
BLU
BRN
EAC-1 HSIR
L2
BLWM
OL
HI
COM
NEUTRAL
L1
LO MED LO MED HI NOTE #7
SPARE-1 HEAT
MAKE THERMOSTAT CONNECTIONS TO ONLY THE LH FURNACE
TO 115VAC FIELD DISCONNECT SCHEMATIC DIAGRAM NOTE #4 (NATURAL GAS & PROPANE)
MASTER OR LH FURNACE NEUTRAL
COM 24V
9
BLK
9 PL6
ORN
ALS-S ORN
ORN
BLU
1 BLU
ILK-1
BLU
NOTE # 8
2
LEGEND ALS-M ALS-S BLWM BLWR CAP CPU EAC-1 EAC-2 FRS FSE FU
MASTER AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) SLAVE AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) BLOWER MOTOR, 3- OR 4-SPEED, PERMANENT SPLIT-CAPACITOR BLOWER MOTOR RELAY, SPST-(N.O.) CAPACITOR MICROPROCESSOR AND CIRCUITRY ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.) ELECTRONIC AIR CLEANER CONNECTION (COMMON) FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.) FLAME-PROVING SENSOR ELECTRODE FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
GV GVR HI/LO HSI HSIR HUM IDM IDR ILK ILK-1
GAS VALVE-REDUNDANT OPERATORS GAS VALVE RELAY, DPST-(N.O.) -1 = VALVE -2 = HUMIDIFIER BLOWER MOTOR SPEED CHANGE RELAY, SPDT HOT SURFACE IGNITER (115 VAC) HOT SURFACE IGNITER RELAY, SPST-(N.O.) 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.) INDUCED DRAFT MOTOR INDUCER MOTOR RELAY, SPST-(N.O.) BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) SLAVE AUX. BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.)
—30—
LED LGPS LS OL PCB PL1 PL2 PL3 PL4 PL5 PL6
LIGHT-EMITTING DIODE FOR STAT LOW GAS PRESSURE SWITCH, SPS LIMIT SWITCH, AUTO RESET, SPST AUTO-RESET INTERNAL MOTOR O PRINTED CIRCUIT BOARD 9-CIRCUIT CONNECTOR 2-CIRCUIT CONNECTOR 3-CIRCUIT IDM CONNECTOR 3-CIRCUIT IDM EXTENSION CONNE 2-CIRCUIT HSI CONNECTOR 2-CIRCUIT TWINNING KIT CONNEC
26 15/16″ 26 1/4 TYP
A
24 1/2″ 22 1/4″
AIRFLOW
AIRFLOW 13/16″
2-IN. COMBUSTIONAIR CONN
F D OUTLET
D OUTLET
13/16″
7/8-IN. 1/2-IN.
DIA POWER CONN
GAS CONN
2-IN. VENT CONN
32
1/2-IN.
DIA THERMOSTAT ENTRY 22 11/16″
14 1/2″
11/4″ 1"
23 1/4″ SIDE INLET
30 13/16″ TYP 29 5/8″ TYP 5 27 /8″
7/8-IN.
DIA ACCESSORY POWER ENTRY
30 1/2″
27 1/2″ TYP
CONDENSATE DRAIN TRAP LOCATION (USED FOR LH FURNACES BEFORE SERIAL NO. 2894A00001) SIDE INLET
33 1/4″ TYP
5/8″TYP
24
1/2″
17 5/16″
18 1/4″
9 3/8″ TYP
CONDENSATE DRAIN LOCATION
11/16″
26 15/16″ TYP
INLET
INLET
E
E
11/16″
CONDENSATE DRAIN LOCATIO
—31—
Table 5—58MTA and 352MAV 2-Speed Condensing Furnace Dimensions (In.) INPUT HEATING SIZE (BTUH) 80,000 100,000 100,000 120,000
NOMINAL COOLING SIZE
A
D
E
F
48,000 48,000 60,000 60,000
35 42 42 49
15-7/8 19-3/8 19-3/8 22-7/8
16 19-1/2 19-1/2 23
33-3/8 40-3/8 40-3/8 47-3/8
2. Remove bottom closure panels from both furnaces. (See Fig. 3.) a. Remove 2 screws from front filler panel. b. Rotate front filler panel downward to remove. c. Remove bottom closure panel and discard. d. Reinstall front filler panel. 3. Apply 2 factory-supplied foam strips to mating side of each furnace. Locate strips equal distance from top and bottom as shown in Fig. 19. 4. Position furnaces against each other on return-air plenum. Adjust and shim each furnace to align unused condensate drain line holes in lower section of both furnaces holes which will be used for wire routing between furnaces. (See Fig. 19.) 5. Drill two 1/8-in. holes, approximately 1 in. below discharge air flange, from inside top of discharge opening and through both furnaces. (See Fig. 20.) 6. Drive 1 factory-supplied No. 6 X 3/4-in. LG screw through each hole and tighten until furnaces are secure and foam strips have sealed gap between furnaces. 7. Insert 1 snap bushing through each adjoining unused condensate drain line hole of each furnace. (See Fig. 30 and 18.) 8. Connect return- and supply-air ducts to furnaces. Seal duct connections to prevent air leakage. —32—
9. 115-V junction boxes JB must be located on right side of right-hand furnace and left side of left-hand furnace. Relocate as necessary. (See Fig. 18.) WARNING: DO NOT use the back of the furnace for return-air duct connections as limit cycling will occur. A failure to follow this warning can cause a fire, personal injury, or death. PROCEDURE 2—CONNECT ELECTRICAL COMPONENTS—HEATING WARNING: Make no connections between the R 24-vac connector in 1 furnace and the R 24-vac connector in other furnace. Failure to follow this warning can cause a fire, personal injury, or death. See electrostatic discharge precaution on page 2. 1. Remove control and blower access doors from both furnaces. 2. Determine desired furnace control operation and see appropriate section for use and application of twinning kit relay and harness assembly (TKR). Two-Stage Heat with Single-Stage Gas-Heat Thermostat (Field-Supplied) NOTE: This application allows both furnaces to operate in either high- or low-gas-heat as determined by adaptive mode of both furnace controls. See furnace Installation, Start-Up, and Operating Instructions for further details on this heating mode. a. Remove black and yellow wires from wire-tied TKR harness assembly for later use. b. Discard relay, red wire, and both white wires from TKR harness assembly. c. Use field-supplied electrical tape to insulate black wire’s 1/4-in. quick-connect terminal labeled 3. d. Connect black wire terminal labeled C to LH furnace control thermostat connection COM 24. e. Connect yellow wire terminal labeled TEST to LH furnace control TWIN/TEST terminal. f. Route black and yellow wire loose ends through snap bushings previously installed between furnaces. g. Connect black wire terminal labeled C-SLAVE to RH furnace control thermostat connection COM 24. h. Connect yellow wire terminal labeled TEST SLAVE to RH furnace control TWIN/TEST terminal. i. Proceed to item 3 “Install LH furnace auxiliary limit switch harness ALS-M” to complete electrical connections. Two-Stage Heat with 2-Stage Gas-Heat Thermostat (Field Supplied) NOTE: This attachment allows both furnaces to operate in either high- or low-gas heat as determined by thermostat’s 2-stage operation. See furnace Installation, Start-Up, and Operating Instructions for further details on this heating mode. a. Mount TKR assembly to underside of LH furnace control center enclosure using 1 No. 6 sheet metal screw (field supplied). Screw hole is located to left of door switch near front edge of control. (See Fig. 21.) b. Route 3 loose wires (black, yellow, and white) from TKR assembly wire harness through T-STAT/HUM hole adjacent to door switch. (See Fig. 21.) c. Connect TKR white wire labeled W from TKR to LH furnace control thermostat connection W/W1. d. Connect TKR black wire labeled C from TKR to LH furnace control thermostat connection COM 24. e. Connect TKR yellow wire labeled TEST (loose wire end near TKR) to LH furnace control TWIN/TEST terminal. f. Refer to Fig. 17, 18, and 21 and route remaining 4 loose wires through the following: (1.) Snap bushing previously installed between furnaces in unused condensate drain holes. (2.) RH furnace T-STAT/HUM hole in control center box. g. Connect TKR red wire labeled R-SLAVE from TKR to RH furnace control thermostat connection R. h. Connect TKR white wire labeled W-SLAVE from TKR to RH furnace control thermostat connection W/W1. i. Connect TKR black wire labeled C-SLAVE from TKR to RH furnace control thermostat connection COM 24V. j. Connect TKR yellow wire labeled TEST SLAVE from LH furnace control TWIN/TEST terminal to RH furnace control TWIN/TEST terminal. k. Proceed to item 3 “Install LH furnace auxiliary limit switch harness ALS-M” to complete electrical connections. 3. Install LH furnace auxiliary limit switch harness ALS-M. NOTE: LH furnace ALS-M assembly DOES NOT include door switch. a. Drill 1/8-in. hole in blower housing 8 in. below blower shelf. (See Fig. 18.) b. Position ALS-M so reset button faces front of furnace. c. Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. d. Disconnect red transformer wire from LH furnace control SEC-1 connection. e. Cut off the 3/16-in. quick-connect terminal from red transformer wire. f. Strip red wire 1/8 in. and secure factory-supplied 1/4-in. quick-connect terminal. g. Connect red transformer wire connector to ALS-M wire connector labeled TRANS ASSY. —33—
h. Connect ALS-M wire connector labeled DOOR SWITCH or SEC 1 to LH furnace control SEC-1 terminal. Cut wire tie and reoute wire through T-STAT/HUM hole in control box to control board. i. Route 2-wire ALS-M connector form LH furnace to RH furnace control through unused condensate drain line hole with snap bushing. 4. Install RH furnace auxiliary door switch and auxiliary limit switch harness ALS-S/ILK-1. NOTE: RH furnace auxiliary limit switch harness assembly ALS-S/ILK-1 has door switch included. a. Install auxiliary limit switch (ALS-S). (1.) Drill 1/8-in. hole in blower housing 8 in. below blower shelf as shown in Fig. 18. (2.) Position ALS-S so terminals face front of furnace. (3.) Secure bracket to blower housing using factory-supplied No. 6 X 3/4-in. LG screw. b. Install auxiliary door switch (ILK-1). (1.) Remove wires from ALS-S door switch (ILK-1). (2.) Reverse bracket on ALS-S door switch (ILK-1). (See Fig. 22.) NOTE: It is easier to remove switch from bracket by pushing the switch away from flexible catch side and rotating the flexible side through the bracket first. Door switch will only fit in bracket 1 way. Pivot side of switch will be located toward notched opening of bracket. (3.) Reconnect wires to ALS-S door switch (ILK-1). (4.) Drill 7/32-in. hole in left side of RH furnace blower shelf for mounting door switch as shown in Fig. 18. (5.) Secure ALS-S door switch (ILK-1) using factory-supplied No. 6 X 3/4-in. LG screw. c. Connect RH furnace 2-wire ALS-S connector PL6 to LH furnace 2-wire ALS-M connector PL6 that was routed through furnace casings. 5. Select identical blower speed taps at blower motor connectors in both furnaces. CAUTION: Failure to select identical blower speed taps in both furnaces can result in overheating of furnace components and possible loss of furnace operation and damage to the furnaces. 6. Dress wires to ensure they do not contact sharp or moving parts nor interfere with blower operation, removal of filters, or operation of switches. 7. Make all thermostat connections to LH furnace only. PROCEDURE 3—CONNECT ELECTRICAL COMPONENTS—COOLING WARNING: Make no connections between the R 24-vac connector in 1 furnace and the R 24-vac connector in other furnace. Failure to follow this warning can cause a fire, personal injury, or death. When installing twinned outdoor units with twinned gas furnaces, it is necessary to use a field-supplied 24-vac pilot-duty relay and a field-supplied 24/115-vac transformer as shown in Fig. 13 to prevent overloading furnace 24/115-vac transformer. PROCEDURE 4—VENTING Refer to Installation, Start-Up, and Operating Instructions supplied with each furnace for venting information. Each furnace must always be individually vented. Do not common-vent or breach-vent condensing furnaces. For direct-vent installations, refer to Fig. 23, 24, 25, 26, or 27 for proper termination. It is important that vent terminations be made as shown to avoid recirculation of flue gases. PROCEDURE 5—GAS SUPPLY PIPING NOTE: All gas connections must be made through exposed outer side of each furnace. Do not common connect any connection other than supplyand return-air ducts. Furnaces are recommended to be provided with a single shutoff valve. However, individual shutoff valves may be required by local codes or jurisdictions. Refer to Installation, Start-Up, and Operating Instructions provided with each furnace for additional gas supply information. PROCEDURE 6—CONDENSATE DRAIN CONNECTIONS The condensate trap is factory installed in blower shelf and factory connected for UPFLOW applications. Install condensate trap extension drain such that field drain connection are on the left side for LH (MASTER) furnace and on right side for RH (SLAVE) furnace. (See Fig. 18.) See furnace Installation, Start-Up, and Operating Instructions for details on attaching field drain. PROCEDURE 7—ELECTRICAL SUPPLY CONNECTIONS NOTE: All electrical power connections must be made through exposed outer side of each furnace. Do not common connect any connection other than supply- and return-air ducts. 1. Each furnace shall be connected to its own 115-vac power supply. The twinning kit installation interconnects the furnaces, allowing them to operate as a single furnace. The L1 (black) connection to each furnace must be connected to circuit breakers connected to the same service panel 115-vac phase leg. On single-phase (residential) systems, each furnace circuit breaker should be located directly across from each other in service panel, or each furnace circuit breaker should be located on the same side of service panel, but must skip 1 space to be connected to the same leg of the 1-phase power supply. On 3-phase (commercial) systems, each furnace circuit breaker should be located directly across from each other in service panel, or each furnace circuit breaker should be located on the same side of service panel, but must skip 2 spaces to be connected to the same leg of the 3-phase power supply. The proper 115-vac phasing of furnace connections permits 24-vac transformer phasing as described below. —34—
2. Phasing of the connected 24-vac transformer secondary circuits can be determined with the LED status of both furnaces. See furnace Installation, Start-Up, and Operating Instructions and status code label on blower access door or main furnace door. The furnaces’ transformers’ black leads should be connected to PR1 connectors and white leads to PR2 connectors on controls. If 1 or both LEDs are rapidly flashing, disconnect lead at TEST/TWIN terminal of LH furnace and observe LED at each furnace. IF: a. Both LEDs are on continuously: System phasing is okay. b. One or both LEDs are rapidly flashing: (1.) Line voltage polarity is reversed. (2.) Reverse SEC-1 and SEC-2 in furnace with rapid flashing LED. c. One LED is off, 1 LED is on continuously: (1.) The 24-vac circuit is inoperative on furnace with LED light off. (2.) Check transformers, auxiliary limits, and door switches in both furnaces and correct problem. 3. Reconnect lead at TWIN/TEST terminal of LH furnace and observe LED at each furnace. The LEDs will glow steady for proper phasing. PROCEDURE 8—START-UP AND ADJUSTMENT Refer to Installation, Start-Up, and Operating Instructions supplied with furnace for detailed information. 1. Shut off all power and gas to both furnaces. 2. Position TWINNING JUMPERS TJ on furnace controls. (See Fig. 14.) a. The LH furnace control TWINNING JUMPER TJ MUST remain in the MASTER position. b. The RH furnace control TWINNING JUMPER TJ MUST be moved to the SLAVE position. 3. Determine desired furnace control operation and position set-up switches on furnace control. (See Fig. 14.) Two-Stage Heat with Single-Stage Gas-Heat Thermostat a. Position SW1 switch on controls in BOTH furnaces to OFF. b. Position SW2 switch on controls in BOTH furnaces to OFF. c. Position SW3 and SW4 switches on control in BOTH furnaces to desired gas-heat blower off delay. (See furnace Installation, Start-Up, and Operating Instructions for further details.) Two-Stage Heat with 2-Stage Gas-Heat Thermostat a. Position SW1 switch on controls in BOTH furnaces to OFF. b. Position SW2 switch on controls in BOTH furnaces to ON. c. Position SW3 and SW4 switches on controls in BOTH furnaces to desired gas-heat blower off delay. (See furnace Installation, Start-Up, and Operating Instructions for further details.) 4. Attach twinning connection diagram label over existing wiring label on inside of LH furnace blower door. 5. Attach twinning schematic diagram label over existing wiring label on inside of RH furnace blower door. 6. Turn on power and gas to both furnaces. 7. Reinstall blower access doors on both furnaces. 8. Using appropriate section below, operate furnaces through 2 cycles in each mode to confirm correct operation by operating only the thermostat. a. Single- or 2-stage gas heating thermostat R-to-W/W1 for low-gas heat. Single-stage thermostat with adaptive heating mode causes furnace to operate in low-gas-heat mode for up to 16 minutes, and then furnace automatically switches to high-gas heat. First stage of a 2-stage thermostat without adaptive heating mode causes furnace to operate in low-gas-heat mode indefinitely. b. First- and second-stage of 2-stage heating thermostat R-to-W/W1-and-W2 for high-gas-heat. c. Thermostat R-to-G for continuous fan or 2-speed cooling low-cool blower. d. Cooling thermostat R-to-G-and-Y/Y2 for single-speed cooling blower or for 2-speed cooling high-cool blower. 9. Reinstall control doors on both furnaces.Reinstall control doors on both furnaces. 10. Instruct user in operation of furnaces and thermostat. PROCEDURE 9—SEQUENCE OF OPERATION See Fig. 31 and 32 for 2-speed non-condensing furnace twinning connection and schematic wiring diagrams while reviewing sequence of operation. Twinning operation is controlled by LH or MASTER furnace. The TWIN/TEST and COM 24V connection wires ensure the 2 furnaces coordinate their blower operation. When either furnace requires blower operation, both furnaces operate their blowers at the same speed (the highest speed required by either furnace). Both furnaces operate simultaneously in the same mode: low-gas heat, high-gas heat, low-cool, high-cool, or continuous fan. Exceptions can occur if a safety device on either furnace is activated (such as low-gas-heat or high-gas-heat pressure switch, flame roll-out switch, limit switch, twinning kit auxiliary limit switch, or flame-proving sensor). In such a case, the other furnace continues to operate unless the safety device is the flame roll-out, limit, or twinning kit auxiliary limit switch, in which case both furnaces respond. —35—
Two-Stage Heat with Single-Stage Gas-Heat Thermostat See Section IV, Procedure 2 for furnace and kit components used. NOTE: Set-up switches SW1 and SW2 in BOTH furnaces are in OFF position. 1. LH furnace control determines whether furnaces are both operating in low-gas heat or high-gas heat, depending on the control’s adaptive gas heating mode when the R-to-W/W1 circuit is closed in LH furnace. 2. Operation in all modes is the same for twinned furnaces as for an individual furnace. See furnace Installation, Start-Up, and Operating Instructions for more information on sequence of operation. Two-Stage Heat with 2-Stage Gas-Heat Thermostat See Section IV, Procedure 2 for furnace and kit components used. NOTE: Set-up switches SW1 in BOTH furnaces are in OFF position, and set-up switches SW2 in BOTH furnaces are in ON position. 1. The 2-stage thermostat (NOT furnace control’s adaptive gas heating mode) determines whether furnaces are both operating in low-gas heat or high-gas heat, depending on whether 1 or both thermostat stages (W/W1 or W/W1-and-W2) are calling for heat. 2. Operation in all modes is the same for twinned furnaces as for an individual furnace. See furnace Installation, Start-Up, and Operating Instructions for more information on sequence of operation.
—36—
FURNACE CONNECTION DIAGRAM
ORN
W2
RED
MED-LO BLU LO RED
BLWM
BLU
BLU PL9
ALS-M
ORN
ORN BLU
KEEP TWINNING JUMPER IN "MASTER" POSITION ON MASTER FURNACE.
W/W1 R G H U COM Y/Y2 M 24V
PL8 2 1
MASTER AUX. LIMIT SWITCH, OVERTEMP. - MANUAL RESET, SPST (N.C.) SLAVE AUX. LIMIT SWITCH, OVERTEMP. - MANUAL RESET, SPST (N.C.) BLOWER MOTOR, 4 or 5 SPEED, PERMANENT-SPLIT-CAPACITOR CAPACITOR -1 = BLWM -2 = IDM MICROPROCESSOR AND CIRCUITRY ELECTRONIC AIR CLEANER CONNECTION (115 VAC, 1 AMP MAX.) ELECTRONIC AIR CLEANER CONNECTION (COMMON) FLAME ROLLOUT SWITCH OVERTEMP.-MANUAL RESET, SPST (N.C.) FLAME-PROVING SENSOR ELECTRODE FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED FUSE, FIELD INSTALLED GAS VALVE, REDUNDANT LOW-HEAT OPERATORS, 2-STAGE HIGH-HEAT PRESSURE SWITCH, SPST (N.O.) HOT-SURFACE IGNITER (115 VAC) 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.) INDUCED DRAFT MOTOR, 2-SPEED, SHADED-POLE SLAVE AUX. BLOWER DOOR INTERLOCK SWITCH, SPST (N.O.) BLOWER DOOR INTERLOCK SWITCH, SPST (N.O.) JUNCTION BOX LIGHT-EMITTING DIODE FOR STATUS CODES LOW GAS-PRESSURE SWITCH, SPST (N.O.)
LPS LS
* * *
PL1 PL2 PL3 PL6 PL8 PL9 SW1 SW2 SW3 & 4 TJ
TKR TRAN TWIN / TEST
LOW-HEAT PRESSURE SWITCH, SPST (N.O.) LIMIT SWITCH, OVERTEMPERATURE-AUTO RESET, SPST (N.C.) 12-CIRCUIT CONNECTOR 9-CIRCUIT CONNECTOR 3-CIRCUIT IDM CONNECTOR 2-CIRCUIT HSI CONNECTOR 2-CIRCUIT TWINNING CONNECTOR 1-CIRCUIT TWINNING CONNECTOR HIGH-HEAT-ONLY SWITCH, SPST (MANUAL) LOW-HEAT-ONLY SWITCH, SPST (MANUAL) BLOWER-OFF DELAY SETTING SWITCHES, SPST (MANUAL) TWINNING JUMPER, SPDT FOR MASTER OR SLAVE STATUS-(MANUAL-CHANGE-OVER) TWINNING KIT RELAY, SPST (N.O.) TRANSFORMER-115VAC / 24VAC 1-CIRCUIT TWINNING BUSS CONNECTOR, ALSO COMPONENT TEST JUNCTION TERMINAL CONTROL TERMINAL
—37—
A01276 FSE
GRY
WHT BLU
9 8 7
3 2 GRN
SEC1 SEC2
FU1
MOVE TWINNING JUMPER T
MAKE NO THERMOSTAT CONNECTIONS TO RIGHT HAND FURNACE. ILK-1 ALS-S YEL
To initiate the component test sequ Purge and Blower-Off Delay period terminal for about two seconds. Th inducer motor Low-Speed, blower Speed, and blower motor High-Co ON the entire length of the test). N
LEGEND ALS-M ALS-S BLWM CAP CPU EAC-1 EAC-2 FRS FSE FU1 FU2 GV HPS HSI HUM IDM ILK-1 ILK JB LED LGPS
WHT 1
TJ M LED S
BLK
ORN BLU
MED
FACTORY POWER WIRING (115VAC) FACTORY CONTROL WIRING (24VAC) FIELD POWER WIRING (115VAC) FIELD ACCESSORY WIRING (24VAC) FIELD WIRING SCREW TERMINAL FIELD GROUND EQUIPMENT GROUND FIELD SPLICE PLUG RECEPTACLE
326684-201 REV. A
*
HEAT SET-UP SWITCH SWITCH 2 1 NORM HI HT LO HT ON OFF ON
Diagram for Twinned 2-Speed Condensing Furnace NOTE #13
FU1
BRN TWIN TEST
BLOWER OFF DELAY SWITCH (SEC) 4 3 90 SEC 135 SEC 180 SEC 225 SEC ON OFF ON
RED WHT
TRAN
YEL
12 11 10
MED-HI
BLOWER-OFF DELAY BLOWER-OFF DELAY LOW-HEAT ONLY HIGH-HEAT ONLY
PR2
L2 L1 COMMON HI-COOL HI-GAS HEAT EAC-2 LO-GAS HEAT EAC-1 P1 SPARE SPARE
RED
WHT BLK
BLK
ON OFF
HI
BRN
COM
WHT
PASSES THROUGH HOLES IN CASINGS
PR1
ORN RED
1
CAP-1
NOTE #4
BRN
GRY
WHT
12 3 4
BLK
GRN
12 11 10
(WHEN USED) YEL
* FACTORY SETTINGS
WHT
3 2
9 8 7
1 YEL
ORN
RED
PL2
SEC1 SEC2
BLK
BLK
WHT
4
RED
MAKE THERMOSTAT CONNECTIONS TO ONLY THE LEFT HAND FURNACE.
3 2
BRN
Fig.
TWIN TEST TJ M W2 W/W1 R G H COM Y/Y2 U LED S M 24V
BLU
BLOWER-OFF DELAY BLOWER-OFF DELAY LOW-HEAT ONLY HIGH-HEAT ONLY RED
1
WHT BLK
PR2 L2 L1 COMMON HI-COOL HI-GAS HEAT EAC-2 LO-GAS HEAT 31—Connection EAC-1 P1 SPARE SPARE
PL6 1 2
P
2-STAGE FURNACE CONTROL
PR1
ORN RED
3 2
ON OFF
123 4
*
FACTORY SETTINGS
HSI
GRN
PL2 2-STAGE FURNACE CONTROL
CAP-2 BRN
RED
WHT
2 3
B
LGPS NOTE #7
WHT FU2
L2 GND
G
GRY
BLK
BLK
WHT
NOTE #6
FUSED DISCONNECT SWITCH (WHEN REQ’D) JB NOTE #1 BLK L1
ILK
GRN YEL
FRS
WHT
1
RED
RED
WHT
RED BLK
GRY
OL GRN/YEL
FSE
BRN IDM
PL3
LPS
LS
ORN
ORN (WHEN USED) YEL
PL6 1 2
2 WHT
C GRN/YEL
M
GRN/YEL
HSI
4 RED
1 TKR
GV BLU
CAP-2 BRN
3
WHT BLK HI
BRN
BRN
LGPS NOTE #7
RED
RED
FRS
ORN
RED
WHT
LS
HPS
GRY
LPS
BLK
ORN
MASTER OR LH FURNACE
EAC-2
HSIR EAC-1
PL2 IHI / LOR IDR
1
4
4 1 2 3
8 TRAN SEC-2 24VAC
FU SEC-1 NOTE #5
HPSR
RED
ORN
HSI
2
PL3
PL3
115VAC PR2
PR1
BRN BLWM
3 PL6 9
7
PL9
SET-UP * HEAT SWITCH SWITCH 1 2 NORM HI HT LO HT
LO HI OL IDM
COM
1 N/A 5 6 N/A
2 FRS 3
BLWR
COMMON
LS
PL2 IHI / LOR IDR
PR1 FU
KEEP TWINNING JUMPER IN "MASTER" POSITION ON MASTER FURNACE.
NOTE #5
YEL
W2
M
1 10
Y/Y2
RED
JUMPER TO "SLAVE" POSITION ON SLAVE FURNACE.
HPS
MGVR-1
C
TWINNING JUMPER TJ
FSE
CPU
MGVR-1
Y/Y2 G
TKR
COM
RED 4 2
PL8
WHT
ORN 1 BLU 2
LEGEND IDM IDR IHI/LOR ILK ILK-1 JB LED LGPS LPS LS MGVR
* * *
W2
BLK
BLK BLK 3 WHT1
BLK
MASTER AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) SLAVE AUX. LIMIT SW., OVERTEMP-MANUAL RESET, SPST-(N.C.) BLOWER MOTOR SPEED CHANGE RELAY, SPDT BLOWER MOTOR SPEED CHANGE RELAY, SPDT BLOWER MOTOR, 4 or 5 SPEED, PERMANENT-SPLIT-CAPACITOR BLOWER MOTOR RELAY, SPST-(N.O.) CAPACITOR -1 = BLWM -2 = IDM MICROPROCESSOR AND CIRCUITRY ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.) ELECTRONIC AIR CLEANER CONNECTION (COMMON) FLAME ROLLOUT SWITCH OVERTEMP. -MANUAL RESET, SPST-(N.C.) FLAME-PROVING SENSOR ELECTRODE FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED GAS VALVE-REDUNDANT LOW-HEAT OPERATORS, 2-STAGE HIGH-HEAT PRESSURE SWITCH, SPST-(N.O.) HIGH-HEAT PRESSURE SWITCH RELAY, SPST-(N.C.) HOT SURFACE IGINITER (115 VAC) HOT SURFACE IGNITER RELAY, SPST-(N.O.) 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
MASTER
GV
NOTE#6
7 8 11
COM
PL1
W/W1
PASSES THROUGH HOLES IN CASINGS
ALS-M
ALS-M ALS-S BHI/LOR BHT/CLR BLWM BLWR CAP CPU EAC-1 EAC-2 FRS FSE FU GV HPS HPSR HSI HSIR HUM
WHT
HI
G
BLU
TWIN TEST SLAVE
NOTE #7 (WHEN USED) LGPS
4 CPU
MGVR-2
HUM
RED
5 Fig. 32—Schematic Diagram for Twinned 2-Speed Condensing Furnace MOVE TWINNING
MASTER
TRAN SEC-2 24VAC
YEL
PL1
TJ
W/W1
WHT
LPS
6
TWINNING JUMPER
115VAC PR2
SEC-1
R
9 SLAVE
EAC-2
HSIR EAC-1
R TWIN TEST
SPARE SPARE
HI-COOL
COMPONENT TEST
12 N/A MGVR-2
LO-GAS HEAT HI-GAS HEAT
L1
BLOWER OFF DELAY SWITCH (SEC) 3 4 90 SEC 135 SEC 180 SEC 225 SEC
To initiate the component test sequence with no thermostat inputs and with all inducer Post-Purge and Blower-Off Delay periods completed, short the "TWIN/TEST" terminal to the "COM" terminal for about two seconds. The control will turn ON the inducer motor High-Speed, HSI inducer motor LowSpeed, blower motor Low-Gas-Heat Speed, blower motor High-Gas-Heat Speed, and blower motor High-Cool Speed for 7-15 seconds each (the inducer motor will be ON the entire length of the test). Neither the gas valve nor the humidifier will be turned ON.
2
HUM
BHI/LOR BHT/CLR
HPSR
HI-COOL
CAP-1
BLWR
MED-LO NOTE #13 SPARE MED SPARE MED-HI HI COMMON COM NOTE #4
ILK
MAKE NO THERMOSTAT CONNECTIONS TO RIGHT HAND FURNACE
L2
ON OFF ON OFF
BRN
CAP-2
L1
MAKE THERMOSTAT CONNECTIONS TO ONLY THE LEFT HAND FURNACE
LO
LO-GAS HEAT HI-GAS HEAT
ON OFF ON OFF
BHI/LOR BHT/CLR
TO 115VAC FIELD DISCONNECT SWITCH EQUIPMENT GROUND NO
FURNACE SCHEMATIC DIAGRAM
A01277
TO 115VAC FIELD DISCONNECT SWITCH EQUIPMENT GROUND NOTE #1
MASTER ILK OR LH FURNACE
INDUCED DRAFT MOTOR, 2-SPEED, SHADED-POLE INDUCER MOTOR RELAY, SPST-(N.O.) INDUCER MOTOR SPEED CHANGE RELAY, SPDT BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) SLAVE AUX. BLOWER DOOR INTERLOCK SWITCH, SPST-(N.O.) JUNCTION BOX LIGHT-EMITTING DIODE FOR STATUS CODES LOW GAS PRESSURE SWITCH, SPST-(N.O.) LOW-HEAT PRESSURE SWITCH, SPST-(N.O.) LIMIT SWITCH, OVERTEMPERTURE-AUTO RESET, SPST(N.C.) MAIN GAS VALVE RELAY, DPST-(N.O.) -1 = VALVE -2 = HUMIDIFIER N/A NOT APPLICABLE PL1 12-CIRCUIT CONNECTOR PL2 9-CIRCUIT CONNECTOR PL3 3-CIRCUIT IDM CONNECTOR PL6 2-CIRCUIT HSI CONNECTOR PL8 2-CIRCUIT TWINNING CONNECTOR PL9 1-CIRCUIT TWINNING CONNECTOR SW1 HIGH-HEAT-ONLY SWITCH, SPST-(MANUAL) SW2 LOW-HEAT-ONLY SWITCH, SPST-(MANUAL) SW3 & 4 BLOWER-OFF DELAY SETTING SWITCHES, SPST-(MANUAL)
—38—
ALS-S ORN BLU
ORN
ILK-1 ORN BLU
TJ
TWINNING JUMPER, SPDT FOR MASTER OR SLAVE STATUS-(MANUAL CHANGE-OVER) TKR TWINNING KIT RELAY, SPST-(N.O.) TRAN TRANSFORMER-115VAC / 24VAC TWIN / TEST 1-CIRCUIT TWINNING BUSS CONNECTOR, ALSO COMPONENT TEST JUNCTION TERMINAL CONTROL TERMINAL FACTORY POWER WIRING (115VAC) FACTORY CONTROL WIRING (24VAC) FIELD ACCESSORY WIRING (24VAC) CONDUCTOR ON PCB EQUIPMENT GROUND FIELD WIRING SCREW TERMINAL FIELD SPLICE FIELD GROUND PLUG RECEPTACLE
326685-201 REV. A
