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WeatherMaker 8000™

58ZAV

Downflow/Horizontal Induced-Combustion Furnaces

Installation, Start-Up, and Operating Instructions

Sizes 050—135, Series 141

NOTE:

Read the entire instruction manual before starting the

installation.

This symbol

indicates a change since the last issue.

Index

Page

SAFETY CONSIDERATIONS ................................................1-2

Clearances From Combustible Materials .................................1
Dimensional Drawing ...............................................................2

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE........................................................................2-3

INTRODUCTION ..........................................................................3
LOCATION ................................................................................3-4

General ......................................................................................3
Location Relative to Cooling Equipment ................................3
Hazardous Locations.................................................................4

AIR FOR COMBUSTION AND VENTILATION ...................4-5

Unconfined Space .....................................................................4
Confined Space......................................................................4-5

SUPPLY-AIR PLENUM INSTALLATION (DOWNFLOW)..5-6

Downflow Installation .............................................................5
Installation On a Combustible Floor ....................................5-6

HORIZONTAL ATTIC INSTALLATION ...................................6

Construct a Working Platform .................................................6
Install Furnace...........................................................................6

HORIZONTAL CRAWLSPACE INSTALLATION....................6
FILTER ARRANGEMENT...........................................................7
GAS PIPING...............................................................................7-9
ELECTRICAL CONNECTIONS.............................................9-10

115-v Wiring........................................................................9-10
24-v Wiring.............................................................................10
Accessories..............................................................................10

VENTING ....................................................................................10
START-UP, ADJUSTMENT, AND SAFETY CHECK .......10-18

General ....................................................................................10
Sequence Of Operation .....................................................10-12
Heating Mode..........................................................................12
Cooling Mode .........................................................................12
Continuous Blower Mode.......................................................12
Heat Pump Mode ....................................................................12
Start-up Procedures............................................................12-14
Adjustments .......................................................................14-18
Set Gas Input Rate ............................................................14-17
Set Temperature Rise ........................................................17-18
Set Thermostat Heat Anticipator............................................18
Check Safety Controls.......................................................18-19
Checklist..................................................................................19

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified person-
nel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on

®

ama

CANADIAN   GAS   ASSOCIATION

A PP R O VED

R

Table 1—Clearances From Combustible

Materials (In.)

UNIT SIZE

050 AND 070

096-135

DOWNFLOW (In Alcove or Closet)

Sides

Single-Wall Vent

1

0

Type B-1 Double-Wall Vent

0

0

Back

0

0

Top

1

1

Front

Single-Wall Vent

6†

6†

Type B-1 Double-Wall Vent

3†

3†

Vent

Single-Wall Vent

6

6

Type B-1 Double-Wall Vent

1

1

HORIZONTAL (Attic, Alcove, or Crawlspace)

Sides *

1

0

Back

0

0

Top

Single-Wall Vent

1

1

Type B-1 Double-Wall Vent

1

1

Front‡

Single-Wall Vent

6†

6†

Type B-1 Double-Wall Vent

3†

3†

Vent

Single-Wall Vent

6

6

Type B-1 Double-Wall Vent

1

1

HORIZONTAL (In Closet)

Sides *

1

1

Back

3

3

Top

Single-Wall Vent

2

2

Type B-1 Double-Wall Vent

2

2

Front

Single-Wall Vent

6

6

Type B-1 Double-Wall Vent

3

3

Vent

Single-Wall Vent

6

6

Type B-1 Double-Wall Vent

1

1

* Indicates supply or return sides when furnace is in the horizontal position.

† Clearance shown is for outlet end. The inlet end must maintain 6-in.
minimum clearance from the vent to combustible materials when using
single-wall vent.

‡ Minimum 18-in. front clearance required for alcove.
NOTES:
1. Provide 30-in. front clearance for servicing. An open door in front of the
furnace can meet this requirement.
2. A minimum clearance of 3 in. must be provided in front of the furnace for
combustion air and proper operation.
3. Line contact is permitted as shown in Fig. 7.

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

Book 1

4

Tab

6a 8a

PC 101

Catalog No. 535-860

Printed in U.S.A.

Form 58ZAV-9SI

Pg 1

1-97

Replaces: 58ZAV-8SI

Summary of Contents for 58ZAV Series

Page 1: ...enance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on ama CANADIAN GAS ASSOCIATION APPROVED R Table 1 Clearances From Combustible Materials In UNIT SIZE 050 AND 070 096 135 DOWNFLOW In Alcove or Closet Sides Single Wall Vent 1 0 Type B 1 Double Wall Vent 0 0 Back 0 0 Top 1 1 Front Single Wall Vent 6 6 Type B ...

Page 2: ...arge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will pre vent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the sa...

Page 3: ...e NFGC This furnace is designed for a minimum continuous return air temperature of 60 F db or intermittent operation down to 55 F db such as when used with a night setback thermostat Return air temperature must not exceed a maximum of 85 F db Improper installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning explo sion fire electrical shock or other conditi...

Page 4: ...s or spaces freely communicating with the outdoors Combustion and ventilation openings must be sized the same as for a confined space A minimum opening with a total of at least 1 sq in per 5000 Btuh of total input rating for all equipment must be provided Return air must not be taken from the room unless an equal or greater amount of air is supplied to the room CONFINED SPACE A confined space has ...

Page 5: ...No CD5 or CK5 or Coil Box Part No KCAKC is used 1 Determine application being installed from Table 3 2 Construct hole in floor per dimensions specified in Table 3 and Fig 4 3 Construct plenum to dimensions specified in Table 3 4 If downflow subbase KGASB is used install as shown in Fig 5 If coil assembly CD5 CK5 or Coil Box KCAKC is used install as shown in Fig 6 INSTALLATION ON A COMBUSTIBLE FLOO...

Page 6: ...lat washer 3 8 in lockwasher and 3 8 in nut Dimples are provided for hole locations See Fig 1 Since horizontal crawlspace installation is very similar to attic installation refer to Step 4 The installation of a sheet metal shield in front of louvered control panel is covered in Step 4 For a crawlspace installation this same sheet metal shield must be installed above louvered control panel Extend s...

Page 7: ...s must be installed in accordance with NSC NGPIC and all authorities having jurisdiction Refer to Table 5 for recommended gas pipe sizing Risers should be used to connect to the furnace and to the meter Fig 5 Furnace Plenum and Subbase Installed on a Combustible Floor A96285 DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR OPENING FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING Fig 6 Furnace Plenum...

Page 8: ...tant to the action of propane gas An accessible manual shutoff valve MUST be installed upstream of the furnace gas controls and within 72 in of the furnace A 1 8 in NPT plugged tapping accessible for test gage connection MUST be installed immediately upstream of the gas supply connection to the furnace and downstream of the manual shutoff valve Place a ground joint union between the gas control ma...

Page 9: ...NFPA 70 1996 and any local codes or ordinances that might apply For Canadian installations all electrical connections must be made in accordance with Canadian Electrical Code CSA C22 1 or authori ties having jurisdiction NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control board fault code indicator light will flash rapidly and furnace will not operate Table 4 ...

Page 10: ... GENERAL NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control board fault indicator light will flash rapidly and furnace will not operate The furnace must have a 115 v power supply properly connected and grounded Proper polarity must be maintained for correct operation Thermostat wire connections at R W C and Y must be made at the 24 v terminal block on the con...

Page 11: ...E R G C W C R G Y GND GND FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING 208 230 OR 460 VOLT THREE PHASE 208 230 VOLT SINGLE PHASE WHT BLK WHT BLK NOTES Connect Y terminal as shown for proper operation Some thermostats require a C terminal connection as shown If any of the original wire as supplied must be replaced use same type or equivalent ...

Page 12: ...ol auto matically changes the timing sequence to avoid long blower off time during demand defrost cycles When the W Y or W Y G thermostat inputs are received at the same time the control changes the blower to heating speed or starts the blower if it was off and begins a heating cycle The blower remains on until the end of the prepurge period then shuts off until the end of the ignition warm up and...

Page 13: ... WIRING 24VAC FIELD WIRING 115VAC FIELD WIRING 24VAC CONDUCTOR ON PCB FIELD WIRING TERMINAL FIELD GROUND EQUIPMENT GROUND FIELD SPLICE PLUG RECEPTACLE L1 NEUTRAL L1 BLWR HI LO TO 115VAC FIELD DISCONNECT NOTE 4 EQUIPMENT GROUND SPARE 2 HEAT SPARE 1 COOL NOTE 8 COM HSIR EAC 1 START OL COM HI MED HI MED LO LO BLWM SCHEMATIC DIAGRAM NATURAL GAS PROPANE EAC 2 1 1 HSI 2 PL5 2 PL2 3 PL3 PR2 115VAC PR1 TR...

Page 14: ...is can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for proper flame characteristics 3 After correct manifold pressure is o...

Page 15: ... 3 1 43 3 2 to 1000 43 2 7 43 2 8 43 2 9 43 3 0 43 3 1 4500 1025 43 2 6 43 2 6 43 2 7 43 2 8 43 2 9 ALTITUDE RANGE FT AVG GAS HEAT VALUE AT ALTITUDE BTU CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 0 66 Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure U S A Only 750 42 3 4 42 3 6 42 3 7 42 ...

Page 16: ... 7 43 2 8 7000 825 43 2 3 43 2 4 43 2 5 43 2 5 43 2 6 850 43 2 2 43 2 2 43 2 3 43 2 4 43 2 5 875 43 2 0 43 2 1 43 2 2 43 2 3 43 2 3 ALTITUDE RANGE FT AVG GAS HEAT VALUE AT ALTITUDE BTU CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 0 66 Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure U S A O...

Page 17: ... 22 500 Btuh Deduct 0 1 in wc from manifold pressure shown in table Change orifice size if manifold pressure falls below 3 2 in wc on altitudes up to 2000 ft otherwise change orifice size if manifold pressure falls below 2 0 in wc Table 9 Gas Rate Cu Ft Hr SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL SECONDS FOR 1 REVOLUTION SIZE OF TEST DIAL 1 cu ft 2 cu ft 5 cu ft 1 cu ft 2 cu ft 5 cu ft 10 11 12 ...

Page 18: ...circulating air blower motor if the furnace overheats The preferred method of checking the limit control is to gradually block off the return air after the furnace has been operating for a period of at least 5 minutes As soon as the limit has shut off the burners the return air opening should be unblocked By using this method to check the limit control it can be established that the limit is funct...

Page 19: ...oor k Turn on 115 v power to furnace CHECKLIST 1 Put away tools instruments and clean up debris 2 Verify manual reset switches have continuity 3 Ensure blower and control access doors are properly installed 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer s instruc tions 6 Review User s Manual with owner 7 Leave literature packet near furnace A94328 SERVI...

Page 20: ...6231 58zav9si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 Tab 6a 8a PC 101 Catalog No 535 860 Printed in U S A Form 58ZAV 9SI Pg 20 1 97 Replaces 58ZAV 8SI ...

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