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CANADIAN GAS ASSOCIATION
WeatherMaker 8000™
58ZAV
Downflow/Horizontal Induced-Combustion Furnaces
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Installation, Start-Up, and Operating Instructions
Sizes 050—135, Series 140
NOTE: Read the entire instruction manual before starting the
installation.
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ama
Index Page
SAFETY CONSIDERATIONS .....................................................1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
®
APPROVED
PROCEDURE ..............
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1 28 ⁄ † 2 VENT CONNECTION 1 ⁄ † DIA 2 20† 2† D THERMOSTAT 3 4 ⁄ † 16 13 13 ⁄ † ⁄ † 16 WIRE ENTRY 16 INLET 7 ⁄ † DIA 8 ACCESSORY 15 2 ⁄ † 16 7 ⁄ † DIA HOLE 8 POWER ENTRY 7 39 ⁄ † 8 1 1 ⁄ † DIA 2 R.H. GAS ENTRY 7 ⁄ † DIA 1 8 9 ⁄ † 8 ACCESSORY 1 16 ⁄ † 1† TYP 16 7 3 1 ⁄ † DIA HOLE ⁄ † DIA 4 1 8 10 ⁄ † 4 GAS ENTRY ACCESSORY 1 OUTLET 1 ⁄ † 16 5 11 13 ⁄ † E 16 ⁄16† 1 5 2 ⁄ † 8 ⁄ † TYP 1 8 10 ⁄ † 4 1 19† 8 ⁄ † A 11 4 ⁄ † 1 16 1 ⁄ † 16 11 ⁄ † 16 1 2 ⁄ † 8 NOTE: 7 AIRFLOW DIMPLES TO DRILL HOLES ADDITIO
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MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION This furnace is approved for DOWNFLOW and HORIZONTAL This forced air furnace is equipped for use with natural installations. gas at altitudes 0-10,000 ft (0-3,050m). An accessory kit, supplied by the manufacturer,shall be used to convert to propane gas use or may be required for Clearance arrows some natural gas applications. do not change with This furnace is for indoor installation in a building furnace orientation. 1" constructed on site. T
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Locate the furnace as close to the chimney/vent and as near the center of the air distribution system as possible. The furnace should be installed as level as possible. Provide ample space for servicing and cleaning. Always comply with the minimum fire protection clearances shown on the unit rating plate. This furnace shall not be installed directly on FRONT carpeting, tile, or any combustible material other than wood °F °F flooring. The furnace may be installed on combustible flooring when inst
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c. If furnace is installed on a raised platform to provide a return-air plenum, and return air is taken directly from The operation of exhaust fans, kitchen ventilation fans, hallway or space adjacent to furnace, all air for combustion clothes dryers, or fireplaces could create a NEGATIVE must come from outdoors. PRESSURE CONDITION at the furnace. Make-up air MUST 2. Air from outside the structure requires 1 of the following be provided for the ventilation devices, in addition to that methods: r
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DUCTS TO
OUTDOORS 1 SQ IN.
PER 4000
BTUH * VENT THROUGH ROOF
(CATEGORY I) 12″ MAX D 12″ 1 SQ IN.
MAX RETURN
VENT
PER 2000
A AIR THROUGH
F BTUH RETURN
* ROOF
12″ MAX AIR (CATEGORY I) 1 SQ IN.
PER 4000
1 SQ IN.
BTUH * PER 1000
DUCTS
BTUH IN DOOR
* TO
OUTDOORS OR WALL OUTSIDE INTERIOR
HEATED
UNCONFINED
1 SQ IN.
SPACE SPACE PER 4000
6″ MIN
BTUH * † (FRONT) 1 SQ IN.
G 1 SQ IN.
E PER 2000
B PER 1000
12″ BTUH * BTUH IN DOOR
MAX * C 12″ MAX OR WALL 12″ MAX 12″ MAX SU
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A PLENUM
OPENING B D FLOOR
OPENING C A96283 Fig. 5—Floor and Plenum Opening Dimensions Table 3—Opening Dimensions (In.) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION AB C D WIDTH Non-Combustible Flooring 12-11/16 19 13-3/8 19-5/8 Combustible Flooring Using KGASB Subbase 11-13/16 19 13-7/16 20-3/8 14-3/16 Combustible Flooring with CD5 or CK5 Coil Assembly or 12-5/16 19 13-5/16 20 KCAKC Coil Box Non-Combustible Flooring 16 19 16-5/8 19-5/8 Combustible Flooring Using KGASB Subbase 15-1/
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FURNACE
FURNACE (OR COIL CASING
WHEN USED) CD5 OR CK5
COIL ASSEMBLY
OR KCAKC
COIL BOX COMBUSTIBLE
COMBUSTIBLE
FLOORING FLOORING DOWNFLOW
SUBBASE SHEET METAL
SHEET METAL
PLENUM PLENUM FLOOR
FLOOR
OPENING OPENING A96285 A96284 Fig. 6—Furnace, Plenum, and Subbase Installed Fig. 7—Furnace, Plenum, and Coil Assembly or on a Combustible Floor Coil Box Installed on a Combustible Floor LINE CONTACT ONLY PERMISSIBLE BETWEEN
LINES FORMED BY INTERSECTIONS OF
THE TOP AND TWO SIDES OF THE FURNA
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3 ⁄8-IN. ROD ANGLE
IRON OR
EQUIVALENT (B) (A) (B) (A) (B) (A) ROD LOCATION
USING DIMPLE
(A) (B) LOCATORS
3 /8-IN. HEX NUT
(SEE DIMENSIONAL
& WASHER (4)
DWG FOR
REQD PER ROD LOCATIONS) NOTES: 1. A 1 In. clearance minimum between top of furnace and combustible material.
(A) PREFERRED ROD LOCATION
2. The entire length of furnace must be (B) ALTERNATE ROD LOCATION supported when furnace is used in horizontal position. A96633 Fig. 10—Horizontal Crawlspace Installation on Hanger Rods
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Table 5—Maximum Capacity of Gas Pipe * NOMINAL IRON INTERNAL LENGTH OF PIPE (FT) PIPE SIZE DIAMETER 10 20 30 40 50 (IN.) (IN.) 1/2 0.622 175 120 97 82 73 3/4 0.824 360 250 200 170 151 1 1.049 680 465 375 320 285 1-1/4 1.380 1400 950 770 660 580 AIRFLOW 1-1/2 1.610 2100 1460 1180 990 900 * Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a 12″ pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table 10-2
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Table 6—Electrical Data VOLTS— MAXIMUM OPERATING VOLTAGE RANGE MAXIMUM MINIMUM MAXIMUM WIRE UNIT SIZE HERTZ— FUSE OR CKT BKR UNIT AMPS WIRE GAGE LENGTH FT‡ Maximum* Minimum* PHASE AMPS† 050-08 115—60—1 127 104 6.6 14 42 15 050-12 115—60—1 127 104 8.1 14 34 15 070-08 115—60—1 127 104 6.7 14 42 15 070-12 115—60—1 127 104 8.4 14 33 15 096-12 115—60—1 127 104 9.2 14 30 15 096-16 115—60—1 127 104 10.2 14 28 15 115-16 115—60—1 127 104 10.1 14 28 15 115-20 115—60—1 127 104 13.3 12 33 20 115-22 115—60—1
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BLOWER OFF DELAY ADJUSTMENT SWITCH 24V THERMOSTAT G TERMINALS R Y W TEST/TWIN HUMIDIFIER TERMINAL COM 24V (24-VAC 0.5 AMP MAX) HUM LED OPERATION & STATUS LIGHT HARNESS CONNECTOR SEC-1 24V TRANSFORMER SEC-2 3-AMP FUSE SPARE 1 COOL BLOWER SPEED HEAT SELECTION TERMINALS SPARE 2 EAC 1 (BLACK) EAC-ELECTRONIC AIR CLEANER TERMINALS (115-VAC 1.0 AMP MAX) 115-VAC (L1) EAC 2 (WHITE) POWER 115-VAC (L2) NEUTRAL SUPPLY CONNECTION HOT SURFACE INDUCER MOTOR IGNITER CONNECTOR CONNECTOR A99258 Fig. 14—Furnace Co
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c. Ignition sequence—When the igniter warm-up period is completed, the gas valve opens, permitting gas flow to the burners where it is ignited. After 5 sec, the igniter is de-energized and a 2-sec flame-sensing period begins. d. HUM terminal is energized with the gas valve. See Accessories in Electrical Connections section. e. Flame-sensing—When burner flame is sensed, the control EAC1 begins the blower on delay period and continues holding the gas valve open. If burner flame is not sensed, the
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14 TO 115VAC FIELD DISCONNECT (WHEN USED) (WHEN USED) SCHEMATIC DIAGRAM SW2 G NEUTRAL NOTE #14 NOTE #11 (WHEN USED) BLOWER NOTE #4 R L1 (NATURAL GAS & PROPANE) PCB BVSS ALS PRS NOTE #9 DSS LGPS OFF Y EQUIPMENT GROUND DELAY (NOT ON ALL MODELS) W SW1 ORN ORN L2 ORN ORN ORN ILK COM LO BLOWER OFF DELAY SPARE-2 HUM MED LO SELECTION CHART HEAT YEL MED HI TEST/TWIN NOTE #13 HI 90 SEC NOTE #14 START SPARE-1 HI/LO OL L1 NOTE #7 LED BLWR 135 SEC COOL BLU LS CAP 180 SEC COM COM RED BLWM 1-M 3-P EAC-1 PL1
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until the end of the ignition warm up and trial for ignition 4. With furnace operating, set thermostat below room tempera- periods (a total of 24 sec). The blower then comes back on at ture and observe that furnace goes off. Set thermostat above heating speed. room temperature and observe that furnace restarts. When the W input signal disappears, the control begins the ADJUSTMENTS normal inducer post-purge period and the blower changes to cooling speed after a 1-sec delay. If the W-Y-G signals 1
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→Table 7—Model 58ZAV Orifice Size† and Manifold Pressure for Correct Input (Tabulated Data Based on 23,000 BTUH Per Burner, Derated 4 Percent per 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 0.66 RANGE AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (FT) (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure No. Pressure 850 41 3.6 41 3.7 41 3.8 40 3.6 40 3.8 875 42 3.8 41 3.5 4
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→Table 7—Model 58ZAV Orifice Size† and Manifold Pressure for Correct Input (Continued) (Tabulated Data Based on 23,000 BTUH Per Burner, Derated 4 percent per 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 0.66 RANGE AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (FT) (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure No. Pressure 700 43 3.7 43 3.8 42 3.2 42 3.3 42 3.4 725 43
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→Table 7—Model 58ZAV Orifice Size† and Manifold Pressure for Correct Input (Continued) (Tabulated Data Based on 23,000 BTUH Per Burner, Derated 4 percent per 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 0.66 RANGE AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold (FT) (BTU/CU FT) No. Pressure No. Pressure No. Pressure No. Pressure No. Pressure 575 43 3.0 43 3.1 43 3.2 43 3.3 43 3.4 600 43
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Table 9—Gas Rate (Cu Ft/Hr) ON AND
SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS OFF SWITCH FOR 1 FOR 1 1 2 5 1 2 5 REVOLUTION REVOLUTION cu ft cu ft cu ft cu ft cu ft cu ft GAS
PRESSURE
10 360 720 1800 50 72 144 360 REGULATOR
11 327 655 1636 51 71 141 355 ADJUSTMENT 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 9
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b. Restore power to furnace and set room thermostat above room temperature. Recheck temperature rise. It must be within limits specified c. After normal start-up, allow furnace to operate for 2 on unit rating plate. Recommended operation is at midpoint of minutes, then block flue outlet 100 percent. Furnace should rise or above. cycle off within 2 minutes. 3. Set thermostat heat anticipator. d. Remove blockage and reconnect vent pipe to furnace outlet collar. The thermostat heat anticipation mus
