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Carrier 58MSA Series, Installation, Start-Up, And Operating Instructions Manual

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Carrier 58MSA Series Installation, Start-Up, And Operating Instructions Manual Download Page 5

Step 7—Electrical Connections

•

US: National Electrical Code (NEC) ANSI/NFPA 70-2002

•

CANADA: Canadian Electrical Code CSA C22.1

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will pre-
vent electrostatic discharges from personnel and hand tools
which are held during the procedure. These precautions will
help to avoid exposing the control to electrostatic discharge
by putting the furnace, the control, and the person at the same
electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may

be required. DO NOT TOUCH THE CONTROL OR ANY
WIRE CONNECTED TO THE CONTROL PRIOR TO DIS-
CHARGING 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 the unpainted metal surface of
the 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.

INTRODUCTION

The model 58MSA 4-way multipoise, Gas-Fired, Category IV,
condensing furnaces are available in model sizes ranging in gas
input rates of 40,000 to 120,000 Btuh.

Fig. 5—Condensate Trap

A93026

1

⁄

2

 OD

INDUCER HOUSING
DRAIN CONNECTION

1

⁄

4

 OD

COLLECTOR BOX TO
TRAP RELIEF PORT

5

⁄

8

 OD

COLLECTOR BOX
DRAIN CONNECTION

1

⁄

2

-IN. PVC OR CPVC

SCREW HOLE FOR
UPFLOW OR DOWN-
FLOW APPLICATIONS
(OPTIONAL)

1 4

2

7 8

1 8

7

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

WIRE TIE
GUIDES
(WHEN USED)

1 2

1

3 4

1

3 4

FRONT VIEW

SIDE VIEW

FURNACE
DOOR

FURNACE
DOOR

CONDENSATE
TRAP

78

1 4

26

4

FURNACE
SIDE

FURNACE

SIDE

1 2

1

1 4

26

4

3 4

5

3 4

5

4

SIDE VIEW

FRONT VIEW

END VIEW

FRONT VIEW

3 4

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

HORIZONTAL

APPLICATIONS

FIELD

DRAIN

CONN

FIELD

DRAIN

CONN

CONDENSATE
TRAP (INSIDE)

BLOWER SHELF

ALTERNATE DRAIN
TUBE LOCATION

UPFLOW APPLICATIONS

CONDENSATE TRAP

DRAIN TUBE LOCATION

5

Summary of Contents for 58MSA Series

Page 1: ...NG 25 30 Removal of Existing Furnaces from Common Vent Systems 25 Combustion Air and Vent Piping 25 29 Vent Termination 29 30 Multiventing 30 CONDENSATE DRAIN 30 32 General 30 Application 32 Condensate Drain Protection 32 SEQUENCE OF OPERATION 33 36 Heating Mode 33 34 Cooling Mode 34 Continuous Blower Mode 35 Heat Pump Mode 35 Component Test 35 36 START UP PROCEDURES 36 42 General 36 Prime Condens...

Page 2: ...ed installation reliability or operation The 58MSA Multipoise Condensing Gas Fired Furnaces are CSA design certified for natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped for use with natural gas A CSA listed gas conversion kit is required to convert furnace for use with p...

Page 3: ...8 1 4 22 11 16 CONDENSATE DRAIN TRAP LOCATION DOWNFLOW HORIZONTAL RIGHT OR ALTERNATE 1 2 IN DIA GAS CONN 2 IN COMBUSTION AIR CONN 1 2 IN DIA GAS CONN 7 8 IN DIA POWER CONN 1 2 IN DIA THERMOSTAT ENTRY 2 IN VENT CONN DIMPLE LOCATORS FOR HORIZONTAL HANGING 14 1 2 TYP SIDE INLET NOTES 1 Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recomme...

Page 4: ...n site This furnace may be installed in a manufactured mobile home when stated on rating plate and using factory authorized kit This furnace may be installed on combustible flooring in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below This furnace requires a special venting system Refer to the installation instructions for parts list and method of installa...

Page 5: ...ouch the unpainted metal surface of the 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 ...

Page 6: ...ssure switch ready for use in UPFLOW applications These tubes can be identified by their connection location and also by a color label on each tube These tubes are identified as follows collector box drain tube blue label inducer housing drain tube violet label or molded relief port tube green label and pressure switch tube pink label 2 Condensate Trap Drain Tube The condensate trap drain connecti...

Page 7: ...ts bag to connect LOWER inducer housing drain connection to the condensate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage 3 Relief Port Tube a Connect relief port tube green label to condensate trap b Use smaller diameter tube factory supplied in loose parts bag to extend this tube if required c Determine appropriate length cut and connect t...

Page 8: ...LOWER inducer housing drain connection b Remove and discard UPPER molded inducer housing drain tube which was previously connected to condensate trap c Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed d Use inducer housing drain tube violet label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to the conde...

Page 9: ...nnected to pressure switch 5 Route this extended tube pink label to condensate trap relief port connection 6 Determine appropriate length cut and connect tube 7 Clamp tube to relief port connection CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda tions and procedures Step 4 Horizontal Left Supply Air Discharge Applications A horizontal left furnace appl...

Page 10: ...ctions Modify tube as described below 1 Disconnect collector box pressure tube pink label attached to pressure switch 2 Use smaller diameter tube factory supplied in loose parts bag to extend tube disconnected in item 1 3 Route extended tube a Behind inducer housing b Between blower shelf and inducer housing c Behind inducer motor bracket d Between inducer motor and pressure switch 4 Determine app...

Page 11: ...label and factory supplied in loose parts bag to connect LOWER inducer housing drain connection to condensate trap e Determine appropriate length cut and connect tube to condensate trap f Clamp tube to prevent any condensate leakage 3 Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure CONDENSATE TRAP FIELD DRAIN ATTACHMENT Refer to Condensate Drain section for recomm...

Page 12: ...to an open drain Failure to follow this caution will result in intermittent unit operation NOTE Vent pipe length is restricted to a minimum of 5 ft See Table 6 NOTE A 12 in minimum horizontal pipe section is recom mended with short 5 to 8 ft vent systems This recommendation is to reduce excessive condensate droplets from exiting the vent pipe See Fig 11 or 38 LOCATION Step 1 General This furnace m...

Page 13: ... the corrosive effects of adhesives sealers and other construction materials It also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is no less than 55 degrees F with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be ...

Page 14: ... equipment must be supplied with air for combus tion of the fuel Sufficient air MUST be provided to ensure there will not be a negative pressure in the equipment room or space In addition a positive seal MUST be made between the furnace cabinet and the return air duct to prevent pulling air from the burner area and draft safeguard opening into the circulating air The operation of exhaust fans kitc...

Page 15: ...hey must be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of ducts must not be less than 3 in See Fig 18 INSTALLATION Step 1 Leveling Legs If Desired When furnace is used in upflow position with side inlet s leveling legs may be desired See Fig 19 Install field supplied corrosion resistant 5 16 in machine bolts and nuts NOTE The maxim...

Page 16: ...ce can either be hung from floor joist or installed on suitable blocks or pad Furnace can be suspended from each corner by hanger bolts and angle iron supports See Fig 24 Cut hanger bolts 4 each 3 8 in Fig 17 Confined Space Air for Combustion and Ventilation from an Unconfined Space A96185 SUPPLY AIR 3 MIN FRONT RETURN AIR VENT THROUGH ROOF OR SIDEWALL 1 SQ IN PER 1000 BTUH IN DOOR OR WALL 12 MAX ...

Page 17: ...nge on furnace supply air outlet The supply air duct attachment must ONLY be connected to furnace supply outlet air duct flanges or air conditioning coil casing when used DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accesso ries MUST be connected external to furnace main casing DOWNFLOW FURNACES Connect supply air duct to supply air opening on f...

Page 18: ...plications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box 19 19 20 20 24 1 2 Upflow Applications 23 24 1 8 23 5 8 24 3 4 Downflow Applications on Non Combustible Flooring 22 7 8 19 23 1 2 19 5 8 Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 1 8 19 23 3 ...

Page 19: ...dition of NFGC in the United States Canadian installations must be made in accordance with NSCNG PIC and all authorities having jurisdiction Gas supply line should be a separate line running directly from meter to furnace if possible Refer to Table 3 for recommended gas pipe sizing Risers must be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use...

Page 20: ...tream of gas supply connection to furnace and downstream of manual shutoff valve NOTE The gas valve inlet press tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas valve See Fig 46 Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada local and national plum...

Page 21: ...be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and burner box screw Failure to follow this caution will result in mior unit opera tion Step 1 115 v Wiring Before proceeding with electrical connections make certain that voltage frequency and phase correspond to that specified on unit Fig 26 Bottom Filter Arrangement A00290...

Page 22: ...and Canadian Elec trical Code CSA C22 1 or local codes to minimize personal injury if an electrical fault should occur This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes Do not use gas piping as an electrical ground Failure to follow this warning could result in electrical shock fire or death J Box Relocation 1 ...

Page 23: ...RAFT MOTOR PSC IDR INDUCED DRAFT MOTOR RELAY SPST N O ILK BLOWER ACCESS PANEL INTERLOCK SWITCH SPST N O J1 BLOWER OFF DELAY JUMPER SELECTOR J2 COOLING OFF DELAY JUMPER JB JUNCTION BOX LED LIGHT EMITTING DIODE FOR STATUS CODES RED LGPS LOW GAS PRESSURE SWITCH SPST N O LS LIMIT SWITCH AUTO RESET SPST N C OL AUTO RESET INTERNAL MOTOR OVERLOAD TEMPERATURE SWITCH N C PCB PRINTED CIRCUIT BOARD CONTROL P...

Page 24: ...is energized with 24v 0 5 amp maximum when gas valve is energized Table 4 Electrical Data UNIT SIZE VOLTS HERTZ PHASE OPERATING VOLTAGE RANGE MAX UNIT AMPS UNIT AMPACITY MIN WIRE SIZE MAX WIRE LENGTH FT MAX FUSE OR CKT BKR AMPS Max Min 040 08 115 60 1 127 104 6 1 8 4 14 44 15 040 12 115 60 1 127 104 7 3 10 0 14 37 15 060 08 115 60 1 127 104 6 1 8 4 14 44 15 060 12 115 60 1 127 104 7 1 9 8 14 38 15...

Page 25: ...y need to be resized For any other appliances when resizing vent systems or vent connectors system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSC NGPIC Step 2 Combustion Air and Vent Piping GENERAL Solvent cements are combustible Keep away from heat sparks and open flame Use only in well ventilated areas Avoid breathing in vapor o...

Page 26: ...T TERMINALS 3 AMP FUSE LED OPERATION DIAGNOSTIC LIGHT 115 VAC L2 NEUTRAL CONNECTIONS COOL HEAT SPARE 1 SPARE 2 BLOWER SPEED SELECTION TERMINALS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX 115 VAC L1 LINE VOLTAGE CONNECTION PL2 HOT SURFACE IGNITER INDUCER MOTOR CONNECTOR PL1 LOW VOLTAGE MAIN HARNESS CONNECTOR TRANSFORMER 24 VAC CONNECTIONS HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX TWINNING AND OR COMPONENT TES...

Page 27: ...a field supplied No 6 or No 8 sheet metal screw NOTE DO NOT OVERTIGHTEN SCREW Breakage of intake housing or fitting may cause air leakage to occur A plugged drain connection has been provided on this fitting for use when moisture is found in combustion air intake pipe and combustion box If use of this drain connection is desired drill out fitting s tap plug with a 3 16 in drill and connect a field...

Page 28: ...quire 2 1 2 in vent pipe At 5001 to 6000 ft elevation 2 in pipe is allowed for up to 23 ft with 3 elbows but 2 1 2 in pipe can be used for up to 70 ft with 3 elbows Install vent pipe as follows 1 Determine location of vent pipe connection to inducer housing as shown in Fig 34 for application 2 Reposition elastomeric rubber inducer housing outlet cap and clamp to appropriate unused inducer housing ...

Page 29: ... outside ambient by insulating pipe as indicated in Table 7 1 Determine vent pipe diameter as stated above using total pipe length and number of elbows 2 Find appropriate temperature for your application and furnace model using winter design temperature used in load calcula tions 3 Determine required insulation thickness for exposed pipe lengths NOTE Pipe length ft specified for maximum pipe lengt...

Page 30: ...060 12 060 16 2 Pipe or 2 in Concentric 1 1 2 20 15 10 5 NA NA 2 70 70 70 70 70 70 080 12 080 16 080 20 2 Pipe or 2 in Concentric 1 1 2 10 NA NA NA NA NA 2 55 50 35 30 30 20 2 1 2 70 70 70 70 70 70 100 16 100 20 2 Pipe or 3 in Concentric 2 5 NA NA NA NA NA 2 1 2 40 30 20 20 10 NA 3 70 70 70 70 70 70 120 20 2 Pipe or 3 in Concentric 2 1 2 one disk 10 NA NA NA NA NA 3 45 40 35 30 25 20 3 no disk 70 ...

Page 31: ...NA NA 3 70 67 62 57 52 47 120 20 2 Pipe or 3 in Concentric 3 no disk 42 35 29 22 15 9 4 no disk 70 70 70 70 70 70 ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN NUMBER OF 90 ELBOWS 1 2 3 4 5 6 6001 to 7000 040 08 040 12 2 Pipe or 2 in Concentric 1 1 2 53 48 43 38 37 32 2 70 70 68 67 66 64 060 08 060 12 060 16 2 Pipe or 2 in Concentric 1 1 2 13 8 NA NA NA NA 2 57 52 50 45 44 43 080 12 080 16 08...

Page 32: ...rap field drain pipe with remaining heat tape approximately 1 wrap per ft 5 When using field supplied heat tape follow heat tape manu facturer s instructions for all other installation guidelines Table 6 Maximum Allowable Pipe Length ft Continued ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN NUMBER OF 90 ELBOWS 1 2 3 4 5 6 8001 to 9000 040 08 040 12 2 Pipe or 2 in Concentric 1 1 2 46 41 36 31...

Page 33: ... the end of the prepurge period the Hot Surface Igniter HSI is energized for a 17 second igniter warm up period c Trial for Ignition Sequence When the igniter warm up period is completed the main gas valve relay contacts GVR close to energize the gas valve GV the gas valve opens The gas valve GV permits gas flow to the burners where it is ignited by the Hot Surface Igniter HSI Five seconds after t...

Page 34: ...bustion air opening 1 3 From service regulator vent electric and gas meters and relief equipment See Note 6 See Note 6 Above grade when adjacent to public walkway See Note 3 See Note 3 18 in above roof surface NOTES 1 If installing 2 adjacent Furnaces refer to Multiventing and Vent Terminations section for proper vent configurations 2 When locating vent terminations consideration must be given to ...

Page 35: ... control CPU will continue to turn on the blower motor BLWM at HEAT speed and begin a heating cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HEAT speed When the W input signal disappears the furnace control begins a normal inducer post purge period and the blower switches to COOL speed after a 3 second delay If the ...

Page 36: ...trap Failure to follow this caution will result in minor unit operation or performance satisfaction 1 Remove upper inducer housing drain connection cap See Fig 44 2 Connect field supplied 1 2 in ID tube to upper inducer housing drain connection 3 Insert field supplied funnel into tube 4 Pour 1 quart of water into funnel tube Water should run through inducer housing overfill condensate trap and flo...

Page 37: ...ole 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 e Replace gas valve regulator adjustment screw cap f Replace burner enclosure front and verify adjusted gas input rate using method outlined in item 3 DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause exces...

Page 38: ...re U S A and Canada U S A 775 43 3 8 42 3 2 42 3 3 42 3 4 42 3 5 Altitudes 800 43 3 5 43 3 7 43 3 8 42 3 2 42 3 3 2001 to 825 44 3 8 43 3 4 43 3 6 43 3 7 43 3 8 3000 850 44 3 6 44 3 7 44 3 8 43 3 5 43 3 6 or 875 44 3 4 44 3 5 44 3 6 44 3 7 43 3 4 Canada 900 44 3 2 44 3 3 44 3 4 44 3 5 44 3 6 Altitudes 925 45 3 7 45 3 8 44 3 2 44 3 3 44 3 4 2001 to 950 45 3 5 45 3 6 45 3 7 45 3 8 44 3 3 4500 975 45...

Page 39: ...ly 700 43 3 6 43 3 7 42 3 2 42 3 3 42 3 4 725 43 3 4 43 3 5 43 3 6 43 3 7 43 3 8 750 44 3 6 44 3 7 43 3 4 43 3 5 43 3 6 775 44 3 4 44 3 5 44 3 6 44 3 7 43 3 4 5001 800 44 3 2 44 3 3 44 3 4 44 3 5 44 3 6 825 45 3 6 45 3 7 44 3 2 44 3 3 44 3 4 to 850 45 3 4 45 3 5 45 3 6 45 3 8 44 3 2 875 45 3 2 45 3 3 45 3 4 45 3 6 45 3 7 6000 900 45 3 0 45 3 1 45 3 3 45 3 4 45 3 5 925 45 2 9 45 3 0 45 3 1 45 3 2 4...

Page 40: ...Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure U S A Only 600 43 3 8 42 3 3 42 3 4 42 3 5 42 3 6 625 43 3 5 43 3 6 43 3 8 42 3 2 42 3 3 8001 650 44 3 7 43 3 4 43 3 5 43 3 6 43 3 7 675 44 3 5 44 3 6 44 3 7 44 3 8 43 3 4 to 700 44 3 2 44 3 3 44 3 4 44 3 6 44 3 7 725 45 3 6 45 3 8 44 3 2 44 3 3 44 3 4 9000 750 45 3 4 45 3 5 45 3 6 45 3 8 44 3 2 17 775 ...

Page 41: ...FLAME BURNER MANIFOLD Table 10 Altitude Derate Multiplier for U S A ALTITUDE FT OF DERATE DERATE MULTIPLIER FACTOR FOR U S A 0 2000 0 1 00 2001 3000 4 6 0 95 3001 4000 6 8 0 93 4001 5000 8 10 0 91 5001 6000 10 12 0 89 6001 7000 12 14 0 87 7001 8000 14 16 0 85 8001 9000 16 18 0 83 9001 10 000 18 20 0 81 Derate multiplier factor is based on midpoint altitude for altitude range Table 11 Gas Rate Cu F...

Page 42: ... delay setting is 120 sec Table 13 Blower Off Delay Setup Position PINS 1 AND 2 2 AND 3 3 AND 4 4 AND 5 Time in sec 90 120 150 180 SET THERMOSTAT HEAT ANTICIPATOR When using a nonelectronic thermostat the thermostat heat anticipator must be set to match amp draw of components in R W circuit Accurate amp draw measurements can be obtained at thermostat subbase terminals R and W Fig 49 illustrates an...

Page 43: ... surface igniter glows when inducer motor is disconnected shut furnace down immediately Determine reason pressure switch did not function properly and correct condition 5 Turn off 115 v power to furnace 6 Reconnect inducer motor leads reinstall main furnace door and turn on 115 v power supply CHECKLIST 1 Put away tools and instruments Clean up debris 2 Verify flame rollout manual reset switch has ...

Page 44: ...w Ambient Exposed Pipes Condensate Drain ________ Unit Level or Pitched Forward ________ Internal Tubing Connections Free of Kinks and Traps ________ External Drain Connection Leak Tight and Sloped ________ Condensate Trap Primed before Start Up ________ Heat Tape Installed if Required CHECKLIST START UP ________ Gas Input Rate Set Within 2 percent of Rating Plate ________ Temperature Rise Adjuste...

Page 45: ...roduct theory and skills programs is available using popular video based formats and materials All include video and or slides plus companion book Classroom ServiceTraining plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 644 5544...

Page 46: ...46 ...

Page 47: ...47 ...

Page 48: ...31 58msa7si 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 80113 Printed in U S A Form 58MSA 7SI Pg 48 10 03 Replaces 58MSA 6SI ...

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