Carrier 59CU5A Installation, Start-Up, Operating And Service And Maintenance Instructions Download Page 4

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59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions

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

Most states in the USA and jurisdictions in Canada have laws that

require the use of Carbon Monoxide (CO) alarms with fuel burning

products. Examples of fuel burning products are furnaces, boilers, space

heaters, generators, water heaters, stoves/ranges, clothes dryers,

fireplaces, incinerators, automobiles, and other internal combustion

engines. Even if there are no laws in your jurisdiction requiring a CO

Alarm, it’s highly recommended that whenever any fuel burning product

is used in or around the home or business that the dwelling be equipped

with a CO Alarm(s). The Consumer Product Safety Commission

recommends the use of CO Alarm(s). The CO Alarm(s) must be

installed, operated, and maintained according to the CO Alarm

manufacturer’s instructions. For more information about Carbon

Monoxide, local laws, or to purchase a CO Alarm online, please visit the

following website. https://www.kidde.com.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or

use can cause explosion, fire, electrical shock, or other conditions which

may cause death, personal injury, or property damage. Consult a

qualified installer, service agency, or your distributor or branch for

information or assistance. The qualified installer or agency must use

factory-authorized kits or accessories when modifying this product.

Refer to the individual instructions packaged with the kits or accessories

when installing.
Installing and servicing heating equipment can be hazardous due to gas

and electrical components. Only trained and qualified personnel 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 heating equipment, observe precautions in

literature, on tags, and on labels attached to or shipped with furnace and

other safety precautions that may apply.
These instructions cover minimum requirements and conform to existing

national standards and safety codes. In some instances, these instructions

exceed certain local codes and ordinances, especially those that may not

have kept up with changing residential construction practices. We

require these instructions as a minimum for a safe installation.
Follow all safety codes. Wear safety glasses, protective clothing, and

work gloves. Have a fire extinguisher available. Read these instructions

thoroughly and follow all warnings or cautions included in literature and

attached to the unit.

This is the safety-alert symbol . When you see this symbol on the

furnace and in instructions or manuals, be 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 hazards which may result

in minor personal injury or product and property damage. NOTE and

NOTICE are used to highlight suggestions which will result in enhanced

installation, reliability, or operation.

1. Use only with type of gas approved for this furnace. Refer to the

furnace rating plate.

2. Install this furnace only in a location and position as specified in the

“Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace

space as specified in “Air for Combustion and Ventilation” section.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury and/or

death.

Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous

gas that can be fatal when inhaled. Follow all installation, maintenance,

and service instructions. See additional information below regarding

the installation of a CO Alarm.

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation,

personal injury, death, or property damage.

Improper installation, adjustment, alteration, service, maintenance, or

use can cause carbon monoxide poisoning, explosion, fire, electrical

shock, or other conditions which may cause personal injury or property

damage. Consult a qualified service agency, local gas supplier, or your

distributor or branch for information or assistance. The qualified

service agency must use only factory-authorized and listed kits or

accessories when modifying this product.

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation,

personal injury, death, or property damage.

Furnaces shall NOT be twinned. These furnaces are not approved for

installation

recreational

vehicles,

outdoors

manufactured/mobile homes.

WARNING

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or

property damage.

Solvents, cements and primers are combustible. Keep away from heat,

sparks and open flame. Use only in well-ventilated areas. Avoid

breathing in vapor or allowing contact with skin or eyes.

CAUTION

FURNACE RELIABILITY HAZARD

Faulure to follow this caution may result in unit component damage.
Application of this furnace should be indoors with special attention

given to vent sizing and material, gas input rate, air temperature rize,

unit leveling, and unit sizing.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and wear

appropriate protective clothing, safety glasses and gloves when

handling parts, and servicing furnaces.

Summary of Contents for 59CU5A

Page 1: ...ctrical Data 29 NOTES FOR THERMOSTATS 31 VENTING 31 Table 14 Vent Termination Kit for Direct Vent 2 pipe Systems32 Table 15 Hanger Spacing 38 Notes for Venting Options 40 Table 16 Approved Combustion Air and Vent Pipe Fitting and Ce ment Materials U S A Installations 41 Table 17 Maximum Allowable Exposed Vent Length in Uncondi tioned Space Ft 41 Table 18 Maximum Equivalent Vent Length Ft 42 Table ...

Page 2: ...e exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally ven...

Page 3: ...CE SIZE A B C D SHIP WT LB KG CABINET WIDTH OUTLET WIDTH BOTTOM INLET WIDTH AIR INTAKE 060C17 16 17 1 2 445 15 7 8 403 16 406 8 3 4 222 149 6 67 9 080C21 20 21 533 19 3 8 492 19 1 2 495 10 1 2 267 173 1 78 5 100C21 22 21 533 19 3 8 492 19 1 2 495 10 1 2 267 180 0 81 6 U S ECCN Not Subject to Regulation N S R SD5543 4 REV B NOTE ALL DIMENSIONS IN INCH MM U S ECCN Not Subject to Regulation N S R SD5...

Page 4: ...ls be 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 hazards which may result in minor personal injur...

Page 5: ... INTRODUCTION A190213 Fig 2 Upflow Horizontal Orientations NOTE Downflow not permitted This Upflow Horizontal Category IV condensing furnace is CSA design certified as a direct vent 2 pipe furnace using outside air for combustion see Fig 2 It is also certified as a non direct vent 1 pipe furnace using indoor air for combustion or air from a well ventilated attic or crawl space where permitted by l...

Page 6: ... W Washington DC 20001 Combustion and Ventilation Air US Current edition of Section 9 3 of the NFPA54 ANSI Z223 1 Air for Combustion and Ventilation Duct Systems US Current edition of Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE Funda...

Page 7: ...NT IMPORTANT Clearances for Condensate Trap Before locating furnace refer to condensate trap installation instructions section for required clearances for trap installation A200083 Fig 6 Trap Clearance in Horizontal Application NOTE Local codes may require a drain pan and condensate tray when a condensing furnace is installed over a finished ceiling A200084 Fig 7 Trap Clearance in Upflow Applicati...

Page 8: ...ust freely communicate with the outdoor to provide sufficient air for combustion The combustion air pipe cannot be terminated in attics or crawlspaces that use ventilation fans designed to operate during the heating season If ventilation fans are present in these areas the combustion air pipe must terminate outdoors as a 2 Pipe system All air for combustion is piped directly to the furnace from a ...

Page 9: ...nges per hour ACH The Known Air Infiltration Rate Method shall be used if the infiltration rate is known to be 3 Less than 0 40 ACH and 4 Equal to or greater than 0 10 ACH Infiltration rates greater than 0 60 ACH shall not be used The minimum required volume of the space varies with the number of ACH and shall be determined see Table 4 or Equations 1 and 2 Determine the minimum required volume for...

Page 10: ...mension of air openings shall be not less than 3 in 80 mm Table 3 Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors EXAMPLES Determining Free Area Table 4 Minimum Space Volumes for 100 Combustion Ventilation and Dilution Air from Outdoors NP Not Permitted FURNACE INPUT BTUH TWO HORIZONTAL DUCTS 1 SQ IN 2 000 BTUH 1 100 SQ MM KW SINGLE DUCT OR OPENING 1 SQ IN 3 000 BTUH...

Page 11: ... the drain line from sagging or being dislocated from the furnace or termination point In the absence of local codes consult the current edition of the National Standard Plumbing Code in the U S An indoor coil condensate drain or humidifier drain can be connected to the external furnace condensate drain provided The drains are not hard piped together and WARNING CARBON MONOXIDE POISONING AND PROPE...

Page 12: ...t the point where the two drain lines meet or All condensate piping is at least 3 4 PVC and there is a relief tee at the top of condensate drain piping as shown see Fig 11 A200069 A200070 A200071 Fig 10 Example of Field Drain Attachment Not Allowed A200072 A200073 A200074 NOTE Coil may require metal spacer or shield between furnace and coil See coil install requirements see Table 6 Fig 11 Example ...

Page 13: ...tion Horizontal Upflow Upflow Offset Required Required Required Not Required Required Required Not Required Required Required Not Required Not Required Required accessory kit purchased separately NOTICE Upflow installation utlilizing the right side air return opening should follow the Upflow Specific Steps Offset Installation to ensure the full opening is available for return ductwork CAUTION CUT ...

Page 14: ...eft of the collector box to the relief port on the trap adapter see Fig 19 If the tube is too long cut any extra length from the tube Upflow Specific Steps Offset Installation 1 Trap Offset Adapter Accessory Kit purchased separately is required Instead of installing the trap to the adapter plate screw the trap offset adapter to the adapter plate see Fig 16 2 Screw the trap to the trap offset adapt...

Page 15: ... 1 The trap can be installed using a second adapter plate purchased separately Install trap adapter to the collector box using provided machine screw see Fig 14 2 Screw the adapter plate to the side of casing using six 6 of the provided sheet metal screws see Fig 15 3 Screw the adapter plate to the trap adapter using provided machine screw see Fig 23 Drilling pilot holes is recommended to better a...

Page 16: ... 3 For 3rd party unshielded coils consult manufacturer for design of a field fabricated shield that completely shields all plastic composite materials from direct exposure to any part of the heat exchanger All adapters are field fabricated according to the dimensions for the metal shield see Fig 25 and for the 8 in tall sheet metal spacer see Fig 26 A190295 A190296 Fig 25 Dimensions Metal Shield N...

Page 17: ...r condensate drainage see Fig 31 Supply Air Connections For a furnace not equipped with a cooling coil the outlet duct shall be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream The ...

Page 18: ...ig 30 Install field supplied 5 16 x 1 1 2 in 8 x 38 mm max corrosion resistant machine bolts washers and nuts A89014 Fig 30 Leveling Legs NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure panel to install leveling legs To remove bottom closure panel see Fig 34 To install leveling legs 7 Position furnace on its back Locate and dr...

Page 19: ... requirements NOTE Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling A200085 Fig 33 Suspended Furnace Installation NOTE Furnace shown is a direct vent application Refer to the venting section for allowable vent configurations NOTE N Coil only add 8 in separation between coil and furnace for all other unshielded coils see evaporat...

Page 20: ... and Return Duct Sizing Pressure drop must be taken into account when sizing filters filter racks IAQ devices and associated system ductwork For a comparison of Pressure Drop initial clean resistance to airflow versus Airflow for a variety of filter media types and sizes see Table 9 These are representative numbers Consult the filter or IAQ device manufacturers specification sheet for performance ...

Page 21: ...on the flange temporarily while the remaining attachment and sealing of the coil are performed Table 7 Air Filter Selection and Duct Sizing In mm Recommended to maintain air filter face velocity See Specification Product Data for part number Table 8 Opening Dimensions In mm Table 9 Filter Media Pressure Drop Clean Versus Airflow In W C Pa If the filter size that you are looking for is not containe...

Page 22: ...FF 1470 1465 1455 1420 1385 1350 1315 1275 1240 1200 ON ON ON 1470 1465 1455 1420 1385 1350 1315 1275 1240 1200 Maximum Clg Airflow2 1515 1480 1455 1420 1385 1350 1315 1275 1240 1200 CF Switches SW3 3 SW3 2 SW3 1 Cont Fan Default OFF OFF OFF 545 545 540 Note 4 Continuous Fan SW3 OFF OFF ON 545 545 540 Note 4 OFF ON OFF 710 720 720 725 720 Note 4 OFF ON ON 895 910 920 920 920 915 895 885 Note 4 ON ...

Page 23: ...n connecting the gas line to the gas valve Unit Size 100C21 226 Clg CF Switch settings External Static Pressure ESP Clg Switches SW2 3 SW2 2 SW2 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 Clg Default OFF OFF OFF 1765 1775 1790 1805 1810 1820 1820 1820 1820 1820 CF Switches SW3 3 SW3 2 SW3 1 Cooling SW2 Low Cooling SW3 OFF OFF ON 630 Note 4 OFF ON OFF 805 830 Note 4 OFF ON ON 1065 1075 1080 1085 Not...

Page 24: ...e at furnace prior to operating furnace The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF Gas entry can be from left or right side or top panel see Fig 35 and Fig 36 Gas Pipe Grommet For direct vent 2 pipe applications the knockout for the gas pipe must be sealed to prevent air leakage Remove the kn...

Page 25: ...cations see Fig 38 WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnection Rec...

Page 26: ...Fig 39 Field Supplied External Electrical Box on Furnace Casing 6 Route field power wiring into external electrical box 7 Pull furnace line voltage power wires through strain relief bushing of the external electrical box 8 Pull the ground wire of the field line voltage wiring through the strain relief bushing into the furnace casing 9 Install the green ground screw to the J Box bracket and attach ...

Page 27: ...ection for additional details Consult the thermostat installation instructions for specific information about configuring the thermostat see Fig 42 and Thermostat wiring ACCESSORIES 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 and EAC 2 Th...

Page 28: ... VOLT FIELD SUPPLIED FUSED DISCONNECT JUNCTION BOX CONTROL BOX 24 VOLT TERMINAL BLOCK THREE WIRE HEATING ONLY FIVE WIRE NOTE 2 NOTE 1 1 STAGE THERMOSTAT TERMINALS FIELD SUPPLIED FUSED DISCONNECT CONDENSING UNIT FURNACE COM R W C Y R G GND GND FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING Connect Y Y2 terminal as shown for proper operation Som...

Page 29: ...MAXIMUM FUSE OR CKT BKR AMPS Time delay type is recommended Maximum Minimum 060C17 16 115 60 1 127 104 11 4 12 6 14 29 15 080C21 20 115 60 1 127 104 14 3 15 4 12 37 20 100C21 22 115 60 1 127 104 14 3 15 4 12 37 20 24 V THERMOSTAT TERMINALS PL2 HOT SURFACE IGNITER INDUCER MOTOR CONNECTOR 115 VAC L2 NEUTRAL CONNECTIONS 115 VAC L1 LINE VOLTAGE CONNECTIONS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX PL1 LOW VO...

Page 30: ...1 Speed Variable Furnace with Single Speed Air Conditioner A190369 Fig 44 1 Speed Variable Furnace with Two Speed Air Conditioner A190368 Fig 45 1 Speed Variable Furnace with Single Speed Heat Pump Dual Fuel A190370 Fig 46 1 Speed Variable Furnace with Two Speed Heat Pump Dual Fuel THERMOSTAT THERMOSTAT See notes 2 5 8 10 11 THERMOSTAT See notes 1 2 4 6 7 9 10 14 See notes 1 2 3 4 6 8 9 10 11 12 1...

Page 31: ...systems This furnace is also CSA approved for venting with M G DuraVentR PolyProR polypropylene venting systems NOTE THESE INSTRUCTIONS DO NOT CONTAIN DETAILED INSTALLATION INSTRUCTIONS FOR POLYPROPYLENE VENTING SYSTEMS Refer to the polypropylene venting system manufacturer s installation instructions for the polypropylene venting system installation NOTE When using polypropylene venting systems a...

Page 32: ...learances required by National code authorities see Fig 61 All air for combustion is piped directly to the furnace from a space that is well ventilated with outdoor air such as an attic or crawl space and the space is well isolated from the living space or garage Combustion air requirements for this option are the same as the requirements for providing outside air for combustion for a single pipe ...

Page 33: ... terminate outside the structure For references to vent clearances required by National code authorities see Fig 60 Allowable vent and combustion air terminations see Fig 62 Ventilated Combustion Air The vent pipe for a Ventilated Combustion Air System must terminate outdoors For references to vent clearances required by National code authorities see Fig 61 Allowable vent terminations see Fig 63 T...

Page 34: ...number of fittings multiplied by the deduction for each type of fitting used see Table 19 A200089 NOTE Only connect combustion air inlet moisture drain downstream of the furnace trap assembly as shown A200366 Fig 49 Recommended Combustion Air Inlet Moisture Trap 12 256mm minimum to 60 1524 mm or 1 additional elbow maximum CASING SIDE OR TOP ATTACHMENT COMBUSTION AIR PIPE NON DIRECT VENT FOR ALL MO...

Page 35: ...n used for Alberta and Saskatchewan terminations NOTE Polypropylene venting systems MAY require additional deductions from the MEVL or additions to the TEVL for vent terminations and flexible pipe sections See the polypropylene venting system manufacturer s instructions for details on equivalent lengths of vent terminations and flexible vent pipes and for calculating total vent lengths To calculat...

Page 36: ...onnection see Fig 12 Use a flat blade screwdriver and tap on the knockout on opposite sides where the knockout meets the casing Fold the knockout down with duct pliers and work the knockout back and forth until it is removed Trim any excess metal from the knockout with tin snips The vent elbow can be rotated to the required location on the casing if necessary see Fig 54 To rotate the vent elbow 1 ...

Page 37: ... with sheet metal screws DO NOT DRILL INTO POLYPROPYLENE VENT PIPES Use an optional accessory vent coupling if needed 12 Seal around the combustion air pipe with silicone or foil tape SILICONE SEALERS MAY NOT BE APPROPRIATE FOR POLYPROPYLENE VENT SYSTEMS SEE POLYPROPYLENE VENT SYSTEM MANUFACTURER S INSTRUCTIONS 13 After pipes have been cut and pre assembled apply generous layer of cement primer to...

Page 38: ...tional Vent Pipe Flush with Adaptor Installing the Vent Termination Roof Terminations A roof termination of any type will require a 4 in 102 mm flashing for a 2 in 50 mm ND concentric vent or a 5 in diameter 127 mm flashing for a 3 in 80 mm ND concentric vent kit For two pipe or single pipe vent systems a flashing for each pipe of the required diameter will be necessary It is recommended that the ...

Page 39: ... it through hole 4 Locate assembly through sidewall with rain shield positioned no more than 1 in 25 mm from wall see Fig 62 5 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping DO NOT CEMENT POLYPROPYLENE FITTINGS 2 Pipe and 1 Pipe Vent Termination NOTE Follow the instructions of the vent terminal manufacturer These instructions are provided as a refe...

Page 40: ...rance may vary See Notes for Venting Options Notes for Venting Options 1 Attach vent pipe adapter with gasket to furnace casing 2 Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling 3 Slide vent pipe through adapter and coupling into vent elbow 4 Insert vent pipe into vent elbow 5 Torque all clamps 15 lb in 6 Attach combustion air pipe adapter with gasket to f...

Page 41: ...F493 SDR N A F442 N A IPEX Schedule 40 ULC S636 ULC S636 ULC S636 ULC S636 Royal Pipe Schedule 40 ULC S636 ULC S636 ULC S636 ULC S636 PVC and ABS pipe may use either DWV or pressure rated fittings Colored or tinted solvents or primers must be used where required by code in the USA ABS plastic does not require a primer before solvent cementing A cleaner for ABS is recommended to remove any surface ...

Page 42: ... some cases 6 Elbow and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count 7 The minimum pipe length is 5 ft 2 M linear feet meters for all applications 8 Use 3 in 76 mm diameter vent termination kit for installations requiring 4 in 102 mm diameter pipe Unit Size 60 000 80 000 100 000 Altitude feet Pipe Dia in 1 2 2 3 1 2 2 3 4 ...

Page 43: ...here 70 ft 22 M Use length of the longer of the vent or air inlet piping system Add equiv length of 3 90º long radius elbows use the highest number of elbows for either the vent or inlet pipe 3 x 3 ft 0 9 M 9 ft 2 7 M From Table 19 Add equiv length of 2 45º long radius elbows use the highest number of elbows for either the vent or inlet pipe 2 x 1 5 ft 0 5 M 3 ft 0 9 M From Table 19 Add equiv leng...

Page 44: ...y located on public property 7 ft 2 1 M Clearance under a veranda porch deck or balcony N P No operable windows doors or intakes of any type are permitted on Wall B between the vent termination and the inside corner when the vent termination is at least 3 ft 1 M away and not more than 6 ft 2 M away from an inside corner The following items on Wall A must be located at least 3 ft 1 M away from the ...

Page 45: ...nical air supply inlet 6 ft 1 8 M 3ft 9 M above if within 10 ft 3 M horizontally L Clearance under a veranda porch deck or balcony 12 in 305 mm Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor See Note 4 Manufacturer s Recommendation See Notes 3 8 M Clearance to each side of the centerline extended above or below vent terminal of the furnace...

Page 46: ...ommendation See Note 8 K Clearance to a mechanical air supply inlet 6 ft 1 8 M 3ft 9 M above if within 10 ft 3 M horizontally L Clearance under a veranda porch deck or balcony 12 in 305 mm Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor See Note 4 Manufacturer s Recommendation See Notes 3 8 M Clearance to each side of the centerline extende...

Page 47: ... 172mm for 2 in 51mm Abandoned masonry used as raceway per code 12 in 305 mm min from overhang or roof Maintain 12 in 305mm minimum clearance above highest anticipated snow level or grade whichever is greater Side wall termination with 2 elbows preferred 12 in min 305 mm from overhang or roof Maintain 12 in 305mm minimum clearance above highest anticipated snow level or grade whichever is greater ...

Page 48: ...he airflow settings for Air Conditioning and Continuous Fan airflows The Setup Switch locations are shown and described on Fig 65 The setup switches are also shown on the unit wiring label Setup Switches SW1 The furnace control has 8 setup switches that may be set to meet the application requirements Refer to the Adjustments section for setup 3 76 mm 12 305 mm Pipe hangar Ventilated Combustion Air...

Page 49: ...ontrol has three additional setup switches labeled SW4 Setup switches SW4 are used for applications using a communicating User Interface and to adjust airflow SW4 3 is used to adjust airflow Refer to the Adjustments section for setup switch configurations Refer to User Interface instructions for other SW4 switch configurations 1 Remove blower door 2 Locate setup switch SW 4 on furnace control 3 Co...

Page 50: ...ted j Turn furnace gas valve electric switch to OFF position k Turn gas supply manual shutoff valve to OFF position l Turn off furnace power supply m Remove manometer from the inlet pressure tap of the gas valve n Tighten set screw on inlet tower pressure tap with 3 32 in hex wrench or if 1 8 in NPT plug was removed apply pipe dope sparingly to end of plug and re install in the gas valve 4 Adjust ...

Page 51: ...is ON g Turn 115 VAC power on h Recheck heating temperature rise After the termperature rise has been verified 1 Remove jumpers from thermostat terminals 2 Allow the blower off delay to complete 3 Proceed to Adjust Blower off delay or install blower door if complete Adjust Blower Off Delay Heat Mode a Remove blower door if installed b Turn Dip switch SW1 7 or SW1 8 ON or OFF for desired blower off...

Page 52: ...lf or casing 5 Cycle test furnace with room thermostat 6 Check operation of accessories per manufacturer s instructions 7 Review Owner s Manual with owner 8 Attach literature packet to furnace 9 Attach entire literature packet to furnace Table 22 Gas Rate CU ft hr WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Gas valve outlet pressu...

Page 53: ... 3 0 1525 800 2 4 2 5 2 6 2 7 2 7 2 8 825 2 3 2 3 2 4 2 5 2 6 2 7 to 850 2 1 2 2 2 3 2 4 2 4 2 5 875 2 0 2 1 2 2 2 2 2 3 2 4 900 1 9 2 0 2 0 2 1 2 2 2 2 5400 925 1 8 1 9 1 9 2 0 2 1 2 1 1646 950 1 8 1 8 1 8 1 9 1 9 2 0 975 1 8 1 8 1 8 1 8 1 9 1 9 1000 1 8 1 8 1 8 1 8 1 8 1 8 Tabulated Data Based on 80 000 BTUH Input for 0 ft 0m to 5400 ft 1646 M above sea level ALTITUDE RANGE ft m AVG GAS HEAT VAL...

Page 54: ...3 1 3 1 775 2 7 2 8 2 9 2 9 3 0 3 1 4001 800 2 5 2 6 2 7 2 8 2 8 2 9 1220 825 2 4 2 4 2 5 2 6 2 7 2 8 850 2 2 2 3 2 4 2 4 2 5 2 6 to 875 2 1 2 2 2 2 2 3 2 4 2 5 900 2 0 2 0 2 1 2 2 2 3 2 3 5000 925 1 9 1 9 2 0 2 1 2 1 2 2 1524 950 1 8 1 8 1 9 2 0 2 0 2 1 975 1 8 1 8 1 8 1 9 1 9 2 0 1000 1 8 1 8 1 8 1 8 1 8 1 9 725 2 8 2 9 3 0 3 1 3 1 3 1 750 2 7 2 8 2 8 2 9 3 0 3 1 5001 775 2 5 2 6 2 7 2 7 2 8 2 9...

Page 55: ...cond digit is the number of long flashes For an explanation of status codes refer to service booklet located on blower access door see Fig 70 or the Service guide at the end of this manual The stored status code will not be erased from the control memory if 115 or 24 v power is interrupted The control will store up to the last 7 Status Codes in order of occurrence 1 To retrieve status code proceed...

Page 56: ...ows 1 Turn off electrical supply to furnace 2 Remove filter cabinet door 3 Slide filter out of cabinet 4 If equipped with permanent washable filter clean filter by spraying cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oiling or coating of the filter is not recommended 5 If equipped with factory specified disposable media filter replace only with a factory...

Page 57: ... wrapper sits on top of the two tabs on blower sidewalls see Fig 72 9 Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 10 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 11 Reinstall blower assembly in furnace 12 Reinstall two screws secur...

Page 58: ...ew that secures the flame sensor on the bracket and remove the flame sensor 7 To replace flame sensor and bracket assembly reverse items 6a through 6d 8 Reconnect flame sensor wire to the wire harness dressing the sensor wires to ensure there is no tension on the flame sensor itself see Fig 73 WARNING ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or dea...

Page 59: ...o the pressure transducer 9 Clean pressure transducer port on collect box with a small wire Shake any water out of pressure transducer tube 10 Reconnect tube to pressure transducer and pressure transducer port 11 Remove the relief tube from the port on the collector box and the trap 12 Clean the relief port on collector box and the trap with a small wire Shake any water out of the tube 13 Reconnec...

Page 60: ... flow of combustion products 8 Reverse items 6 through 1 for reassembly Torque burner screws to 45 inch pound to ensure a tight burner seal 9 Refer to furnace wiring diagram and reconnect wires to burner thermal switch gas valve igniter and flame sensor 10 Turn on gas and electrical supplies to furnace 11 Check furnace operation through two complete heat operating cycles 12 Check for gas leaks 13 ...

Page 61: ...no pressure present and starts the inducer motor IDM ramp to prepurge a Inducer Prepurge Period The furnace control CPU ramps up the inducer motor IDM to prepurge pressure then the furnace control CPU begins a 15 second prepurge period If the transducer fails to reach target pressure the inducer motor IDM will remain running until target pressure is maintained b Ignitor Warm Up At the end of the p...

Page 62: ... Y circuit are opened The outdoor unit stops and the furnace blower BLWM and electronic air cleaner terminal EAC 1 will remain energized for an additional 90 sec Jumper Y1 to DHUM to reduce the cooling off delay to 5 sec See Fig 42 c Two Stage Thermostat and Two Speed Cooling See Fig 42 and thermostat wiring for connections NOTE The air conditioning relay disable jumper ACRDJ must be disconnected ...

Page 63: ...or BLWM operation Continuous Blower Speed Selection from Thermostat To select different continuous blower airflow from the room thermostat momentarily turn off the FAN switch or push button on the room thermostat for 1 3 sec after the blower motor BLWM is operating The furnace control CPU will shift the continuous blower airflow from the factory setting to the next highest CF selection airflow as ...

Page 64: ...ut setup switch SW1 1 in the ON position The AMBER LED are erased after 72 hours or can be manually erased by putting setup switch SW1 1 in the ON position and jumpering R W W1 and Y Y2 simultaneously setup switch SW1 1 in the OFF position Was there a previous status code other than 11 Go to section below for the status code Does the control respond to W W1 W2 Y1 Y Y2 and G 24V thermostat signals ...

Page 65: ...d during the trial for ignition period the control will repeat the ignition sequence 3 more times before lockout 14 occurs Iffl ame signal is lost during the blower on delay period blower will come on for the selected blower off delay Check the following items first before proceeding to the next step Gas valve turned off Manual shut offvalve GREEN YELLOW wire MUST be connected to furnace sheet met...

Page 66: ... either the BLACK or WHITE power leads between the furnace control and the blower motor If you have a power choke disconnect it and check continuity YES YES NO NO Is there 12 VDC at PL13 7 RED and PL13 1 GREEN YES NO Is there 12 VDC at PL3 1 RED and PL3 2 GREEN Replace the furnace control NO You have an open wire or bad terminal on either the RED or GREEN wire between the furnace control and the b...

Page 67: ...art up Operating and Service and Maintenance Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 67 346011 2 revA A200312 Fig 76 Wiring Diagram ...

Page 68: ...mesh Poor inducer flow Excess wind 31 PRESSURE TRANSDUCER INPUT DOES NOT SENSE TARGET PRESSURE OR PRESSURE IS OUT OF RANGE Check for Excessive wind Proper vent sizing Restricted vent Defective inducer motor Inadequate combustion air supply Defective pressure transducer Low inlet gas pressure if LGPS used Low inducer voltage 115VAC Frozen or blocked drain Disconnected or obstructed pressure tubing ...

Page 69: ...dealer listing by brand name or contact CARRIER Consumer Relations Department P O Box 4808 Syracuse New York 13221 1 800 CARRIER Have available the model number series number and serial number located on the unit rating plate to ensure correct replacement part Model Nomenclature Training My Learning Center is your central location for professional residential HVAC training resources that help stre...

Page 70: ...e 08 20 Catalog No 59CU5A 01SI Replaces NEW 59CU5A Installation Start up Operating and Service and Maintenance Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 70 ...

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Carrier 59CU5A, Installation, Start-Up, Operating And Service And Maintenance Instructions

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