Carrier 59MN7A Installation, Start-Up, Operating And Service And Maintenance Instructions Download

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59MN7A

Modulating 4---Way Multipoise

Condensing Gas Furnace

Series 200

Installation, Start---up, Operating and

Service and Maintenance Instructions

NOTE

: Read the entire instruction manual before starting the

installation.
SAFETY CONSIDERATIONS

. . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CODES AND STANDARDS

. . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

. . .

ACCESSORIES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FOR COMBUSTION AND VENTILATION

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CONDENSATE TRAP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upflow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Downflow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horizontal

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CONDENSATE DRAIN

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upflow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Downflow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horizontal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Arrangement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR DUCTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ductwork Acoustical Treatment

. . . . . . . . . . . . . . . . . . . . .

GAS PIPING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS

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115--V Wiring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

J--Box Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24--V Wiring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternate Power Supplies

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VENTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Venting Requirements for Installations in Canada

Materials

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Venting Systems

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locating Vent Termination

. . . . . . . . . . . . . . . . . . . . . . . . .

Size the Vent and Combustion Air Pipes

. . . . . . . . . . . . . . .

Combustion Air and Vent Piping Insulation Guidelines

. . .

Configure the Furnace

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Vent Termination

. . . . . . . . . . . . . . . . . . . . . .

Venting System Length Calculations

. . . . . . . . . . . . . . . . .

START--UP, ADJUSTMENT, AND SAFETY CHECK

. . . . . .

Select Setup Switch Positions

. . . . . . . . . . . . . . . . . . . . . . . .

Prime Condensate Trap

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Purge Gas Lines

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments

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Check Safety Controls

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Checklist

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SERVICE AND MAINTENANCE PROCEDURES

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Cleaning Heat Exchangers

. . . . . . . . . . . . . . . . . . . . . . . . . . .

SEQUENCE OF OPERATION

. . . . . . . . . . . . . . . . . . . . . . . .

PARTS REPLACEMENT GUIDE

. . . . . . . . . . . . . . . . . . . . . .

TABLE

Loose Parts Bag Contents

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Minimum Clearances to Combustible Materials

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Minimum Free Area Required

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Minimum Space Volumes

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Filter Size Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Delivery CFM

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Maximum Capacity of Pipe

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Electrical Data

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Vent Termination Kit for Direct Vent (2--Pipe) Systems

. . . . . .

Combustion--Air Vent Pipe, Fitting & Cement Material..

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Maximum Allowable Exposed Vent Lengths Insulation

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Maximum Equivalent Vent Length

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Deductions from Maximum Equivalent Vent Length

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Altitude Derate Multiplier for U.S.A.

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Blower Off Delay Setup Switch

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Gas Rate

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Orifice Size and Manifold Pressure

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C E RT I F I E D

Use of the AHRI Certified

Mark indicates a

manufacturer’s participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.

Portions of the text and tables are reprinted from NFPA 54/ANSI

Z223.1--2009

, with permission of National Fire Protection

Association, Quincy, MA 02269 and American Gas Association,

Washington DC 20001. This reprinted material is not the complete

and official position of the NFPA or ANSI on the referenced
subject, which is represented only by the standard in its entirety.

Summary of Contents for 59MN7A

Page 1: ...Lines 65 Adjustments 66 Check Safety Controls 69 Checklist 69 SERVICE AND MAINTENANCE PROCEDURES 79 Cleaning Heat Exchangers 85 SEQUENCE OF OPERATION 92 PARTS REPLACEMENT GUIDE 97 TABLE Loose Parts Bag Contents 6 Minimum Clearances to Combustible Materials 6 Minimum Free Area Required 10 Minimum Space Volumes 10 Filter Size Information 22 Opening Dimensions 24 Air Delivery CFM 29 Maximum Capacity ...

Page 2: ...aust 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 vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observe...

Page 3: ...nal 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 CAUTION 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 word...

Page 4: ...stallation S US NFGC and the NFPA 90B For copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or for only the NFGC contact the American Gas Association 400 N Capitol N W Washington DC 20001 S CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario M9W 1R3 Canada Combustion and Ventilation Air S US...

Page 5: ...s from all HVAC system components after construction is completed Verify proper furnace operating conditions including ignition gas input rate air temperature rise and venting according to these installation instructions CAUTION General These furnaces are shipped with materials to assist in proper furnace installation These materials are shipped in the main blower compartment See Table 1 for loose...

Page 6: ... to Cooling Equipment The cooling coil must be installed parallel with or on the downstream side of the unit to avoid condensation in the heat exchangers When installed parallel with the furnace dampers or other flow control must prevent chilled air from entering the furnace If the dampers are manually operated they must be equipped with means to prevent operation of either unit unless the damper ...

Page 7: ...ION NOTE ALL DIMENSIONS IN INCH MM 22 2 7 8 7 8 22 2 POWER CONN AIR FLOW SEE NOTE 3 NOTES 1 Doors may vary by model 2 Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations for equivalent diameters a For 800 CFM 16 in 406 mm round or 14 1 2 x 12 in 368 x 305 mm rectangle b For 1200 CFM 20 in 508 mm round or 14 1 2 x 19 1 2 in 36...

Page 8: ...DITIONED AIR IS DISCHARGED DOWNWARD THE BLOWER IS LOCATED TO THE LEFT OF THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED TO THE RIGHT A12181 Fig 2 Multipoise Orientations 60 80 27 C 16 C SUPPLY AIR A10490 Fig 3 Freeze Protection and Return Air Temperature BACK POSITIONED DOWNWARD AIR RETURN CUT IN BACK BACK POSITIONED UPWARD A12182 Fig 4 Prohibited Installations 18 IN 457 2 mm MINIMUM TO BURN...

Page 9: ...changers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products CAUTION CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The operation of exhaust fans kitchen ventilation fans clothes dryers attic exhaust fans or fireplaces could create a NE...

Page 10: ...gle Duct or Opening 80 000 30 000 110 000 divided by 2 000 55 0 Sq In for each two Horizontal Ducts Table 4 Minimum Space Volumes for 100 Combustion Ventilation and Dilution Air from Outdoors OTHER THAN FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE ACH 30 40 50 40 60 80 100 120 140 Space Volume Ft3 M3 0 60 1 050 29 7 1 400 39 6 1 750 49 5 1 400 39 6 ...

Page 11: ...See the bottom images in Fig 9 and 10 A field supplied accessory Horizontal Installation kit trap grommet is required for all direct vent horizontal installations only The kit contains a rubber casing grommet designed to seal between the furnace casing and the condensate trap See Fig 17 The field supplied accessory horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS It it N...

Page 12: ...orts on collector box Connect relief tube to port on collector box Rotate elbow to desired position and tighten clamp to 15 lb in Slide tube in stand offs to adjust length Trim excess tube Connect pressure switch tube to port on collector box Attach condensate trap with screw to collector box Connect relief tube to relief port on condensate trap Align condensate trap over middle and bottom ports o...

Page 13: ...n open port on collector box Slide relief tube in stand offs to adjust length Vent elbow shown in alternate orientation Tighten clamp on inlet to vent elbow 15 lb in Align trap over middle and right hand port on collector box Horizontal Right Trap Configuration Unconverted Factory Trap Configuration As Viewed in the Horizontal Right Orientation A11278 Fig 9 Horizontal Right Trap Configuration Appe...

Page 14: ...lide relief tube in stand offs to adjust length Attach condensate trap to collector box with screw Align trap over middle and right hand port on collector box Install plugs in open ports on collector box Connect relief tube to port on collector box Trim excess tube Route pressure switch tube underneath relief tube and connect to port on collector box Connect relief tube to relief port on condensat...

Page 15: ... knockout in the casing 5 Pull the grommet through the casing from the outside until it is seated in the knockout 6 Attach the plain end of the drain elbow to the outlet stub on the drain trap Secure the drain elbow to the trap with the spring clamp The remaining drain line can be constructed from field supplied 1 2 in CPVC or 3 4 in PVC pipe in compliance with local building codes A factory suppl...

Page 16: ...may cause kinks in the elbow Horizontal Orientation 1 The condensate trap outlet extends 2 in 51 mm below the furnace casing Leave enough clearance between the furnace and the furnace platform for the trap 2 To allow for servicing the trap the condensate drain elbow in the loose parts bag can be used to make a coupler to allow for future service of the condensate trap and drain line 3 Remove the k...

Page 17: ...irect vent applications A11582 Fig 15 Horizontal Drain Trap Grommet s TRAP DRAIN ELBOW WITH DISCHARGE PIPE Attach elbow to condensate trap Cut formed end off condensate drain elbow Connect short end of Z pipe to modified drain elbow Factory supplied 1 2ïin CPVC to 3 4ïin PVC adapter LEFT SIDE DRAIN ROUTED BEHIND INDUCER Formed end of grommet Open spring clamp Insert 1 2ïin to 3 4ïin CPVC to PVC ad...

Page 18: ...See Fig 23 24 and 25 Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 20 Install field supplied 5 16 x 1 1 2 in 8 x 38 mm max corrosion resistant machine bolts washers and nuts 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 c...

Page 19: ...iece of sheet metal for flame roll out protection in front of burner area for furnaces closer than 12 in 305 mm above the combustible deck or suspended furnaces closer than 12 in 305 mm to joists The sheet metal MUST extend underneath the furnace casing by 1 in 25 mm with the door removed The bottom closure panel on furnaces of widths 17 1 2 in 445 mm and larger may be used for flame roll out prot...

Page 20: ...any orientation Refer to the instructions supplied with Media Cabinet or accessory air filter for assembly and other details See Table 7 for filter size details Filter and Return Duct Sizing Pressure drop must be taken into account when sizing filters filter racks IAQ devices and associated system ductwork See Table 5 for a comparison of Pressure Drop initial clean resistance to airflow versus Air...

Page 21: ...51 0 31 79 1600 755 0 08 19 0 15 38 0 16 40 0 24 61 1800 850 0 08 21 0 18 47 0 18 47 0 29 73 2000 944 0 09 23 0 22 56 0 21 54 2200 1038 0 09 24 0 26 66 0 25 62 25 x 25 Filter 635 x 635 mm Factory Accessory Washable Factory Accessory Media Representative After Market Filter Media Fiberglass Pleated CFM L s 1 in 2 5 cm 4 in 10 cm 1 in 2 5 cm 2 in 5 cm 1 in 2 5 cm 2 in 5 cm 800 378 0 03 9 0 03 8 0 05...

Page 22: ... Product Data for part number Air Filter Located in Filter Cabinet FILTER CABINET HEIGHT IN MM FILTER SIZE IN MM FILTER TYPE 16 406 1 16 x 25 x 3 4 406 x 635 x 19 or 1 16 x 25 x 4 5 16 406 x 635 x 110 Washable or Media 20 508 1 20 x 25 x 3 4 508 x 635 x 19 or 1 20 x 25 x 4 5 16 508 x 635 x 110 Washable or Media 24 610 1 24 x 25 x 3 4 or 610 x 635 x 19 or 1 24 x 25 x 4 5 16 610 x 635 x 110 Washable...

Page 23: ...ace Filler plates Screw 14 3 16 in Furnace with Filler Plates Centered 14 3 16 in Furnace Filler plate Screws 14 3 16 in Furnace with Filler Plates Off Set to Right Media Cabinet Installation Option for 4 Ton or Less A C Capacity 20 or 24 in Media Cabinet Installation with Angled Transition 20 or 24 in Media Cabinet Installation for Combination Side and Bottom Return Media Cabinet Installation Sid...

Page 24: ... 15 1 2 394 19 483 16 1 2 419 20 508 21 533 Upflow Applications on Combustible or Noncombustible Floor ing KGASB subbase not required 19 1 2 495 21 5 8 549 20 1 8 511 22 1 4 565 Downflow Applications on Noncombustible Flooring KGASB subbase not required 19 3 8 492 19 483 20 508 19 5 8 498 Downflow applications on combustible flooring KGASB sub base required 18 5 8 473 19 483 20 1 4 514 20 5 8 600 ...

Page 25: ...t Flanges 1 3 4 1 3 4 1 3 4 1 3 4 5 16 5 16 5 16 5 16 44mm 8mm 44mm 8mm 8mm 8mm 44mm 44mm A89014 Fig 20 Leveling Legs BOTTOMPLATE BOTTOM CLOSURE PANEL A11092 Fig 21 Removing Bottom Closure Panel LEVEL 0 IN 0 MM TO 1 2 IN 13 MM MAX UPFLOW OR DOWNFLOW HORIZONTAL MIN 1 4 IN 6 MM TO 1 2 IN 13 MM MAX A11237 Fig 22 Furnace Pitch Requirements 59MN7A ...

Page 26: ... Fig 23 Upflow Return Air Configurations and Restrictions A11037 Fig 24 Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig 25 Horizontal Return Air Configurations and Restrictions 59MN7A ...

Page 27: ...ig 26 Working Platform for Attic Installation NOTE Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling 2 IN 51 mm COMBUSTION AIR PIPE SEE VENTING SECTION A11155 Fig 27 Suspended Furnace Installation NOTE Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling 59MN7A ...

Page 28: ...ctions to furnace with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in 25 mm clearance from combustible materials to supply air ductwor...

Page 29: ...1095 1095 1090 1080 1065 1050 1035 1020 Intermediate Heat Airflow 3 535 515 505 515 495 See note 4 Minimum Heat Airflow 3 420 410 415 400 380 See note 4 Unit Size Clg CF Switch Settings External Static Pressure ESP SWx 3 SWx 2 SWx 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 060 20 Clg Default OFF OFF OFF 1735 1735 1725 1715 1700 1685 1665 1650 1625 1605 CF Default OFF OFF OFF 545 530 520 525 510 See...

Page 30: ...5 1190 Intermediate Heat Airflow 3 755 745 755 755 765 See note 4 Minimum Heat Airflow 3 620 625 630 620 610 See note 4 Unit Size Clg CF Switch Settings External Static Pressure ESP SWx 3 SWx 2 SWx 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 080 20 Clg Default OFF OFF OFF 1745 1755 1755 1760 1755 1750 1745 1725 1705 1685 CF Default OFF OFF OFF 700 710 750 725 750 See note 4 Cooling SW2 Cont Fan SW3 ...

Page 31: ...OFF ON ON 1095 1100 1110 1105 1085 See note 4 ON OFF OFF 1265 1255 1265 1280 1275 1285 1270 1260 1250 1230 ON OFF ON 1465 1455 1470 1465 1465 1470 1455 1450 1435 1415 ON ON OFF 1850 1855 1860 1855 1850 1830 1805 1775 1750 1730 ON ON ON 2200 2200 2200 2190 2185 2170 2145 2085 1990 1890 Clg SW2 Maximum Clg Airflow 2 2200 2200 2200 2190 2185 2170 2145 2085 1990 1890 Heating SW1 Maximum Heat Airflow 3...

Page 32: ... new listed connector Do not use a connector which has previously served another gas appliance Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in 51 mm outside the furnace WARNING FURNACE DAMAGE HAZARD Failure to follow this caution may result in furnace damage Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls and burner ...

Page 33: ...unded power cord where permitted by local code when installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gauge Do not use gas piping as an electrical ground WARNING FURNACE MAY NOT OPERATE HAZARD Failure to follow this caution may result in intermittent furnace operation Furnace control must be grounded for proper operation or else c...

Page 34: ... bushing or a connector approved for the type of cord used 4 Pull furnace power wires through 1 2 in 12 mm diameter hole in J Box If necessary loosen power wires from strain relief wire tie on furnace wiring harness 5 Connect field ground wire and factory ground wire to green ground screw on J Box mounting bracket as shown in Fig 30 6 Connect power cord power and neutral leads to furnace power lea...

Page 35: ...veform If the furnace is to be operated on a generator or other alternate power supply the alternate power supply must produce a smooth sinusoidal waveform for compatibility with the furnace electronics The alternate power supply must generate the same voltage phase and frequency Hz as shown in Table 11 or the furnace rating plate Power from an alternate power supply that is non sinusoidal may dam...

Page 36: ...6 Fig 30 Installing J Box When Used Appearance May Vary COPPER WIRE ONLY ELECTRIC DISCONNECT SWITCH ALUMINUM WIRE GROUND NEUTRAL LINE VOLTAGE A11146 Fig 31 Field Supplied Electrical Box on Furnace Casing 59MN7A ...

Page 37: ...w Terminal on Thermostat Strip To HUM Terminal On Furnace Control Board To Humidifier Leads A11157 Fig 32 Field supplied Isolation Relay for Humidifiers with Internal Power Supply W W1 W2 COM Y Y2 R G A11401 Fig 33 Typical Field Wiring Diagram 59MN7A ...

Page 38: ...S AND COMM LED LIGHTS SW1 SETUP SWITCHES AND BLOWER OFF DELAY MODEL PLUG CONNECTOR AIR CONDITIONING A C AIRFLOW SETUP SWITCHES COMMUNICATION CONNECTOR CONTINUOUS FAN CF AIRFLOW SETUP SWITCHES OUTDOOR AIR TEMP CONNECTOR HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX ACRDJ AIR CONDITIONING RELAY DISABLE JUMPER FLASH UPGRADE CONNECTOR FACTORY ONLY SW4 SETUP SWITCHES SOFTWARE VERSION PART NUMBER AND DATE CODE...

Page 39: ...tage Furnace with Single Speed Heat Pump Modulating and 2 Stage Furnace with Two Speed Heat Pump See notes 2 5 7 10 11 16 and 17 See notes 1 2 4 6 7 9 10 11 15 16 and 17 THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT D D D D See notes 2 5 8 10 11 12 16 and 17 See notes 1 2 3 4 6 8 9 10 12 13 15 16 and 17 A12222 Fig 35 Thermostat Wiring Diagrams 59MN7A ...

Page 40: ... available from the furnace manufacturer have been certified to ULC S636 for use with those Royal Pipe and IPEX PVC vent components which have been certified to this standard In Canada the primer and cement must be of the same manufacturer as the vent system GVS 65 Primer Purple for Royal Pipe or IPEX System 636 PVC CPVC Primer Purple Violet for Flue Gas Venting and GVS 65 PVC Solvent Cement for R...

Page 41: ...Direct Vent 2 Pipe system or Fig 47 for ventilated combustion air option A furnace shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel Other gas appliances with their own venting system may also use the abandoned chimney as a raceway providing it is permitted by local code the current edition of the National Fuel Gas Code and the vent or liner manufact...

Page 42: ...ation could result in carbon monoxide poisoning or death The instructions included with this furnace DO NOT APPLY to vent systems that are located below the furnace CAREFULLY FOLLOW THE INSTRUCTIONS PROVIDED WITH THE EXTERNAL VENT TRAP KIT FOR LAYING OUT THE VENTING SYSTEM AND THE DRAIN SYSTEM when all or part of the venting system is placed below the furnace Proper configuration of the venting an...

Page 43: ...le pipe termination when permitted with ventilated combustion air applications that re directs the flue gas away by use of an elbow or tee certified to ULC S636 from the adjacent property line must be used See Fig 48 The concentric vent kit currently cannot be modified to attach an elbow to the vent portion of the rain cap A tee attached to the rain cap could potentially direct the flue gas plume ...

Page 44: ...ication for that specific furnace input size Compare the Total Equivalent Vent Length TEVL to the MEVL 8 If the Total Equivalent Vent Length is shorter than the Maximum Equivalent Vent Length for the diameter of pipe chosen then that diameter of pipe selected may be used 9 If the Total Vent Length is longer than the Maximum Equivalent Vent Length for the diameter of pipe chosen that diameter pipe ...

Page 45: ...furnace with sheet metal screws 4 Slide the end of the rubber vent coupling with notches in it over the standoffs on the vent pipe adapter 5 Insert a length of vent pipe through the coupling into the outlet of the vent elbow 6 Tighten the clamp around the outlet of the vent elbow Torque the clamp to 15 lb in The following instructions are for PVC ABS DWV vent piping only DO NOT USE THESE TECHNIQUE...

Page 46: ...for each pipe of the required diameter will be necessary It is recommended that the flashing be installed by a roofer or competent professional prior to installing the concentric vent The terminations can be installed on a flat or pitched roof Concentric Vent Single or multiple concentric vent must be installed as shown in Fig 46 Maintain the required separation distance between vents or pairs of ...

Page 47: ...t elbow 90_ from position 4 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping DO NOT CE MENT POLYPROPYLENE FITTINGS For ventilated Combustion Air Terminations terminate as shown in Fig 47 Direct Vent 2 Pipe System ONLY When two or more furnaces are vented near each other two vent terminations may be installed as shown in Fig 46 but next vent terminati...

Page 48: ...6 10 7 36 0 32 6 28 0 23 2 10 7 39 6 38 1 33 2 27 4 0 20 Ft 22 0 16 0 14 0 7 0 0 0 35 0 69 0 60 0 49 0 35 0 35 0 83 0 72 0 60 0 45 0 M 6 7 4 9 4 3 2 1 0 0 10 7 21 0 18 3 14 9 10 7 10 7 25 3 21 9 18 3 13 7 20 30 Ft 11 0 5 0 2 0 0 0 0 0 35 0 46 0 39 0 29 0 16 0 35 0 57 0 48 0 37 0 23 0 M 3 4 1 5 0 6 0 0 0 0 10 7 14 0 11 9 8 8 4 9 10 7 17 4 14 6 11 3 7 0 40 40 Ft 4 0 0 0 0 0 0 0 0 0 35 0 33 0 26 0 17...

Page 49: ...4 0 235 71 6 NA 80 000 25 7 6 85 25 9 155 47 2 210 64 0 232 70 7 100 000 NA 40 12 2 98 29 9 211 64 3 236 71 9 120 000 NA NA 8 2 4 86 26 2 224 68 3 4001 to 4500 1219 to 1370 60 000 35 10 7 115 35 1 204 62 2 228 69 5 NA 80 000 23 7 0 85 25 9 150 45 7 202 61 6 224 68 3 100 000 NA 40 12 2 94 28 7 205 62 5 229 69 8 120 000 NA NA NA 83 25 3 217 66 1 See notes at end of venting tables See Table 17 for al...

Page 50: ...lent Vent Length TEVL 112 ft Add all of the above lines Maximum Equivalent Vent Length MEVL 127 ft For 2 pipe from Table 15 Is TEVL less than MEVL YES Therefore 2 pipe may be used Example 2 A direct vent 60 000 Btuh furnace installed at 2100 ft 640 M Venting system includes FOR EACH PIPE 100 feet 30 M of vent pipe 95 feet 28 M of combustion air inlet pipe 3 90_ long radius elbows and a polypropyle...

Page 51: ...A 29 8 8 73 22 3 167 50 9 182 55 5 120 000 NA NA NA 62 18 9 175 53 3 8001 to 9000 2438 to 2743 60 000 30 9 1 82 25 0 152 46 3 168 51 2 NA 80 000 17 5 2 62 18 9 111 33 8 148 45 1 156 47 5 100 000 NA 27 8 2 67 20 4 157 47 9 170 51 8 120 000 NA NA NA 56 17 1 164 50 0 9001 to 10 000 2743 to 3048 60 000 27 8 2 76 23 2 142 43 3 156 47 5 NA 80 000 15 4 6 57 17 4 103 31 4 137 41 8 142 43 3 100 000 NA 24 7...

Page 52: ...s Vent Coupling and Adapter A11314 Fig 36 Vent Coupling and Adapter with Gaskets MODULATING INDUCER ASSEMBLY INDUCER OUTLET VENT ELBOW CLAMP TORQUE 15 LB IN VENT ELBOW VENT PIPE CLAMP TORQUE 15 LB IN A11286 Fig 37 Inducer Vent Elbow Appearance May Vary 59MN7A ...

Page 53: ...upling over standoffs on adapter Slide clamps over the coupling Slide vent pipe through adapter and coupling into vent elbow Insert vent pipe into vent elbow Torque all clamps 15 lb in Attach combustion air pipe adapter with gasket to furnace Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw 1 2 3 4 5 6 7 1 2 3 4...

Page 54: ...o furnace Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw 1 2 3 4 5 6 7 1 2 3 4 5 6 7 5 Rotate vent elbow to required position A11311 1 2 3 4 5 6 7 5 Rotate vent elbow to required position Any other unused knockout may be used for combustion air connection A11312 Requires Accessory Internal Vent Kit See Product...

Page 55: ...otches in rubber coupling over standoffs on adapter Slide clamps over the coupling Slide vent pipe through adapter and coupling into vent elbow Insert vent pipe into vent elbow Torque all clamps 15 lb in Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw 1 2 3 4 5 6 7 Attach combustion air pipe adapter with gasket...

Page 56: ...es in rubber coupling over standoffs on adapter Slide clamps over the coupling Slide vent pipe through adapter and coupling into vent elbow Insert vent pipe into vent elbow Torque all clamps 15 lb in Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw 1 2 3 4 5 6 7 Attach combustion air pipe adapter with gasket to ...

Page 57: ...COUPLING OVER STAND OFF ON ADAPTER TORQUE LOWER CLAMP 15 LB IN WHEN REMAINING VENT PIPE IS INSTALLED TORQUE UPPER CLAMP TO 15 LB IN A11339 Fig 42 Vent Pipe Flush with Adaptor 12 256mm minimum to 60 1524 mm or 1 additional elbow maximum CASING SIDE ATTACHMENT COMBUSTION AIR PIPE NON DIRECT VENT Point elbow down towards back of furnace L12F042 Fig 43 Combustion Air Pipe Attachment 59MN7A ...

Page 58: ...y 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 to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 in 305 mm 12 in 305 mm N Inlet air clearance to a moisture exhaust duct dryer vent spa exhaust etc 3 ft 9 M 3 ft...

Page 59: ...ly 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 to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 in 305 mm 12 in 305 mm N Inlet air clearance to a moisture exhaust duct dryer vent spa exhaust etc 3 ft 9 M 3 f...

Page 60: ...l Maintain 12 in 305mm min Clearï ance above highest anticipated snow level or grade whichever is greater Typ Concentric Vent and Combustion Air Side Termination Roof Termination Preferred Note A denotes 0 To 2 in 51mm Between the first 2 vents Third vent and fourth vent if used must be 36 in Away 914mm Note 36ïin separation between pairs of inlets only required for directïvent systems L12F032 Fig...

Page 61: ...F COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN 305 MM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER COMBUSTION AIR ELBOW PARALLEL TO WALL OVERHANG 12 IN 305 MM MIN GROUND LEVEL OR SNOW LEVEL EXHAUST CLEARANCE TO OVERHANG PER CODE OPTIONAL BRACKET COUPLING A12221 Fig 48 Alberta and Saskatchewan Vent Termination 59MN7A ...

Page 62: ...ipe hangar Ventilated Combustion Air intake termination in crawl space Ventilated Combustion Air intake pipe CRAWL SPACE ATTIC highest level of insulation A10497 Fig 49 Vent Terminations for Ventilated Combustion Air 59MN7A ...

Page 63: ...IGURATIONS A12220 Fig 50 Sample Inlet Air Pipe Connection for Polypropylene Venting Systems Representative drawing only some models may vary in appearance TO CODEïAPPROVED DRAIN OR CONDENSATE PUMP L1 L12F028 Fig 51 Optional Combustion Air Inlet Moisture Trap 59MN7A ...

Page 64: ...difier is used setup switch SW1 3 Min Int Heat Rise Adjust should be in ON position This compensates for the increased temperature in return air resulting from bypass NOTE If modulating dampers are used blower motor automatically compensates for modulating dampers Air Conditioning A C Setup Switches SW2 The air conditioning setup switches are used to match furnace airflow to required cooling airfl...

Page 65: ...resulting in incorrect manifold pressure which can result in a no heat situation or shorten the life of the heat exchangers WARNING FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of he...

Page 66: ...ll not be able to adjust the manifold pressure to obtain the proper input rate To check the inlet gas pressure 1 Make sure the gas supply is turned off to the furnace and at the electric switch on the gas valve 2 Remove the 1 8 in NPT plug from the inlet pressure tap on the gas valve 3 Connect a manometer to the inlet pressure tap on gas valve 4 Turn on furnace power supply 5 Turn gas supply manua...

Page 67: ...cked in low heat operation when only W W1 is energized or high heat operation when R to W W1 and W2 are jumpered 3 Jumper R to W W1 and W2 Run furnace for 3 minutes in maximum heat operation 4 Measure time in sec for gas meter to complete one revolution and note reading The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow 5 Refer to Table 20 for cubic ft of gas per hr Multip...

Page 68: ...nect a jumper across R and W W1 at the thermostat terminals at the furnace control 3 Allow the burners to ignite and the blower to turn on 4 Allow the supply temperature to stabilize and verify the proper rise range If the temperature rise is too high or too low in Intermediate Heat 1 Remove jumpers from R and W W1 2 Wait until the blower off delay is completed 3 Turn 115 VAC power off 4 Check the...

Page 69: ...rcuit while measuring current a Set SW1 2 switch on furnace control board to ON b Remove thermostat from subbase or from wall c Connect an amp meter as shown in Fig 54 across the R and W subbase terminals or R and W wires at wall d Record amp draw across terminals when furnace is in minimum heat and after blower starts e Set heat anticipator on thermostat per thermostat instructions and install on...

Page 70: ...clockwise to decrease rate A10496 Fig 52 Gas Valve BURNER ORIFICE A93059 Fig 53 Orifice Hole R Y W G 10 TURNS THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER EXAMPLE 5 0 AMPS ON AMMETER 10 TURNS AROUND JAWS 0 5 AMPS FOR THERMOSTAT ANTICIPATOR SETTING FROM UNIT 24 V CONTROL TERMINALS A96316 Fig 54 Amp Draw Check with Ammeter 59M...

Page 71: ...71 338307 201 Rev F A11594 Fig 55 Service Label Information 59MN7A ...

Page 72: ...72 A11623 Fig 56 Furnace Setup Switches and Description 59MN7A ...

Page 73: ... Blower Off Delay time adjustable 90 seconds to 180 seconds See table in Adjustments section or refer to unit wiring diagram SW4 2 Intermendiate Heat Only Adaptive Heat Mode when both SW1 2 and SW4 2 are OFF OFF Allows additional CFM per ton selections when used with SW SW4 3 CFM per ton Adjust OFF Allows additional CFM per ton selections when used with SW 1 5 325 CFM per ton nominal when SW 4 3 O...

Page 74: ...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 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138...

Page 75: ...43 3 7 0 60 875 44 3 6 0 60 44 3 7 0 60 43 3 4 0 55 43 3 5 0 55 4000 900 44 3 4 0 55 44 3 5 0 55 44 3 7 0 60 44 3 8 0 60 1219 925 44 3 2 0 50 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 950 45 3 7 0 60 44 3 2 0 50 44 3 3 0 55 44 3 4 0 55 750 42 3 3 0 50 42 3 4 0 55 42 3 5 0 55 42 3 6 0 55 4001 775 43 3 7 0 60 43 3 8 0 60 42 3 3 0 50 42 3 4 0 55 1220 800 43 3 5 0 55 43 3 6 0 60 43 3 7 0 60 43 3 8 0 60 825 ...

Page 76: ...44 3 3 0 55 44 3 4 0 55 44 3 5 0 55 44 3 7 0 60 2438 800 45 3 8 0 60 44 3 2 0 50 44 3 3 0 55 44 3 4 0 55 825 46 3 7 0 60 46 3 8 0 60 45 3 8 0 60 44 3 2 0 50 625 42 3 4 0 55 42 3 5 0 55 42 3 6 0 55 42 3 7 0 60 8001 650 43 3 8 0 60 42 3 2 0 50 42 3 3 0 55 42 3 4 0 55 2439 675 43 3 5 0 55 43 3 6 0 60 43 3 7 0 60 42 3 2 0 50 700 44 3 7 0 60 43 3 4 0 55 43 3 5 0 55 43 3 6 0 55 725 44 3 5 0 55 44 3 6 0 ...

Page 77: ... 6 0 55 43 3 8 0 60 875 44 3 7 0 60 44 3 8 0 60 43 3 4 0 55 43 3 6 0 55 4000 900 44 3 5 0 55 44 3 6 0 55 44 3 7 0 60 43 3 4 0 55 1219 925 44 3 3 0 50 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 950 45 3 8 0 60 44 3 2 0 50 44 3 4 0 55 44 3 5 0 55 750 42 3 3 0 50 42 3 4 0 55 42 3 6 0 55 42 3 7 0 55 4001 775 43 3 8 0 60 42 3 2 0 50 42 3 3 0 50 42 3 4 0 55 1220 800 43 3 6 0 55 43 3 7 0 60 43 3 8 0 60 42 3 2 0...

Page 78: ...000 775 44 3 4 0 55 44 3 5 0 55 44 3 6 0 55 44 3 7 0 60 2438 800 44 3 2 0 50 44 3 3 0 50 44 3 4 0 55 44 3 5 0 55 825 46 3 8 0 60 45 3 7 0 60 44 3 2 0 50 44 3 3 0 50 625 42 3 4 0 55 42 3 5 0 55 42 3 7 0 55 42 3 8 0 60 8001 650 42 3 2 0 50 42 3 3 0 50 42 3 4 0 55 42 3 5 0 55 2439 675 43 3 6 0 55 43 3 7 0 60 43 3 8 0 60 42 3 2 0 50 700 44 3 8 0 60 43 3 4 0 55 43 3 6 0 55 43 3 7 0 55 725 44 3 6 0 55 4...

Page 79: ...d polarity for 115 v wiring must be properly maintained Refer to Fig 33 for field wiring information and to Fig 65 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash rapidly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit co...

Page 80: ...etup switch SW1 6 to OFF and then back ON f Turn setup switch SW1 6 OFF 6 RELEASE BLOWER DOOR SWITCH reattach wire to R terminal on furnace control board and replace blower door Care and Maintenance FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never store flammable or combustible materials on near or in contact with the furnac...

Page 81: ...se motors can be identified by the absence of oil ports on each end of the motor The following items should be performed by a qualified service technician Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove blower door 3 All factory wires can be left connected but field thermostat and accessory wiring may need to be disconnected depend ing on their length and r...

Page 82: ... 1 Disconnect power at external disconnect fuse or circuit breaker 2 Turn off gas at external shut off or gas meter 3 Remove control door and set aside 4 Turn electric switch on gas valve to OFF 5 Disconnect the gas pipe from gas valve and remove pipe from the furnace casing 6 Disconnect the connector harness from gas valve Modulat ing only or remove individual wires from terminals on gas valve Al...

Page 83: ... supplies to the furnace and install lockout tag before performing any maintenance or service Follow the operating instructions on the label attached to the furnace WARNING 1 Turn off gas and electrical supplies to furnace 2 Remove control door 3 Disconnect pressure switch tube from pressure switch port NOTE Ensure the pressure switch tube disconnected from the pressure switch is higher than the c...

Page 84: ... of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger primary or secondary Action must be taken to correct the problem 1 Turn off gas and electrical supplies to furna...

Page 85: ...ed Follow these procedures to winterize your furnace UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the furnace and other property damage Do not use ethylene glycol automotive antifreeze coolant or equivalent Failure of plastic components may occur CAUTION 1 Obtain propylene glycol RV swimming pool antifreeze or equivalent 2 Turn off gas and electrical supplies...

Page 86: ...86 A11392 Fig 59 Priming Condensate Trap Appearance May Vary A11273 Fig 60 Cleaning Heat Exchanger Cell Burner Flame Burner Manifold A11461 Fig 61 Burner Flame 59MN7A ...

Page 87: ...CREW MOTOR ARM GROMMET SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT SEE DETAIL A CAPACITOR OR POWER CHOKE WHEN USED BRACKET SCREW GND BLOWER HSG ASSY MOTOR BLOWER WHEEL BLOWER CUTOFF BLOWER DETAIL A A11584 Fig 62 Blower Assembly 59MN7A ...

Page 88: ...88 FLAME SENSOR BELOW BURNER FLAME ROLLOUT SWITCH BRACKET IGNITER IGNITER BURNER SUPT ASSY BURNER ASSY A11403 Fig 63 Burner Assembly 59MN7A ...

Page 89: ... will repeat Status codes 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 until status code 11 is flashed When done put 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 that was flashed Does the control respond to W W1 W2 Y1 ...

Page 90: ...s before lockout 14 occurs If flame 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 off valve GREEN YELLOW wire MUST be connected to furnace sheet metal Flame sensor must not be grounded To determine whether the problem is in the gas valve ignit...

Page 91: ...2 YELLOW and PL13 4 GREEN Is there 5 VDC at PL3 3 YELLOW and PL3 2 GREEN NO NO You have an open wire or bad terminal on the YELLOW wire between the furnace control and the blower motor YES YES The voltage just measured should be very stable and should not fluctuate more than 02 VDC If the voltage fluctuates more than this get a different voltmeter before proceeding Turn power off disconnect PL13 a...

Page 92: ...ing rate after starting and operating for 45 seconds at intermediate heat The furnace control CPU defaults to minimum heat on the first thermostat cycle and calculates the modulating rate that the furnace should run at for 19 minutes on subsequent heat cycles If the power is interrupted the stored modulating rate is erased and the furnace control will select intermediate heat for 45 seconds minimu...

Page 93: ...l increase the inducer motor speed to the maximum heat inducer motor RPM The blower motor BLWM will trans ition to the maximum heat airflow five seconds after the furnace control CPU switches from a medium range input to maximum heat As the inducer RPM increases the high pressure switch HPS should close 8 Blower Off Delay When the thermostat is satisfied the R to W circuit is opened de energizing ...

Page 94: ...J must be connected to enable the adaptive cooling mode in response to a call for cooling See Fig 34 When in place the furnace control CPU can turn on the air conditioning relay ACR to energize the Y Y2 terminal and switch the outdoor unit to high cooling The furnace control CPU can start up the cooling unit in either low or high cooling If starting up in low cooling the furnace control CPU determ...

Page 95: ... and 25 seconds in maximum heat allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at modulating or maximum heat airflow respectively The blower motor BLWM will revert to continuous blower airflow after the heating cycle is completed When the thermostat satisfies the furnace control CPU will drop the blower motor BLWM to minimum heat...

Page 96: ...96 338307 201 Rev F A11595 Fig 65 Wiring Diagram 59MN7A ...

Page 97: ...aler or classified section of your local telephone directory under Heating Equipment or Air Conditioning Contractors and Systems headings for dealer listing by brand name or contact CARRIER CORPORATION 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 re...

Page 98: ...D 7310 W Morris St D Indianapolis IN 46231 Edition Date 06 12 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No 59MN7A 05SI Replaces 59MN7A 04SI 59MN7A ...

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