Carrier 59SP6A Installation, Start-Up, Operating, Service And Maintenance Instructions Download

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Installation, Start-up, Operating,

Service and Maintenance Instructions

NOTE:

Read the entire instruction manual before starting the

installation.
TABLE OF CONTENTS

REQUIRED NOTICE FOR MASSACHUSETTS INSTALLATIONS

IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Table 1 – Minimum Clearances to Combustible Materials for All Units

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Table 2 – Loose Parts Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CODES AND STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCE

DURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . . . . . 8

CONDENSATE TRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Table 3 – Minimum Free Area Required for Each Combustion Air

Opening or Duct to Outdoors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Table 4 – Minimum Space Volumes for 100% Combustion, Ventila

tion and Dilution Air from Outdoors . . . . . . . . . . . . . . . . . . . . . . 10

CONDENSATE DRAIN CONNECTION . . . . . . . . . . . . . . . . . . . . 12

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 5 – Opening Dimensions - In. (mm) . . . . . . . . . . . . . . . . . 17

Table 6 – Air Filter Selection and Duct Sizing - In. (mm) . . . . . 18

Table 7 – Filter Media Pressure Drop (Clean) Versus Airflow - In.

W.C. (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 8 – Filter Media Pressure Drop (Clean) Versus Face Velocity-

In. W.C. (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 9 – Cooling

and Heating Air Delivery - CFM (Bottom Return

with Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

GAS PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table 10 – Maximum Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 28

ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Table 11 – Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table 12 – Vent Termination Kit for Direct Vent (2-pipe) Systems38

Table 13 – Maximum Equivalent Vent Length - Ft. (M). . . . . . . 43

Table 14 – Deductions from Maximum Equivalent Vent Length - Ft.

(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Table 15 – Maximum Allowable Exposed Vent Lengths in Uncondi

tioned Space Insulation Table - Ft. / M . . . . . . . . . . . . . . . . . . . . 46

Table 16 – Hanger Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Table 17 – Approved Combustion-Air and Vent Pipe, Fitting and Ce

ment Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

START-UP, ADJUSTMENT, AND SAFETY CHECK . . . . . . . . . 54

Table 18 – Altitude Derate Multiplier for USA. . . . . . . . . . . . . . 57

Table 19 – Blower Off Delay Setup Switch . . . . . . . . . . . . . . . . 59

Table 20 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input

Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Table 21 – Gas Rate (CU ft./hr). . . . . . . . . . . . . . . . . . . . . . . . . . 61

SERVICE AND MAINTENANCE

PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

WINTERIZATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . . . . . 74

MODEL NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

TRAINING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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.

A200352

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1E, 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.

59SP6A

Single-Stage, Non-Communicating, Variable-Speed,

ECM Multipoise, Condensing Gas Furnace

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.

Summary of Contents for 59SP6A

Page 1: ...re In W C for Gas Input Rate 60 Table 21 Gas Rate CU ft hr 61 SERVICE AND MAINTENANCE PROCEDURES 61 WINTERIZATION 68 TROUBLESHOOTING 69 Sequence of Operation 71 PARTS REPLACEMENT INFORMATION GUIDE 74 MODEL NOMENCLATURE 74 TRAINING 74 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 pro...

Page 2: ...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 vente...

Page 3: ...ation 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 ...

Page 4: ...ally available soap solution made specifically for the detection of leaks to check all connections as specified in the Gas Piping section 6 Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in the Start Up Adjustments and Safety Check section See furnace rating plat...

Page 5: ...ping materials loose parts bag and literature before operating the furnace See Table 2 Table 2 Loose Parts Bag NOTE The 40K models are the only furnaces that receive the outlet restrictor in loose parts bag See Maximum Equivalent Vent Length Table for usage A12182 Fig 4 Prohibited Installations NOTICE IMPORTANT INSTALLATION AND START UP PROCEDURES Failure to follow this procedure may result in a n...

Page 6: ...e NEC NFPA 70 CANADA Current edition of Canadian Electrical Code CSA C22 1 Condensate Drain Connection US Current edition of National Standard Plumbing Code Section 8 7 Canada Current edition of National Plumbing Code of Canada ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED ...

Page 7: ...nace is permanently installed with all electrical wiring piping venting and ducting installed according to these installation instructions A return air duct is provided sealed to the furnace casing and terminated outside the space containing the furnace This prevents a negative pressure condition as created by the circulating air blower causing a flame rollout and or drawing combustion products in...

Page 8: ... Air Infiltration Method Outdoor Combustion Air Method 1 Provide the space with sufficient air for proper combustion ventilation and dilution of flue gases using permanent horizontal or vertical duct s or opening s directly communicating with the outdoors or spaces that freely communicate with the outdoors 2 Fig 6 illustrates how to provide TWO OUTDOOR OPENINGS one inlet and one outlet combustion ...

Page 9: ...lly tight construction is defined as Construction with a Walls and ceilings exposed to the outdoors have a continuous sealed vapor barrier Openings are gasketed or sealed and b Doors and openable windows are weatherstripped and c Other openings are caulked or sealed These include joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at ...

Page 10: ...9355 6 152 140 000 70 45161 10 254 47 30435 8 203 35 22581 7 178 FURNACE WATER HEATER TOTAL INPUT 100 000 30 000 130 000 divided by 4 000 32 5 Sq In for each two Vertical Ducts or Openings 60 000 40 000 100 000 divided by 3 000 33 3 Sq In for each Single Duct or Opening 80 000 30 000 110 000 divided by 2 000 55 0 Sq In for each two Horizontal Ducts OTHER THAN FAN ASSISTED TOTAL 1 000 S BTUH GAS IN...

Page 11: ...ap Relief Port Collector Box Plug Vent Elbow Vent Elbow Clamp Vent Pipe Clamp UPFLOW TRAP CONFIGURATION 1 2 Stage Units Remove relief tube from relief port on condensate trap Remove the screw that secures the trap to the collector box and remove trap Loosen clamp on inlet to vent elbow Remove pressure switch tube from front pressure switch and discard A new tube is shipped in the loose parts bag R...

Page 12: ...ÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ Evaporator Coil Blower 3 4 PVC 3 4 3 4 3 4 3 4 Positive pressure Pressure lower than areas with ï Negative pressure 3 4 PVC DIRECTION OF AIRFLOW 3 4 Open standpipe LQ KLJK PLQLPXP Air gap required when another drain is connected to furnace drain TEE 1 2 CPVC to 3 4 PVC adapter from loose parts bag Condensing Furnace ï ï ï ï ï Evaporator C...

Page 13: ...be easier to remove the condensate trap connect the drain line components and re install the condensate trap Read the steps thoroughly to familiarize yourself with the required steps For Right Side Condensate Drain 1 Remove the 7 8 in knock out from the right side of the casing See Fig 15 for suggested knockout removal technique 2 Remove the pre formed rubber drain elbow and two spring clamps from...

Page 14: ... side of the casing should be facing the front of the furnace 11 Slide a spring clamp over the end of the remaining rubber drain elbow 12 Attach the drain elbow to the angled end of Z pipe and the drain trap outlet stub Adjust the length of Z pipe inserted into the grommet at the opposite side of the furnace as necessary for proper fit and positioning In both upflow and downflow orientations the Z...

Page 15: ...ne INSTALLATION Upflow Installation NOTE The furnace must be pitched as shown in Fig 19 for proper condensate drainage A11237 Fig 19 Furnace Pitch Requirements A10493A Fig 20 Duct Flanges 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...

Page 16: ...ecial Base KGASB Cased Coil Assembly Part No CNPV CNRV CAP or CAR Coil Box Part No KCAKC 1 Determine application being installed from Table 5 2 Construct hole in floor per Table 5 and Fig 25 3 Construct plenum to dimensions specified in Table 5 and Fig 25 4 Install special base coil assembly or coil box as shown in Fig 25 NOTE It is recommended that the perforated supply air duct flanges be comple...

Page 17: ...PLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace FURNACECASING WIDTH IN mm APPLICATION PLENUM OPENING FLOOR OP...

Page 18: ...ce or side and bottom when a bottom plenum is used See Fig 21 and Fig 27 For downflow applications the Media Cabinet or field supplied accessory air cleaner must only be connected to the bottom opening on the furnace See Fig 22 and Fig 27 For horizontal applications the Media Cabinet or field supplied accessory air cleaner for all models can be connected to the bottom opening on the furnace For si...

Page 19: ...oling 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 is in the full heat or full ...

Page 20: ...Bottom Return Plenum 21 or 24 1 2 in Furnace Up to 5 Ton AC capacity airflow 45 Transition 20 or 24 in Media Cabinet Screw 14 3 16 in Furnace 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 Instal...

Page 21: ...0 11 28 0 17 43 0 27 67 1200 566 0 07 18 0 15 37 0 14 36 0 22 56 1400 661 0 08 21 0 19 48 0 18 45 0 28 70 1600 755 0 09 23 0 24 60 0 21 54 1800 850 0 10 25 0 26 64 20 x 25 Filter 508 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 04 11 0 05 1...

Page 22: ... The sheet metal MUST extend underneath the furnace casing by 1 in 25 mm with the door removed The bottom closure panel may be used for flame roll out protection when bottom of furnace is used for return air connection 30 IN 762 mm MIN WORK AREA COMBUSTION AIR PIPE SEE VENTING SECTION 2 IN 51 mm COMBUSTION AIR PIPE SEE VENTING SECTION Install 12 x 22 204 x 559 mm sheet metal in front of and above ...

Page 23: ...0 245 See Note 4 OFF ON ON 385 335 See Note 4 ON OFF OFF 385 335 See Note 4 ON OFF ON 385 335 See Note 4 ON ON OFF 385 335 See Note 4 ON ON ON 385 335 See Note 4 Heating SW1 Heat Airflow3 785 750 715 685 655 625 595 560 535 505 Unit Size 040V17 12 Clg CF Switch settings External Static Pressure ESP Clg Switches SW2 8 SW2 7 SW2 6 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 1240 ...

Page 24: ...ON ON OFF 375 315 See Note 4 ON ON ON 375 315 See Note 4 Heating SW1 Heat Airflow3 980 950 920 890 860 825 795 765 735 705 Unit Size 060V17 14 Clg CF Switch settings External Static Pressure ESP Clg Switches SW2 8 SW2 7 SW2 6 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 1350 1315 1285 1250 1215 1180 1150 1115 1085 1050 Cooling SW2 8 7 6 OFF OFF ON 635 575 515 See Note 4 OFF ON O...

Page 25: ... 4 ON ON OFF 690 630 570 510 445 See Note 4 ON ON ON 690 630 570 510 445 See Note 4 Heating SW1 Heat Airflow3 1375 1340 1300 1265 1230 1195 1155 1120 1090 1050 Unit Size 080V21 20 Clg CF Switch settings External Static Pressure ESP Clg Switches SW2 8 SW2 7 SW2 6 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 1950 1910 1870 1835 1795 1760 1720 1680 1645 1605 Cooling SW2 8 7 6 OFF O...

Page 26: ...ches SW2 5 SW2 4 SW2 3 Low Clg Default OFF OFF OFF 840 760 675 See Note 4 Low Cooling SW2 5 4 3 OFF OFF ON 700 605 See Note 4 OFF ON OFF 840 760 675 See Note 4 OFF ON ON 1065 1000 935 865 See Note 4 ON OFF OFF 1250 1190 1135 1075 1015 See Note 4 ON OFF ON 1435 1380 1330 1280 1230 1175 See Note 4 ON ON OFF 1640 1590 1545 1500 1455 1410 1365 1320 See Note 4 ON ON ON 2015 1975 1935 1895 1855 1820 178...

Page 27: ...n duct to the first branch take off may require internal acoustical lining As an alternative fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts NOTE For horizontal applicat...

Page 28: ...test pressures in excess of psig 3 5 kPa PRESSURE TESTING BELOW psig The furnace must be isolated from the gas supply piping by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than psig 3 5 kPa An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft 2 M of f...

Page 29: ...ous 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 Reconnect wires correctly Verify proper operation after servicing Always reinstall access doors after completing service and maintenance WARNING E...

Page 30: ...ed to the outside of the furnace casing The field ground wire and furnace main ground wire are grounded when the J Box bracket is attached to the furnace and the field ground wire and factory ground wire are secured to the bracket grounding screw If the J Box cover is not used the field and factory spliced connections must be located inside the external electrical box Do not leave splice connectio...

Page 31: ...o furnace power leads inside the external electrical box as shown in Fig 32 For a top panel mounted external electrical box complete the following 1 Drill two 2 1 8 in 3 mm pilot holes through the dimples in the furnace casing near the 7 8 in knock out on the side of the casing Do not remove the knock out in the side of the casing 2 Align the J Box bracket with the pilot holes inside the furnace c...

Page 32: ...umper from the furnace control board Refer to typical thermostat wiring diagrams and the Sequence of Operation section for additional details Consult the thermostat installation instructions for specific information about configuring the thermostat See Fig 39 and Fig 40 A11157 Fig 38 Field supplied Isolation Relay for Humidifiers with Internal Power Supply A190207 Fig 39 Example of Single Stage Fu...

Page 33: ...VAC output energized when the blower is operating during a call for heat 3 Twinning Connector The furnace can only be controlled by a single or two stage thermostat A Communicating User Interface will not operate this furnace when connected to the Communication Connector The Communication Connector on the furnace control board is only for communication between furnaces twinned together using a fac...

Page 34: ...tat instructions 7 Configure thermostat for single stage compressor operation Refer to thermostat instructions 8 Configure thermostat for HYBRIDHEATr dual fuel operation Refer to thermostat instructions 9 NO connection should be made to the furnace HUM terminal when using a thermostat with a 24 volt humidifier output 10 The RVS Sensing terminal L should not be connected This is used internally to ...

Page 35: ...n des composantes Royal Pipe IPEX PVC qui sont certifiées à ce standard Au Canada l apprêt et le ciment doivent être du même fabricant que le système d évacuation L apprêt GVS 65 Purple et le ciment solvant GVS 65 doivent être utilisé avec les Royal Pipe Système IPEX 636 apprêt PVC CPVC Purple pour évacuation des gaz de combustion et système IPEX 636 1 t ciment PVC pour évacuation des gaz de combu...

Page 36: ...mbustion air inlet pipe a moisture trap may be added to the inlet pipe to help prevent moisture from entering the furnace from the combustion air inlet pipe See Fig 52 When sizing venting systems the equivalent length of the optional inlet pipe moisture trap must be taken into account WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected t...

Page 37: ...ation consider the following guidelines 1 Comply with all clearance requirements stated in Fig 43 or Fig 44 per application 2 Termination or termination kit should be positioned where vent vapors will not damage plants shrubs air conditioning equipment or utility meters 3 Do not locate termination directly into prevailing winds Termination should be positioned so that it will not be affected by su...

Page 38: ...o No Yes No 2 in 51 mm 3 in 76 mm 3 in 76 mm No No No Yes No 3 in 76 mm 4 in 102 mm No No No Yes Yes 3 in 76 mm in 222mm for 3 in 76mm 12 in 305mm min separation between bottom of combustion air and bottom of vent Typ in 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 o...

Page 39: ...l 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 to ...

Page 40: ...mendation 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 extended ...

Page 41: ...istances when vent termination is located more than 6 ft 2 M away from an inside corner refer to the appropriate Direct Vent or Non Direct Vent Clearance Table Clearance description when termination is at least 3 ft 1 M away and not more than 6 ft 2 M away from an inside corner Clearance above grade veranda porch deck balcony or anticipated snow level 12 in 305 mm Clearance to a permanently closed...

Page 42: ...he vent portion of the rain cap A tee attached to the rain cap could potentially direct the flue gas plume toward the intake air stream and contaminate the incoming combustion air for the furnace Refer to Fig 49 for terminations approved for use in Alberta and Saskatchewan NOTICE RECOMMENDED SUPPORT FOR VENT TERMINATIONS It is recommended that sidewall vent terminations in excess of 24 inches 6 M ...

Page 43: ...re trap may be added to the inlet pipe to help prevent moisture from entering the furnace from the combustion air inlet pipe See Fig 52 When sizing venting systems the equivalent length of the optional moisture trap 15 feet 5 M must be taken into account FURNACE PIPE DIAMETER TRANSITION IN VERTICAL SECTION NOT IN HORIZONTAL SECTION Unit Size 40 000 1 60 000 2 80 000 100 000 120 000 3 140 000 3 Alt...

Page 44: ... pipe near the furnace To prevent moisture connecting a drain line to the trap is recommended as trace amounts of moisture will evaporate into the intake air stream If the combustion air inlet is located near a moisture exhaust duct or there are other concerns of excessive moisture being drawn into the combustion air inlet it is encouraged to connect a drain line to the trap The trap can be constr...

Page 45: ...Total Equivalent Vent Length TEVL of the venting system 1 Measure the individual distance from the furnace to the termination for each pipe 2 Count the number of elbows for each pipe 3 For each pipe multiply the number of elbows by the equivalent length for the type of elbow used Record the equivalent length of all the elbows for each pipe 4 If a Tee is used on the termination Alberta and Saskatch...

Page 46: ...tion such as Armaflex or other equivalent type of insulation 5 Insulate combustion air inlet piping when run in warm humid spaces 6 Install the insulation per the insulation manufacturer s installation instructions NOTE Pipe length ft M specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as calculated from Table 13 Configure the Furnace Near...

Page 47: ... Size 40 000 BTUH 60 000 BTUH Uninsulated 3 8 in Insulation 1 2 in Insulation Uninsulated 3 8 in Insulation 1 2 in Insulation Pipe Dia mm 38 51 64 38 51 64 38 51 64 38 51 64 76 38 51 64 76 38 51 64 76 7 6 1 6 1 6 1 6 1 15 2 13 7 6 1 18 3 15 2 6 1 9 1 9 1 7 6 6 1 22 9 19 8 18 3 6 1 25 9 22 9 19 8 18 3 0 1 5 1 5 6 1 7 6 6 1 6 1 9 1 7 6 4 6 4 6 3 0 3 0 6 1 12 2 9 1 7 6 6 1 13 7 12 2 9 1 29 1 5 6 1 4 ...

Page 48: ...RIZONTAL LEFT VERTICAL VENT CONFIGURATION A11328A HORIZONAL LEFT LEFT VENT CONFIGURATION 1 2 3 4 6 7 5 5 Rotate vent elbow to required position Any other unused knockout may be used for combustion air connection 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 1 2 3 4 5 6 7 5 Any other unused knockout may be used for combust...

Page 49: ...ter 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 furnace 7 Attach combustion air pipe to adapter with silicone Pilot drill a1 8 in hole in adapter and secure with a 7 x 1 2 in sheet metal screw A14546 Fig 57 Near Furnace Vent Connectio...

Page 50: ...T 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 pipe fitting socket and end o...

Page 51: ...tal screws 10 Loosen the clamps on the rubber vent coupling 11 Slide the end of the coupling with notches in it over the standoffs in the vent pipe adapter 12 Tighten the clamp of the coupling over the vent pipe adapter Torque the lower clamp around the vent pipe adapter to 15 lb in 13 Pilot drill a 1 8 in hole in the combustion air pipe adapter 14 Complete the vent and combustion air pipe as show...

Page 52: ...3 Slide assembled kit with rain shield REMOVED through hole NOTE Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole 4 Locate assembly through sidewall with rain shield positioned no more than 1 in 25 mm from wall as shown in Fig 41 5 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping DO NOT ...

Page 53: ...tion Type ASTM ULC UL Specification Pipe Fittings Solvents Primers Cements PVC Pressure Pipe Schedule 40 D1785 UL 1738 DWV Schedule 40 D1785 D2665 D2466 Cellular Core Schedule 40 F891 or F656 D2564 SDR 26 N A D2241 D2665 SDR 21 N A D2241 IPEX Schedule 40 ULC S636 ULC S636 ULC S636 ULC S636 Royal Pipe Schedule 40 ULC S636 ULC S636 ULC S636 ULC S636 ABS ABS Schedule 40 D1527 D2468 Clear Cleaner For ...

Page 54: ...te requirement 1 Remove blower door 2 Locate setup switches on furnace control 3 Configure the setup switches as necessary for the application 4 Replace blower door Measure the required linear length of RIGID air inlet and vent pipe insert the longest of the two here 100 ft Of rigid pipe 20 ft Of flexible pipe 80 ft 24 M Use length of the longer of the vent or air inlet piping system Add equiv len...

Page 55: ...ay cause condensate blow off or a frozen indoor coil in the cooling mode 5 Replace blower door Continuous Fan CF Setup Switches SW2 3 4 5 The CF setup switches are used to select desired airflow when thermostat is in continuous fan mode or to select low cooling airflow for two speed cooling units Refer to the Adjustments section for setup switch configurations To set desired cooling airflow 1 Remo...

Page 56: ...Stage A C airflow when CF switches are in OFF position WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow these warnings could result in personal injury or death Failure to use a properly configured trap or NOT water priming trap before operating furnace may allow positive pressure vent gases to enter the structure through drain tube Vent gases contain carbon monoxide which is tasteless an...

Page 57: ...le pressures to Pascals multiply the in w c value by 249 1 Pa in w c 1 in w c 249 1 Pa Check Inlet Gas Pressure The inlet gas pressure must be checked with the furnace operating in maximum heat This is necessary to make sure the inlet gas pressure does not fall below the minimum pressure of 4 5 in w c for natural gas The maximum inlet gas pressure is 13 6 in of water column If the inlet pressure i...

Page 58: ...n burner flame should be clear blue almost transparent see Fig 66 j Remove jumpers R to W A89020 Fig 66 Burner Flame Clocking the Meter 1 Verify natural gas input rate by clocking meter NOTE Contact your HVAC distributor or gas supplier for metric gas meter tables if required a Turn off all other gas appliances and pilots served by the meter b Jumper R to W c Run furnace for 3 minutes d Measure ti...

Page 59: ...s SW2 is also the airflow for low speed cooling when the furnace is used with a 2 speed cooling or heat pump unit Adjust SW2 3 4 5 to match the airflow required for low speed cooling Select the required airflow from Table 9 and Fig 61 NOTE The airflow selected via SW2 3 4 5 Low Speed Cooling Airflow cannot exceed the airflow selected via SW2 6 7 8 High Speed Cooling Airflow For other CFM per ton S...

Page 60: ... 2 42 3 3 42 3 4 915 825 43 3 6 43 3 7 43 3 8 42 3 2 850 44 3 8 43 3 5 43 3 6 43 3 7 875 44 3 6 44 3 7 43 3 4 43 3 5 4000 900 44 3 4 44 3 5 44 3 7 44 3 8 1219 925 44 3 2 44 3 4 44 3 5 44 3 6 950 44 3 1 44 3 2 44 3 3 44 3 4 750 42 3 3 42 3 4 42 3 5 42 3 6 4001 775 43 3 7 43 3 8 42 3 3 42 3 4 1220 800 43 3 5 43 3 6 43 3 7 43 3 8 825 44 3 8 43 3 4 43 3 5 43 3 6 850 44 3 5 44 3 7 44 3 8 43 3 4 5000 87...

Page 61: ...aximum make point of SEC FOR 1 REV SIZE OF TEST DIAL SEC FOR 1 REV SIZE OF TEST DIAL 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 3...

Page 62: ... 3 Manually close blower door switch 4 Control will flash up to 7 Status Codes 5 The last Status Code or 8th Code will be Code 11 6 Turn SW1 1 OFF 7 Amber will be ON continuous which indicates proper operation 8 Release blower door switch install blower door and refer to the SERVICE label on the blower door for more information Component Self Test Component Test can ONLY be initiated by performing...

Page 63: ...ing 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 specified media filter of the same size 6 Slide filter into cabinet 7 Replace filter cabinet door 8 Turn on electrical supply to furnace WARNING ELECTRICAL SHOCK AND FI...

Page 64: ...b Loosen setscrew holding blower wheel on motor shaft NOTE Mark blower mounting arms and blower housing so each arm is positioned at the same hole location during reassembly c Mark blower wheel orientation and cutoff plate location to ensure proper reassembly d Remove screws securing cutoff plate and remove cutoff plate from housing e Remove bolts holding motor mounts to blower housing and slide m...

Page 65: ... Igniter HSI and bracket from the burner assembly 18 Check igniter resistance Nominal resistance is 40 to 70 ohms at room temperature and is stable over the life of the igniter 19 Clean burner with a brush and a vacuum 20 Clean the flame sensor with fine steel wool 0000 grade Do not use sand paper or emery cloth To reinstall burner assembly 1 Install the Hot Surface Igniter HSI and bracket in burn...

Page 66: ...ing or water will flow out of tube 4 Remove the collector box plug from the top port on the upper corner of the collector box See Fig 63 5 Attach a funnel with a flexible tube to port on the collector box 6 Flush inside of collector box with water until discharge water from condensate trap is clean and runs freely 7 Repeat steps 4 through 6 with bottom plug on upper corner of collector box 8 Remov...

Page 67: ... 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 furnace 2 Remove control door 3 Disconnect wires or connectors to flame ro...

Page 68: ... funnel tube Antifreeze should run through the inducer housing overfill condensate trap and flow to an open drain 8 Replace the rubber plug in the port on the collector box 9 Remove the middle unused rubber plug from the port on the collector box opposite the condensate trap See Fig 63 10 Repeat Steps 5 through 8 11 If a condensate pump is used check with pump manufacturer to verify pump is safe f...

Page 69: ... h c o t urs or can be manually erased by o h 2 7 r e t f a putting setup switch SW1 1 in the ON position and jumpering R W and Y Y2 simultaneously until status code 11 is flashed l o r t n o c e c a n r u f e c a l p e R d e s o l c h c t i w s r o o d s I d e s o l c r e k a e r b t i u c r i c s I r e k a e r b t i u c r i c m o r f e r i w n i y t i u n i t n o c r o f k c e h C e c a n r u f ...

Page 70: ...ollowing 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 igniter or flame sensor the system can be operated in the component test mode to check the igniter First remove the R thermostat connection from the contro...

Page 71: ...difier terminal HUM The inducer motor IDM will remain energized for a 15 sec post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized for 90 120 150 or 180 sec depending on the blower OFF delay selection The furnace control CPU is factory set for a 120 sec Blower OFF delay 2 Cooling mode The thermostat calls for cooling a Single Speed Cooling See Fig 39 and Fig ...

Page 72: ...s blower airflow or heat airflow whichever is lowest The blower motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower ON delay 25 seconds in heat allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at heat airflow The blower motor BLWM will revert to continuous blower airflow after the hea...

Page 73: ...Start up Operating Service and Maintenance Instructions Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 73 346265 2 REVA A200284 Fig 75 Wiring Diagram ...

Page 74: ...r installing dealer or a licensed Heating and Air Conditioning company of your choice CARRIER 7310 West Morris Street Indianapolis IN 46231 U S A 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 resourc...

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Carrier 59SP6A, Installation, Start-Up, Operating, Service And Maintenance Instructions

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