Carrier 59TP6A Installation, Start-Up, Operating And Service And Maintenance Instructions Download

Page: 1 / 92

59TP6A

Two---Stage Variable Speed ECM Multipoise

Condensing Gas Furnace

Series 1

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

. . . . . . . . .

CONDENSATE TRAP

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

Upflow

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

Downflow

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

Horizontal

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

CONDENSATE DRAIN

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

INSTALLATION

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

Upflow

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

Downflow

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

Horizontal

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

Filter Arrangement

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

AIR DUCTS

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

Ductwork Acoustical Treatment

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

GAS PIPING

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

ELECTRICAL CONNECTIONS

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

115--V Wiring

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

J--Box Installation

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

24--V Wiring

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

Accessories

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

Alternate Power Supplies

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

VENTING

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

Special Venting Requirements for Installations in Canada

Materials

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

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

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

Check Safety Controls

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

Checklist

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

SERVICE AND MAINTENANCE PROCEDURES

. . . . . . . .

Cleaning Heat Exchangers

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

SEQUENCE OF OPERATION

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

PARTS REPLACEMENT GUIDE

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

TABLES

Loose Parts Bag Contents

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

Minimum Clearances to Combustible Materials

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

Minimum Free Area Required

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

Minimum Space Volumes

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

Filter Size Information

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

Opening Dimensions

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

Air Delivery CFM

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

Maximum Capacity of Pipe

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

Electrical Data

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

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

. . . . . .

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

. . . . .

Maximum Allowable Exposed Vent Lengths Insulation

. . . . . .

Maximum Equivalent Vent Length

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

Deductions from Maximum Equivalent Vent Length

. . . . . . . .

Altitude Derate Multiplier for U.S.A.

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

Blower Off Delay Setup Switch

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

Gas Rate

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

Orifice Size and Manifold Pressure

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

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--2012

, 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 59TP6A

Page 1: ... Gas Lines 66 Adjustments 67 Check Safety Controls 69 Checklist 70 SERVICE AND MAINTENANCE PROCEDURES 76 Cleaning Heat Exchangers 81 SEQUENCE OF OPERATION 85 PARTS REPLACEMENT GUIDE 91 TABLES Loose Parts Bag Contents 7 Minimum Clearances to Combustible Materials 7 Minimum Free Area Required 12 Minimum Space Volumes 12 Filter Size Information 23 Opening Dimensions 26 Air Delivery CFM 31 Maximum Cap...

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: ...al building heating plumbing and other codes In absence of local codes the installation must comply with the national codes listed below and all authorities having jurisdiction In the United States and Canada follow all codes and standards for the following Safety S US National Fuel Gas Code NFGC NFPA 54 2012 ANSI Z223 1 2012 and the Installation Standards Warm Air Heating and Air Conditioning Sys...

Page 5: ...e used for heating buildings under construction provided that The furnace 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...

Page 6: ...ns S Chlorinated waxes and cleaners S Chlorine based swimming pool chemicals S Water softening chemicals S De icing salts or chemicals S Carbon tetrachloride S Halogen type refrigerants S Cleaning solvents such as perchloroethylene S Printing inks paint removers varnishes etc S Hydrochloric acid S Cements and glues S Antistatic fabric softeners for clothes dryers S Masonry acid washing materials A...

Page 7: ... Box Cover 1 Junction Box Base 1 Green Ground Screw 1 Blunt Tip Screws Junction Box 3 Thermostat Wire Grommet 1 Drain Extension Tube Z pipe Provided separately in furnace 1 NOTE Only used for 40K BTUH furnaces from 0 2000 ft 0 to 610 M above sea level for total equivalent vent lengths under 10 ft 3 M Table 2 Minimum Clearances to Combustible Materials for All Units POSITION CLEARANCE Rear 0 0 mm F...

Page 8: ... 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 368 x 495 mm rectangle c For 1600 CFM 22 in...

Page 9: ...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 10: ...rten 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 NEGATIVE PRESSURE ...

Page 11: ...W of the total input rating of all gas appliances in the space but not less than 100 in 2 0 06 m2 One opening shall commence within 12 in 300 mm of the ceiling and the second opening shall commence within 12 in 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Fig 7 c Combining space on different floor levels The volumes of spaces on different floor levels ...

Page 12: ...able 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 1 500 42 5 2 000 56 6 2 500 70 8 3 000 84 9 3 500 99 1 0 50 1 260 35 6 1 680 47 5 2 100 59 4 1 680 47...

Page 13: ...g 10 and 11 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 16 The field supplied accessory horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS It it NOT required for applicatio...

Page 14: ... ports of the collector box Connect relief tube to port on collector box Rotate elbow to desired position and tighten clamp to 15 lb ïin Slide tube in standïoffs to adjust length Connect the new pressure switch tube from Loose Parts bag to port on front pressure switch Route tube through inducer standïoffs to adjust position of the tube Trim excess tube Connect pressure switch tube to port on coll...

Page 15: ...on Attach condensate trap with screw to collector box Slide relief tube in standïoffs to adjust length Vent elbow shown in alternate orientation Tighten clamp on inlet to vent elbow 15 lb ïin Align trap over middle and rightïhand port on collector box NOTE Remove knockout in casing before reïinstalling the condensate trap Install plug on open port of collector box Horizontal Right Trap Configurati...

Page 16: ...osition and torque clamp on inlet 15 lb in Slide relief tube in stand offs to adjust length Attach condensate trap with screw to collector box Align trap over middle and right hand port on collector box Install two plugs previously removed in open ports on collector box Connect relief tube to port on collector box Connect the new pressure switch tube from Loose Parts bag to port on front pressure ...

Page 17: ...sier 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 12 for suggested knockout removal tech nique 2 Remove the pre formed rubber drain elbow and two spring clamps from the...

Page 18: ...air venting NOTICE TIP FROM CONTRACTORS When installing the furnace horizontally use the entire drain elbow that is do NOT cut as shown in Fig 15 to connect the trap to the drain line This helps to prevent bumps and shocks to the drain line from damaging the furnace drain trap Avoid misalignment of the drain pipe which may cause kinks in the elbow Horizontal Orientation 1 The condensate trap outle...

Page 19: ...t is required only for direct vent applications A11582 Fig 16 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 ...

Page 20: ...sired In upflow position with side return inlet s leveling legs may be used See Fig 21 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 closure panel see Item 1 in Bottom Return...

Page 21: ...m piece 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 p...

Page 22: ... 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 Airflow for a variety of filter media types and sizes These are representative number...

Page 23: ...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 24: ...lter face velocity See Product Data for part number Not all families have these models 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 ...

Page 25: ...iller 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 Side Ret...

Page 26: ...2 419 19 5 8 498 Downflow applications on combustible flooring KGASB sub base required 15 1 8 384 19 483 16 3 4 425 20 5 8 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR or CAP Coil Assembly or KCAKC coil box KGASB subbase not required 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 49...

Page 27: ...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 21 Leveling Legs BOTTOMPLATE BOTTOM CLOSURE PANEL A11092 Fig 22 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 23 Furnace Pitch Requirements 59TP6A ...

Page 28: ... Fig 24 Upflow Return Air Configurations and Restrictions A11037 Fig 25 Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig 26 Horizontal Return Air Configurations and Restrictions 59TP6A ...

Page 29: ...ig 27 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 28 Suspended Furnace Installation NOTE Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling 59TP6A ...

Page 30: ...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 31: ...40 490 435 385 See note 4 OFF ON OFF 770 725 685 640 600 560 515 480 See note 4 OFF ON ON 945 910 875 835 800 770 735 695 665 635 ON OFF OFF 1140 1105 1075 1040 1005 970 930 885 835 790 ON OFF ON 1250 1210 1165 1115 1065 1015 965 915 860 810 ON ON OFF 1250 1210 1165 1115 1065 1015 965 915 860 810 ON ON ON 1250 1210 1165 1115 1065 1015 965 915 860 810 Clg SW2 Maximum Clg Airflow 2 1250 1210 1165 11...

Page 32: ...FF ON ON 995 955 910 860 815 770 720 660 620 585 ON OFF OFF 1175 1140 1090 1060 1025 980 940 905 855 815 ON OFF ON 1325 1280 1245 1210 1180 1140 1105 1070 1025 990 ON ON OFF 1545 1515 1480 1445 1410 1380 1350 1315 1245 1175 ON ON ON 1805 1765 1720 1665 1610 1540 1475 1400 1315 1235 Clg SW2 Maximum Clg Airflow 2 1805 1765 1720 1665 1610 1540 1475 1400 1315 1235 Heating SW1 High Heat Airflow 3 1520 ...

Page 33: ... 8 2375 2300 2205 2115 2010 1890 1750 1645 1550 Clg SW2 Maximum Clg Airflow 2 note 8 2375 2300 2205 2115 2010 1890 1750 1645 1550 Heating SW1 High Heat Airflow 3 note 8 2375 2300 2205 2115 2010 1890 1750 1645 1550 Low Heat Airflow 3 1735 1675 1625 1560 1500 1455 1395 1345 1285 1225 1 Nominal 350 CFM ton cooling airflow is delivered with SW1 5 and SW2 2 set to OFF Set both SW1 5 and SW2 2 to ON for...

Page 34: ...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 m...

Page 35: ...r servicing WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower door switch opens 115 v power to control No component operation can occur Do not bypass or close switch with blower door removed WARNING See Fig 34 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical connections for tightness Fiel...

Page 36: ... Side NOTE Check that duct on side of furnace will not interfere with installed electrical box 1 Fasten a field supplied external electrical box to the outside of the casing by driving two field supplied screws from in side electrical box into casing See Fig 32 2 Route field power wiring into external electrical box 3 Pull furnace power wires through 1 2 in 12 mm diameter hole in J Box If necessar...

Page 37: ...24 VAC output energized when the blower is operating during a call for heat Connect an accessory 24 VAC 0 5 amp maximum humidifier if used to the in male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip NOTE If the humidifier has its own 24 VAC power supply an isolation relay may be required Connect the 24 VAC coil of the isolation relay to the HUM and CO...

Page 38: ...20 115 60 1 127 104 11 8 15 6 12 36 11 0 20 120 22 115 60 1 127 104 11 8 15 6 12 36 11 0 20 Permissible limits of the voltage range at which the unit operates satisfactorily Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other potential operating components EAC humidifier etc full load amps Time delay type is recommended Length shown is as measure...

Page 39: ...minal on Thermostat Strip To HUM Terminal On Furnace Control Board To Humidifier Leads A11157 Fig 33 Field supplied Isolation Relay for Humidifiers with Internal Power Supply W W1 W2 COM Y Y2 R G A11401 Fig 34 Typical Two Stage Field Wiring Diagram 59TP6A ...

Page 40: ... 24 VAC CONNECTIONS 3 AMP FUSE STATUS AND COMM LED LIGHTS SW1 SETUP SWITCHES AND BLOWER OFF DELAY MODEL PLUG CONNECTOR COMMUNICATION CONNECTOR AIR CONDITIONING A C 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 SOFTWARE VERSION A14316 Fig 35 Example of Variab...

Page 41: ...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 36 Thermostat Wiring Diagrams 59TP6A ...

Page 42: ...ap 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...

Page 43: ...Pipe system or Fig 49 for single pipe or 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 manufac...

Page 44: ... See Fig 50 This short inlet air pipe helps to ensure stable combustion as well as allow for sound attenuation To aid sound attenuation point the inlet air pipe away from occupants An extra elbow and or five feet of pipe may be used to accomplish the sound attenuation function OPTIONAL VENTING BELOW THE FURNACE The venting system may be positioned below the furnace ONLY IF the factory accessory Ex...

Page 45: ...n air inlet pipe to the outdoors is not required for a Non Direct single pipe Vent System A 12 in long section of pipe with a tight radius 2 in 51 mm 90 degree elbow is required to be attached to the furnace See Fig 50 This short inlet air pipe helps to ensure stable combustion as well as allow for sound attenuation To aid sound attenuation point the inlet air pipe away from occupants An extra elb...

Page 46: ...ble vent pipe Factory accessory concentric vent terminations or pipe lengths and elbows used for standard vent terminations see vent termination figures associated with Table 15 do not require a deduction from the Maximum Equivalent Vent Length Include a deduction for a Tee when used for Alberta and Saskatchewan terminations NOTE Polypropylene venting systems MAY require additional deductions from...

Page 47: ...d the vent elbow Torque the clamp to 15 lb in See Fig 40 43 Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death To route the vent pipe and combustion air pipe through the furnace the manufacturer supplied kit must be used Failure to properly seal the blower compartment from the fur...

Page 48: ...the vent pipe down to the furnace casing Mark the pipe where it is flush with the outlet of the adapter 3 Remove the pipe from the furnace and the adapter and cut off any excess pipe 4 Clean and prime the end of the pipe that is flush with the vent adapter with a primer that is appropriate for the type of pipe being used 5 Re insert the pipe through the casing into the vent elbow 6 Tighten the cla...

Page 49: ...ssemble loose pipe fittings Clean and cement using same procedures as used for system piping DO NOT CE MENT POLYPROPYLENE FITTINGS 2 Pipe and 1 Pipe Vent Termination NOTE Follow the instructions of the vent terminal manufacturer These instructions are provided as a reference only RECOMMENDED SUPPORT FOR VENT TERMINATIONS It is recommended that sidewall vent terminations in excess of 24 inches 6 M ...

Page 50: ...Cement For ABS D2241 PVC Pipe SDR 21 SDR 26 D2466 PVC Fittings Schedule 40 D2468 ABS Fittings Schedule 40 D2564 For PVC Solvent Cement For PVC D2661 ABS Pipe Fittings DWV at Schedule 40 IPS sizes D2665 PVC Pipe Fittings DWV F438 CPVC Fittings Schedule 40 F441 CPVC Pipe Schedule 40 F442 CPVC Pipe SDR F493 For CPVC Solvent Cement For CPVC F628 ABS Pipe Cellular Core DWV at Schedule 40 IPS sizes F656...

Page 51: ...53 9 44 8 0 20 Ft 20 0 32 0 30 0 22 0 11 0 20 0 70 0 104 0 87 0 67 0 20 0 70 0 124 0 104 0 82 0 M 6 1 9 8 9 1 6 7 3 4 6 1 21 3 31 7 26 5 20 4 6 1 21 3 37 8 31 7 25 0 20 30 Ft 20 0 17 0 14 0 6 0 0 0 20 0 70 0 71 0 57 0 40 0 20 0 70 0 86 0 71 0 52 0 M 6 1 5 2 4 3 1 8 0 0 6 1 21 3 21 6 17 4 12 2 6 1 21 3 26 2 21 6 15 8 40 40 Ft 15 0 7 0 5 0 0 0 0 0 20 0 61 0 52 0 40 0 24 0 20 0 70 0 64 0 50 0 33 0 M ...

Page 52: ...0 119 36 3 210 64 0 235 71 6 NA 80 000 15 4 6 59 18 0 155 47 2 210 64 0 232 70 7 100 000 NA 19 5 8 98 29 9 211 64 3 236 71 9 120 000 NA NA 8 2 4 86 26 2 224 68 3 140 000 4 NA NA NA 79 24 1 158 48 2 4001 to 4500 1219 to 1370 40 000 36 11 0 177 53 9 205 62 5 NA NA 60 000 21 6 4 115 35 1 204 62 2 228 69 5 NA 80 000 14 4 3 56 17 1 150 45 7 202 61 6 224 68 3 100 000 NA 17 5 2 94 28 7 205 62 5 229 69 8 ...

Page 53: ...alent 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 polypropyl...

Page 54: ...000 2438 to 2743 40 000 10 3 0 121 36 9 130 39 6 NA NA 60 000 7 2 1 82 25 0 152 46 3 168 51 2 NA 80 000 NA 35 10 7 111 33 8 148 45 1 156 47 5 100 000 NA NA 67 20 4 157 47 9 170 51 8 120 000 NA NA NA 56 17 1 164 50 0 140 000 4 NA NA NA 23 7 0 42 12 8 9001 to 10 000 2743 to 3048 40 000 5 1 5 110 33 5 115 35 1 NA NA 60 000 NA 76 23 2 142 43 3 156 47 5 NA 80 000 NA 31 9 4 103 31 4 137 41 8 142 43 3 10...

Page 55: ...UTLET VENT ELBOW CLAMP TORQUE 15 LB IN VENT PIPE CLAMP TORQUE 15 LB IN VENT ELBOW INDUCER OUTLET CHOKE 40 000 BTUH MODELS WITH 10 FT 3 1 M OF VENT OR LESS A14277 Fig 38 Inducer Vent Elbow FURNACE PIPE DIAMETER TRANSITION IN VERTICAL SECTION NOT IN HORIZONTAL SECTION A93034 Fig 39 Combustion Air and Vent Pipe Diameter Transition Location and Elbow Configuration 59TP6A ...

Page 56: ...r combustion air connection UPFLOW VERTICAL VENT A11310A Fig 40 Upflow Configuration Appearance May Vary See Notes for Venting Options 1 2 3 4 5 6 7 5 Rotate vent elbow to required position DOWNFLOW LEFT CONFIGURATION A11311A 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 DOWNFLOW RIGHT CONFIGURATION A11312A Requires Acces...

Page 57: ...T RIGHT VENT CONFIGURATION A11329A Fig 42 Horizontal Left Appearance May Vary See Notes for Venting Options ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL RIGHT VERTICAL VENT CONFIGURATION A11337 Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT LEFT VENT CONFIGURATION A11336 ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL RIGHT RIGHT VENT CONFIGURATION A11335 Fi...

Page 58: ... VENT PIPE FLUSH SHOWING COUPLING VENT PIPE FLUSH WITH ADAPTER VENT PIPE ADAPTER WITH GASKET INSTALLED ON FURNACE VENT PIPE IS CUT FLUSH WITH TOP OF ADAPTER PRIME AND CEMENT VENT PIPE TO ADAPTER ALLOW TO DRY BEFORE INSTALLING VENT COUPLING ALIGN NOTCHES IN VENT PIPE 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 A...

Page 59: ...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 Furnace combustion air intake clearance to a water heater vent dryer vent or other types of appliance exhaust 3 ft 9 M 3...

Page 60: ...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 Clearance to a moisture exhaust duct dryer vent spa exhaust etc 12 in 305 mm See Note 4 12 in 305 mm See No...

Page 61: ...r 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 6 in 152mm minimum clearance between wall and end of vent pipe 10 in 254mm maximum pipe lengt h Sidewall Termination with Straight Pipe preferred Roof Termination Preferred Vent Maintain 12 in min...

Page 62: ... 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 ANTICIPATED SNOW LEVEL EXHAUST CLEARANCE TO OVERHANG PER CODE OPTIONAL BRACKET COUPLING 12 IN 305 MM MIN SEPARATION BETWEEN BOTTOM OFCOMBUSTION AIR AND BOTTOM OF VENT A13078 Fig 50 Alberta and Saskatchewan Vent Termination 59TP6A ...

Page 63: ...ipe hangar Ventilated Combustion Air intake termination in crawl space Ventilated Combustion Air intake pipe CRAWL SPACE ATTIC highest level of insulation A10497 Fig 51 Vent Terminations for Ventilated Combustion Air 59TP6A ...

Page 64: ...IGURATIONS A12220 Fig 52 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 53 Optional Combustion Air Inlet Moisture Trap 59TP6A ...

Page 65: ...tup switches that may be set to meet the application requirements Refer to the Adjustments section for setup switch configurations To set these setup switches for the appropriate 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 NOTE If a bypass humidifier is used setup switch SW1 3 Low ...

Page 66: ...ation and long term reliability the Furnace input rate must be within 2 percent of input rate on furnace rating plate or as adjusted for altitude The gas input rate on rating plate is for installations at altitudes up to 2000 ft 609 6M The NATURAL GAS manifold pressure adjustments in Table 21 compensate for BOTH altitude AND gas heating value DO NOT apply an additional derate factor to the pressur...

Page 67: ...witch to OFF position 11 Turn gas supply manual shutoff valve to OFF position 12 Turn off furnace power supply 13 Remove manometer from the inlet pressure tap of the gas valve FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Reinstall manifold pressure tap plug in gas valve to prevent gas leak WARNING 14 Apply pipe dope sparingly to end of inl...

Page 68: ...eating the heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate S Shortened furnace life S Component damage Temperature rise must be within limits specified on furnace rating plate Recommended operation is at midpoint of rise range or slightly above CAUTION When setup switch SW1 4 is ON operation will be near the high end of the rise range for improved comfo...

Page 69: ...sted at a conventional thermostat using the continuous fan speed select function Changing the continuous fan speed at a conventional thermostat DOES NOT change the low speed cooling airflow selected via SW2 at the control board NOTE When the furnace is used with a 2 speed cooling or heat pump unit adjust the Continuous Fan CFM Setup switches SW2 to match the airflow required for low speed cooling ...

Page 70: ...iew Owner s Manual with owner 7 Attach literature packet to furnace ON OFF Switch Regulator Seal Cap Regulator Adjustment Regulator Seal Cap under Cap 1 2 NPT Outlet 1 8 NPT Manifold Pressure Tap 1 8 NPT Inlet Pressure Tap 1 2 NPT Inlet TWO STAGE A11152 Fig 54 Gas Valve BURNER ORIFICE A93059 Fig 55 Orifice Hole R Y W G 10 TURNS THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOC...

Page 71: ...71 A14317 Fig 57 Service Label Information 59TP6A ...

Page 72: ...d See kit instructions for further directions on installation and setup Allows additional CFM per ton selections when used with SW 1 5 325 CFM per ton nominal when SW 2 2 ON and SW 1 5 OFF 350 CFM per ton nominal when SW 2 2 OFF and SW 1 5 OFF 370 CFM per ton nominal when SW2 2 ON and SW 1 5 ON 400 CFM per ton nominal when SW 2 2 OFF and SW 1 5 ON See Air Delivery Tables for model specific CFM vs ...

Page 73: ...9 138 346 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 74: ...44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 4000 900 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 1219 925 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 950 45 3 7 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 750 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 4001 775 43 3 7 1 6 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 1220 800 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 825 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 ...

Page 75: ... 1 4 8000 775 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 2438 800 45 3 8 1 6 44 3 2 1 4 44 3 3 1 4 44 3 4 1 4 825 46 3 7 1 6 46 3 8 1 6 45 3 8 1 6 44 3 2 1 4 625 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 42 3 7 1 6 8001 650 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 42 3 4 1 4 2439 675 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 42 3 2 1 3 700 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 725 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 44...

Page 76: ...ch is 0 68 in W C The minimum break point of the switch is 0 63 in W C The maximum break point of the switch is 0 73 in W C The maximum make point of the switch is 0 83 in W C ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death There may be more than one electrical supply to the furnace Check accessories and cooling unit for additional electrical supplie...

Page 77: ...hen back ON e 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 furnace such as 1 Spray or aerosol c...

Page 78: ...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 routing 4 If the vent and combustion air pipe passes through the blower compartment it will be necessary to remo...

Page 79: ...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 Remove individual wires from terminals on gas valve 7 Disconnect Hot Surface Igniter HSI wires from HSI 8 Disconnect Flame Sensor wire from Flame Sensor 9 Support the manifold and remove th...

Page 80: ...nace 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 collector box opening or water will flow out of tube 4 Remove the collector box plug from the top port on the up per corner of the collector box See Fig 61 5 Attach a funnel with a flexible tube to port on the collector...

Page 81: ...property damage Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death...

Page 82: ...emove furnace control door 4 Remove the top unused rubber plug from the port on the collector box opposite the condensate trap See Fig 61 5 Connect a field supplied 3 8 in 9 5 mm ID tube to the open port on the collector box 6 Insert a field supplied funnel into the tube 7 Pour 1 quart of anti freeze solution into the funnel tube Antifreeze should run through the inducer housing overfill condensat...

Page 83: ...83 A11273 Fig 62 Cleaning Heat Exchanger Cell Burner Flame Burner Manifold A89020 Fig 63 Burner Flame 59TP6A ...

Page 84: ...CKET 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 64 Blower Assembly FLAME SENSOR BELOW BURNER FLAME ROLLOUT SWITCH BRACKET IGNITER IGNITER BURNER SUPT ASSY BURNER ASSY A11403 Fig 65 Burner Assembly 59TP6A ...

Page 85: ...igh heat gas valve solenoid GV HI is energized The furnace control CPU begins a 15 second prepurge period after the low heat pressure switch LPS closes If the high heat pressure switch HPS fails to close and the low heat pressure switch LPS closes the furnace will operate at low heat gas flow rate until the high heat pressure switch closes for a maximum of 2 minutes after ignition b Igniter Warm U...

Page 86: ...gle stage thermostat NOTE The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to a call for cooling See Fig 35 When ACRDJ is 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...

Page 87: ... at high cooling airflow When the thermostat is satisfied the blower motor BLWM will operate an additional 90 seconds at high cooling airflow before transitioning back to continuous blower airflow When the R to G circuit is opened the blower motor BLWM will continue operating for an additional 5 seconds if no other function requires blower motor BLWM opera tion Continuous Blower Speed Selection fr...

Page 88: ...G 24V thermostat signals Run system through a low heat high heat or cooling cycle to check operation 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 Is 24V present at W W1 W2 Y1 Y Y2 or G thermostat terminals on the furnace control Check room thermostat or ...

Page 89: ...UTRAL L2 on the control Was 115V present for the 15 second period Check connections and retry If current is near typical value 4 0 6 0 nominal and burners will not stay on repeat check in high heat If burners will still not stay on replace control If burners operate in high heat then switch to low heat check manifold pressure If OK check burner carryover and flame sensor location Clean flame senso...

Page 90: ...90 A14370 Fig 67 Wiring Diagram 59TP6A ...

Page 91: ...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 92: ...S 7310 W Morris St S Indianapolis IN 46231 Edition Date 07 14 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No 59TP6A 02SI Replaces 59TP6A 01SI 59TP6A ...

Search results

Summary of Contents for 59TP6A

Reviews:

Related manuals for 59TP6A

Brands by name

Popular brands

Carrier 59TP6A, Installation, Start-Up, Operating And Service And Maintenance Instructions

Search results

Summary of Contents for 59TP6A

Reviews:

Related manuals for 59TP6A

Brands by name

Popular brands