Carrier 045-08/024045, Installation, Start-Up, Operating And Service And Maintenance Instructions

Page 1: ...n lit Bottom Return Air Inlet lit Side Return Air Inlet lit Leveling Legs If Desired lit Downflow Installation 1It Bottom Return Air Inlet 11 Horizontal Installation 12 Suspended Unit Support 12 Platlorm Unit Support 12 Roll Out Protection 12 Bottom Return Air Inlet 13 Side Return Air Inlet 13 Filter Arrangement 13 Air Ducts 13 General Requirements 13 Ductwork Acoustical Treatment 13 Supply Air Co...

Page 2: ...azardous due to gas and electrical components Only trained and qualified personnel should install repair or service heating equipment Untrained personnel can perlkmn basic maintenance limctions such as cleaning and replacing air filters All other operations nmst be perlbrmed by trained service personneh When working on heating equipment observe precautions in literature on tags and on labels attac...

Page 3: ... is factory shipped liar use with natural gas A CSA listed gas conversion kit is required to convert limmce liar use with propane gas 11 See Fig 2 lot required clearances to combustible construction 12 Maintain a 1 in clearance from combustible materials to supply air ductwork lot a distance of 36 inches horizontally li om the furnace See NFPA 90B or local code liar lurther requirements 13 These l...

Page 4: ...nimum d espace libre des mat iaux combustibfas tel Vent Clearance to combustibles qulndique sur fa diagramme ForSingleWail venis 6 inches 6 po Cette foumaise peut _tre uti isee ave un ForType B 1venttype 1inch 1po Degagement de l ent avec combustibles conduit d evacuation de Type Bq ou connectee Pourcondui_d evacuationa paroisimple6po 6 inches au conduit ommun d autres appareils a gaz Pourconduitd...

Page 5: ...hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electrostatic potential 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DIS CHARGING YOUR BODY S ELECTROSTAT...

Page 6: ...th indoor pools Laundry rooms Hobby or el all rooms and Chemical storage areas If air is exposed to the lollowing substances it should not be used lkwcombustion air and outdoor air may be required lot conlbus tion Permanent wave solutions Chlorinated waxes and cleaners Chlorine based swinnning pool chemicals Water soflening chenficals De icing salts or chemicals Carbon tetrachloride Halogen type r...

Page 7: ...n ust 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 n ust prevent chilled air li om entering the furnace If the dampers are manually operate they must be equipped with means to prevent operation of either unit unless the damper is in the full heat or lull cool posi...

Page 8: ...utdoors a One opening MUST commence within 12 300 ram of the ceiling and the second opening MUST colnmence within 12 300 rain of the floor b Size openings and ducts per Fig 7 and Table 2 c TWO HORIZONTAL DUCTS require 1 square inch of free area per 2 000 Btuh l lO0 nnn2 kW of cembined input R r all gas appliances in the space per Fig 7 and Table 2 d TWO OPENINGS OR VERTICAL DUCTS require 1 square ...

Page 9: ...ACE 6 MIN FRONT t z_ 1SQIN Lu PER 1000 rr a_ BTUH IN DOOR O __ ORWALL iii L12 MAX Minimum opening size is 100 sq in with minimum dimensions of 3 in tMinimum of 3 in when type B1 vent is used A03175 Fig 8 Air for Combustion Ventilation and Dilution from Indoors l lo combined input ol all other than fan assisted appli ances in Btu hr lh combined input of all fan assisted appliances in Btu hr ACH air...

Page 10: ...ir opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perlorm the lollowing 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs Fig 10 Leveling Legs A89014 10 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws Side Return Air Inlet These...

Page 11: ...hown in Fig 13 NOTE It is recommended that the perlbrated supply air duct flanges be completely fblded over or removed li om furnace when installing the fimlace on a factory supplied cased coil or coil box To remove the supply air duct flange use wide duct pliers or hand seamers to bend flange back and lbrth until it breaks off Be careful of sharp edges See Fig 14 II Bottom Return Air Inlet These ...

Page 12: ...re to lk llow this walTning could result in personal injury death and or property damage Do not install the furnace on its back or hang lklrnace with control compamnent facing downward Sali ty control opera tion will be adversely al_i cted Never connect return air ducts to the back of the furnace The lurnace can be installed horizontally in an attic or crawl space on either the leli hand LH or rig...

Page 13: ...tenz s De sign G id_ lines rclierence tables available li om your local distributor The duct system should be sized to handle the required system design CFM at the design external static pressure The furnace airflow rates are provided in Table 5 AIR DELIVERY CFM With Filter When a lk_rnace is installed so that the supply ducts carry air circulated by the lin nace to areas outside the space contain...

Page 14: ...e connected to ONLY the limmce supply outlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the accessory subbase KGASB0201ALL or a factory approved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or other accesso ries All accessories MUST be connected to duct external ...

Page 15: ... AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES Fig 16 Horizontal Suspension with Straps LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING 17 3 4 OVER ALL 4 3 4 UNDER DOOR 1 UNDER FURNACE EXTEND OUT 12 OUT FROM FACE OF DOOR A03176 30 IN MIN WHEN USED WITH SINGLE WALL VENT CONNE...

Page 16: ... 1950 1910 1855 1795 1730 1650 Low 1730 1695 1650 1600 1535 1470 High 1625 1575 1515 1445 1355 1260 Med High 1510 1470 1415 1355 1285 1185 Med Low 1360 1335 1295 1250 1180 1100 Low 1195 1180 1155 1115 1085 980 High 2035 1965 1880 1790 1680 1495 Med High 1745 1710 1650 1560 1450 1340 Med Low 1530 1515 1470 1400 1310 1215 Low 1270 1265 1235 1195 1130 1055 High 2530 2470 2400 2320 2220 2115 Med High ...

Page 17: ... be made in accordance with all authorities having jurisdiction If possible the gas supply line should be a separate line running directly l om meter to lurnace NOTE In the state of Massachusetts 1 Gas supply connections MUST be perlormed by a licensed plumber or gas fitter 2 When flexible connectors are used the maxiumm length shall not exceed 36 inches 915 ram 3 When lever handle type manual equ...

Page 18: ... MODELS ALL OTHER MODELS YES NO NO suPPLY AIR RETURN AIR RETURN AIR CONNECTION 3 COMBINATIONS ONLY OF 1 2 AND 3 NO NO NO Fig 19 Downflow Return Air Configurations and Restrictions A02163 RETURN AIRFtOWMODELS i J IIII li o 2 IIII _ _ IIII z_ IIII j orP RMIrr_r FORi 066 C _0 22 0 i AIR F_OW MODELS i i RE_ URN AIR _ ORIZOAL NOTE RESTRICTIONLEFT SAM Q _ AIR Rf S _IC IO S HORIZONTAL RETURN AIR CONFIGUR...

Page 19: ...TOFF J_ VALVE REQUIRED f J_ SEDIMENT t TRAP UNION J A02035 Fig 21 b Typical Gas Pipe Arrangement Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada local and national plumbing and gas codes beik_re the furnace has been connected After all connections have been made purge lines and check liar leakage at furnace prior to operating furnace If ...

Page 20: ...lding J Box See Fig 22 NOTE The J Box cover need not be removed fl om the J Box in order to move the J Box Do NOT remove green ground screw inside J Box The ground screw is not threaded into the casing flange and can be lifted out of the clearance hole in casing while swinging the front edge of the J Box outboard of the casing 2 Cut wire tie on loop in furnace wires attached to J box 3 Move J Box ...

Page 21: ...s as shown in Fig 25 6 Reinstall cover to J Box Do not pinch wires between cover and bracket 24 V WIRING Make field 24 v connections at the 24 v terminal strip See Fig 23 Connect terminal Y Y2 as shown in Fig 24 lot proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during i...

Page 22: ...0 V WIRING FACTORY 24 V WIRING FACTORY 115 VWIRING NOTE 2 F VEWIRE THREE WIRE _ _ _ I I L HEATING ONLY _ _ _G_i i BLOWER DOOR SWITCH _ _ c i N I 115 V FIELD AUXILIARY O SUPPLIED J BOX L DISCONNECT 24 _ TERMINAL BLOCK FURNACE NOTE 1 THERMOSTAT _ _ TERMNALS I L I I I I I FIELD SUPPLIED DISCONNECT ii iiiiiii iiiiiiii_i_ i CONDENS NG L TWO UNIT WIRE 208 230 OR 460 V THREE PHASE 208 230 V SINGLE PHASE ...

Page 23: ...c pmssurc to minimize the potential lbr vent gas leakage Category 1 lhrnaces operate with a flue loss not less than 17 percent to minimize the potential lbr condensation in the venting system These furnaces are approved lot common venting and multistory venting with other fan assisted or drali hood equipped appliances in accordance with the NFGC or the NSCNGPIC the local building codes and lurnace...

Page 24: ... _ HUM z_ _ l UM D F ER t i 24 MAC OUTDOOR SENSOR See notes 2 5 8 and 10 on the page following these figures RVS COOLING N A _ HEAT STAGE 2 FURNACE HEAT COOL STAGE 1 COMPRESSOR FAN _ 24 VAC HOT _ DEHUMIDIFY _ 24 VAC COMM _ HUMIDIFY _ N A _ OUTDOOR _ 2_ coS_ 2_ _ HUM HOM D F ER 24 VAC page following these figures A04217 Fig 28 Single Stage Furnace with Single Speed Heat Pump Dual Fuel THERM D STAT ...

Page 25: ...tage Furnace and Single Speed Heat Pump RVS COOLING HEAT COOL STAGE 1 COMPRESSOR LO HEAT COOL STAGE 2 COMPRESSOR HI FAN _ 24 VAC HOT _ 24 VAC COMM _ RVS SENSING _ OUTDOOR _ _ coS_ _ _ 7 f i i i See notes 1 2 3 4 11 12 and 14 on the page following these figures A04220 Fig 31 Dual Fuel Thermostat with Single Stage Furnace and Two Speed Heat Pump TWO STAGE SINGLE STAGE TWO SPEED THERMOSTAT FURNACE AI...

Page 26: ...tory default 7 Dip switch No 2 on Thermidistat should be set in ON position lk_rtwo speed compressor operation 8 Configuration Option No 10 Dual Fuel Selection nmst be turned ON in all dual fuel applications 9 NO connection should be made to the lin nace HUM terminal when using a Thermidistat 10 The RVS Sensing terminal should not be connected This is internally used to sense del_ ost operation 11...

Page 27: ...he annular space between the cbinmey and the metal liner Exterior Masonry Chimney FAN NAT installations with Type B Double WaJJ Vent Connectors NFPA AGA Table A Combined Appliance Maximum input Rating in Thousands of BTU per Hour iNTERNAL AREA OF CHIMNEY VENT HEIGHT FT SQ IN 6 8 10 15 20 30 38 74 119 178 257 80 130 193 279 84 138 207 299 NR 152 233 334 NR NR 250 368 NR NR NR 404 o 2 o o T Table B ...

Page 28: ...due r liner _ Clay tile misalignment missing sections gaps No Condensate drainage at bottom of chimney Chimney exposed to outdoors below roof line No Chimney is acceptable for use Yes Suitable I _ _ _ _ _ Line chimney with property Suttable _ __v _ I bulTaDle sized listed flexible metal _ _ _ _ _ _ _ V Ye_ I liner orType B vent per _ype 15 vent s _ NFGC or NSCNGPIC Ven _ _ Sizing Tables and liner ...

Page 29: ...e extension is used fasten the flue extension to the vent elbow with at least two field supplied_ corrosion resistant sheet metal screws located 18 apart Fasten the vent connector to the flue extension with at least two lield supplied corrosion resistant sheet metal screws located 18 apart 2 Vent the furnace with the appropriate connector as shown in Fig 34_ 6 CUT HAZARD Failure to ff_llow this ca...

Page 30: ...he pages following these figures A03209 Fig 35 Upflow Application Vent Elbow Right SEE NOTES 1 2 4 5 6 7 8 9 10 on the page following these figures Fig 38 Downfiow Application Vent Elbow Left then A03207 SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures Fig 36 Downfiow Application Vent Elbow Up then Left A03210 SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures Fig 39 Downfi...

Page 31: ... 4 7 8 9 on the page following these figures Fig 44 Horizontal Right Application Vent Elbow Right A03218 SEE NOTES 1 2 4 5 7 8 9 on the page following these figures Fig 42 Horizontal Left Application Vent ElboA _ 5 SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03216 Fig 43 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 on the page following these figures Fig 45...

Page 32: ...rnal to the furnace 6 Accessory Downflow Vent Guard Kit KGAVG0101DFG required in downflow installations with lower vent configuration 7 Chimney Adapter Kit may be required lot exterior masonry chimney applications Rel_ r to Chimney Adapter Kit KGACA 12014FC or KGACA02015FC Ibr sizing and complete application details 8 Secure vent connector to furnace elbow with 2 corrosion resistant sheet metal sc...

Page 33: ...sali ty glasses and gloves when handling parts and servicing furnaces 1 Maintain l lS v wiring and ground hnproper polarity will result in rapid flashing LED and no furnace operation 2 Make thermostat wire connections at the 24 v terminal block on the furnace control Faihn e to make proper connections will result in improper operation See Fig 25 3 Gas supply pressure to the lilrnace must be greate...

Page 34: ...nproper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in l ame impingement of heat exchangers causing failures See Fig 53 Furnace gas input rate on rating plate is li_r installations at altitudes up to 2 t t t It Furnace input rate must be within _ 2 percent of furnace rating plate input For altitudes above 5500 It a field ...

Page 35: ...li om gas valve See Fig 52 c Connect a water cohlnln manon_eter or similar device to manifl ld pressure tap d Turn gas valve N OFF switch to ON e Manually close blower door switch f Set thermostat to call lk_r heat 35 g Remove regulator seal cap and turn regulator adjusting screw counterclockwise out to decrease input rate of clockwise in to increase input rate h Install regulator seal cap i Leave...

Page 36: ...s valve ON OFF switch to ON FURNACE OVERHEATING HAZARD Failure to this caution u ay result in 17educed l_ trnace lilk Recheck ten perature rise It nmst be within liudts specified on the rating plate Reconnnended operation is at the mid point of rise range or slightly above 6 Set theru ostal heat anticipator a Mechanical thern ostat Set thermostat heat anticipator to match the an p draw of the elec...

Page 37: ...s disconnected shut down l_lrnace immediately e Determine reason pressure switch did not lunction properly and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace outer door and turn on 115 v power 37 Table 10 GAS RATE CU FT HR SECONDS SIZE OF TEST DiAL SECONDS SIZE OF TEST DiAL FOR 1 1 2 5 FOR 1 1 2 5 REVOLUTION Cu Ft Cu Ft Cu Ft REVOLUTION iCu Ft Cu Ft Cu ...

Page 38: ... 3 2 42 3 3 3 7 43 3 8 43 3 6 43 3 5 43 3 3 43 3 2 0 60 0 62 0 64 Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure 42 I 3 4 42 I 42 I 3 2 42 I 43 I 3 7 43 43 I 3 5 43 43 I 3 3 43 43 I 3 1 43 43 I 2 9 43 43 I 2 8 43 43 I 2 6 43 0 58 Orifice Manifold No Pressure 3 5 42 3 3 42 3 8 42 3 6 43 3 4 43 3 2 43 3 3 3 0 43 3 1 2 9 43 3 0 2 7 43 2 8 3 6 42 3 7 3 4 42 3 5 ...

Page 39: ... 43 43 43 43 43 43 43 SPECIFIC 0 60 Orifice No 43 43 43 43 43 43 43 43 SPECIFIC 0 60 Orifice No 43 43 43 43 43 43 43 43 SPECIFIC 0 60 Orifice No 43 43 43 43 43 43 48 675 700 725 750 778 800 828 850 AVG GAS HEAT VALUE AT ALTITUDE BTU CU FT 0 62 Manifold Pressure 3 6 3 4 3 1 2 9 2 7 2 6 2 4 2 3 Manifold Pressure ALTITUDE RANGE FT Orifice No 43 3 2 43 43 3 0 43 43 2 8 43 O 7001 to 43 2 6 43 _ 8000 43...

Page 40: ...ELECTRICAL SHOCK HAZARD Failure to RUlow 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 fl r addifional electrical supplies that nmst be shut o11 during li rnace servicing The electrical ground and polarity R r l15 v wiring n ust be properly maintained Reli r to Fig 25 lot field wiring inlormation...

Page 41: ... Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure 3 5 3 3 3 8 3 7 3 5 3 3 3 2 3 4 3 3 0 64 Orifice Manifold No Pressure 43 I 3 8 42 3 2 42 3 3 42 43 I 3 5 i 43 3 7 43 3 8 42 431 3 3 i43 3 5 43 3 6 43 431 3 2 i 43 3 3 43 3 4 43 431 3 0 i 43 3 1 43 3 2 43 431 2 8 i 43 2 9 43 3 0 43 431 2 7 i 43 2 8 43 2 9 43 43 I 2 5 43 2 6 43 2 7 43 43 I 2 4 i 43 2 5 43 2 6 43 SPECIFIC...

Page 42: ...ld Pressure 3 1 2 9 2 7 2 5 2 3 2 2 2 1 3 7 0 58 Manifold Pressure 2 9 2 7 2 5 2 3 2 1 2 0 3 6 3 3 0 58 Manifold Pressure 2 7 2 5 2 3 2 1 3 7 3 5 3 8 O 8001 to 9000 0 60 Orifice Manifold No Pressure 43 3 2 43 3 0 43 2 8 43 2 6 43 2 4 43 2 3 43 2 1 43 2 0 0 62 Manifold Pressure 43 3 3 43 3 1 43 2 9 43 2 7 43 2 6 43 2 4 43 2 3 43 2 1 NATURAL GAS 0 62 Orifice Manifold No Pressure 43 43 43 43 43 43 43...

Page 43: ... to the Corn 24V terminal Status LED component test The hot surface ignitor blower motor fan speed on AMBER LED boards will flash code and then turn ON the inducer motor The klducer motor will run for the entire only blower motor heat speed and blower motor cool speed will be turned ON for 1o 15 I seconds each Gas Valve and Humidifier will riot be turned on 327596 1 01 REV B 31 PRESSURE SWITCH DID...

Page 44: ...e sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency 6 Inspect any accessories attached to the lilrnace such as a humidifier or electronic air cleaner Perlbml any service or 44 Table 13 FiRer Size information iN FURNACE CASING WIDTH 14 1 2 17 1 2 21 24 Recommended FILTER SIZE Side Return Bottom Return 16X25X1 14X25X1 16X25X1 16X25X1 16X25X1 20X25X1 ...

Page 45: ...wheel by hand to verify that the wheel does not rub on the housing 15 Reinstall blower assembly in lurnace 16 Reinstall control box assembly in li rnace 45 UNIT DAMAGE HAZARD Failure to lk llow this caution may result in shortened heat exchanger lile Heating fan speed s MUST be adjusted to provide proper air temperature rise as specified on the rating plate Rec m mended operation is at the midpoin...

Page 46: ...TOR SHADED POLE IDR INDUCED DRAFT _TOR RELAy SPST N O _ FIELD WiRiNG SCREW TERMINAL ILK BLOWER ACCESS PANEL INTERLOCK SWITCH S PST N O _ FIELD EARTH GROUND J1 BLOWE R _OFF DELAY JUMPER SELECTOR O jB JUNCTION BOX _ EQUIPMENT GROUND LED UGHT EMITTING DIODE FOR STATUS CODES AMBER _ FIELD SPUCE o wisP i URi SPSi i ODD i o I E A O0 OO_ 115VAC FIELD _S ONNECT SW1TCH SCHEMATIC DIAGRAM NA JRAL PAOPANE GA_...

Page 47: ...en hammer TIGHTNESS 1S VERY IMPORTANT NOTE The materials needed in item 9 can usually be purchased at local hardware stores 47 l Attach variable speed reversible drill to the end of spring cable end opposite brush 2 Insert brush end oI_cable into the outlet opening of cell and slowly rotate with drill DO NOT lorce cable Gradually insert cable into upper pass oI_celh See Fig 59 3 Work cable in and ...

Page 48: ... second prepurge period b Igniter Warm Up At the end of the prepurge period the Hot Surlhce igniter HSI is energized r a 17 second igniter warn up period c Trlal for lgnltlon Sequence When the igniter warn up period is completed the main gas valve relay contacts GVR close to energize the gas valve GV the gas valve opens and 24 vac power is supplied r a field installed humidi fier at the HUM termin...

Page 49: ...ooling is satisfied and there is a demand liar dehumidification the cooling blower off delay is decreased fi om 9 1 seconds to 5 seconds 4 Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on continuous blower speed can be adjusted to FAN HEAT or COOL speed at the thermostat Factory default is FAN speed Terminal EAC I is energized as long...

Page 50: ...delay If the R to W and Y Y2 and G or R to W and Yl and Y Y2 and G signals disappear at the same time the blower l flotor BLWM will remain on _ rthe selected blower OFF delay period If the R to W and Y Y2 or R to W and Yl and Y Y2 signals disappear leaving the G signal the blower motor BLWM will remain on lot the selected blower OFF delay period then switch to continuous blower speed Step 4 Wiring...

Page 51: ...can also recall the previous status code by momentarily shorting the TEST TWIN terminal to Com24V terminal until the LED goes ouL LED will flash the status cede of the previous fault or status code 11 1 short and 1 long flash if there was no previous fault After the control repeats the code 4 times the control will go through a brief component test sequence The inducer will start and run for the e...

Page 52: ...or Inadequate combustion air supply flame rollout switch open Restricted vent Proper vent sizing Excessive wind 34 IGNITION PROVING FAILURE If flame is not sensed during the trial for ignition period the control will repeat the ignition sequence 3 more times 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 Chec...