Carrier 100/A Series, Installation, Start-Up, Operating And Service And Maintenance Instructions

Page 1: ...4 Gas Piping 17 115 V Wiring 22 START UP ADJUSTMENT AND SAFETY CHECK 36 General 36 Start up Procedures 36 Adjustments 36 Check Safety Controls 39 Checklist 40 SERVICE AND MAINTENANCE PROCEDURES 43 Introduction 43 Care and Maintenance 46 Sequence of Operation 49 Wiring Diagrams 51 Troubleshooting 51 iso 9001 2000 NOTE Read the entire instruction manual before starting the installation Portions of t...

Page 2: ...19 1 2 495 13 5 16 338 4 102 150 68 20 508 110 20 060110 21 533 19 3 8 492 19 1 2 495 13 5 16 338 4 102 162 73 20 508 135 20 060135 24 1 2 622 22 7 8 581 23 584 15 1 16 383 4 102 173 78 24 610 5 in or 6 in 127 or 152 mm vent connector may be required in some cases SAFETY CONSIDERATIONS FIRE EXPLOSION ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result ...

Page 3: ...space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace See Air Ducts section 8 A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in the Location section 9 The furnace may be used for construction heat provided that the furnace insta...

Page 4: ...0m 0 10 000 pi Utiliser one trousse de conversion foumie par le fabricant pour passer au gaz propane ou pour certaines installationsau gaz natural Cettefuumaise est pr6vue pour 6be instaHeedans un b timent construitsur piece Cettefuumaise peut _tre instam6e sur plancher combustible dans une alcSve ou darts un garde robe en raspectant le minimum d espaca libra des mat6riaux combustibles tel qu indi...

Page 5: ...23 1 2006 Chapters 12 and 13 CANADA CAN CSA BI49 1 05 Part 8 and Appendix C ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation an...

Page 6: ...s section be provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustible label The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures Commercial buildings Buildings with indoor pools Laundry rooms Hobby or craft rooms and Chemical storage areas CARBON MONOX...

Page 7: ...It also prevents the entrainment of drywall dust into combustion air which can cause fouling and plugging of furnace components The temperature of the return air to the furnace is maintained between 55 F 13 C and 80 F 27 C with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be internfittent operation per our installation instructions Th...

Page 8: ...uipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion ventilation and dilution air must be provided in accordance with U S installations Section 9 3 of the NFGC NFPA54 ANSI Z223 1 2006 Air for Combustion and Ventilation and applicable provisions of the local building co...

Page 9: ...rnace combustion air supply must be provided in accordance with this instruction manual The Standard Method 1 The space has no less volume than 50 cubic feet per 1 000 Btuh of the maximum input ratings for all gas appliances installed in the space and 2 The air infiltration rate is not known to be less than 0 40 air changes per hour ACH The Known Air Infiltration Rate Method shall be used if the i...

Page 10: ...ed as follows a Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method below BOTTOM FILLER PANEL I I1 BOTTOM CLOSURE PANEL A02098 Fig 9 Removing Bottom Closure Panel b Outdoor opening size reduction Factor is 1 nfinus the Ratio in a above c Minimum size of Outdoor openings shall be the size required in Outdoor Combustion Air Method above nmltipli...

Page 11: ...TE It is recommended that the perforated supply air duct flanges be completely folded over or removed from furnace when installing the furnace 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 forth until it breaks off Be careful of sharp edges See Fig 14 Bottom Return Air Inlet These furnaces are shipped ...

Page 12: ...FURNACE APPROVED COIL ASSEMBLY OR COIL BOX COMBUSTIBLE _ FLOORING I SHEET METAL _ PLENUM FLOOR OPENING i Fig 13 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor A08556 12 ...

Page 13: ...erty 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 The furnace can be installed horizontally in an attic or crawl space on either the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or trusses or ...

Page 14: ...and sealed to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in 25 ram clearance from combustible materials to supply air ductwork for a distance of 36 in 914 ram horizontally from the furnace See NFPA 90B or local code for further requirements Ductwork Acoustical Treatment NOTE Metal duct systems that do not have a 90 degree elbow and 10 ft 3 ...

Page 15: ...020 il 4 6mm THREADED ROD 4 REQ 8 203mm MIN FOR DOOR REMOVAL SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 8 xS 4 t9mm SCREWS TYPICAL FOR 2 SUPPORTS 1 25ram SQUARE 1 1 4 xl 1 4 xl 8 32x32x3mm ANGLE IRON OR UNFSTRUT MAY BE USED 2 HEX NUTS 2 WASHERS 2 LOCK WASHERS REQ PER ROD Fig 15 Horizontal Unit Suspension A05027 15 ...

Page 16: ...TAL SCREWS 12SCREWS IN SIDE AND 2 SCREWS IN BOTTOM AIR OPENING Fig 16 Horizontal Suspension with Straps A03176 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 EQUIPMENT MANUAL SHUT OFF GAS VALVE SEDIMENT UNION TRAP ENTRY VENT Fig 17 Typical Attic Installation 17 3 4 451 mm OVERALL 4 3 4 121mm UN...

Page 17: ...mum of 2 in 51 mm outside the furnace Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S the CAN CSA B149 1 05 in Canada Installations must be made in accordance with all authorities having jurisdiction If possible the gas supply line should be a separate line running directly from meter to furnace NOTE In the state of Massachusetts...

Page 18: ...ded 3 4 in 19 mm washable filter media such as contained in factory authorized accessory filter rack To determine airflow performance without this filter assume an additional 0 1 in wc available external static pressure Indicates unstable operating conditions Table 6 Maximum Capacity of Pipe NOMINAL iRON iNTERNAL LENGTH OF PiPE FT M PiPE DIAMETER SIZE IN mm In mm 10 20 30 40 50 1 2 13 0 822 16 175...

Page 19: ...ALL OTHER MODELS YES YES YES YES P TO Fig 18 Upflow Return Air Configurations and Restrictions A02075 il 1_ RETURN AIR RETURN AIR DOWNFLOWRETURNAIRCONFIGURATIONSAND RESTRICTIONS AiR FLOW MODELS RETURN AIR RETURN AIR RETURN AiR RETURN AIR CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1 2 AND 3 066 060 22 AND YES NO NO NO 20 MODELS ALL OTHER MODELS YES NO NO NO Fig 19 Downflo...

Page 20: ...NTAL RETURN AiR CONFiGURATiONS AND RESTRiCTiONS AiR FLOW MODELS RETURN AiR RETURN AIR RETURN AiR RETURN AIR CONNECTION 1 CONNECTION 2 CONNECTION 3 COMBINATIONS ONLY ONLY ONLY OF 1 2_ AND 3 066 060 22 AND YES NO NO NO 20 MODELS ALL OTHER MODELS YES YES YES YES Fig 20 Horizontal Return Air Configurations and Restrictions A02162 TOP VIEW OF BURNER AND MANIFOLD ASSEMBLY 90 Elbow Gas Supply 2 51 mm Nip...

Page 21: ... Pipe Arrangement A02035 ELECTRICAL CONNECTIONS ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal iniury or death Blower access panel door switch opens l15 v power to control No component operation can occur Do not bypass or close switch with panel removed See Fig 25 for field wiring diagram showing typical field 115 v wiring Check all factory and field electrical con...

Page 22: ... 1 5 Route J Box wires within furnace away from sharp edges rotating parts and hot surfaces ELECTRICAL CONNECTION TO J BOX Field Supplied Electrical Box on Furnace J Box Bracket See Fig 23 1 Remove cover from furnace J Box 2 Attach electrical box to furnace J Box bracket with at least two field supplied screws through holes in electrical box into holes in bracket Use blunt nose screws that will no...

Page 23: ...is required use ONLY a 3 amp fuse of identical size ACCESSORIES 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using l 4 in female quick connect terminals to the two male l 4 in quick connect terminals on the control board marked EAC I and EAC 2 The terminals are rated for 115 VAC 1 0 amps maximum and are energized during blower motor operation See Fig 24 2 Humidi...

Page 24: ...rnace Control PL1 LOW VOLTAGE DRAIN HARNESS CONNECTOR PL2 HOT SURFACE IGNITER INDUCER MOTOR CONNECTOR A08063 FIELD 24 V WIRING FIELD 115 208 230 460 VWIRING FACTORY 24 VWIRING FACTORY 115 V WIRING TERMINAL BLOCK FURNACE NOTES 1 2 3 ConnectY terminal in furnace as shown for proper blower operation Some thermostats require a C terminal connection as shown If any of the original wire as supplied must...

Page 25: ...ith ANSI Z21 47 2006 CSA 2 3 2006 and operate with a non positive vent static pressure to nfininfize the potential for vent gas leakage Category I furnaces operate with a flue loss not less than 17 percent to nfininfize the potential for condensation in the venting system These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances...

Page 26: ...7 Fig 28 Single Stage Furnace with Single Speed Heat Pump Dual Fuel THERMIDISTAT SINGLE STAGE TWO SPEED FURNACE AIR CONDITIONER THERMIDISTAT SINGLE STAGE TWO SPEED FURNACE HEAT PUMP N A 2_ COOL STAGE 1 HEAT STAGE 1 COOL STAGE 2 FAN _ 24 MAC HOT _ DEHUMIDIFY _ 24 VAC COMM _ HUMIDIFY _ N A _ s_T o _ CONNECT ON L 2_ E2_ E2_ E2_ __ I HUM 24 MAC OUTDOOR SENSOR i See notes 2 5 8 and 10 on the page follo...

Page 27: ...r equipment Installation Instructions for additional information and setup procedure 3 Outdoor Air Temperature Sensor nmst be attached in all dual fuel applications 4 Dip switch No 1 on Thermidistat should be set in OFF position for air conditioner installations This is factory default 5 Dip switch No 1 on Thermidistat should be set in ON position for heat pump installations 6 Dip switch No 2 on T...

Page 28: ...xterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors NFPA AGA Table 8 Combined Appliance Maximum Input Rating in Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY VENT HEIGHT FT M 6 1 8 8 2 4 10 3 0 15 4 5 20 6 0 30 9 1 12 7741 74 8O 84 NR NR NR IN 2 MM 2 19 28 12258 18064 119 178 130 193 138 207 152 233 NR 250 NR NR 38 24518 257 279 299 334 388 404 Table 9 Minim...

Page 29: ...Remove mortar and tile debris Clay tile misalignment missing sections gaps No Condensate drainage at bottom of chimney No Chimney exposed to outdoors below roof line No Yes i_ _Not Suitable _No _ instructions for J A_ J _ _ application __ i_ _ _ _ _l _ V_ Line chimney with property bultaDle _ _ _ Y _ I bu aD e sized listed flexible metal _ z__ _u _ _ U _Yes I liner or Type B vent per NFGC or NSCNG...

Page 30: ... furnace casing If flue extension is used fasten the flue extension to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart Fasten the vent connector to the flue extension with at least two field supplied corrosion resistant sheet metal screws located 180 apart 2 Vent the furnace with the appropriate connector as shown in Fig 34 46 CUT HAZARD Fai...

Page 31: ...8 Fig 34 Upflow Application Vent Elbow Up A03210 Fig 36 Downflow Application Vent Elbow Up then Left f_ SEE NOTES 1 2 3 4 7 8 9 on the pages following these figures Fig 35 Upflow Application Vent Elbow Right A03209 SEE NOTES 1 2 4 5 7 8 9 on the page following these figures Fig 37 Downflow Application Vent Elbow Up A03211 31 ...

Page 32: ...8 9 on the page following these figures A03213 Fig 40 Horizontal Left Application Vent Elbow Left SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures oo _0o SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03212 Fig 39 Downflow Application Vent Elbow Up then Right A03214 Fig 41 Horizontal Left Application Vent Elbow Right then Up 32 ...

Page 33: ... NOTES 1 2 4 5 7 8 9 on the page following these figures A03215 Fig 43 Horizontal Left Application Vent Elbow Up A03219 Fig 44 Horizontal Right Application Vent Elbow Left then Up oOC SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03216 Fig 45 Horizontal Left Application Vent Elbow Right H SEE NOTES 1 2 4 5 7 8 9 Fig 46 Horizontal Right Application Vent Elbow Left A02068 33 ...

Page 34: ...ga min vent must be used inside furnace casing and when the KGAVG0101DFG Downflow Vent Guard Kit is used external 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 for exterior masonry chimney applications Refer to Chimney Adapter Kit KGACA02014FC or KGACA02015FC for sizing and comp...

Page 35: ...Fig 48 Rounded End of Knockout A04128 A04130 Fig 50 Hammer and Screwdriver Used for Knockout Fig 49 Knockout Pulled Loose A04129 A04131 Fig 51 Remove Knockout with Hammer 35 ...

Page 36: ...ned on See Fig 24 ELECTRICALSHOCK HAZARD Failure to follow this warning could result in personal iniury or death Blower access door switch opens l15 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes NOTE The furnace control allows all components except the gas valve to be run for short period of ...

Page 37: ...32 000 NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 4 in 102 mm inside casing or vent guard Including 4 in 102 mm vent section s MIN VENT MIN VERTICAL VENT DIAMETER HEIGHT IN MM FT M 5 127 12 4 5 127 7 2 5 127 7 2 Table 10 Altitude Derate Multiplier for U S A ALTITUDE PERCENT DERATE FT M OF MULTIPLIER DERATE FACTOR 0 2000 0 610 0 1 00 2001 3000 610 9...

Page 38: ...mometer readings stabilize subtract return air temperature from supply air temperature to determine air temperature rise NOTE Blower access door must be installed for proper temperature rise measurement NOTE If the temperature rise is outside this range first check 1 Gas input for heating operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing sta...

Page 39: ... not function during this test cause nmst be determined and corrected a Run furnace for at least 5 minutes b Gradually block off return air with a piece of cardboard or sheet metal until the limit trips c Unblock return air to permit normal circulation d Burners will re light when furnace cools down 2 Check draft safeguard switch The purpose of this control is to cause the safe shutdown of the fur...

Page 40: ...6 200 500 92 39 37 195 486 94 38 38 189 474 96 38 39 185 462 98 37 40 180 450 100 36 41 176 439 102 35 42 172 429 104 35 43 167 419 106 34 44 164 409 108 33 45 160 400 110 33 46 157 391 112 32 47 153 383 116 31 48 150 375 120 30 49 147 367 2 Cu Ft 144 141 138 136 133 131 129 126 124 122 120 116 112 109 106 103 100 97 95 92 90 88 86 84 82 80 78 76 75 74 72 71 69 68 67 65 64 62 60 SIZE OF TEST DiAL ...

Page 41: ... 43 2 8 43 2 9 43 3 0 43 3 1 4500 11372 1000 43 2 6 43 2 7 43 2 8 43 2 9 775 42 3 2 42 3 3 42 3 4 42 3 5 3001 800 43 3 6 43 3 8 42 3 2 42 3 3 915 825 43 3 4 43 3 5 43 3 7 43 3 8 850 43 3 2 43 3 3 43 3 4 43 3 6 to 875 43 3 0 43 3 1 43 3 3 43 3 4 4000 900 43 2 9 43 3 0 43 3 1 43 3 2 1219 925 43 2 7 43 2 8 43 2 9 43 3 0 950 43 2 6 43 2 7 43 2 8 43 2 8 750 43 3 6 43 3 8 42 3 2 42 3 3 4001 775 43 3 4 4...

Page 42: ...43 2 5 43 2 6 43 2 7 43 2 8 to 750 43 2 4 43 2 4 43 2 5 43 2 6 8000 775 43 2 2 43 2 3 43 2 4 43 2 4 2438 800 43 2 1 43 2 1 43 2 2 43 2 3 825 48 3 7 43 2 0 43 2 1 43 2 2 625 43 2 9 43 3 0 43 3 1 43 3 2 g ___ 8001 650 43 2 7 43 2 8 43 2 9 43 3 0 2439 675 43 2 5 43 2 6 43 2 7 43 2 8 0 to 700 43 2 3 43 2 4 43 2 5 43 2 6 725 43 2 2 43 2 2 43 2 3 43 2 4 9000 750 43 2 0 43 2 1 43 2 2 43 2 2 c O 12743 775...

Page 43: ...ating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 24 Any shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control LED will display status...

Page 44: ...to 975 43 2 5 43 2 6 43 2 7 43 2 8 4500 11372 1000 43 2 4 43 2 5 43 2 6 43 2 7 775 43 3 5 43 3 7 43 3 8 42 3 2 3001 800 43 3 3 43 3 4 43 3 5 43 3 7 915 825 43 3 1 43 3 2 43 3 3 43 3 4 850 43 2 9 43 3 0 43 3 1 43 3 2 to 875 43 2 8 43 2 9 43 3 0 43 3 1 4000 900 43 2 6 43 2 7 43 2 8 43 2 9 1219 925 43 2 5 43 2 6 43 2 7 43 2 7 950 43 2 4 43 2 4 43 2 5 43 2 6 750 43 3 3 43 3 4 43 3 5 43 3 6 4001 775 43...

Page 45: ...out occurs if the iimit draft safeguard flame rottout or If it opene during biower on detay period biower will come on for the selected biower blocked vent switch if used is open ionger than 3 minutes off delay Controi will auto reset after three hours Refer to 33 33 LIMIT CIRCUIT FAULT Indicates a limit draft safeguard flame roitout or biocked vent 14 IGNITION LOCKOUT Controi will auto reset afte...

Page 46: ...in the accessory instructions CLEANING AND OR REPLACING AIR FILTER The air filter arrangement will vary depending on the application The filter is exterior to the furnace casing NOTE If the filter has an airflow direction arrow the arrow must point towards the blower Table 15 Filter Size Information In mm FURNACE CASING WIDTH In ram 14 1 2 368 17 1 2 445 FILTER SIZE in ram FILTER TYPE Side Return ...

Page 47: ...d in blower housing and set screw contacts the flat portion of the motor shaft Loosen set screw on blower wheel and reposition if necessary 14 Spin the blower wheel by hand to verify that the wheel does not rub on the housing 15 Reinstall blower assembly in furnace 16 Reinstall control box assembly in furnace UNIT DAMAGE HAZARD Failure to follow this caution may result in shortened heat exchanger ...

Page 48: ...r rifle cleaning brush 36 in 914 mm long 1 4 6 mm diameter steel spring cable a variable speed reversible electric drill and vacuum cleaner clean cells as follows a Remove metal screw fitting from wire brush to allow insertion into cable b Insert the twisted wire end of brush into end of spring cable and crimp tight with crimping tool or crimp by striking with ball peen hammer TIGHTNESS IS VERY IM...

Page 49: ...er motor IDM blower motor BLWM hot surface igniter HSI and gas valve GV 1 Heating See Fig 25 for thermostat connections The wall thermostat calls for heat closing the R to W circuit The furnace control performs a self check verifies the pressure switch contacts PRS are open and starts the inducer motor IDM a Inducer Prepurge Period As the inducer motor IDM comes up to speed the pressure switch con...

Page 50: ... b When the R to G and Y Y2 circuit is closed and there is a demand for dehunfidification the furnace blower motor BLWM will drop the blower speed from COOL to HEAT for a maxinmna of 10 nfinutes before reverting back to COOL speed If there is still a demand for dehunfidification after 20 nfinutes the furnace control CPU will drop the blower speed back to HEAT speed This alternating 10 nfinute cycl...

Page 51: ... Y Y2 and G R to W and Yl and Y Y2 or R to W and Yl and Y Y2 and G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at HEAT speed and begin a heating cycle The blower motor BLWM will remain on until the end of the prepurge period then shut off for 24 seconds then come back on at HEAT speed When theWinput signal disappears the furnace control begins a n...

Page 52: ...TRANSFORMER 115VAC 24VAC JUNCTION UNMARKEDTERMINAL PCBCONTROLTERMINAL FACTORYWIRING 115VAC FACTORYWIRING 24VAC FIELD WIRING 115VAC FIELD WIRING 24VAC CONDUCTORON CONTROLPCB FIELD WIRING SCREWTERMINAL FIELD EARTHGROUND EQUIPMENT GROUND FIELD SPLICE PLUG RECEPTACLE XXXXXXXXXXXXXXXXXXXXXXXXXXXXXX TO 115MAC FIELD DISCONNECT NOTE 2 EOU ENT ROONO IDR PL2 _IDM BFANR PL5 L2 I BLWR X X X X X X X X X X X X ...

Page 53: ...h the status code 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 entire component test The HSl blower motor FAN speed AMBER LED boards only HEAT speed and COOL speed will run for 10 15 seconds each Gas valve a...

Page 54: ...ate combustion air supply flame rollout switch open Restricted vent Proper vent sizing Excessive wind 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 Check the followi...