Carrier 58CTA, Installation And Service Instructions Manual

Page 1: ...nt Districts STANDARD FEATURES ComfortHeat Technology Two stage heating with single stage thermostat Very low operating sound through low stage operation and QuieTech system Media Filter Cabinet Available Microprocessor based smart control center Adapts heating stages to meet demand Dehumidification selection for summer time cooling Adjustable heating air temperature rise Adjustable cooling airflo...

Page 2: ...e Switch when used For conversions to propane gas refer to the instructions in the Natural to Propane Conversion Kit KGANP3001ALL Fig 1 Two Stage Gas Valve The major difference in the two stage G valve besides the compact design is the location of the Low and High stage regulators Both regulators are located on top of the valve and are marked Lo and Hi next to the regulator seal caps Both regulato...

Page 3: ...om Return Air Inlet 11 Horizontal Installation 11 Suspended Unit Support 11 Platform Unit Support 11 Roll Out Protection 11 Bottom Return Air Inlet 11 Side Return Air Inlet 11 Filter Arrangement 15 Air Ducts 15 General Requirements 15 Ductwork Acoustical Treatment 15 Supply Air Connections 15 Return Air Connections 17 Gas Piping 17 Electrical Connections 19 115 V Wiring 20 J Box Relocation 20 Elec...

Page 4: ... furnaces Wear safety glasses and work gloves Have fire extinguisher available during start up and adjustment procedures and service calls 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 CAU TION These words are used with the safety alert symbol DAN GE...

Page 5: ...d See Fig 2 for clearance to combustible construction information INTRODUCTION The Series 110 B 4 way multipoise Category I fan assisted furnace is CSA formerly A G A and C G A design certified A Category I fan assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and or heat ex changer The furnace ...

Page 6: ...conduit ommun d autres appareils à gaz MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION Installation on non combusibible floors only For Installation on combustible flooring only when installed on special base Part No KGASB0201ALL Coil Assembly Part No CD5 or CK5 or Coil Casing Part No KCAKC 18 inches front clearance required for alcove Indicates supply or return sides when furnace is in the h...

Page 7: ... 1 Step 8 Venting US NFGC chapters 10 and 13 CANADA NSCNGPIC Part 7 and Appendix C ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause prema ture furnace component failure Electrostatic discharge can affect electronic components Follow the Electrostatic Discharge Precautions Procedure listed below during furnace install...

Page 8: ...l codes and ordinances The following types of furnace installations may require OUT DOOR AIR for combustion due to chemical exposures Commercial buildings Buildings with indoor pools Laundry rooms Hobby or craft rooms and Chemical storage areas If air is exposed to the following substances it should not be used for combustion air and outdoor air may be required for combus tion Permanent wave solut...

Page 9: ... the nameplate value The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy The furnace ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed Verify proper furnace operating conditions including igni tion gas i...

Page 10: ... OR VERTICAL DUCTS require 1 square inch of free area per 4 000 Btuh 550 mm2 kW for combined input of all gas appliances in the space per Fig 7 and Table 2 3 ONE OUTDOOR OPENING requires a 1 square inch of free area per 3 000 Btuh 734 mm2 kW for combined input of all gas appliances in the space per Table 2 and b Not less than the sum of the areas of all vent connectors in the space Table 2 Minimum...

Page 11: ...ce varies with the number of ACH and shall be determined per Table 3 or Equations 1 and 2 Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space Table 3 Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223 1 2002 NFPA 54 2002 8 3 2 2 1 For o...

Page 12: ...ndoor and Outdoor Air 1 Indoor openings shall compy with the Indoor Combustion Air Method below and 2 Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previously and 3 Outdoor openings shall be sized as follows a Calculate the Ratio of all Indoor Space volume divided by required volume for Indoor Combustion Air Method below b Outdoor opening size reducti...

Page 13: ...l plumber s strap as shown See Fig 15 and 16 Secure angle iron to bottom of furnace as shown Heavy gauge sheet metal straps plumber s straps may be used to suspend the furnace from each bottom corner To prevent screws from pulling out use 2 8 x in screw into the side and 2 8 x in screw in the bottom of the furnace casing for each strap See Fig 15 and 16 If the screws are attached to ONLY the furna...

Page 14: ...G FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING A96285 Fig 12 Furnace Plenum and Subbase Installed on a Combustible Floor A04140 CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX FURNACE SHEET METAL PLENUM FLOOR OPENING COMBUSTIBLE FLOORING A04140 Fig 13 Furnace Plenum and Coil Assembly or Coil Box Installed on a Combustible Floor 12 ...

Page 15: ...l Assembly or KCAKC coil box KGASB subbase not required 15 1 2 19 16 1 2 20 21 Upflow Applications on Combustible or Noncombustible Flooring KGASB subbase not required 19 1 2 21 5 8 20 1 8 22 1 4 Downflow Applications on Noncombustible Flooring KGASB subbase not required 19 3 8 19 20 19 5 8 Downflow applications on combustible flooring KGASB subbase required 18 5 8 19 20 1 4 20 5 8 Downflow Applic...

Page 16: ...EX NUTS 2 WASHERS 2 LOCK WASHERS REQ PER ROD 8 MIN FOR DOOR REMOVAL OUTER DOOR ASSEMBLY Fig 16 Horizontal Suspension with Straps A03176 METHOD 2 USE 4 8 x 3 4 SHEET METAL SCREWS FOR EACH STRAP THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH 4 8 x 3 4 SHEET METAL SCREWS 2 SCREWS IN SIDE AND 2 SCRE...

Page 17: ...gh unconditioned space should be insu lated to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 in 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 ...

Page 18: ...1900 1770 1590 1355 1120 1775 1655 1490 1275 1040 1650 1535 1390 1160 955 1510 1400 1245 1055 850 1335 1240 1110 920 750 Both Side or 1 Side Bottom High Med High Medium Med Low Low 2485 2175 1845 1540 1280 2415 2130 1815 1515 1250 2330 2070 1770 1475 1220 2230 2000 1720 1435 1190 2135 1930 1655 1385 115 2030 1840 1580 1335 1105 1920 1740 1500 1270 1035 1790 1620 1395 1175 945 1645 1495 1270 1045 8...

Page 19: ...d the NSCNGPIC 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 1 Gas supply connections MUST be performed by a licensed plumber or gas fitter 2 When flexible connectors are used the maximum length shall not exceed 36 inches ...

Page 20: ...A02075 Fig 18 Upflow Return Air Configurations and Restrictions A02163 Fig 19 Downflow Return Air Configurations and Restrictions A02162 Fig 20 Horizontal Return Air Configurations and Restrictions 18 ...

Page 21: ...iately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve 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 before the furnace has been connected After all connections have been made purge lines and check for leakage at furnace prior to operating furnace I...

Page 22: ... Use a separate branch electrical circuit with a properly sized fuse or circuit breaker for this furnace See Table 7 for wire size and fuse specifications A readily accessible means of electrical disconnect must be located within sight of the furnace NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control LED status indicator light will flash rapidly and furnace w...

Page 23: ...Electrical Data FURNACE SIZE VOLTS HERTZ PHASE OPERATING VOLTAGE RANGE MAXIMUM UNIT AMPS UNIT AMPACITY MAXIMUM WIRE LENGTH FT MAXIMUM FUSE OR CKT BKR AMPS MINIMUM WIRE GAUGE Maximum Minimum 045 08 024045 115 60 1 127 104 5 3 7 42 49 15 14 045 12 036045 115 60 1 127 104 7 1 9 67 38 15 14 070 08 024070 115 60 1 127 104 5 2 7 22 51 15 14 070 12 036070 115 60 1 127 104 7 3 9 90 37 15 14 070 16 048070 ...

Page 24: ...ound wire to green ground screw on J Box bracket 5 Connect line voltage leads as shown in Fig 22 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 32 Connect terminal Y Y2 as shown in Fig 25 31 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24 v circuit contains ...

Page 25: ...llowing these figures See notes 1 2 4 6 7 9 10 11 and 15 on the page following these figures A03180 Fig 26 Two Stage Furnace with Single Speed Heat Pump Dual Fuel See notes 1 2 3 4 6 8 9 10 12 13 and 15 on the page following these figures A03178 Fig 27 Two Stage Furnace with Two Speed Heat Pump Dual Fuel 23 ...

Page 26: ...ce and Two Speed Heat Pump A03182 1 See notes 1 2 3 4 12 13 14 15 and 17 on the page following these figures See notes 2 11 and 12 on the page following these figures A03183 Fig 30 Two Stage Thermostat with Two Stage Furnace and Two Speed Air Conditioner See notes 1 and 2 on the page following these figures A03184 Fig 31 Single Stage Thermostat with Two Stage Furnace and Two Speed Air Conditioner ...

Page 27: ...st control its own high stage heating operation via furnace control algorithm 13 The RVS Sensing terminal L should not be connected This is internally used to sense defrost operation 14 DO NOT SELECT the FURNACE INTERFACE or BALANCE POINT option on the two speed heat pump control board This is controlled internally by the Thermidistat Dual Fuel Thermostat 15 Dip switch D on Dual Fuel Thermostat sh...

Page 28: ...alignment missing sections gaps Debris in cleanout Mortar tile metal vent fuel oil residue Is liner and top seal in good condition Is chimney property lined with clay tile liner Crown condition Missing mortar or brick Rebuild crown Yes Yes No No No Reline Yes Repair Yes Yes Yes No No Remove mortar and tile debris Remove metal vent or liner No No No No Yes Yes Suitable Suitable Not Suitable Line ch...

Page 29: ...ting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the NSCNGPIC local building codes and furnace and vent manufac turers instructions The following information and warning must be considered in addition to the requirements defined in the NFGC or the NSCNG PIC CARBON MONOXIDE WARNING HAZARD Failure to follow this warning could result in a build up of carbo...

Page 30: ...chimney and the metal liner APPLIANCE APPLICATION REQUIREMENTS Appliance operation has a significant impact on the performance of the venting system If the appliances are sized installed adjusted and operated properly the venting system and or the appliances should not suffer from condensation and corrosion The venting system and all appliances shall be installed in accordance with applicable list...

Page 31: ...he page following these figures A03210 Fig 36 Downflow Application Vent Elbow Up then Left SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Fig 37 Downflow Application Vent Elbow Up SEE NOTES 1 2 4 5 6 7 8 9 10 on the page following these figures A03207 Fig 38 Downflow Application Vent Elbow Left then Up SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures A03212 Fig 39 ...

Page 32: ...salt and air freshener and can cause corrosion of furnaces and vents Avoid using such products in the combustion air supply Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds causing premature failure of the furnace or venting system due to corrosion Vent dampers on any appliance connected to the common vent can cause condensation and corrosi...

Page 33: ...t connector sizing and vent material United States use the NFGC Canada use the NSCNGPIC 2 Immediately increase to 5 inch or 6 inch vent connector outside furnace casing when 5 inch vent connector is required refer to Note 1 above 3 Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace except when KGAVG0101DFG Downflow Vent Guard Kit is us...

Page 34: ...ocated 180 apart 2 Vent the furnace with the appropriate connector as shown in Fig 34 46 CUT HAZARD Failure to follow this caution may result in personal 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 3 Orient the door to determine the correct location of the door cutout t...

Page 35: ...property damage personal injury or death This furnace is equipped with manual reset limit switches in the gas control area The switches open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the gas control area DO NOT bypass the switches Correct problem before resetting the switches 1 Maintain 115 v wiring and ground Improper polarity will result in rapid f...

Page 36: ...egulated manifold pressure and result in excess overfire and heat exchanger failures FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of heat exchangers causing failures See Fig 48 Furna...

Page 37: ...pressure is outside this range change main burner orifices i Install low heat regulator adjustment cap j Leave manometer or similar device connected and proceed to Step 4 NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for p...

Page 38: ... is achieved proceed to Step 6 6 Adjust Manifold Pressure to Obtain High Heat Rate a Remove high fire regulator adjustment cap from gas valve pressure regulator b Manually close blower access door switch c Jumper R W W1 and W2 thermostat connections on control to run furnace in high heat See Fig 32 d Turn high heat adjusting screw 5 64 hex Allen wrench counterclockwise out to decrease input rate o...

Page 39: ...NOTE If the temperature rise is outside this range first check 1 Gas input for low and high heat operation 2 Derate for altitude if applicable 3 Return and supply ducts for excessive restrictions causing static pressures greater than 0 50 in wc 4 Dirty filter c Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase t...

Page 40: ... to furnace and remove vent connector from furnace vent elbow c Restore power to furnace and set room thermostat above room temperature d After normal start up allow furnace to operate for 2 minutes then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal e Furnace should cycle off within 2 minutes If gas does not shut off within 2 minutes determine reason draft sa...

Page 41: ... 1 6 43 3 8 1 7 900 43 3 3 1 4 43 3 4 1 5 43 3 5 1 5 43 3 6 1 6 925 44 3 5 1 5 43 3 2 1 4 43 3 3 1 4 43 3 4 1 5 950 44 3 4 1 5 44 3 5 1 5 44 3 6 1 6 43 3 2 1 4 975 44 3 2 1 4 44 3 3 1 4 44 3 4 1 5 44 3 5 1 5 1000 45 3 7 1 6 45 3 8 1 7 44 3 2 1 4 44 3 4 1 5 ALTITUDE RANGE FT AVG GAS HEAT VALUE BTU CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 Orifice no Manifold Pressure Orifice no Mani...

Page 42: ... 3 5 1 5 775 46 3 7 1 6 45 3 7 1 6 45 3 8 1 7 44 3 2 1 4 800 46 3 5 1 5 46 3 6 1 6 46 3 8 1 6 45 3 7 1 6 825 47 3 7 1 6 46 3 4 1 5 46 3 5 1 5 46 3 6 1 6 850 47 3 5 1 5 47 3 6 1 6 47 3 8 1 6 46 3 4 1 5 ALTITUDE RANGE FT AVG GAS HEAT VALUE AT ALTITUDE BTU CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 Orifice No Mainifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure ...

Page 43: ...dly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 30 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 ...

Page 44: ... 1 6 43 3 5 1 7 900 44 3 4 1 6 44 3 5 1 7 43 3 2 1 5 43 3 3 1 6 925 44 3 2 1 5 44 3 3 1 6 44 3 5 1 6 44 3 6 1 7 950 45 3 7 1 8 45 3 8 1 8 44 3 3 1 6 44 3 4 1 6 975 46 3 7 1 8 46 3 8 1 8 45 3 8 1 8 44 3 2 1 5 1000 46 3 5 1 7 46 3 6 1 7 46 3 8 1 8 45 3 7 1 8 ALTITUDE RANGE FT AVG GAS HEAT VALUE BTU CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 Orifice no Manifold Pressure Orifice no Mani...

Page 45: ...3 5 1 7 46 3 6 1 7 46 3 8 1 8 800 47 3 6 1 7 47 3 8 1 8 46 3 4 1 6 46 3 5 1 7 825 47 3 4 1 6 47 3 5 1 7 47 3 6 1 7 47 3 8 1 8 850 48 3 7 1 7 48 3 8 1 8 47 3 4 1 6 47 3 5 1 7 ALTITUDE RANGE FT AVG GAS HEAT VALUE AT ALTITUDE BTU CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure...

Page 46: ...ours Refer to 33 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 21 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control valve relay 22 ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve 23 PRESSURE SWITCH DID NOT OPE...

Page 47: ...MMON FRS 1 2 FLAME ROLLOUT SW MANUAL RESET SPST N C FSE FLAME PROVING ELECTRODE FU1 FUSE 3 AMP AUTOMOTIVE BLADE TYPE FACTORY INSTALLED FU2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE FIELD SUPPLIED AND INSTALLED GND EQUIPMENT GROUND GV GAS VAL VE REDUNDANT GVR 1 2 GAS VAL VE RELA Y DPST N O HPS HIGH HEA T PRESSURE SWITCH SPST N O HPSR HIGH HEA T PRESSURE SWITCH RELA Y SPST N C HSI HOT SURFACE...

Page 48: ...er cabinet door 3 Slide filter out of cabinet 4 If equipped with permanent washable 1 in filter clean filter by spraying cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oiling or coating of the filter is not recommended See Table 15 for size information 5 If equipped with factory specified disposable media filter replace only with media filter having the sam...

Page 49: ...ical shock personal injury or death Blower access door switch opens 115 v power to furnace control No component operation can occur unless switch is closed Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes b Manually close blower access door switch NOTE If thermostat terminals are jumpered at the time blower access ...

Page 50: ...rce Reverse drill and gradually work cable out 4 Insert brush end of cable in burner inlet opening of cell and proceed to clean 2 lower passes of cell in same manner as upper pass 5 Repeat foregoing procedures until each cell in furnace has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly 8 Clean flame sensor ...

Page 51: ...s a self check verifies the low heat and high heat pressure switch contacts LPS and HPS are open and starts the inducer motor IDM in high speed a Inducer Prepurge Period 1 If the furnace control CPU selects low heat operation the inducer motor IDM comes up to speed the low heat pressure switch LPS closes and the furnace control CPU begins a 15 second prepurge period After the low heat pressure swi...

Page 52: ...er the R to W2 circuit opens 3 Cooling Mode The thermostat calls for cooling a Single Speed Cooling See Fig 26 for thermostat connections The thermostat closes the R to G and Y circuits The R to Y circuit starts the outdoor unit and the R to G and Y Y2 circuits start the furnace blower motor BLWM on COOL speed The electronic air cleaner terminal EAC 1 is energized with 115 vac when the blower moto...

Page 53: ...then restarts at the end of the blower ON delay period at LO HEAT or HI HEAT speed respectively The blower motor BLWM will revert to continuous blower speed after the heating cycle is completed In high heat the furnace control CPU will hold the blower motor BLWM at HI HEAT speed during the selected blower OFF delay period before reverting to continuous blower speed When the thermostat calls for lo...

Page 54: ...e G signal the blower motor BLWM will remain on for the selected blower OFF delay period then switch to continuous blower speed Step 4 Wiring Diagrams Refer to wiring diagram Fig 56 Step 5 Troubleshooting Refer to the service label See Fig 55 Service Label The Troubleshooting Guide can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and f...

Page 55: ...he control will go through a brief component test sequence The inducer will start and run for the entire component test The HSI blower motor LO HEAT speed HI HEAT speed and COOL speed will run for 10 15 seconds each Gas valve and humidifier will not be turned on Was there a previous status code other than 11 Is door switch closed Is there 115V going to switch Replace door switch Replace transforme...

Page 56: ...VING 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 following items first before proceeding to the next step Gas valve turned off Manual shut off valve Green Yellow wire MUS...

Page 57: ...55 ...

Page 58: ...ufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 Tab 6a 8a PC 101 Catalog No See Cover Printed in U S A Form 58CT 5SI Pg 56 1 05 Replaces 58CT 4SI ...