Carrier 58CVA, Installation, Start-Up, Operating And Service And Maintenance Instructions

Page 1: ... operation and QuieTech noise reduction system Integral part of the IdealHumidity System Maximum dehumidification selection for summer time cooling Full IdealHumidity benefits including Super Dehumidify Variable speed blower motor Super low electrical use up to 80 percent less than standard models Increased SEER ratings for AC and HP systems Perfectly matches CFM to cooling system at all static po...

Page 2: ...Ductwork Acoustical Treatment 12 Supply Air Connections 13 Return Air Connections 15 Gas Piping 15 Electrical Connections 16 115 V Wiring 16 J Box Relocation 16 Electrical Connection to J Box 16 For Power Cord Installation 16 For BX Cable Installation 17 For J Box Cover Installation 17 24 V Wiring 17 Accessories 18 Venting 18 General Venting Requirements 21 Masonry Chimney Requirements 23 Applianc...

Page 3: ...onal injury Understand the signal words DANGER WARNING CAUTION and NOTE These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and prop...

Page 4: ...r any other combustible material other than wood flooring For downflow installations a factory accessory floor base must be used when installed on combustible materials and wood flooring This special base is not required when this furnace is installed on the manufacturer s coil assembly or when the manufacturer s coil box is used See Figure 2 for clearance to combustible material information This ...

Page 5: ...S I DE C Ô T É F R O N T A V A N T B C K A R R I È A E R S E R VI E C ENTR T E N E I V A N A T FRONT S I E C Ô T È F OU U F RNA C S E E I A RN Ø Vent Clearance to combustibles For Single Wall vents 6 inches 6 po For Type B 1 vent type 1 inch 1 po Dégagement de l évent avec combustibles Pour conduit d évacuation à paroi simple 6 po 6 inches Pour conduit d évacuation de Type B 1 1 po 1 inch TOP PLEN...

Page 6: ...touch ungrounded objects and recharge your body with static electricity firmly touch a clean unpainted metal surface of the furnace again before touching control or wires 5 Use this procedure for installed and uninstalled ungrounded furnaces 6 Before removing a new control from its container discharge your body s electrostatic charge to ground to protect the control from damage If the control is t...

Page 7: ...o remove drywall dust and construction debris from all HVAC system components after construction is completed Do not install the furnace on its back or hang furnace with control compartment facing downward Safety control opera tion will be adversely affected Never connect return air ducts to the back of the furnace Failure to follow this warning could result in fire personal injury or death See Fi...

Page 8: ... that space A confined space must have provisions for supplying air for com bustion ventilation and dilution of flue gases using one of the following methods in Table 2 and Fig 7 and 8 NOTE When determining the free area of an opening the blocking effect of louvers grilles and screens must be considered If the free area of the louver or grille design is unknown assume wood louvers have a 20 percen...

Page 9: ...in 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 Step 1 above To install leveling legs 1 Position furnace on its back Locate and drill a hole in each bottom corner of furnace See Fig 10 2 For each leg inst...

Page 10: ...furnace Failure to follow this warning could result in fire personal injury or death 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 installed on a platform non combustible blocks bricks or pad SUSPENDED UNIT SUPPORT The furnace may be supported under each end with ...

Page 11: ...r connection See Fig 17 for proper orientation of roll out shield BOTTOM RETURN AIR INLET These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler...

Page 12: ... between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insu lated to enhance system performance When air conditioning is used a vapor barrier is recommended Table 3 Opening Dimensions In FURNACE CASING WIDTH APPLICATION PLENUM OPENING FLOOR OPENING A B C D 14 3 16 Upflow Applications on Combustible or Noncombustible Flooring KGASB ...

Page 13: ... to the first branch take off may require internal acoustical lining As an alternative fibrous duct work may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts Fig 14 Duct Flanges A02329 UPFLOW...

Page 14: ... humidifier or other accessories All accessories MUST be con nected external to furnace main casing Installation tip For horizontal applications the top most flange may be bent past 90 degrees to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed Downflow Furnaces Connect supply air duct to supply air opening on furnace ...

Page 15: ...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 14 ...

Page 16: ...ust be used to connect to furnace and to meter Support all gas piping with appropriate straps hangers etc Use a minimum of 1 hanger every 6 ft Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to the action of propane gas If local codes allow the use of a flexible gas appliance connector always use a new listed connector Do not use ...

Page 17: ...5 for equipment electrical specifications Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 2002 and any local codes or ordinances that might apply For Canadian instal lations all electrical connections must be made in accordance with Canadian Electrical Code CSA C22 1 or authorities having juris diction Do not connect aluminum wire between disconnect swi...

Page 18: ...G ONLY FIVE WIRE NOTE 2 NOTE 1 1 STAGE THERMOSTAT TERMINALS FIELD SUPPLIED FUSED DISCONNECT CONDENSING UNIT FURNACE COM R W C Y R G GND GND FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING Connect Y Y2 terminal as shown for proper operation Some thermostats require a C terminal connection as shown If any of the original wire as supplied must be ...

Page 19: ...n 1 Seal any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Codes and these instructions Deter mine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far a...

Page 20: ...Fig 25 Two Stage Furnace with Two Speed Air Conditioner A00276 A00277 Fig 26 Two Stage Furnace with Single Speed Heat Pump Dual Fuel A00278 Fig 27 Two Stage Furnace with Two Speed Heat Pump Dual Fuel 19 ...

Page 21: ...d Heat Pump Fig 29 Dual Fuel Thermostat with Two Stage Furnace and Two Speed Heat Pump A00280 A00281 Fig 30 Two Stage Thermostat with Two Stage Furnace and Two Speed Air Conditioner A00282 Fig 31 Single Stage Thermostat with Two Stage Furnace and Two Speed Air Conditioner 20 ...

Page 22: ...terminal when using a Thermidistat 11 Optional connection If wire is connected dip switch No 1 on furnace control should be set in ON position to allow Thermidistat Thermostat to control furnace staging 12 Optional connection If wire is connected ACRDJ jumper on furnace control should be removed to allow Thermidistat Thermostat to control outdoor unit staging 13 Furnace must control its own high s...

Page 23: ...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 24: ...ith a factory accessory Chim ney Adapter Kit Refer to the furnace rating plate for correct kit usage The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit numbers marked on the furnace rating plate If a clay tile lined masonry chimney is being used and it is exposed to the outdoors below the roof line relining might be required Chimneys shall conform to the Standard ...

Page 25: ...e a vent in a chase If a metal liner or Type B vent is used to line a chimney no other appliance shall be vented into the annular space between the 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 appl...

Page 26: ... Right SEE NOTES 1 2 3 4 5 7 8 9 A02060 Fig 36 Downflow Application Vent Elbow Up then Left SEE NOTES 1 2 4 5 7 8 9 A02061 Fig 37 Downflow Application Vent Elbow Up SEE NOTES 1 2 4 5 6 7 8 9 A02062 Fig 38 Downflow Application Vent Elbow Left then Up SEE NOTES 1 2 3 4 5 7 8 9 A02297 Fig 39 Downflow Application Vent Elbow Up then Right 25 ...

Page 27: ...1 Horizontal Left Application Vent Elbow Right then Up A02065 SEE NOTES 1 2 4 5 7 8 9 SEE NOTES 1 2 4 5 7 8 9 A02066 Fig 42 Horizontal Left Application Vent Elbow Up SEE NOTES 1 2 4 5 7 8 9 A02067 Fig 43 Horizontal Left Application Vent Elbow Right Venting Notes for Figure 34 46 1 For common vent vent connector sizing and vent material United States latest edition of the National Fuel Gas Code NFG...

Page 28: ...tional Fuel Gas Code FURNACE ORIENTATION VENT ORIENTATION FURNACE INPUT BTU HR VENT MINIMUM DIAMETER IN MINIMUM VERTICAL VENT HEIGHT FT Downflow Vent elbow left then up Fig 38 154 000 132 000 110 000 036 12 only 5 12 Horizontal Left Vent elbow right then up Fig 41 154 000 132 000 5 7 Horizontal Left Vent Elbow up Fig 42 154 000 132 000 5 7 Horizontal Left Vent elbow right Fig 43 154 000 5 7 Downfl...

Page 29: ...sed Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in electrical shock personal injury or death 3 To Begin Component Self Test Remove Blower Access Door Disconnect the thermostat R lead from from furnace control board Manually close blower door switch Turn Setup DIP switch SW1 6 ON See Fig 32 51 and Table 6 NOTE The furnace ...

Page 30: ...tions must use Table 11 21 000 Btuh per burner See input listed on rating plate a Obtain average yearly gas heat value at installed altitude from local gas supplier b Obtain average yearly gas specific gravity from local gas supplier c Find installation altitude in Table 10 or 11 d Find closest natural gas heat value and specific gravity in Table 10 or 11 e Follow heat value and specific gravity l...

Page 31: ... low fire per Step 4 Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see radiant heat from heat exchangers Radiant heat affects temperature rise readings This practice is particularly important with straight run ducts b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine air temperatu...

Page 32: ...tch SW1 4 is ON operation will be near the high end of the rise range for improved comfort This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on unit rating plate NOTE If the temperature rise is outside this range first check 1 Gas input for low and high fire opeation 2 Derate for altitude if applicable 3 Return and supply ...

Page 33: ...42 3 7 1 6 825 42 3 2 1 4 42 3 3 1 4 42 3 4 1 5 42 3 5 1 5 850 43 3 7 1 6 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 875 43 3 5 1 5 43 3 6 1 6 43 3 7 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 ALTI...

Page 34: ...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 Orifice No Manifold Pressur...

Page 35: ...ck Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switches This control shuts off combustion control system and ener gizes air circulating blower motor if furnace overheats By using this method to check limit control it can be established that limit is functioning properly and will ope...

Page 36: ...S A and Canada U S A Altitudes 2001 to 3000 or Canada Altitudes 2001 to 4500 800 43 3 8 1 8 42 3 2 1 5 42 3 3 1 6 42 3 4 1 6 825 43 3 5 1 7 43 3 7 1 7 43 3 8 1 8 42 3 2 1 5 850 43 3 3 1 6 43 3 5 1 6 43 3 6 1 7 43 3 7 1 8 875 43 3 2 1 5 43 3 3 1 6 43 3 4 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 ...

Page 37: ...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 38: ... improper and dangerous operation Step 1 Introduction GENERAL These instructions are written as if the furnace is installed in an upflow application An upflow furnace application is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can be installed in any of the 4 positions shown in Fig 4 you must revise...

Page 39: ...ips occurred during high heat Control will auto reset after three hours Refer to status code 33 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to status code 34 15 BLOWER MOTOR LOCKOUT Indicates the blower failed to reach 250 RPM or the blower failed to communicate within 30 seconds after being turned ON in two successive heating cycles Control will auto reset after 3 hours Re...

Page 40: ... a qualified professional 5 Inspect the vent pipe vent system before each heating season for rust corrosion water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified professional 6 Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the acces s...

Page 41: ... blower leads to furnace control Refer to furnace wiring diagram and connect thermostat leads if previously disconnected 18 To check blower for proper rotation a Turn on electrical supply Blower access door switch opens 115 v power to furnace control No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could re...

Page 42: ... N C PCB Printed Circuit Board PL1 12 Circuit Connector PL2 4 Circuit HSI IDM Connector PL3 4 Circuit ECM BLWM Connector PL4 4 Circuit Model Plug Connector PL7 4 Circuit Communication Connector PL9 2 Circuit OAT Connector PL10 2 Circuit HSI Connector PL11 IDM Connector 3 Circuit PL12 1 Circuit Inductor Splice Connector PL13 16 Circuit ECM Blower Ctrl Connector PL14 5 Circuit ECM Blower Power Conne...

Page 43: ...eat force 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 s...

Page 44: ...riod 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 If the low heat pressure switch LPS fails to remain closed the inducer motor IDM will remain running at high speed After the low heat pressure switch re closes the furnace control CPU will begin a 1...

Page 45: ...tions 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 cooling airflow Cooling airflow is based on the A C selection shown in Fig 55 The electronic air cleaner terminal EAC 1 is energized with 115 vac when the blower motor BLWM is operating When the thermostat is satisfied the R to G a...

Page 46: ...distat The exceptions are listed below a Low cooling When the R to G and Y1 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower airflow to 86 percent of low cooling airflow which is the true on board CF selec tion as shown in Fig 55 b High cooling When the R to G and Y Y2 circuit is closed and there is a demand for dehumidification the fu...

Page 47: ...west CF selection as shown in Table 1 The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption 7 Heat pump See Fig 26 29 for thermostat connections When installed with a heat pump the furnace control auto matically changes the timing sequence to avoid long blower off times during demand defrost cycles Whenever W W1 is...

Page 48: ...4V transformer phasing Was there a previous status code other than 11 Is door switch closed Is there 115V going to switch Replace door switch Replace transformer Does the control respond to W W1 W2 Y1 Y Y2 and G 24V thermostat signals Replace furnace control NO NO NO NO Is 24V present at W W1 W2 Y1 Y Y2 or G thermostat terminals on the furnace control NO YES YES Replace furnace control Is there 24...

Page 49: ...witch 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 Check the following items first before proceeding to th...

Page 50: ...step Replace the blower control module attached to the blower motor Follow the instructions with the blower control module to make sure the entire blower motor does not need to be replaced Turn power back on Is there 115VAC at PL14 5 and PL14 4 Is there 12 VDC at PL13 7 RED and PL13 1 GREEN Is there 12 VDC at PL3 1 RED and PL3 2 GREEN Replace the furnace control Is there 5 VDC at PL13 16 YELLOW an...

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Page 53: ...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 58CV 3SI Pg 52 12 02 Replaces 58CV 1SI ...