Carrier 58MEC, Installation, Start-Up, And Operating Instructions Manual

Page 1: ...stem be checked once a year by qualified service personnel The authority having jurisdiction gas inspection authority municipal building department fire department etc should be consulted before installation to determine the need to obtain a permit Consignes spéciales pour l installation de ventillation au Canada L installation faite au Canada doit se conformer aux exigences du code CSA B149 Ce sy...

Page 2: ... exhaust 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 obs...

Page 3: ...is product WARNING Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified personnel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating e...

Page 4: ...lly for the detection of leaks to check all connections as specified in the GAS PIPING section of these instructions Always install furnace to operate within the furnace s intended rise range with a duct system which has an external static pressure within the allowable range as specified in the SET TEMPERATURE RISE section of these instructions and furnace rating plate When a furnace is installed ...

Page 5: ...d the NFPA 90B For copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or for only the NFGC contact the American Gas Association 400 N Capitol N W Washington DC 20001 S CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario M9W 1R3 Canada Step 3 Combustion and Ventilation Air S US Section 9 3 of ...

Page 6: ... CFM 16 in 406mm round or 14 1 2 368mm x 12 in 305mm rectangle b For 1200 CFM 20 in 508mm round or 14 1 2 368mm x 19 1 2 in 495mm rectangle c For 1600 CFM 22 in 559mm round or 14 1 2 368mm x 23 1 4 in 591mm rectangle d For airflow requirements above 1800 CFM see Air Delivery table in Product Data literature for specific use of single side inlets The use of both side inlets a combination of 1 side ...

Page 7: ...OSTATIC CHARGE TO GROUND 4 Firmly touch the clean unpainted metal surface of the furnace chassis which is close to the control Tools held in hand during grounding will be discharged 5 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing to recharge your body moving or shuffling feet touching ungrounded objects etc 6 If you touch ungrounded...

Page 8: ...Fig 5 CONDENSATE TRAP TUBING FACTORY SHIPPED ORIENTATION NOTE See Fig 6 or tube routing label on main furnace door to confirm location of these tubes 1 Collector Box Drain Inducer Housing Drain Relief Port and Pressure Switch Tubes These tubes should be factory attached to condensate trap and pressure switch ready for use in upflow applications These tubes can be identified by their connection loc...

Page 9: ...by gently pushing tabs inward and rotating trap 3 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being...

Page 10: ...connected to the High Pressure Switch and should not require any modification COLLECTOR BOX TUBE PINK CONDENSATE TRAP COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE BLUE INDUCER HOUSING DRAIN TUBE VIOLET CAP COLLECTOR BOX DRAIN TUBE BLUE WHITE STRIPED PLUG A01031 Fig 7 Alternate Upflow Configuration and Trap Location NOTE See Fig 6 or 7 or tube routing label on main furnace door to check for pr...

Page 11: ... LOWER collector box drain tube blue and white striped label PLUG COLLECTOR BOX TUBE GREEN COLLECTOR BOX TUBE PINK COLLECTOR BOX DRAIN TUBE BLUE WHITE STRIPED COLLECTOR BOX EXTENSION DRAIN TUBE CONDENSATE TRAP INDUCER HOUSING DRAIN TUBE VIOLET COLLECTOR BOX EXTENSION TUBE DRAIN TUBE COUPLING COLLECTOR BOX DRAIN TUBE BLUE CAP COLLECTOR BOX EXTENSION TUBE A01024 Fig 9 Downflow Tube Configuration Rig...

Page 12: ...f port connection 6 Determine appropriate length cut and connect tube 7 Clamp tube to relief port connection CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommendations and procedures Step 4 Horizontal Left Supply Air Discharge Applications In a horizontal left furnace application the blower is located to the right of the burner section and conditioned air is...

Page 13: ... on main furnace door to check for proper connections Modify tube as described below 1 Disconnect collector box pressure tube pink label attached to High Pressure Switch 2 Use smaller diameter tube factory supplied in loose parts bag to extend tube disconnected in item 1 3 Route extended tube a Behind inducer housing b Between blower shelf and inducer housing 4 Determine appropriate length cut and...

Page 14: ...lf to desired location perform the following 1 Remove 3 tubes connected to condensate trap 2 Remove trap from blower shelf by gently pushing tabs inward and rotating trap 3 Install casing hole filler cap factory supplied in loose parts bag into blower shelf hole where trap was removed CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Casing ho...

Page 15: ...ecommendations and procedures PRESSURE SWITCH TUBING One collector box pressure tube pink label is factory connected to the High Pressure Switch for use when furnace is installed in UPFLOW applications This tube MUST be disconnected and used for the condensate trap relief port tube The other collector box pressure tube green label which was factory connected to the condensate trap relief port conn...

Page 16: ... available electric power and gas supplies meet specifications on the furnace rating plate S be attached to an air distribution system and be located as close to the center of the distribution system as possible Refer to Air Ducts section S be provided with ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on the furnace clearance to combustibles la...

Page 17: ...ebris from all HVAC system components after construction is completed After construction is complete verify furnace operating conditions including ignition input rate temperature rise and venting according to the manufacturer s instructions CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in property or unit damage If this furnace is installed in an unconditioned space where th...

Page 18: ... air must be provided to avoid negative pressure in the equipment room or space A positive seal must be made between the furnace cabinet and the return air duct to prevent pulling air from the burner area and from draft safeguard opening CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The operation of exhaust fans kitchen ventilation fans cl...

Page 19: ...6 300 178 3 8 400 237 8 10 500 297 3 6 600 186 8 9 900 280 3 13 200 373 7 16 500 467 2 19 800 560 6 23 100 654 1 0 00 NP NP NP NP NP NP NP NP NP b Not less than the sum of the areas of all vent connectors in the space The opening shall commence within 12 in 305 mm of the ceiling Appliances in the space shall have clearances of at least 1 in 25 mm from the sides and back and 6 in 153 mm from the fr...

Page 20: ...CTS VENT THROUGH ROOF 1 SQ IN PER 1000 BTUH IN DOOR OR WALL 12 MAX 1 SQ IN PER 1000 BTUH IN DOOR OR WALL 12 MAX UNCONFINED SPACE INTERIOR HEATED SPACE CLEARANCE IN FRONT OF COMBUSTION AIR OPENINGS SHALL BE A T LEAST 3 IN 305mm 152mm 305mm A03175 Fig 19 Air for Combustion Ventilation and Dilution from Indoors c Combining space on different floor levels The volumes of spaces on different floor level...

Page 21: ...t and tighten inside Nut to secure arrangement NOTE Bottom closure must be used when leveling legs are used See Bottom Closure Panel section Step 2 Installation in Upflow and Downflow Applications NOTE For downflow applications this furnace is approved for use on combustible flooring when special base available from manufacturer Part No KGASB0201ALL is used Special base is not required when this f...

Page 22: ...ociation SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Systems Design Guidelines reference tables available from your local distributor The duct system should be sized to handle the required system design CFM at the design static pressure PLENUM OPENING C A B D FLOOR OPENING A96283 Fig 21 Floor and Plenum Opening Dimensions DOWNFLOW SU...

Page 23: ...hall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream The cover attachment shall prevent leaks DUCTWORK ACOUSTICAL TREATMENT Metal duct systems that do not have a 90 degree elbow and 10 ft 3 M of main duct to the first branch take off may require internal acoustical lining As an alternative f...

Page 24: ... to ensure proper drainage 3 For non direct vent 1 pipe application bottom side combustion air entry cannot be used when furnace is installed with hangers as shown A PREFERRED ROD LOCATION B ALTERNATE ROD LOCATION DRAIN 5 3 4 3 8 IN HEX NUT WASHER 4 REQD PER ROD VENT COMBUSTION AIR PIPE DIRECT VENT 2 PIPE APPLICATION ALL SIZES COMBUSTION AIR INTAKE NON DIRECT VENT 1 PIPE APPLICATION 3 IN 76 mm MIN...

Page 25: ...er or a factory specified high efficiency disposable filter see cabinet instructions If installing the filter in the furnace blower compartment determine location for filter and relocate filter retaining wire if necessary See Table 4 to determine correct filter size for desired filter location Table 4 indicates filter size location and quantity shipped with this furnace See Fig 2 for location and ...

Page 26: ... 5 in wc based on a 0 60 specific gravity gas Ref Table 5 and the NFGC Step 7 Gas Piping Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the United States Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction Gas supply line should be a separate line running directly from meter to furnace...

Page 27: ...h an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections WARNING Gas line grommet factory supplied loose parts bag should be used when installing gas piping Gas line entry hole filler plug should be installed in unused gas line entry hole See Fig 30 NOTE The gas valve inlet pressure tap connection is suitable to use as test ga...

Page 28: ...ontrol will lock out Control is grounded through green yellow wire routed to gas valve C terminal and burner box screw CAUTION See Fig 31 32 and 50 57 for field wiring diagram showing typical field 115 v and 24 v wiring Check all factory and field electrical connections for tightness Field supplied wiring shall conform with the limitations of 63 rise 115 V WIRING Before proceeding with electrical ...

Page 29: ...Heating and Cooling Application Wiring Diagram 1 Stage Thermostat and Condensing Unit 115 V FUSED DISCONNECT SWITCH WHEN REQUIRED JUNCTION BOX CONTROL BOX 24 V TERMINAL BLOCK THREE WIRE HEATING ONLY SEVEN WIRE 2 STAGE THERMOSTAT TERMINALS FIELD SUPPLIED FUSED DISCONNECT 2 SPEED CONDENSING UNIT FURNACE G R W2 Y2 G Y1 C GND GND GND GND GND GND FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY...

Page 30: ... POWER ENTRY HOLES POWER ENTRY HOLE FILLER PLUG FACTORY SUPPLIED LOOSE PARTS BAG A05113 Fig 34 Factory Installed J Box Location 24 V WIRING Make field 24 v connections at 24 v terminal block on furnace See Fig 36 Connect terminal Y Y2 as shown in Fig 31 and 32 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire for lengths up to 100 ft For wire lengths over 100 ft us...

Page 31: ...ONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused...

Page 32: ...32 A08343 Fig 36 Wiring Diagram 58MEC ...

Page 33: ...ystem and Fig 45 for non direct vent 1 pipe system WARNING An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion air when applicable and vent pipes Each furnace must have its own set of combustion air and vent pipes and be terminated individually as shown in Fig 44 for Direct Vent 2 Pipe system and Fig 45 for Non Direct Vent 1 Pipe system A furnace s...

Page 34: ...ed in loose parts bag in combustion air elbow using RTV or by cementing as shown in Fig 39 For 120 000 Btuh size units only separate the 2 halves of perforated disk assembly and use only the shouldered disk half 2 Determine the length of straight portion of combustion air inlet pipe from Fig 39 3 Cut field supplied 2 in 51 mm diameter PVC pipe to length as determined per Fig 39 4 Permanently attac...

Page 35: ...35 A05009 Table 8 Direct Vent Termination Clearance 58MEC ...

Page 36: ...36 A05013 Table 9 Other than Direct Vent Termination Clearance 58MEC ...

Page 37: ...pe permanently to combustion air intake housing since it may be necessary to remove pipe for service of burner box components or flame sensor Attachment of Combustion Air Intake Housing Plug Fitting The combustion air intake plug fitting must be installed in unused combustion air intake housing This fitting must be attached by using RTV sealant or by drilling a 1 8 in hole in fitting using hole in...

Page 38: ...tem ONLY NOTE Do not count elbows or pipe sections in terminations or within furnace all elbows shown in Fig 44 and 45 are not be to counted 2 Determine location of vent pipe connection to inducer housing as shown in Fig 38 for application 3 Install vent pipe grommet factory supplied in loose parts bag into selected furnace casing vent pipe hole See Fig 40 4 Reposition elastomeric rubber inducer h...

Page 39: ... 18 6 61 18 6 80 000 2 Pipe or 2 in Concentric 2 51 2 51 49 14 9 44 13 4 30 9 1 25 7 6 25 7 6 15 4 6 2 1 2 64 2 1 2 64 70 21 3 70 21 3 70 21 3 70 21 3 70 21 3 70 21 3 100 000 2 Pipe or 3 in Concentric 2 1 2 64 2 1 2 64 35 10 7 26 7 9 16 4 9 16 4 9 6 1 8 NA 3 76 3 76 70 21 3 70 21 3 70 21 3 70 21 3 66 20 1 61 18 6 120 000 2 Pipe or 3 in Concentric 3 76 NA 14 4 3 9 2 7 NA NA NA NA NA 3 76 63 19 2 62...

Page 40: ...A 2 51 2 51 60 18 3 55 16 8 54 16 5 49 14 9 48 14 6 47 14 3 80 000 2 Pipe or 2 in Concentric 2 51 2 51 41 12 5 36 11 0 23 7 0 18 5 5 17 5 2 8 2 4 2 1 2 64 2 1 2 64 70 21 3 70 21 3 70 21 3 70 21 3 70 21 3 70 21 3 100 000 2 Pipe or 3 in Concentric 2 1 2 64 2 1 2 64 29 8 8 21 6 4 12 3 7 11 3 4 NA NA 3 76 3 76 70 21 3 67 20 4 62 18 9 57 17 4 52 15 8 47 14 3 120 000 2 Pipe or 3 in Concentric 3 76 no di...

Page 41: ... 6 1 15 4 6 10 3 0 ALTITUDE FT M UNIT SIZE BTUH DIRECT VENT 2 PIPE ONLY NON DIRECT VENT 1 PIPE ONLY NUMBER OF 90 ELBOWS TERMINATION TYPE PIPE DIA IN PIPE DIA IN 1 2 3 4 5 6 9001 to 10 000 2743 to 3048 60 000 2 Pipe or 2 in Concentric 2 51 2 51 45 13 7 40 12 2 38 11 6 33 10 1 31 9 4 29 8 8 80 000 2 Pipe or 2 in Concentric 2 51 2 51 30 9 1 25 7 6 14 4 3 9 2 7 7 2 1 NA 2 1 2 64 2 1 2 64 57 17 4 55 16...

Page 42: ...nsertion depth on pipe 7 After pipes have been cut and preassembled apply generous layer of cement primer to pipe fitting socket and end of pipe to insertion mark Quickly apply approved cement to end of pipe and fitting socket over primer Apply cement in a light uniform coat on inside of socket to prevent buildup of excess cement Apply second coat 8 While cement is still wet twist pipe into socket...

Page 43: ...According to Table 14 2 in 51 mm diameter pipe is good for 35 ft 11 M with 3 elbows but only 30 ft 9 M with 5 elbows Therefore 2 1 2 in 64 mm diameter pipe must be used for both vent and combustion air pipes since larger required diameter must always be used for both pipes For a non direct vent 1 pipe system Table 11 indicates that this application would allow a 2 in 51 mm diameter vent pipe If sa...

Page 44: ...following guidelines 1 Comply with all clearance requirements stated in Table 8 or 9 per application 2 Termination or termination kit should be positioned where vent vapors will not damage plants shrubs or air conditioning equipment 3 Termination or termination kit should be positioned so that it will not be affected by wind eddy such as inside building corners nor by recirculation of flue gases a...

Page 45: ...chever is greater typ A At least 36 in A Maintain 12 in 305mm min clearance above highest anticipated snow level Maximum of 24 in 614mm above roof 90 Note A denotes 0 to 2 in Between the first 2 vents Third vent must be 36 in away typ 914mm 305mm 914mm 305mm 305mm 914mm 914mm 457mm 51mm 914mm A05090 Fig 44 Combustion Air and Vent Pipe Termination for Direct Vent 2 pipe System Abandoned masonry use...

Page 46: ... pipe fittings Clean and cement using same procedures as used for system piping 4 Check required dimensions as shown in Fig 44 Multiventing and Vent Terminations When 2 or more 58MEC Furnaces are vented near each other each furnace must be individually vented NEVER common vent or breach vent 58MEC furnaces Direct Vent 2 Pipe System ONLY When 2 or more 58MEC furnaces are vented near each other 2 ve...

Page 47: ... or control will lockout Control is grounded through green yellow wire connected to gas valve C terminal and burner box screw CAUTION CONDENSATE TRAP WIRE TIE S HEAT TAPE 3 WRAPS MINIMUM A93036 Fig 47 Condensate Trap Heat Tape Table 13 Furnace Setup Switch Description SETUP SWITCH NO SWITCH NAME NORMAL POSITION DESCRIPTION OF USE SW 1 Adaptiv e Heat Mode OFF When off allows 2 stage operation with ...

Page 48: ... caution may result in intermittent unit operation This furnace is equipped with a manual reset limit switch in the burner box area The switch will open and shut off power to the gas valve if a flame rollout or overheating condition occurs in the burner enclosure area DO NOT bypass the switch Correct inadequate combustion air supply component failure or restricted flue gas passageway before resett...

Page 49: ...fficient pressure is available the high heat pressure switch HPS closes and the high 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 ...

Page 50: ...ngth of previous cooling period of the single 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 37 When 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 st...

Page 51: ...sed and there is a demand for dehumidification the furnace blower motor BLWM will continue running at low cool speed same speed as LO HT b When the R to G and Y Y2 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower speed from COOL to HI HT for a maximum of 10 minutes before reverting back to COOL speed If there is still a demand for dehu...

Page 52: ... Fuel A00279 Fig 54 Dual Fuel Thermostat with Two Stage Furnace and Single Speed Heat Pump A00280 Fig 55 Dual Fuel Thermostat With Two Stage Furnace and Two Speed Heat Pump A00281 Fig 56 Two Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner 58MEC ...

Page 53: ...Selection must be turned ON in all dual fuel applications 10 NO connection should be made to the furnace HUM 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 re...

Page 54: ... will remain on for the selected blower OFF delay period then switch to continuous blower speed When the R to W W1 and Y Y2 R to W W1 and Y Y2 and G R to W W1 and Y1 and Y Y2 or R to W W1 and Y1 and Y Y2 and G circuits are energized the furnace control CPU will switch to or turn on the blower motor BLWM at COOL speed and begin a high heat cycle The blower motor BLWM will remain on until the end of...

Page 55: ...VED b Remove regulator seal caps that conceal adjustment screws for low and high heat gas valve pressure regulators See Fig 58 c Move setup switch SW 1 on control center to ON position This keeps furnace locked in low heat operation d Jumper R and W W1 thermostat connections on control to start furnace e Turn low heat adjusting screw counterclockwise out to decrease input rate or clock wise in to ...

Page 56: ...Size and High Low Heat Manifold Pressures for Correct Inputs for Use with 060 Through 120 Size Furnaces Only Tabulated Data Based on 20 000 13 000 Btuh per Burner Derated 2 Percent for Each 1000 ft 305 M Above Sea Level A08376A 58MEC ...

Page 57: ...s for Correct Inputs Continued for Use With 060 Through 120 Size Furnaces Only Tabulated Data Based on 20 000 13 000 Btuh per Burner Derated 2 Percent for Each 1000 ft 305 M Above Sea Level A08376B NOTE Percents of derate are based on midpoints of U S altitude ranges 58MEC ...

Page 58: ...place for proper input to be clocked d Obtain yearly heat value average for local gas supply NOTE Be sure heating value of gas used for calculations is correct for your altitude Consult local gas utility for altitude adjustment of gas heating value e Check and verify orifice size in furnace NEVER ASSUME THE ORIFICE SIZE ALWAYS CHECK AND VERIFY f Turn off all other gas appliances and pilots g Move ...

Page 59: ...4 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 124 29 58 145 SET TEMPERATURE RISE UNIT DAMAGE HAZARD Failure to follow this caution may result in unit 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 Place SW 1 in ON position Jumper R to W W1 and W2 to ...

Page 60: ...er motor speed lead from one of the other motor leads and relocate it to HI HT terminal See Table 18 for lead color identification Reconnect original lead on SPARE terminal Follow this same procedure for proper selection of LO HT and COOL speed selection Set Blower Off Delay a Remove Blower Access Door if installed b Turn Dip switch 2 and 3 ON or OFF for desired blower off delay See Tables 13 and ...

Page 61: ...ower and outer doors are properly installed 5 Cycle test furnace with room thermostat 6 Check operation of accessories per manufacturer s instructions 7 Review User s Guide with owner 8 Leave literature packet near furnace CHECKLIST DIRECT VENT 2 PIPE INSTALLATION LOAD CALCULATION ____________ Heating Load Btuh ____________ Cooling Load Btuh ____________ Furnace Model Selection COMBUSTION AIR AND ...

Page 62: ...f Kinks and Traps ____________ External Drain Connection Leak Tight and Sloped ____________ Condensate Trap Primed before Start Up ____________ Heat Tape Installed if Required CHECKLIST START UP ____________ Gas Input Rate Set Within 2 percent of Rating Plate ____________ Temperature Rise Adjusted Thermostat Anticipator ____________ Anticipator Setting Adjusted or ____________ Cycle Rate 3 Cycles ...