Carrier 58MVP040, Installation, Start-Up, And Operating Instructions Manual

Page 1: ...rom Common Vent Systems 23 Combustion Air and Vent Piping 23 Concentric Vent and Combustion Air Termination Kit Installation 28 31 Multiventing and Vent Terminations 31 CONDENSATE DRAIN 31 33 General 31 32 Application 31 Condensate Drain Protection 31 SEQUENCE OF OPERATION 33 36 Self Test Mode 33 Heating Mode 33 Heating Mode Two Stage 34 Emergency Heat Mode 34 Cooling Mode 34 Heat Pump Mode 34 35 ...

Page 2: ... with static electricity firmly touch 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 to be installed in a furnace follow items 1 through 5 before bringing the control or yo...

Page 3: ...11 16 CONDENSATE DRAIN TRAP LOCATION DOWNFLOW HORIZONTAL RIGHT OR ALTERNATE 1 2 IN DIA GAS CONN 2 IN COMBUSTION AIR CONN 1 2 IN DIA GAS CONN 7 8 IN DIA POWER CONN 1 2 IN DIA THERMOSTAT ENTRY 2 IN VENT CONN DIMPLE LOCATORS FOR HORIZONTAL HANGING 14 1 2 TYP SIDE INLET NOTES 1 Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations ...

Page 4: ...is equipped for use with natural gas at altitudes 0 10 000 ft 0 3 050m An accessory kit supplied by the manufacturer shall be used to convert to propane gas use or may be required for some natural gas applications This furnace is for indoor installation in a building constructed on site This furnace may be installed in a manufactured mobile home when stated on rating plate and using factory author...

Page 5: ... box drain tube blue label inducer housing drain tube violet label or molded relief port tube green label and pressure switch tube pink label 2 Condensate Trap Drain Tube The condensate trap drain connection must be extended for field attachment by doing the following a Determine location of field drain connection See Fig 2 or 5 NOTE If internal filter or side filter media cabinet is used drain tu...

Page 6: ...to blower shelf hole where trap was removed 5 Fill unused condenstate trap casing holes with placstic filler caps factory supplied in loose parts bag CONDENSATE TRAP TUBING ALTERNATE UPFLOW ORI ENTATION NOTE See Fig 6 or tube routing label on main furnace door to confirm location of these tubes 1 Collector Box Drain Tube Connect collector box drain tube blue label to condensate trap NOTE On 17 1 2...

Page 7: ...e Fig 5 or 6 or tube routing label on main furnace door to check for proper connections CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda tions and procedures Step 3 Downflow Applications A downflow furnace application is where furnace blower is located above combustion and controls section of furnace and conditioned air is discharged downwards CONDENSAT...

Page 8: ...n for recommendations and procedures PRESSURE SWITCH TUBING One collector box pressure tube pink label is factory connected to the pressure switch for use when furnace is installed in UPFLOW or HORIZONTAL LEFT applications This tube MUST be dis connected and used for the condensate trap relief port tube The other collector box pressure tube green label which was factory connected to the condensate...

Page 9: ...Route extended collector box pressure tube to relief port connection on condensate trap c Determine appropriate length cut and connect tube d Clamp tube to prevent any condensate leakage CONDENSATE TRAP FIELD DRAIN ATTACHMENT Refer to Condensate Drain section for recommendations and procedures PRESSURE SWITCH TUBING The LOWER collector box pressure tube pink label is factory connected to the press...

Page 10: ...le where trap was removed 4 Install casing hole filler cap into blower shelf hole where trap was removed 5 Fill unused condenstate trap casing holes with placstic filler caps factory supplied in loose parts bag CONDENSATE TRAP TUBING NOTE See Fig 11 or tube routing label on main furnace door to check for proper connections 1 Collector Box Drain Tube a Remove factory installed plug from LOWER colle...

Page 11: ...iameter tube factory supplied in loose parts bag to extend collector box pressure tube pink label which was previously connected to pressure switch 5 Route this extended tube pink label to condensate trap relief 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 fo...

Page 12: ... result in safety and performance related problems Provide ample space for servicing and cleaning Always comply with minimum fire protection clearances shown on unit s clear ance to combustibles label See Fig 3 Locate furnace where available electric power and gas supplies meet specifications on furnace rating plate NOTE For proper furnace operation install furnace so that it is level or pitched f...

Page 13: ...less damper is in full heat or full cool position Step 4 Hazardous Locations INSTALLATION Step 1 Leveling Legs If Desired When furnace is used in upflow position with side inlet s leveling legs may be desired See Fig 12 Install field supplied corrosion resistant 5 16 in machine bolts and nuts NOTE The maximum length of bolt should not exceed 1 1 2 in 1 Position furnace on its back Locate and drill...

Page 14: ... and terminating outside the space containing the furnace Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated to enhance system per...

Page 15: ...plications on Combustible Flooring NOT Using KGASB Subbase Furnace with CD5 or CK5 Coil Assembly or KCAKC Coil Box 19 19 20 20 24 1 2 Upflow Applications 23 24 1 8 23 5 8 24 3 4 Downflow Applications on Non Combustible Flooring 22 7 8 19 23 1 2 19 5 8 Downflow Applications on Combustible Flooring Using KGASB Subbase Furnace with or without CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 1 8 19 23 3 ...

Page 16: ...urnace blower compartment deter mine location for filter and relocate filter retaining wire if necessary See Table 2 to determine correct filter size for desired filter location Table 2 indicates filter size location and quantity shipped with this furnace See Fig 2 for location and size of bottom and side return air openings Fig 16 Duct Flanges A93029 NO YES YES PERFORATED DISCHARGE DUCT FLANGE 21...

Page 17: ...bottom closure panel 4 Reinstall front filler panel and screws Step 7 Gas Piping Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC 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 if possible Refer to Table 3...

Page 18: ...e is equal to or less than 0 5 psig 14 in wc turn off electric shutoff switch located on gas valve before test It is recommended that ground joint union be loosened before pressure testing After all connections have been made purge lines and check for leakage ELECTRICAL CONNECTIONS See Fig 22 for field wiring diagram showing typical field 115 v and 24 v wiring Check all factory and field electrica...

Page 19: ...omotive type fuse located on control center See Fig 25 Any electrical shorts of 24 v wiring during installation service or maintenance may cause fuse to blow If fuse replacement is required use only a fuse of identical size 3 amp Fig 22 Heating and Cooling Application Wiring Diagram A98325 115 V FIELD SUPPLIED DISCONNECT SWITCH 115 V SINGLE PHASE AUXILIARY J BOX FURNACE CONTROL CENTER TWO WIRE 24 ...

Page 20: ...OR PL10 9 CIRCUIT BLOWER ADAPTER CONNECTOR PL11 1 CIRCUIT INDUCTOR SPLICE CONNECTOR PL12 5 CIRCUIT BLOWER POWER CONNECTOR PL13 16 CIRCUIT BLOWER CTRL CONNECTOR SW1 MANUAL SWITCH FAULT DISPLAY SPST N O SW2 MANUAL SWITCH LOWHEAT SPST N O SW3 MANUAL SWITCH BYPASS HUMIDIFIER SPST N O SW4 MANUAL SWITCH EMERGENCY HEAT SPST N O SW5 MANUAL SWITCH MULTIPLE ZONE SPST N O SW6 COMPONENT TEST SPST N O SW7 8 MA...

Page 21: ...tely 1 8 in Table 4 Electrical Data UNIT SIZE VOLTS HERTZ PHASE OPERATING VOLTAGE RANGE MAXIMUM UNIT AMPS UNIT AMPACITY MINIMUM WIRE SIZE MAXIMUM WIRE LENGTH FT MAXIMUM FUSE OR CKT BKR AMPS Maximum Minimum 040 14 115 60 1 127 104 8 9 12 0 14 31 15 060 14 115 60 1 127 104 8 9 12 0 14 31 15 080 14 115 60 1 127 104 8 9 12 0 14 31 15 080 20 115 60 1 127 104 13 8 17 9 12 32 20 100 20 115 60 1 127 104 1...

Page 22: ... the DEHUM input logic is reversed the DEHUM input is turned ON when no dehumidify demand exists and is turned OFF when demand exists This logic reversal has come about from historical use of a standard humidistat to do dehumidi fication since the contacts open on high humidity thus removing the 24 v signal to initiate dehumidification The DEHUM output on the thermidistat control or the humidistat...

Page 23: ... 40 CPVC pipe and F438 schedule 40 CPVC fittings Pipe cement and primer must conform to ASTM standards D2564 or F493 PVC or CPVC D2235 ABS See Table 6 for maximum pipe lengths and Fig 34 35 36 37 and 38 for exterior piping arrangements In Canada construct all combustion air and vent pipes for this unit of CSA or ULC certified schedule 40 PVC PVC DWV or ABS DWV pipe and pipe cement SDR pipe is NOT ...

Page 24: ...g could result in property damage personal injury or death NOTE The minimum combustion air and vent pipe length each for these furnaces is 5 ft Short pipe lengths 5 8 ft may discharge water droplets These droplets may be undesirable and a 12 in minimum offset pipe section is recommended as shown in Fig 31 to reduce excessive droplets from exiting vent pipe outlet COMBUSTION AIR AND VENT PIPE DIAME...

Page 25: ...b Reposition combustion air intake housing plug fitting in appropriate unused intake housing connection c Insert perforated disk assembly factory supplied in intake housing where combustion air intake pipe will be con nected d Install pipe support factory supplied in loose parts bag into selected furnace casing combustion air pipe hole Pipe support should be positioned to bottom of casing hole e I...

Page 26: ...4 2 Pipe or 2 In Concentric 1 1 2 42 37 32 27 22 17 2 70 70 70 70 70 70 060 14 2 Pipe or 2 In Concentric 1 1 2 42 37 32 27 22 17 2 70 70 70 70 70 70 080 14 080 20 2 Pipe or 2 In Concentric 1 1 2 25 20 15 10 5 NA 2 70 70 70 70 70 70 100 20 2 Pipe or 2 In Concentric 2 38 33 28 23 18 13 2 1 2 70 70 70 70 70 70 120 20 2 Pipe or 3 In Concentric 3 29 24 10 NA NA NA 3 59 59 58 57 57 56 ALTITUDE UNIT SIZE...

Page 27: ...2 7 NA NA NA 2 62 60 58 56 51 46 100 20 2 Pipe or 2 In Concentric 2 27 22 17 12 7 NA 2 1 2 62 60 58 56 55 53 120 20 2 Pipe or 3 In Concentric 3 43 41 39 37 35 34 ALTITUDE UNIT SIZE TERMINATION TYPE PIPE DIAMETER IN NUMBER OF 90 ELBOWS 1 2 3 4 5 6 9001 to 10000 040 14 2 Pipe or 2 In Concentric 1 1 2 27 22 17 12 7 NA 2 57 55 53 51 49 47 060 14 2 Pipe or 2 In Concentric 1 1 2 27 22 17 12 7 NA 2 57 55...

Page 28: ...installed and fully seated against inducer housing internal stop Clamp must be tightened to prevent any condensate leakage Failure to follow this warning could result in electrical shock fire personal injury or death NOTE A 2 in diameter pipe must be used within the furnace casing Make all pipe diameter transitions outside furnace casing 3 Working from furnace to outside cut pipe to required lengt...

Page 29: ...TAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER 90 VENT 12 IN SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT BRACKET COUPLING 12 MINIMUM OVERHANG OR ROOF COMBUSTION AIR ELBOW PARALLEL TO WALL Fig 35 Concentric Vent and Combustion Air Side Termination A93055 MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GR...

Page 30: ...air pipe Roof terminations Loosely install pipe coupling on prop erly cut vent pipe Coupling must be positioned so bracket will mount as shown in Fig 33 For applications using combustion air pipe option indicated by dashed lines in Fig 33 install 90 street elbow into 90 elbow making U fitting A 180 U fitting may be used Sidewall terminations Install bracket as shown in Fig 36 or 37 For application...

Page 31: ...te spillage select a pump with an overflow switch Furnace condensate is mildly acidic typically in the pH range of 3 2 to 4 5 Due to corrosive nature of this condensate a condensate pH neutralizing filter may be desired Check with local authorities to determine if a pH neutralizer is required Step 2 Application The furnace A C and humidifier drains may be combined and drained together The A C drai...

Page 32: ...um Separation A93056 COMBUSTION AIR VENT VENT A Fig 42 Sidewall Termination of More Than 12 in Dimension A is Touching or 2 In Maximum Separation A96130 VENT A COMBUSTION AIR COMBUSTION AIR Fig 40 Concentric Vent and Combustion Air Side Termination Dimension A is Touching or 2 In Maximum Separation A93057 COMBUSTION AIR VENT A VENT 1 MAXIMUM TYP Fig 38 Rooftop Termination Dimension A is Touching o...

Page 33: ...d 4 Ignition sequence After HSI ignitor warm up period is completed the gas valve opens permitting gas flow to burners where it is ignited After 5 sec the HSI is de energized and a 2 sec flame sensing period begins NOTE The initial heat mode after 115 v or 24 v power interrup tion will be LOW HEAT Low heat remains energized for 16 minutes before high heat is initiated providing thermostat is still...

Page 34: ...ode only operates in high heat 7 Flame sensing When burner flame is sensed control center holds gas valve open If burner flame is not sensed control center de energizes gas valve and ignition sequence is re peated NOTE Ignition sequence repeats 3 additional times before lock out occurs Lockout automatically resets after 3 hr or can be manually reset by turning 115 v or 24 v power off not at thermo...

Page 35: ... is to optimize combustion for maximum efficiency 10 Call for heat terminated When the call for heat is satisfied the R W W1 signal is terminated de energizing gas valve stopping gas flow to burners and HUM terminal is de energized a R W W1 signal terminated with R Y Y2 and R G still present The blower changes its speed to cooling RPM b R W W1 with R Y Y2 and R G signals terminated The blower cont...

Page 36: ...s Humidifier Mode When setup switch SW 3 BPH is in ON position RPM calculated for low heat is multiplied by 1 15 for all furnace model sizes This compensates for increased return air temperature caused by by passed air supply Step 10 Dehumidification Mode A dehumidification input is provided via a 1 4 in male quick connect terminal labeled DEHUM located next to the transformer secondary connection...

Page 37: ...et to meet the application requirements Position these setup switches for the appropriate requirement 1 Remove main furnace door and blower access panel 2 Locate setup switches on control center See Fig 25 3 See Table 10 for setup switch description See Fig 24 and 48 4 Replace main furnace door and blower access panel NOTE If a bypass humidifier is used setup switch SW 3 BPH should be in ON positi...

Page 38: ...OFF OFF OFF 565 515 690 690 860 1035 600 ON OFF OFF X X X 800 OFF ON OFF X X X X X X 1000 ON ON OFF X X X X X X 1200 OFF OFF ON X X X X X X 1400 ON OFF ON X X X X X X 1600 OFF ON ON X X X 2000 ON ON ON X X X Add 15 additional CFM when Bypass Humidifier switch SW 3 on control board is used X Indicates allowable selection Table 10 Setup Switch Description SETUP SWITCH NO NORMAL POSITION DESCRIPTION ...

Page 39: ...ulator adjusting screw This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures 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 proper flame characteristics f Move setup ...

Page 40: ... 42 3 2 1 4 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 Altitudes 800 43 3 5 1 5 43 3 7 1 5 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 2001 825 44 3 8 1 6 43 3 4 1 5 43 3 6 1 5 43 3 7 1 5 43 3 8 1 6 to 850 44 3 6 1 5 44 3 7 1 6 44 3 8 1 6 43 3 5 1 5 43 3 6 1 5 3000 875 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 or 900 44 3 2 1 4 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 Canada 925 45 3 7 1 5 45 3 8 1 6 4...

Page 41: ...4 1 4 725 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 750 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 775 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 5001 800 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 825 45 3 6 1 5 45 3 7 1 6 44 3 2 1 4 44 3 3 1 4 44 3 4 1 4 to 850 45 3 4 1 4 45 3 5 1 5 45 3 6 1 5 45 3 8 1 6 44 3 2 1 4 875 45 3 2 1 4 45 3 3 1 4 45 3 4...

Page 42: ...Low Orifice No Manifold Pressure High Low Orifice No Manifold Pressure High Low U S A Only 600 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 625 43 3 5 1 5 43 3 6 1 5 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 8001 650 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 675 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 44 3 8 1 6 43 3 4 1 5 to 700 44 3 2 1 4 44 3 3 1 4 44 3 4 1 5 44 3 6 1 5 44 3 7 1 6 725 45...

Page 43: ... 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 setup switch SW 2 to ON position See Fig 25 This keeps furnace locked in low heat operation Fig 50 Redundant Automatic Gas Valve A97386 ON OFF SWITCH INLET PRESSURE TAP ON O F F BURNER ENCLOSURE REFERENC...

Page 44: ...sition For high heat operation place setup switch SW 2 in OFF position and jumper R W2 on control center DO NOT forget to return setup switch to OFF position and remove R W2 jumper upon completion of testing See Fig 25 for switch and terminal location 3 This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range specified on unit rating plate...

Page 45: ...f there is a restricted return air supply or motor failure If the limit control does not function during this test the cause must be determined and corrected Step 2 Check Pressure Switches This control proves operation of the draft inducer Check switch operation as follows 1 Turn off 115 v power to furnace 2 Remove control access door and disconnect inducer motor 12 pin wire harness at inducer mot...

Page 46: ...e Sloped To Furnace Pipe Insulation ________ Over Ceilings ________ Low Ambient Exposed Pipes Condensate Drain ________ Unit Level or Pitched Forward ________ Internal Tubing Connections Free of 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 ...

Page 47: ...roduct theory and skills programs is available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 921...

Page 48: ...1 58mvp11si Manufacturer 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 535 80021 Printed in U S A Form 58MVP 11SI Pg 48 2 01 Replaces 58MVP 10SI ...