Carrier 58UVB series, Installation, Start-Up, And Operating Instructions Manual

Page 1: ...10 Hazardous Locations 10 INSTALLATION 10 Leveling Legs If Desired 10 Air Ducts 11 Filter Arrangement 11 Bottom Closure Panel 12 Gas Piping 12 Electrical Connections 14 Removal of Existing Furnaces from Common Vent Systems 17 Combustion air and Vent Pipe Systems 18 Condensate Drain 32 START UP ADJUSTMENTS AND SAFETY CHECK 33 General 33 UPFLOW AIRFLOW A06340 Fig 1 Furnace Orientation ama CERTIFIED ...

Page 2: ...age NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation 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 and gloves when handling parts CAUTION The 58UVB Condensing Gas Fired Furnaces are CSA formerly AGA and CGA design certi...

Page 3: ... Fig 5 The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions This gas furnace may be used for construction heat provided that S The furnace is permanently installed with all electrical wiring piping air filters venting and ducting installed according to these installation inst...

Page 4: ...in proper furnace installation These materials are shipped in the main blower compartment Installer Packet Includes Installation Startup and Operating Instructions Service and Maintenance Instructions User s Information Manual Warranty Certificate Loose Parts Bag includes Quantity Collector Box or Condensate trap extension tube 1 Inducer housing drain tube 1 1 2 in CPVC street elbow 2 Drain tube c...

Page 5: ... 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 the NFGC Air for Combustion and Ventilation S CANADA Part 7 of the NSCNGPIC Venting Systems and Air Supply for Appliances Step 4 Duct Systems S US and CANADA Air Conditioning...

Page 6: ...in Fig 7 from the factory See appropriate application instructions for these procedures MINOR PROPERTY DAMAGE Failure to follow this caution may result in minor property damage Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling CAUTION NOTE In Canada installations shall be in accordance w...

Page 7: ...ttachment To relocate condensate trap to the left hand side 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 ...

Page 8: ...USING UNUSED DRAIN CONNECTIONS Upper Collector Box Drain Connection Attached to the UPPER collector box drain connection is a factory installed plug This plug prevents condensate leakage in this application Ensure this plug is secure NOTE See Fig 7 or 8 or tube routing label on main furnace door to check for proper connections Upper Inducer Housing Drain Connection Attached to the UPPER unused ind...

Page 9: ... wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials 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 ...

Page 10: ...heat exchanger When installed parallel with a furnace dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering furnace If dampers are manually operated they must be equipped with a means to prevent operation of either unit unless damper is in full heat or full cool position Step 4 Hazardous Locations FIRE EXPLOSION INJURY OR DEATH HAZARD Improper lo...

Page 11: ...A 90B or local code for further requirements For a furnace not equipped with a cooling coil the outlet duct shall be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall 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 attac...

Page 12: ...very table in Product Data literature for specific use of single side inlets The use of both side inlets a combination of 1 side and the bottom or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM CAUTION NOTE Side return air openings can be used for return air connections Install filter s as shown in Fig 14 For bottom return air applications filter m...

Page 13: ...nlet to the gas valve WARNING Install a sediment trap in riser leading to furnace Trap can be installed by connecting a tee to riser leading to furnace so straight through section of tee is vertical Then connect a capped nipple into lower end of tee Capped nipple should extend below level of gas controls Place a ground joint union between gas control manifold and manual gas shutoff valve See Fig 1...

Page 14: ...Do not bypass or close switch with panel removed WARNING UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit operation Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire connected to gas valve and burner box screw WARNING 115 V WIRING Before proceeding with electrical connections make certain ...

Page 15: ...imum 060 14 115 60 1 127 104 8 9 14 31 15 080 14 115 60 1 127 104 8 9 14 31 15 080 20 115 60 1 127 104 13 8 12 32 20 100 20 115 60 1 127 104 13 8 12 32 20 120 20 115 60 1 127 104 13 8 12 32 20 Permissible limits of voltage range at which unit will operate satisfactorily Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other potential operating compo...

Page 16: ... Replace main furnace door and blower access panel NOTE If a bypass humidifier is used setup switch SW1 3 Low Heat Rise Adjust should be in ON position This compensates for the increased temperature in return air resulting from bypass NOTE If modulating dampers are used blower motor automatically compensates for modulating dampers If manual disconnect switch is to be mounted on furnace select a lo...

Page 17: ...5 Manual Switch Cooling CFM Ton SPST N O SW1 6 Manual Switch Component Test SPST N O SW1 7 8 Manual Switches Blower Off Delay SPST N O SW4 1 Manual Switch Twinning Main OFF Sec ON SW4 2 3 FOR FUTURE USE TRAN Transformer 115VAC 24VAC GV M C HI NOTE 3 BLU BRN HPS GRN YEL FRS LS NOTE 8 GRY RED RED RED LPS WHEN USED LGPS BRN FSE WHT PL3 1 4 HSI L1 FUSED OR CIRCUIT BREAKER DISCONNECT SWITCH WHEN REQ D ...

Page 18: ...r option procedures in the same section Common venting prohibited DIRECT VENT 2 PIPE SYSTEM In a direct vent 2 pipe system all air for combustion is taken directly from outdoor atmosphere and all flue products are discharged to outdoor atmosphere Combustion air and vent pipes must terminate together in the same atmospheric pressure zone either through the roof or a sidewall roof termination prefer...

Page 19: ...d outside of pipe 4 Chamfer outside edge of pipe for better distribution of primer and cement 5 Clean and dry all surfaces to be joined 6 Check dry fit of pipe and mark insertion 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 ove...

Page 20: ...PIPE General Furnace combustion air connection must be attached as shown in Fig 25 Combustion air intake housing plug may need to be relocated in some applications NOTE All pipe joints must be cemented except attachment of combustion air pipe to inlet housing connection since it may be necessary to remove pipe for servicing NOTE A 2 in diameter pipe must be used within the furnace casing Make all ...

Page 21: ...bustion box If use of this drain connection is desired drill out fitting s tap plug with 3 16 in drill and connect a field supplied 3 8 in tube This tube should be routed to open condensate drain for furnace and A C if used and should be trapped as shown in Fig 26 UNIT DAMAGE HAZARD Failure to follow this caution may result in unit component damage Inducer housing outlet cap must be installed and ...

Page 22: ...ns Part 7 of the NSCNGPIC Venting Systems and Air Supply for Appliances and all authorities having jurisdiction UNIT CORROSION HAZARD Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements may corrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning WARNING ...

Page 23: ...23 A06495 Fig 28 Crawlspace Termination A06496 Fig 29 Crawlspace Termination 58UVB ...

Page 24: ...sing hole VENT TERMINATION General Combustion air direct vent 2 pipe system only and vent pipe must terminate outside structure either through sidewall or roof For vent termination clearance refer to Fig 34 for Direct Vent 2 Pipe system and Fig 35 for Ventilated Combustion Air option Roof termination is preferred since it is less susceptible to damage or contamination and it has less visible vent ...

Page 25: ...mbustion Air Roof Termination preferred 1 in maximum typ from wall to inlet 12 in minimum from overhang or roof Maintain 12 in min clearance above highest anticipated snow level or grade whichever is greater A At least 36 in Concentric Vent and Combustion Air Side Termination A At least 36 in Side wall termination of less than 12 in above highest snow level 12 in min from overhang or roof 12 in se...

Page 26: ...ALLOWABLE EXPOSED VENT PIPE LENGTH FT WITH INSULATION IN WINTER DESIGN TEMPERATURE AMBIENT UNIT SIZE WINTER DESIGN TEMPERATURE F MAXIMUM PIPE DIAMETER IN INSULATION THICKNESS IN 0 3 8 1 2 3 4 1 060 14 20 2 30 55 61 70 70 0 2 16 33 38 46 53 20 2 9 23 26 33 38 080 14 080 20 20 2 37 65 70 70 70 0 2 20 39 45 55 63 20 2 11 27 31 39 45 100 20 20 2 1 2 41 70 70 70 70 0 2 1 2 21 42 48 59 68 20 2 1 2 11 28...

Page 27: ... vent elbow 90_ from position shown in Fig 31 3 Disassemble loose pipe fittings Clean and cement using same procedures as used for system piping 4 Check required dimensions as shown in Fig 31 Multiventing and Vent Terminations When 2 or more 58UVB Furnaces are vented near each other each furnace must be individually vented NEVER common vent or breach vent 58UVB furnaces Direct Vent 2 Pipe System O...

Page 28: ...28 A05009 Fig 34 Direct Vent Termination Clearance 58UVB ...

Page 29: ...29 A05013 Fig 35 Other than Direct Vent Termination Clearance 58UVB ...

Page 30: ...ER OF 90_ ELBOWS 1 2 3 4 5 6 3001 to 4000 60 000 2 Pipe or 2 In Concentric 1 1 2 42 37 32 27 22 17 2 70 70 70 70 70 70 80 000 2 Pipe or 2 In Concentric 1 1 2 25 20 15 10 5 NA 2 70 70 70 70 70 70 100 000 2 Pipe or 2 In Concentric 2 38 33 28 23 18 13 2 1 2 70 70 70 70 70 70 120 000 2 Pipe or 3 In Concentric 3 one disk 29 24 10 NA NA NA 3 one disk 59 59 58 57 57 56 ALTITUDE UNIT SIZE BTUH Termination...

Page 31: ... 2 Pipe or 3 In Concentric 3 one disk 43 41 39 37 35 34 ALTITUDE UNIT SIZE BTUH Termination Type Pipe Dia IN NUMBER OF 90_ ELBOWS 1 2 3 4 5 6 9001 to 10000 60 000 2 Pipe or 2 In Concentric 1 1 2 27 22 17 12 7 NA 2 57 55 53 51 49 47 80 000 2 Pipe or 2 In Concentric 1 1 2 15 10 5 NA NA NA 2 57 55 53 51 46 41 100 000 2 Pipe or 2 In Concentric 2 24 19 14 9 NA NA 2 1 2 57 55 53 51 49 47 120 000 2 Pipe ...

Page 32: ...des Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit operation Unit must not be installed operated and then turned and left off in an unoccupied structure during cold weather when temperature drops to 32_F or below unless drain trap and drain line have adequate freeze protec...

Page 33: ...rnace UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit operation or performance satisfaction These furnaces are equipped with a manual reset limit switch in burner box This switch opens and shuts off power to the gas valve if an overheat condition flame rollout occurs in burner enclosure Correct inadequate combustion air supply or improper venting condition befor...

Page 34: ...n airflow or low cooling airflow 1 Remove main furnace door and blower access panel 2 Locate CF setup switches on furnace control See Fig 33 3 Determine desired continuous fan airflow or low cooling airflow 4 Use wiring schematic to determine proper setup position of CF switches See Fig 23 and 39 5 Replace main furnace door and blower access panel SETUP SWITCHES SW1 The furnace control has 8 setup...

Page 35: ...Using schematic diagram follow sequence of operation through different modes See Fig 23 Read and follow wiring diagram carefully UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit operation Furnace control must be grounded for proper operation or control will lock out Control is grounded through green yellow wire routed to gas valve and burner box screw CAUTION NOT...

Page 36: ... on inducer motor IDM and slowly increases the inducer motor speed When the low heat pressure switch LPS closes inducer motor RPM is noted by the furnace control CPU and a 25 sec prepurge period begins The RPM is used to evaluate vent system resistance This evaluation is then used to determine the required RPM necessary to operate the inducer motor during the low heat prepurge period and low heat ...

Page 37: ...wer Off delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV M stopping gas flow to the burners and de energizing the humidifier terminal HUM The inducer motor IDM will remain energized for a 15 second post purge period The blower motor BLWM and air cleaner terminal EAC 1 will remain energized at low heat airflow or transition to low heat airflow for 9...

Page 38: ...outdoor unit staging See Fig 33 The thermostat closes the R to G and Y1 circuits for low cooling or closes the R to G and Y1 and Y2 circuits for high cooling The R to Y1 circuit starts the outdoor unit on low cooling speed and the R to G and Y1 circuit starts the furnace blower motor BLWM on low cooling airflow which is the true on board CF selection as shown in Fig 41 The R to Y1 and Y2 circuits ...

Page 39: ...e blower motor BLWM to continuous blower airflow low heat airflow or the midrange airflow whichever is lowest The blower motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower ON delay 30 seconds in low heat and 35 seconds in high heat allowing the furnace heat exchangers to heat more quickly then restarts at the end of the blower ON delay period at low...

Page 40: ...ith Single Speed Air Conditioner A00276 Fig 44 Two Stage Furnace with Two Speed Air Conditioner A00277 Fig 45 Two Stage Furnace with Single Speed Heat Pump Dual Fuel A00278 Fig 46 Two Stage Furnace with Two Speed Heat Pump Dual Fuel 58UVB ...

Page 41: ... Pump A00280 Fig 48 Dual Fuel Thermostat With Two Stage Furnace and Two Speed Heat Pump A00281 Fig 49 Two Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner See note 2 A02348 Fig 50 Single Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner 58UVB ...

Page 42: ...pplications 10 NO connection should be made to the furnace HUM terminal when using a Thermidistat 11 Optional connection If wire is connected dip switch SW1 2 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 con...

Page 43: ...ace control CPU turns the hot surface igniter ON for 15 seconds then OFF 3 The furnace control CPU then turns the blower motor BLWM ON at midrange airflow for 15 seconds then OFF 4 After shutting the blower motor BLWM OFF the furnace control CPU shuts the inducer motor IDM OFF NOTE The EAC terminals are energized when the blower is operating After the component test is completed 1 or more status c...

Page 44: ... 3 825 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 43 3 7 1 5 to 850 44 3 6 1 5 44 3 7 1 6 44 3 8 1 6 43 3 4 1 5 875 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 4000 900 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 925 45 3 7 1 5 45 3 8 1 6 44 3 2 1 4 44 3 3 1 4 950 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 45 3 8 1 6 750 43 3 7 1 6 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 4001 775 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 ...

Page 45: ... 3 7 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 800 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 44 3 2 1 4 825 45 3 3 1 4 45 3 4 1 4 45 3 5 1 5 45 3 6 1 5 625 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 42 3 4 1 5 8001 650 43 3 5 1 5 43 3 6 1 5 43 3 8 1 6 42 3 2 1 3 675 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 to 700 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 44 3 8 1 6 725 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 9000 750 45 3 ...

Page 46: ...high heat manifold pressure less than 3 2 in wc or more than 3 8 in wc for natural gas If manifold pressure is outside this range change main burner orifices to obtain manifold pressures in this range i When correct input is obtained replace caps that conceal gas valve regulator adjustment screws Main burner flame should be clear blue almost transparent See Fig 53 j Remove jumpers R to W W1 and R ...

Page 47: ... flames See Fig 52 CAUTION EXAMPLE High heat operation at 0 2000 ft altitude Furnace input from rating plate is 100 000 Btuh Btuh heating input Btuh cu ft X cu ft hr Heating value of gas 975 Btuh cu ft Time for 1 revolution of 2 cu ft dial 70 sec Gas rate 103 cu ft hr from Table 13 Btuh heating input 103 X 975 100 425 Btuh In this example the orifice size and manifold pressure adjustment is within...

Page 48: ...k all return and supply ducts for excessive restrictions causing static pressure greater than 0 5 in wc d Ensure Low Heat Rise Adjust switch SW1 3 on furnace control is in ON position when a bypass humidifier is used See Fig 33 for switch location e Check Troubleshooting Guide for Variable Speed 2 Stage Electronic Condensing Furnaces Series 100 SET THERMOSTAT HEAT ANTICIPATOR When using a non elec...

Page 49: ...roves 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 motor 3 Turn on 115 v power to furnace 4 Set thermostat to call for heat When pressure switches are functioning properly status code 42 will flash on furnace control approximately 20 sec after thermostat sw...

Page 50: ...r Selected ________________ Crawl Space Safety Controls Check Operation ________________ Termination Kit 2 Pipe or Concentric CHECKLIST START UP ________________ Combustion Air Pipe Length ________________ Gas Input Rate Set Within 2 percent of Rating Plate ________________ Combustion Air Pipe Elbow Quantity ________________ Temperature Rise Adjusted ________________ Vent Pipe Length Thermostat An...