Carrier Deluxe 58DLA, Installation Manual

Page 1: ... door is provided for tighter sealing in sensitive applications The 58DLA DLX furnaces are approved for use with natural or propane gas and the 58DLX is also approved for use in Low NOx Air Quality Management Districts STANDARD FEATURES QuieTech noise reduction system Media Filter Cabinet Included Microprocessor based control center Dehumidification selection for summer time cooling SmartEvap Humi...

Page 2: ...w Installation 10 Bottom Return Air Inlet 11 Horizontal Installation 12 Suspended Unit Support 12 Platform Unit Support 12 Roll Out Protection 12 Bottom Return Air Inlet 13 Side Return Air Inlet 13 Filter Arrangement 13 Air Ducts 13 General Requirements 13 Ductwork Acoustical Treatment 13 Supply Air Connections 13 Return Air Connections 14 Gas Piping 17 Electrical Connections 19 115 V Wiring 19 J ...

Page 3: ...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 GER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which c...

Page 4: ...ign 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 exchanger The furnace is factory shipped for use with natural gas This furnace is not approved for installation in mobile homes recreational vehicles or outdoors This furnace is designed for minimum cont...

Page 5: ...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 6: ...precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electrostatic potential 1 Disconnect all power to the furnace Multiple disconnects may be required DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DIS CHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch the clean unpainte...

Page 7: ...olvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials All fuel burning equipment must be supplied with air for fuel combustion Sufficient air must be provided to avoid negative pressure in the equipment room or space A positive seal must be made between the furna...

Page 8: ...l must be installed parallel with or on the downstream side of the unit to avoid condensation in the heat exchangers When installed parallel with the furnace dampers or other flow control must prevent chilled air from entering the furnace If the dampers are manually operated they must be equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool posi...

Page 9: ...rnace combustion air supply must be provided in accordance with this instruction manual The Standard Method 1 The space has no less volume than 50 cubic feet per 1 000 Btuh of the maximum input ratings for all gas appliances installed in the space and 2 The air infiltration rate is not known to be less than 0 40 air changes per hour ACH Table 2 Minimum Free Area Required for Each Combustion Air Op...

Page 10: ...thin 12 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Fig 8 c Combining space on different floor levels The volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more perma nent openings in doors or floors having free area of at least 2 in 2 1 000 Btuh 4 400 mm2 kW of total input rating of all gas...

Page 11: ...om 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 panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall bottom filler panel and screws Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place wh...

Page 12: ...alled 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 panel downward to release holding tabs 3 Remove bottom closure panel PLENUM OPENING C A B D FLOOR OPENING A96283 Fig 11 Floor and Plenum Opening D...

Page 13: ...s to joists The sheet metal MUST extend underneath the furnace casing by 1 in with the door removed The bottom closure panel on furnaces of widths 17 1 2 in and larger may be used for flame roll out protection when bottom of furnace is used for return air connection See Fig 17 for proper orientation of roll out shield Table 4 Opening Dimensions In FURNACE CASING WIDTH APPLICATION PLENUM OPENING FL...

Page 14: ... the design external static pressure The furnace airflow rates are provided in Table 5 AIR DELIVERY CFM With Filter When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace Secure ductw...

Page 15: ...pply side air duct humidifier or other accesso ries All accessories MUST be connected to duct external to furnace casing Return Air Connections FIRE HAZARD Failure to follow this warning could cause a fire personal injury or death Never connect return air ducts to the back of the furnace Follow instructions below Downflow Furnaces The return air duct must be connected to return air opening bottom ...

Page 16: ...SCREWS IN SIDE AND 2 SCREWS IN BOTTOM Fig 17 Typical Attic Installation A03177 30 IN MIN WORK AREA 6 MIN TYPE B VENT 17 3 4 22 SHEET METAL SEDIMENT TRAP EQUIPMENT MANUAL SHUT OFF GAS VALVE LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING GAS ENTRY 17 3 4 OVER ALL 4 3 4 UNDER DOOR 1 UNDER FURNACE ...

Page 17: ...1880 1715 2130 1995 1805 1645 2025 1895 1730 1565 1920 1785 1630 1480 1790 1675 1535 1390 1660 1565 1420 1280 1530 1420 1275 1145 1350 1260 1135 1005 Both Sides or 1 Side Bottom High Med High Med Low Low 2530 2285 1995 1770 2450 2215 1945 1740 2365 2150 1900 1700 2270 2075 1840 1645 2165 1985 1770 1575 2065 1890 1685 1505 1940 1780 1600 1415 1805 1660 1480 1325 1670 1525 1350 1190 1505 1360 1180 1...

Page 18: ... upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve NOTE The furnace gas control valve inlet pressure tap connec tion is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0 5 psig 14 in wc stated on gas control valve See Fig 52 Some installations require gas entry on right side of furnace as viewed in upflow See Fig ...

Page 19: ...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 20: ...ermitted by local code when installed in accordance with existing electrical codes Refer to the power cord manufacturer s ratings for proper wire gauge Do not use gas piping as an electrical ground FURNACE MAY NOT OPERATE Failure to follow this caution may result in furnace operation stopping and water pipes freezing during cold weather Furnace control must be grounded for proper operation or else...

Page 21: ... Box Do not pinch wires between cover and bracket Electrical Box on Furnace Casing Side See Fig 23 FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury death or property damage If field supplied manual disconnect switch is to be mounted on furnace casing side select a location where a drill or fastener cannot damage electrical or gas components 1 Select an...

Page 22: ...es between cover and bracket 24 V WIRING Make field 24 v connections at the 24 v terminal strip See Fig 23 Connect terminal Y Y2 as shown in Fig 24 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during installation service or maintenance could cause this fuse to blow...

Page 23: ...INAL 24 VAC 0 5 AMP MAX TWINNING AND OR COMPONENT TEST TERMINAL BLOWER OFF DELAY Fig 25 Heating and Cooling Application Wiring Diagram with 1 Stage Thermostat A99440 115 V FIELD SUPPLIED DISCONNECT AUXILIARY J BOX 24 V TERMINAL BLOCK THREE WIRE HEATING ONLY FIVE WIRE NOTE 1 NOTE 2 FIELD SUPPLIED DISCONNECT CONDENSING UNIT TWO WIRE FURNACE C O N T R O L R G COM W C R G Y GND GND FIELD 24 V WIRING F...

Page 24: ...e potential for vent gas leakage Category I furnaces operate with a flue loss not less than 17 percent to minimize the potential for condensation in the venting system These furnaces are approved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFGC or the NSCNGPIC the local building codes and furnace and vent manufacturers ...

Page 25: ...eed Air Conditioner A04216 See notes 2 5 8 and 10 on the page following these figures See notes 1 2 4 6 7 9 10 and 12 on the page following these figures A04217 Fig 28 Single Stage Furnace with Single Speed Heat Pump Dual Fuel See notes 1 2 3 4 6 8 9 10 and 12 on the page following these figures A04218 Fig 29 Single Stage Furnace with Two Speed Heat Pump Dual Fuel 24 ...

Page 26: ...Single Speed Heat Pump HUMIDFIER 24VAC See notes 1 2 3 4 11 12 and 14 on the page following these figures A04220 Fig 31 Dual Fuel Thermostat with Single Stage Furnace and Two Speed Heat Pump HUMIDFIER 24VAC See note 2 on the page following these figures A04221 Fig 32 Two Stage Thermostat with Single Stage Furnace and Two Speed Air Conditioner 25 ...

Page 27: ...y default 7 Dip switch No 2 on Thermidistat should be set in ON position for two speed compressor operation 8 Configuration Option No 10 Dual Fuel Selection must be turned ON in all dual fuel applications 9 NO connection should be made to the furnace HUM terminal when using a Thermidistat 10 The RVS Sensing terminal L should not be connected This is internally used to sense defrost operation 11 DO...

Page 28: ...tween 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 appliances should not suffer from condensation and corrosion The venting system and all appliances shall be installed in accordance with appli...

Page 29: ...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 30: ...If flue extension is used fasten the flue extension to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180 apart Fasten the vent connector to the flue extension with at least two field supplied corrosion resistant sheet metal screws located 180 apart 2 Vent the furnace with the appropriate connector as shown in Fig 34 46 CUT HAZARD Failure to follow t...

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: ... 8 9 on the page following these figures A03215 Fig 42 Horizontal Left Application Vent Elbow Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03216 Fig 43 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 7 8 9 on the page following these figures A03218 Fig 44 Horizontal Right Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03219...

Page 33: ...nal to the furnace 6 Accessory Downflow Vent Guard Kit KGAVG0101DFG required in downflow installations with lower vent configuration 7 Chimney Adapter Kit may be required for exterior masonry chimney applications Refer to Chimney Adapter Kit KGACA02014FC or KGACA02015FC for sizing and complete application details 8 Secure vent connector to furnace elbow with 2 corrosion resistant sheet metal screw...

Page 34: ...onnections at the 24 v terminal block on the furnace control Failure to make proper connections will result in improper operation See Fig 25 3 Gas supply pressure to the furnace must be greater than 4 5 in wc 0 16 psig but not exceed 14 in wc 0 5 psig 4 Check all manual reset switches for continuity 5 Install blower compartment door Door must be in place to operate furnace 6 Replace outer door Ste...

Page 35: ... 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 53 Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft Furnace input rate must be within 2 percent of furnace rating plate input For altitudes ab...

Page 36: ...rilled 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 4 Verify natural gas input rate by clocking meter NOTE Gas valve regulator adjustment cap must be in place for proper input to be clocked a Turn off all other gas appliances and pilots served by the meter b Run furn...

Page 37: ...plate Recommended operation is at the mid point of rise range or slightly above 6 Set thermostat heat anticipator a Mechanical thermostat Set thermostat heat anticipator to match the amp draw of the electrical components in the R W circuit Accurate amp draw readings can be obtained at the wires normally connected to thermostat subbase terminals R and W The thermostat anticipator should NOT be in t...

Page 38: ...ning the call for heat again i Furnace should ignite normally Step 5 Checklist 1 Put away tools and instruments Clean up debris 2 Verify that blower OFF DELAY time is selected as desired 3 Verify that blower and burner access doors are properly installed 4 Cycle test furnace with room thermostat 5 Check operation of accessories per manufacturer s instruc tions 6 Review User s Guide with owner 7 At...

Page 39: ...50 43 3 7 43 3 8 42 3 2 42 3 3 875 43 3 5 43 3 6 43 3 7 43 3 8 900 43 3 3 43 3 4 43 3 5 43 3 6 925 43 3 1 43 3 2 43 3 3 43 3 4 950 43 2 9 43 3 0 43 3 1 43 3 2 975 43 2 8 43 2 9 43 3 0 43 3 1 1000 43 2 6 43 2 7 43 2 8 43 2 9 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 Manifold Pressure Orifice No Manifold...

Page 40: ...43 3 0 43 3 1 43 3 2 750 43 2 7 43 2 8 43 2 9 43 3 0 775 43 2 6 43 2 7 43 2 7 43 2 8 800 43 2 4 43 2 5 43 2 6 43 2 7 825 43 2 3 43 2 3 43 2 4 43 2 5 850 43 2 1 43 2 2 43 2 3 43 2 4 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 P...

Page 41: ...and flame sensing electrode The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 24 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 The control LED will display status code 24 when fuse needs to be replaced Proper instrumentation is required to service elect...

Page 42: ...anifold Pressure Orifice No Manifold Pressure Orifice No Manifold Pressure U S A and Canada U S A Altitudes 2001 to 3000 or Canada Altitudes 2000 to 4500 800 43 3 8 42 3 2 42 3 3 42 3 4 825 43 3 5 43 3 7 43 3 8 42 3 2 850 43 3 3 43 3 5 43 3 6 43 3 7 875 43 3 2 43 3 3 43 3 4 43 3 5 900 43 3 0 43 3 1 43 3 2 43 3 3 925 43 2 8 43 2 9 43 3 0 43 3 1 950 43 2 7 43 2 8 43 2 9 43 2 9 975 43 2 5 43 2 6 43 2...

Page 43: ...43 2 8 43 2 9 43 2 9 750 43 2 5 43 2 6 43 2 7 43 2 8 775 43 2 3 43 2 4 43 2 5 43 2 6 800 43 2 2 43 2 3 43 2 3 43 2 4 825 43 2 1 43 2 1 43 2 2 43 2 3 850 48 3 7 43 2 0 43 2 1 43 2 1 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 P...

Page 44: ...a call for heat R W closed or R W opens during blower on delay 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if the limit draft safeguard flame rollout or blocked vent switch if used is open longer than 3 minutes Control will auto reset after three hours 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 ...

Page 45: ...ck See Table 13 6 Slide filter into cabinet 7 Replace filter cabinet door 8 Turn on electrical supply to furnace BLOWER MOTOR AND WHEEL ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch ...

Page 46: ...ccess door 20 Downflow or horizontal furnaces with vent pipe through furnace only a Install and connect short piece of vent pipe inside furnace to existing vent b Connect vent connector to vent elbow 21 Reinstall casing door 22 Turn on gas supply and cycle furnace through one complete heating and cooling cycle Verify the furnace temperature rise as shown in Adjustments Section Adjust temperature r...

Page 47: ...n optimum speed selection 10 Factory connected when BVSS Chimney Adapter Accessory Kit is not installed 11 Factory connected when LGPS is not used 12 Ignition lockout will occur after four consecutive unsuccessful trials for ignition Control will auto reset after three hours 13 Blower on delay gas heating 25 seconds cooling or heat pump 2 seconds 14 Blower off delay gas heating selections are 90 1...

Page 48: ... flange of collector box and attach to cell panel using existing screws making sure all screws are secure 13 Reconnect wires to the following components Use connec tion diagram on wiring label if wires were not marked for reconnection locations a Draft safeguard switch b Inducer motor c Pressure switch es d Limit over temperature switch e Gas valve f Hot surface igniter g Flame sensing electrode h...

Page 49: ...EAC 1 will remain energized for 90 120 150 or 180 seconds depend ing on the blower OFF delay selection The furnace control CPU is factory set for a 120 second blower OFF delay 2 Cooling Mode The thermostat calls for cooling a Single Speed Cooling See Fig 25 26 28 and 30 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 t...

Page 50: ... can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption 5 Heat pump See Fig 28 31 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 When the R to W and Y1 or R to W and Y1 and G circuits are energize...

Page 51: ...ough a brief component test sequence The inducer will start and run for the entire component test The HSI blower motor FAN speed AMBER LED boards only 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 transformer Does ...

Page 52: ... combustion air supply flame rollout switch 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 followi...

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 58DL 5SI Pg 52 3 05 Replaces 58DL 4SI ...