Carrier GAS FURNACE 58MTA, Installation, Start-Up, And Operating Instructions Manual

Page 1: ...Drain Attachments 10 Pressure Switch Tubing 10 Condensate Trap Freeze Protection 11 Construct a Working Platform 11 Horizontal Right Supply Air Discharge Applications 11 Condensate Trap Location 11 Condensate Trap Tubing 13 Condensate Trap Field Drain Attachment 13 Pressure Switch Tubing 13 Condensate Trap Freeze Protection 13 Construct a Working Platform 13 LOCATION 13 General 13 Furnace Location...

Page 2: ...it and other safety precautions that may apply These instructions cover the minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation Wear...

Page 3: ...L LEFT supply air discharge direction appli cations as shown in Fig 1 See details in Applications section This furnace must be installed with a direct vent combustion air and flue gas system and a factory accessory termination kit In a direct vent system all air for combustion is taken directly from the outdoor atmosphere and flue gases are discharged to the outdoor atmosphere See furnace and fact...

Page 4: ...ONTAL 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 for equivalent diameters 2 Minimum return air openi...

Page 5: ...pprouvée pour l installation HORIZONTALE et la circulation d air VERS LE HAUT et VERS LE BAS BOTTOM DESSOUS 0 Ø 3 0 0 TOP PLENUM DESSUS CHAMBRE D AIR 1 0 24 MIN ALL POSITIONS DOWNFLOW POSITIONS I HORIZONTAL POSITIONS S I DE C O T E S F R O N T A V A N T B C K A R R I E A E R S E R VI E C LÈNTR T E N E I V A N A T FRONT S I DE C O T E S F OU U F RNA C S E E I A RN Les fléches de dégagement ne chang...

Page 6: ...assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig 1 All drain and pressure tubes are connected as shown in Fig 6 See appropriate application instructions for these procedures Step 2 Upflow Applications In an upflow application the blower is located below the burner section and conditioned air is discharged upwards CONDENSATE TRAP LOCATION FACT...

Page 7: ...ed 4 Install condensate trap into left hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position 5 Fill unused condensate trap casing holes with plastic filler caps factory supplied in loose parts bag CONDENSATE TRAP TUBING ALTERNATE UPFLOW ORIENTATION NOTE See Fig 7 or tube routing label on main furnace door to confirm location...

Page 8: ... to the UPPER unused inducer housing drain connection is a cap and clamp This cap is used to prevent condensate leakage in this application Ensure this connection is capped NOTE See Fig 6 or 7 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 A...

Page 9: ...plugged b Connect larger diameter drain tube factory supplied in loose parts bag to drain tube cou pling extending collector box drain tube for connection to condensate trap c Route extended collector box drain tube directly from collector box drain to condensate trap as shown in Fig 9 d Determine appropriate length and cut e Connect to condensate trap f Clamp tube to prevent any condensate leakag...

Page 10: ...d 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 FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in electrical shock fire personal injury or death Casi...

Page 11: ...ht furnace application the blower is located to the left of the burner section and conditioned air is discharged to the right 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 attic application or over a finished ceiling NOTE In Canada installatio...

Page 12: ...S FROM EXITING THE VENT PIPE 5 3 4 NOTE LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS Fig 12 Horizontal Right Tube Configuration A01028 PLUG COLLECTOR BOX DRAIN TUBE BLUE AND WHITE STRIPED INDUCER HOUSING DRAIN TUBE VIOLET COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE GREEN CAP COLLECTOR BOX DRAIN TUBE BLU...

Page 13: ... connections Relocate tubes as described below 1 Disconnect collector box pressure tube pink label attached to High Pressure Switch 2 Extend collector box pressure tube green label which was previously connected to condensate trap relief port connection by splicing to small diameter tube factory supplied in loose parts bag 3 Connect collector box pressure tube green label to High Pressure Switch c...

Page 14: ...The temperature of the return air to the furnace is no less than 55 F with no evening setback or shutdown The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions The air temperature rise is within the rated rise range on the furnace rating plate and the firing rate has been set to the nameplate value The filters used...

Page 15: ...o provide desired height 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 n...

Page 16: ...ox 18 5 8 19 20 1 4 20 3 8 Downflow Applications on Combustible Flooring NOT Using KGASB Subbase Furnace with or without 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 CK...

Page 17: ...n a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 in horizontally from the furnace See NFPA 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...

Page 18: ...removed The air filter arrangement will vary due to application furnace orientation and filter type The filter may be installed in an external Filter Media cabinet if provided or the furnace blower compartment Factory supplied washable filters are shipped in the blower compartment If a factory supplied external Filter Media cabinet is provided instructions for its application assembly and installa...

Page 19: ...This furnace is shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when side return air is used To remove bottom closure panel perform the following 1 Tilt or raise furnace and remove 2 screws holding front filler panel See Fig 25 2 Rotate front filler panel downward to release holding tabs 3 Remove bottom closure panel 4 Reinstall front filler pan...

Page 20: ...e installed external to furnace casing and within 6 ft of furnace A 1 8 in NPT plugged tapping accessible for test gauge connection MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve Piping should be pressure tested in accordance with NFGC local and national plumbing and gas codes before the furnace has been connected In Canada refer t...

Page 21: ...ny of the original wire as supplied must be replaced use same type or equivalent wire Fig 28 Typical Heating and Cooling Application Wiring Diagram 2 Stage Thermostat and Condensing Unit A99072 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 UN...

Page 22: ...mance satisfaction Do not connect aluminum wire between disconnect switch and furnace Use only copper wire See Fig 29 Table 4 ELECTRICAL DATA UNIT SIZE VOLTS HERTZ PHASE OPERATING VOLTAGE RANGE MAX UNIT AMPS UNIT AMPACITY MIN WIRE SIZE MAX WIRE LENGTH FT MAX FUSE OR CKT BKR AMPS Max Min 060 12 115 60 1 127 104 8 4 11 3 14 33 15 080 12 115 60 1 127 104 8 1 10 8 14 34 15 080 16 115 60 1 127 104 11 6...

Page 23: ...eaner EAC Two male quick connect terminals marked EAC 1 and EAC 2 are provided for EAC connection See Fig 32 These terminals are energized with 115 v 1 0 amp maximum during blower motor operation 2 Humidifier HUM Connect an accessory 24 VAC 0 5 amp maximum humidifier if used to the 1 4 in male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip The HUM termi...

Page 24: ... EMITTING DIODE FOR STATUS CODES AMBER LGPS LOW GAS PRESSURE SWITCH SPST N O LPS LOW HEAT PRESSURE SWITCH SPST N O LS LIMIT SWITCH AUTO RESET SPST N C OL AUTO RESET INTERNAL MOTOR OVERLOAD TEMPERATURE SWITCH N C PCB PRINTED CIRCUIT BOARD CONTROL PL1 12 CIRCUIT PCB CONNECTOR PL2 3 CIRCUIT PCB HSI IDM CONNECTOR PL3 6 CIRCUIT ICM MOTOR CONNECTOR NOT SHOWN PL4 4 CIRCUIT IDM CONNECTOR PL5 2 CIRCUIT HSI...

Page 25: ...maximum pipe lengths and Fig 37 38 39 40 and 41 for exterior piping arrangements In Canada construct all combustion air and vent pipes for this unit of CSA or ULC listed schedule 40 PVC PVC DWV or ABS DWV pipe and pipe cement SDR pipe is NOT approved in Canada NOTE Furnace combustion air and vent pipe connections are sized for 2 in pipe Any pipe size change should be made outside furnace casing in...

Page 26: ...in 10 3m horizontally L Clearance under a veranda porch deck or balcony 12 30 cm M Clearance to each side of the centerline extended above or below vent terminal of the furnace to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 30 cm 12 30 cm O Clearance from a plumbing vent stack 3 91 cm 3 91 cm 1 In accordance with the current CSA B149 1 Natural Gas and Propane...

Page 27: ... pipes since larger required diameter must always be used for both pipes If same installation were in Albuquerque elevation 5250 ft above sea level installation would require 2 1 2 in vent pipe and combustion air pipe At 5001 to 6000 ft eleva tion 2 in pipe is only good for 17 ft with 5 elbows and 2 1 2 in pipe is good for 70 ft with 5 elbows Combustion Air and Vent Pipe Attachment NOTE All pipe j...

Page 28: ... 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 intake housing as a guide Install a field supplied No 6 or No 8 sheet metal screw NOTE DO NOT OVERTIGHTEN SCREW Breakage of intake housing or fitting may cause air leakage to occur A plugged drain connection has been provided on this fitting for use when...

Page 29: ...amp screws to 15 in lb of torque e Install casing hole filler plug factory supplied in loose parts bag in unused combustion air pipe casing hole Vent Extension Pipe Furnaces with 100 000 Btuh and larger inputs are supplied with a PVC vent extension pipe 2 in diameter by 12 in long This pipe has a built in channel to assist vent condensate disposal When this vent extension pipe is supplied it must ...

Page 30: ...esired 4 The 3 in concentric vent air termination kit is for 2 1 2 in 3 in and 4 in diameter pipe systems when single penetration of wall or roof is desired NOTE Shaded parts in Fig 37 38 39 40 and 41 are considered to be termination These components should NOT be counted when determining pipe diameter Roof termination is preferred since it is less susceptible to damage has reduced chances to take...

Page 31: ...MUM ALLOWABLE PIPE LENGTH FT Continued ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN NUMBER OF 90 ELBOWS 1 2 3 4 5 6 4001 to 5000 060 12 2 Pipe or 2 in Concentric 1 1 2 15 10 5 NA NA NA 2 64 59 58 53 52 52 080 12 080 16 2 Pipe or 2 in Concentric 2 44 39 26 21 20 11 2 1 2 70 70 70 70 70 70 100 16 100 20 2 Pipe or 3 in Concentric 2 1 2 31 22 13 12 NA NA 3 70 70 67 62 57 52 120 20 2 Pipe or 3 in...

Page 32: ...MUM ALLOWABLE PIPE LENGTH FT Continued ALTITUDE FT UNIT SIZE TERMINATION TYPE PIPE DIA IN NUMBER OF 90 ELBOWS 1 2 3 4 5 6 8001 to 9000 060 12 2 Pipe or 2 in Concentric 1 1 2 11 6 NA NA NA NA 2 49 44 42 37 35 34 080 12 080 16 2 Pipe or 2 in Concentric 2 33 28 17 12 10 NA 2 1 2 62 60 58 56 55 53 100 16 100 20 2 Pipe or 3 in Concentric 2 1 2 23 15 7 5 NA NA 3 59 54 49 44 39 34 120 20 2 Pipe or 3 in C...

Page 33: ...ed structure during cold weather when temperature drops to 32 F and below unless drain trap and drain line have adequate freeze protection See Service and Maintenance Instructions for winterizing procedure See Fig 42 GENERAL Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL app...

Page 34: ...esult in damage to plants CONDENSATE DRAIN PROTECTION Freezing condensate left in condensate trap and drain line may cause cracks and possible water damage may occur If freeze protection is required use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120 v and 40 F self regulating shielded and waterproof heat tape See Installation Instructions supplied with accessory or ...

Page 35: ...WINTER DESIGN TEMPERATURE F MAX PIPE DIAMETER IN WITHOUT INSULATION WITH 3 8 IN OR THICKER INSULATION 060 20 2 44 70 0 2 21 70 20 2 20 57 080 20 2 55 55 0 2 30 55 20 2 16 55 20 2 5 58 70 0 2 5 29 70 20 2 5 14 67 100 20 2 5 40 40 0 2 5 38 40 20 2 5 21 40 20 3 63 70 0 3 30 70 20 3 12 70 120 20 3 70 70 0 3 38 70 20 3 19 70 20 4 65 70 0 4 26 70 20 4 5 65 Pipe length ft specified for maximum pipe lengt...

Page 36: ...on A96128 A Fig 44 Concentric Vent and Combustion Air Roof Termination Dimension A is Touching or 2 in Maximum Separation A93056 COMBUSTION AIR VENT VENT A Fig 45 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 46 Raised Sidewall Termination when Wall Penetration is 12 in or Less Above Snow o...

Page 37: ...ur The condensate trap has internal chambers which can ONLY be primed by pouring water into the inducer drain side of condensate trap 1 Remove upper inducer housing drain connection cap See Fig 50 2 Connect field supplied 1 2 in ID tube to upper inducer housing drain connection 3 Insert field supplied funnel into tube 4 Pour 1 quart of water into funnel tube Water should run through inducer housin...

Page 38: ...ycle times When wall thermostat calls for heat R W W1 circuit closes The furnace control performs a self check verifies the low heat and high heat pressure switch contacts LPS and HPS are open and starts inducer motor IDM in high speed 1 Inducer Prepurge Period 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 ...

Page 39: ...sufficient pres sure is available the high heat pressure switch HPS closes and the high heat gas valve solenoid GV HI is energized The blower motor BLWM will switch to HI HEAT speed five seconds after the R to W2 circuit closes 2 Switching From High To Low Heat If the thermostat R to W2 circuit opens and the R to W1 circuit remains closed the furnace control CPU will switch the inducer motor IDM s...

Page 40: ...th Single Speed Air Conditioner Fig 52B Two Stage Furnace with Two Speed Air Conditioner A00276 A00277 Fig 52C Two Stage Furnace with Single Speed Heat Pump Dual Fuel A00278 Fig 52D Two Stage Furnace with Two Speed Heat Pump Dual Fuel 40 ...

Page 41: ... Heat Pump A00281 Fig 52G Two Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner A00280 Fig 52F Dual Fuel Thermostat With Two Stage Furnace and Two Speed Heat Pump A00282 Fig 52H Single Stage Thermostat With Two Stage Furnace and Two Speed Air Conditioner 41 ...

Page 42: ...urnace control reverts back to non Thermidistat mode The cooling operation described above also applies to operation with a Thermidistat The exceptions are listed below a When the R to G and Y1 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will continue running at low cool speed same speed as LO HEAT b When the R to G and Y Y2 circuit is closed and ther...

Page 43: ... period If the R to W W1 and Y1 signals disappear leaving the G signal the blower motor BLWM 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 ...

Page 44: ...6 1 5 47 3 7 1 6 45 3 2 1 4 45 3 4 1 4 45 3 5 1 5 ALTITUDE RANGE FT AVG GAS HEAT VALUE BTU CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 0 66 Orifice no Manifold Pressure Orifice no Manifold Pressure Orifice no Manifold Pressure Orifice no Manifold Pressure Orifice no Manifold Pressure U S A and Canada U S Altitudes 2001 to 3000 or Canada Altitudes 2001 to 4500 5 derate 775 43 3 8 1 6 ...

Page 45: ...FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 64 0 66 Orifice no Manifold Pressure Orifice no Manifold Pressure Orifice no Manifold Pressure Orifice no Manifold Pressure Orifice no Manifold Pressure U S A Only 5001 to 6000 11 derate 700 43 3 6 1 5 43 3 7 1 6 42 3 2 1 3 42 3 3 1 4 42 3 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...

Page 46: ...3 7 1 6 750 45 3 7 1 6 45 3 8 1 6 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 775 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 45 3 8 1 6 44 3 3 1 4 800 45 3 3 1 4 45 3 4 1 4 45 3 5 1 5 45 3 6 1 5 45 3 7 1 6 825 47 3 6 1 5 45 3 2 1 3 45 3 3 1 4 45 3 4 1 4 45 3 5 1 5 850 47 3 4 1 4 47 3 5 1 5 47 3 7 1 5 45 3 2 1 3 45 3 3 1 4 ALTITUDE RANGE FT AVG GAS HEAT VALUE BTU CU FT SPECIFIC GRAVITY OF NATURAL GAS 0 58 0 60 0 62 0 6...

Page 47: ...ZARD Failure to follow this caution may result in component damage due to flame impingement of burners and heat exchangers DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames 3 Verify Natural Gas Input Rate By Clocking Gas Meter NOTE Be sure all pressure tubing combustion air and vent pipes and burner enclosure f...

Page 48: ... of rise range or slightly above Place SW 1 in ON position Jumper R to W W1 and W2 to check high gas heat temperature rise To check low gas heat temperature rise remove jumper to W2 Determine air temperature rise for both high and low gas heat Do not exceed temperature rise ranges specified on unit rating plate for high and low gas heat This furnace must operate within the temperature rise ranges ...

Page 49: ...of LO HEAT 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 Table 9A and B or Fig 31 and 32 ADJUST BLOWER OFF DELAY HEAT MODE If desired the main blower off time delay period may be lengthened or shortened when operating in the heating mode to provide greater comfort See Table 9 for position ...

Page 50: ...ead wires from wire harness c Turn on 115 v power to furnace d Set thermostat to call for heat and wait 1 minute When pressure switch is functioning properly hot surface igniter should not glow and status code LED flashes a Status Code 32 If hot surface ignitor glows when inducer motor is disconnected shut furnace down immediately Deter mine reason pressure switch did not function properly and cor...

Page 51: ...pe 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 52: ...231 58mta7si 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 80129 Printed in U S A Form 58MTA 7SI Pg 52 5 04 Replaces 58MTA 6SI ...