Carrier Infinity 59TN6A, Installation, Start-Up, Operating And Service And Maintenance Instructions

Page 1: ...ols 64 Checklist 64 SERVICE AND MAINTENANCE PROCEDURES 72 Cleaning Heat Exchangers 77 SEQUENCE OF OPERATION 81 PARTS REPLACEMENT GUIDE 88 TABLE Loose Parts Bag Contents 6 Minimum Clearances to Combustible Materials 6 Minimum Free Area Required 11 Minimum Space Volumes 11 Filter Size Information 21 Opening Dimensions 23 Air Delivery CFM 28 Maximum Capacity of Pipe 32 Electrical Data 35 Vent Termina...

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 in 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 obser...

Page 3: ...ese words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal iniury or death WARNING signifies a hazard which could result in personal iniury or death CAUTION is used to identify hazards which may result in nfinor personal iniury or product and property damage NOTE is used to highlight suggestions which will result in enhanced inst...

Page 4: ...the CAN CSA B149 1 2010 Venting Systems and Air Supply for Appliances Duct Systems US and CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 2005 Fundamentals Handbook Chapter 35 Acoustical Lining and Fibrous Glass Duct US and CANADA...

Page 5: ...stallation These materials are shipped in the main blower compartment See Table 1 for loose parts bag contents This furnace must be installed so the electrical components are protected from water not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS be located close to the chimney or vent and attached to an air distribution system Refer to Ai...

Page 6: ...e furnace dampers or other flow control must prevent chilled air from entering the furnace If the dampers are manually operated they nmst be equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position Table 1 Factory Supplied Installation Parts DESCRIPTION Outlet Choke Plate provided with 40K BTUH furnaces only see Note Air Intake Pipe Flange...

Page 7: ..._ 26 3 8 670 0 25 1 8 63s 7 _ 23 5 16 592 91 20 5 8 _ 522 7 19 1 8 14s5 61_ AIR FLOW CONDENSATE DRAIN TRAP _ LOCAT ON 1o1 _ _ _ 7 8 22 a 2 1 2 _ _ THERMOSTAT ENTRY L 25 4 F_3 76 2 AIR INTAKE 13 4 44 61 _A_ _B_ OUTLET WIDTH AIR FLOW 76 2 22 588 31 21 1834 o1 26 5 16 SSS 8 AIR INTAKE Ill1 I I 1518 8 181 166 2_ 17 5 BOTTOM RETURN 17 5 1 5 16 WIDTH 33 3 NOTE ALL DIMENSIONS IN INCH MM 29 1 2 749 3 283 ...

Page 8: ...NED AiR iS DISCHARGED UPWARD AIRFLOW THE BLOWER iS LOCATED TO THE LEFT OF THE BURNER SECTION AND CONDiTiONED AiR IS DISCHARGED TO THE RIGHT A02097 Fig 2 Multipoise Orientations SUPPLY AIR MAX80 F 27 C 32 F 0 C MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED FRONT RETURN AIR MIN60 F 16 O Fig 3 Freeze Protection and Return Air Temperature BACK FRONT A10490 Fig 4 Prohibited Installations A104...

Page 9: ...ten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal iniury or death The operation of exhaust fans kitchen ventilation fans clothes dryers attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION...

Page 10: ...2 kW of the total input rating of all gas appliances in the space but not less than 100 in 2 0 06 m2 One opening shall commence within 12 in 300 ram of the ceiling and the second opening shall commence within 12 in 300 ram of the floor The minimum dimension of air openings shall be at least 3 in 80 ram See Fig 7 c Combining space on different floor levels The volumes of spaces on different floor l...

Page 11: ...6 49 5 39 6 42 5 56 6 70 8 84 9 99 1 1 260 1 680 2 100 1 680 1 800 2 400 3 000 3 600 4 200 0 50 35 6 47 5 59 4 47 5 51 0 67 9 84 9 101 9 118 9 1 575 2 100 2 625 2 100 2 250 3 000 3 750 4 500 5 250 0 40 44 5 59 4 74 3 59 4 63 7 84 9 106 1 127 3 148 6 2 100 2 800 3 500 2 800 3 000 4 000 5 000 6 000 7 000 0 30 59 4 79 2 99 1 79 2 84 9 113 2 141 5 169 8 198 1 3 150 4 200 5 250 4 200 4 500 6 000 7 500 ...

Page 12: ...allation Kit trap grommet is required for all direct vent horizontal installations only The kit contains a rubber casing grommet designed to seal between the furnace casing and the condensate trap See Fig 16 NOTE The Horizontal Installation Kit trap grommet is NOT required for single pipe ventilated combustion air or other non direct vent applications NOTE The condensate trap extends below the sid...

Page 13: ...ox _ Connect relief tube to port on collector box _ otate elbow to desired position and tighten clamp to 15 lb in _ Slide tube in stand offs to adjust length Connect the new pressure switch tube from Loose Parts bag to f_ Route tube through inducer port on front pressure switch _ stand offs to adjust position _ of the tube N J Trim excess tube Sk J Connect Pressure switch tube to port on collector...

Page 14: ...ation NOTE Remove knockout in casing before re installing the condensate trap Slide relief tube in stand offs to adjust length _ ttach condensate trap with screw to collector box Vent elbow shown in alternate orientation Tighten clamp on inlet to vent elbow 15 lb in _ nstall plug on open port of collector box 1 AND 2 STAGE UNITS Align trap over middle and right hand port on collector box Horizonta...

Page 15: ...asing before re installing the condensate trap _ Rotate elbow to desired position and torque clamp on inlet 15 lb in Install two plugs previously removed in open ports on collector box Connect relief tube to port on collector box _ Slide relief tube in stand offs to adjust length Connect the new pressure switch tube from Loose Parts bag to port on front pressure switch _ ttach condensate trap with...

Page 16: ...the plain end of the drain elbow to the outlet stub on the drain trap Secure the drain tube to the trap with the spring clamp The remaining drain line can be constructed from field supplied l 2 in CPVC or 3 4 in PVC pipe in compliance with local building codes A factory supplied l 2 in CPVC to 3 4 in PVC adapter is supplied in the loose parts bag for use as required 7 Install the adapter or connec...

Page 17: ...r the condensate trap in the side of the casing 4 Install the drain trap grommet in the casing if required for direct vent applications If necessary remove the trap install the grommet and re install the trap 5 Remove the pre formed rubber drain elbow and two spring clamps from the loose parts bag 6 Remove the formed grommet on the elbow to create an elbow or straight connector See Fig 15 7 Connec...

Page 18: ...rap Fig 16 Horizontal Drain Trap Grommet Al1582 Attach tube to condensate Cut line for left side condensate drain Do not disc T l 1 3 8 in 35 ram Cut formed end off condensate drain tube Formed end of grommet Connect short end of Z pipe to modified ube Factory supplied 1 2 in CPVC to 3 4 in PVC adapter TRAP DRAIN ELBOW WITH DISCHARGE PIPE Formed end of grommet Open spring clamp Insert 1 2 in to 3 ...

Page 19: ...machine bolts washers and nuts NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure panel to install leveling legs To remove bottom closure panel see Item 1 in Bottom Return Air Inlet section in Step 1 above To install leveling legs 1 Position furnace on its back Locate and drill a hole in each bottom corner of furnace 2 For each l...

Page 20: ...uct 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 attachment shall prevent leaks Connect supply air duct to flanges on furnace supply air outlet Bend flange up...

Page 21: ...IDTH FILTER TYPE SIDE RETURN BOTTOM RETURN 16 x 25 x 6 4 14 x 25 x 6 4 Washable 14 3 161 360 406 x 635 x 19 356 x 635 x 19 16 x 25 x 3 4 16 x 25 x 3 4 Washable 17 1 2 445 406 x 635 x 19 406 x 635 x 19 16 x 25 x 6 4 20 x 25 x 6 4 Washable 21 533 406 x 635 x 19 508 x 635 x 19 16 x 25 x 6 4 24 x 25 x 6 4 Washable 24 1 2 622 406 x 635 x 19 610 x 635 x 19 Recommended to maintain air filter face velocit...

Page 22: ...capaci b airflow 4 in Block Off Plate 20 in Media Cabinet Media Cabinet Installation Option for 4 Ton or Less A C Capacity it 4 21 in Furnace up to 5 Ton AC Capacity 24 1 2 in Furnace up to 4 Ton AC Capacity _45 Transition j 20 or 24 in Media Cabinet 20 or 24 in Media Cabinet Installation with Angled Transition 14 3 16 in Furnace H Screw _1 I_ Screw 14 3 16 in Furnace with Filler Plates Centered 1...

Page 23: ...ations on combustible flooring KGASB sub 15 1 8 19 16 3 4 20 5 8 base required 384 483 425 600 Downflow Applications on Combustible Flooring with ON PV 15 1 2 19 16 1 2 20 CNRV CAR or CAP Coil Assembly or KCAKC coil box KGASB 394 483 419 508 subbase not required Upflow Applications on Combustible or Noncombustible Floor 19 1 2 21 5 8 20 1 8 22 1 4 ing KGASB subbase not required 495 549 511 565 Dow...

Page 24: ...S NQ YES YES NQ A10493 1 44mm 8mm 44mm 1 3 4 44mm 1 Fig 21 Leveling Legs A89014 BOTTOM CLOSURE PANEL BOTFOMPLATE Fig 22 Removing Bottom Closure Panel Al1092 LEVEL 0 IN 0 MM TO 1 2 1N 13 MM MAX __ J FRONT UPFLOW OR DOWNFLOW MIN 1 4 1N 6 MM TO 1 2 1N 13 MM MAX HORIZONTAL Fig 23 Furnace Pitch Requirements Al1237 24 ...

Page 25: ...igurations and Restrictions NOTE RESTRIO11ON SAME FOR 14ORIZONAI I_T AIR HORIZONTAL RETURN NOT PERMITTED FOR NOT PERMITTED l 0 d dt Fig 25 Downflow Return Air Configurations and Restrictions HORIZONAL RETURN AIR RESTRICTIONS Al1037 Fig 26 Horizontal Return Air Configurations and Restrictions Al1038 25 ...

Page 26: ... NOTE Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling COMBUSTION AIRPIPE _ SEEVENTINGSECTION _1 4 IN ROD NOTE EXTEND ANf IRON OUT FOR COIL SUPPORT HEX NUT WASHER 4 REQD PER ROD ROD LOCATION USING DIMPLE LOCATORS NOTES 1 A 1 In 25mm clearance minimum between top of furnace and combustible material 2 The entire length of furnace ...

Page 27: ...ections to furnace with code approved tape or duct sealer NOTE 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 performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in 25 mm clearance from combustible materials to supply air ductwo...

Page 28: ...370 11335 11300 11260 11225 11190 11155 Low HeotA rf ow3 1655 1655 1660 1670 1670 1665 1660 1655 1645 1765 Unit Size 080 14 CIg Default CFSefault I OFF I OFF OFF OFF OFF ON Clg CF Switch Settings I External Static Pressure ESP swx 3 i swx 2 I swx 1 I 0 110 210 3 10 4 10 5 10 610 7 10 6 10 911 0 OFFI OFFI OFF 11055 11065 11060 11075 11065 11050 11045 11035 11025 11005 I OFF15201505150514951490I See...

Page 29: ...119151900 Htgh Heat Atrflow 3 1340 1355 1370 1385 1380 1385 1400 1400 1385 1380 Low Heat Atrflow 3 1080 1115 1115 1120 1125 1135 1125 1120 1125 1110 Unit Size 100 22 CIg Default Clg CF Switch Settings I External Static Pressure ESP swx 3 i swx 2 I swx 1 i 0 1 0 210 3 0 410 5 0 610 7 0 610 9 OFFI OFFI OFF I 16201625 I 16401645 I 16401635 I 16251605 I 1760 1 0 1770 OFDe_ult I OFFI OFFI OFF1750 740 1...

Page 30: ...ts in airflow are subject to motor horsepower range capacity 2 Maximum cooling airflow is achieved when switches SW2 1 SW2 2 SW2 3 and SW1 5 are set to ON and SW4 3 is set to OFF 3 All heating CFM s are when low heat rise adjustment switch SW1 3 and comfort efficiency adjustment switch SW1 4 are both set to OFF 4 Ductwork must be sized for high heating CFM within the operational range of ESP Opera...

Page 31: ...iate straps hangers etc Use a minimum of 1 hanger every 6 ft 1 8 M Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to the action of propane gas FURNACE DAMAGE HAZARD Failure to follow this caution may result in furnace damage Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls and burner misalignment A...

Page 32: ...d for proper operation or else control will lock out Control nmst remain grounded through green yellow wire routed to gas valve and manifold bracket screw l15 V Wiring Furnace must have a l15 v power supply properly connected and grounded NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control LED status indicator light will flash rapidly and furnace will NOT oper...

Page 33: ...ox bracket 3 Secure power cord to J Box bracket with a strain relief bushing or a connector approved for the type of cord used 4 Pull furnace power wires through l 2 in 12 mm diameter hole in J Box If necessary loosen power wires from strain relief wire tie on furnace wiring harness 5 Connect field ground wire and factory ground wire to green ground screw on J Box mounting bracket as shown in Fig ...

Page 34: ... 35 4 Outside Air Thermistor OAT The OAT connection is used in coniunction with commu nicating User Interface It is not required when the furnace is controlled by a standard type thermostat Refer to the in structions supplied with the User Interface for complete de tails Alternate Power Supplies This furnace is designed to operate on utility generated power which has a smooth sinusoidal waveform I...

Page 35: ...LENGTH FT M I 32 9 8 32 9 8 32 9 8 31 9 4 31 9 4 MAXIMUM FUSE OR CKT BKR AMPSI 15 15 2O 2O 2O Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other potential operating components EAC humidifier etc full load amps 1 Time delay type is recommended Length shown is as measured one way along wire path between furnace and service panel for maximum 2 perc...

Page 36: ...D 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING NOTE 2 208 230 OR 460 VOLT TERMINAL BLOCK FURNACE CONDENSING UNIT NOTES 1 Connect Y Y2 terminal as shown for proper operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire Fig 34 Typical Two Stage Field Wiring Diagram...

Page 37: ...TRANSFORMER_4_VAC _ E_I _ __L_ I I I I CONNECTIONS F_I_ 1 Iq_oo_ I I _V Iv17HK42FZ0433411 _ X I VS S HI LO_ 115 VAC L2 NEUTRAL _ 4 _Z m k c oil T PLH_ARNLOWsVcOoLTNAGcETMoAR_N 1 PA_TNUMB_ANyD VOL_I_VACo L_L NT_oNS SOFTWARE EAC I TERMINAL VERSION 115 VAC 1 0 AMP MAX HUMIDIFIER _ _ TERMINAL 24WAC 0 5 AMP MAX ACRDJ AIR CONDITIONING RELAY DISABLE JUMPER O_ FLASH UPGRADE CONNECTOR FACTORY ONLY PL3 ECM ...

Page 38: ...nd 2 Stage Furnace with Single Speed Heat Pump TWO STAGE TWO SPEED THERMOSTAT FURNACE AIR CONDITIONER THERMOSTAT TWO STAGE TWO SPEED FURNACE HEAT PUMP HEAT STAGE 2 __ COOL STAGE 1 I__ HEAT STAGE 1 __ COOL STAGE 2 __ FAN __ 24 VAC HOT __ DEHUMIDIFY ___ 24 VAC COMM __ HUMIDIFY I_1_ _ N A I_ _E_ OR _ I_ CONNECT ON LIZS NOTE 11 NOTE 12 F_q I_q I_q I HUM i HUMIDIFIER ____ 24 VAC _ OUTDOORsENSOR See not...

Page 39: ...guration thermostat for Dual Fuel Operation Refer to thermostat instructions 10 NO connection should be made to the furnace HUM terminal when using a thermostat with a 24 volt humidifier output 11 Optional connection If wire is connected to W2 on furnace control board either dip switch SWI 2 or SWI LHT on furnace control should be set in ON position to allow thermostat to control furnace staging 1...

Page 40: ...es instructions d installation suivantes ainsi que l usage approprid de l apprat et ciment Tout arrat feu et solin de toit utilisds avec ce systame doivent atre des matdriaux listds UL L acceptation du standard Canadien CAN CSA B149 est directement relid fi l installation conforme aux instructions ci haut mentionndes Le standard Canadien recommande 1 inspection par un personnel qualifid et ce une ...

Page 41: ...m Refer to the Air For Combustion and Ventilation Section Provisions for adequate combustion ventilation and dilution air must be provided in accordance with U S A Installations Section 9 3 NFPA 54 ANSI Z223 1 2009 Air for Combustion and Ventilation and applicable provisions of the local building codes Canadian Installations Part 8 of CAN CSA BI49 1 10 Venting Systems and Air Supply for Appliances...

Page 42: ...quivalent Vent Length in Table 13 or 15 minus the number of fittings nmltiplied by the deduction for each type of fitting used from Table 14 The measured length of pipe used in a single or 2 pipe termination is included in the total vent length Include a deduction for a Tee when used for Alberta and Saskatchewan terminations Concentric vent terminations pipe lengths or elbows do not require a dedu...

Page 43: ...e adapter with the dimples in the casing 3 Pilot drill the screw holes for the adapter in the casing and attach the vent pipe adapter to the furnace with sheet metal screws 4 Slide the end of the rubber vent coupling with notches in it over the standoffs on the vent pipe adapter 5 Insert a length of vent pipe through the coupling into the outlet of the vent elbow 6 Tighten the clamp around the out...

Page 44: ...f vents as shown in Fig 47 and 48 and all clearance shown in Fig 45 and 46 Cut the required number of holes in the roof or sidewall for vent and when used combustion air pipes Sidewall holes for two pipe vent terminations should be side by side allowing space between the pipes for the elbows to fit on the pipes Holes in the roof for two pipe terminations should be spaced no more than 18 in 457 mm ...

Page 45: ...F628 F656 F891 ABS Pipe PVC Pipe For ABS PVC Pipe PVC Fittings ABS Fittings For PVC ABS Pipe Fittings PVC Pipe Fittings CPVC Fittings CPVC Pipe CPVC Pipe For CPVC ABS Pipe For PVC PVC Pipe Solvent Cement Solvent Cement Solvent Cement Primer Schedule 40 Schedule 40 For ABS SDR 21 SDR 26 Schedule 40 Schedule 40 For PVC DWV at Schedule 40 IPS sizes DWV Schedule 40 Schedule 40 SDR For CPVC Cellular Co...

Page 46: ...11 0 20 0 70 0 104 0 87 0 67 0 20 0 70 0 124 0 104 0 82 0 0 20 M 6 1 9 8 9 1 6 7 3 4 6 1 21 3 31 7 26 5 20 4 6 1 21 3 37 8 31 7 25 0 80000 Ft 20 0 17 0 14 0 6 0 0 0 20 0 70 0 71 0 57 0 40 0 20 0 70 0 86 0 71 0 52 0 20 30 M 6 1 5 2 4 3 1 8 0 0 6 1 21 3 21 6 17 4 12 2 6 1 21 3 26 2 21 6 15 8 Ft 15 0 7 0 5 0 0 0 0 0 20 0 61 0 52 0 40 0 24 0 20 0 70 0 64 0 50 0 33 0 40 40 M 4 6 2 1 1 5 0 0 0 0 6 1 18 ...

Page 47: ... 2 140 000 4 80 24 4 185 56 4 40 000 56 1 214 65 2 60 000 36 3 210 64 0 235 71 6 3001 to 4000 80 000 18 0 155 47 2 210 64 0 232 70 7 914 to 1219 100 OOO 5 8 96 29 9 211 64 3 236 71 9 120 000 6 2 4 66 26 2 224 68 3 140 000 4 79 24 1 158 48 2 40 000 53 9 205 62 5 60 OOO 35 1 204 62 2 228 69 5 4001 to 4500 80 000 17 1 150 45 7 202 61 6 224 68 3 1219 to 100 OOO 5 2 94 28 7 205 62 5 229 69 8 1370 120 0...

Page 48: ... vent piping DO NOT ASSUME that one foot of flexible vent pipe is equivalent to one foot of standard PVC vent pipe Example A direct vent 60 000 Btuh furnace installed at 2100 ft 640 M with 2 in 51 mm vent piping Venting system includes FOR EACH PIPE 3 90 long radius elbows 2 45 long radius elbows and a concentric vent kit Maximum Equivalent Vent Length Deduct 3 90 long radius Deduct 2 45 long radi...

Page 49: ...lest diameter pipe possible for venting 2 NA Not allowed Pressure switch will not close or flame disturbance may result 3 Total equivalent vent lengths under 10 for 40 000 BTUH furnaces from 0 to 2000 ft 0 to 610 M above sea level require use of an outlet choke plate Failure to use an outlet choke when required may result in flame disturbance or flame sense lockout 4 Not all furnace families inclu...

Page 50: ...pters Vent Coupling and Adapter Fig 37 Vent Coupling and Adapter with Gaskets Al1314 INDUCER OUTLET VENT ELBOW CLAMP TORQUE 15 LB IN VENT PIPE CLAMP TORQUE 15 LB IN INDUCER OUTLET CHOKE 40 000 BTUH MODELS ONLY ELBOW Fig 38 Inducer Vent Elbow Al1285 50 ...

Page 51: ...edion UPFLOW VERTICAL VENT A11310 C Attach vent pipe adapter with gasket to furnace casing Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling _ Slide vent pipe through adapter and coupling into vent elbow 1_ Insert vent pipe into vent elbow _ Torque all clamps 15 lb in Attach combustion air pipe adapter with gasket to furnace _ Attach combustion air pipe to a...

Page 52: ...Attach vent pipe adapter with gasket to furnace casing _ Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling C Slide vent pipe through adapter and coupling into vent elbow _ Insert vent pipe into vent elbow _ Torque all clamps 15 lb in _ Attach combustion air pipe adapter with gasket to furnace C Attach combustion air pipe to adapter with silicone Pilot drill ...

Page 53: ...ng _ Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling Q Slide vent pipe through adapter and coupling into vent elbow _ Insert vent pipe into vent elbow C Torque all clamps 15 lb in _ Attach combustion air pipe adapter with gasket to furnace _ Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secure with a 7 x 1 2 i...

Page 54: ...ket to furnace casing _ Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling _ Slide vent pipe through adapter and coupling into vent elbow _ Insert vent pipe into vent elbow _ Torque all clamps 15 lb in C Attach combustion air pipe adapter with gasket to furnace _ Attach combustion air pipe to adapter with silicone Pilot drill a 1 8 in hole in adapter and secu...

Page 55: ...N REMAINING VENT PIPE IS INSTALLED TORQUE UPPER CLAMP TO 15 LB IN VENT PIPE FLUSH WITH ADAPTER VENT PIPE FLUSH SHOWING COUPLING Fig 43 Vent Pipe Flush with Adaptor Al1339 Point elbow down towards back of furnace 12 256 0 mm CASING SIDE ATTACHMENT COMBUSTION AIR PIPE NON DIRECT VENT J TOP PLATE ATTACHMENT COMBUSTION AIR PIPE NON DIRECT VENT Fig 44 Combustion Air Pipe Attachment Al1345 55 ...

Page 56: ...r water heater vent or other appliance s direct vent 12 in 305 ram 12 in 305 ram intake or exhaust Clearance to the vent terminal of a dryer vent water N heater vent or other appliances direct vent intake or 3 ft 9 M 3 ft 9 M exhaust O Clearance from a plumbing vent stack 3 ft 9 M 3 ft 9 M For clearances not specified in ANSI Z223 1 NFPA 54 7 ft 2 1 M A vent shall not terminate above a side or CSA...

Page 57: ... inlet to any other appli and t00 000 Btuh 30kW 36 in 914 mm for 3 M above the opening ance appliances 100 000 Btuh 30 kW K Clearance to a mechanical air supply inlet 6 ft 1 8 M 3 ft 9 M For clearances not specified in ANSI Z223 t NFPA 54 12 in 305 mm Permitted only if veranda porch orCSA B149 t clearances shall be in accordance L Clearance under a veranda porch deck or balcony deck or balcony is ...

Page 58: ...12 in rain 305 mm fron overhang or roof 6 in 152ram minimum clearance between wal aid end of vent pipe 10 in 254mm maximum pipe enql Side walHermination with 2 ehbows preferred 12 in 305 ram rain from overhang or roof Maintain 12 in 305ram minimum clearance above highest a_licipated snow level or grade whichever is greater _O5mm ghest anticipated snow level or grade whichever is greater Sidewall T...

Page 59: ...all components shown OVERHANG OR ROOF COMBUSTION AIR ELBOW PARALLEL TO WALL J 12 IN SEPARATION BETWEEN BOTTOM OF _ COMBUSTION AIR AND BOTTOM OF VENT MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER UVL_IN _ EXHAUST I r _ _ _ ea ance to overhang per code Fig 49 Alberta and Saskatchewan Vent Termination Al1346 59 ...

Page 60: ...mm _ Ventilated Combustion Air 12 305 mm intake termination in crawl space CRAWL SPACE Vent through roof flashing Ventilated Combustion Air intake pipe ff 12 305 ram rain above highest level of insulation ATTI C Fig 50 Vent Terminations for Ventilated Combustion Air A10497 dO ...

Page 61: ...r modulating dampers Air Conditioning A C Setup Switches SW2 The air conditioning setup switches are used to match furnace airflow to cooling unit used To set the desired cooling airflow 1 Remove blower door 2 Locate A C setup switches on furnace control 3 Determine air conditioning tonnage used 4 Configure the switches for the required cooling airflow NOTE Excessive airflow caused by improper A C...

Page 62: ...SIZE ALWAYS CHECK AND VERIFY NOTE For Canadian altitudes of 2000 to 4500 ft 609 6 to 1371 6M use USA altitudes of 2001 to 3000 ft 609 6 to 914 4M 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 characteristi...

Page 63: ...n furnace control DO NOT forget to return setup switch to OFF position and remove R W2 jumper upon completion of testing c This furnace is capable of automatically providing proper airflow to maintain the temperature rise within the range d e f g h i specified on furnace rating plate If temperature rise is out side this range proceed as follows 1 Check gas input for low and high heat operation 2 C...

Page 64: ... Turn SWl 2 switch OFF 7 Install blower door b Electronic thermostat Set cycle rate for 3 cycles per hr Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switch This control shuts off combustion system and energizes air circulating blower motor if furnace overheats By using this met...

Page 65: ...2 Orifice Hole BURNER ORIFICE A93059 THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT FROM UNiT 24 V CONTROL TERMINALS EXAMPLE 5 0 AMPS ON AMMETER 0 5 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SETTING Fig 53 Amp Draw Check with Ammeter A96316 d5 ...

Page 66: ...ate drain Low inlet gas pressure ifLGPS used Restricted combustion air supply Improper pressure switch wiring Water invent piping possible sagging pipe Disconnected orobstructed pressure tubing Failed or Out d Calibration pressure switches 33 LIMIT CIRCUIT FAULT Indicates the limit orflame rollout isopen orthe furnace isoperating inhigh heat only mode due to 2successive low heat limit trips Blower...

Page 67: ...600 1600 1600 3 2 1N 1400 1400 2000 2000 2000 2000 3 2 t N 1400 1400 2000 2000 2100 2100 NOMINAL AIRFLOW BASED ON 325 CFM TON SW1 5 OFF SW4 3 ON SW3 CF Default COOLING SW2 AND CONTINUOUS FAN SW3 AIRFLOW SET UP SWITCH POSITIONS Model Size 060 14 080 14 060 20 080 20 100 22 120 22 3 2 1N 488 488 651 651 651 814 SW2 CIg Default 3 2 1N 976 976 1627 1627 1627 1627 3 2 1N 488 488 651 651 651 651 3 2 1 N...

Page 68: ...omponent Self Test for roubleshooting assistance when R thermostat ead is disconnected Turn OFF when Self Test is ompleted 3lower Off Delay time adjustable 90 seconds to 180 seconds See table in Adjustments section or efer to unit wiring diagram llows additional CFM per ton selections when Jaed with SW 1 5 325 CFM per ton nominal when SW 4 3 ON and 3W 1 5 OFF 350 CFM per ton nominal when SW 4 3 OF...

Page 69: ...Cu Ft 2 Cu Ft 72 144 71 141 69 138 68 136 67 133 65 131 64 129 63 126 62 124 61 122 60 120 58 116 56 112 54 109 53 106 51 103 50 100 48 97 47 95 46 92 45 90 44 88 43 86 42 84 41 82 40 80 39 78 38 76 38 75 37 74 36 72 35 71 35 69 34 68 33 67 33 65 32 64 31 62 30 60 660 720 1800 50 627 655 1636 51 300 600 1500 52 277 555 1385 56 257 514 1286 54 240 480 1200 55 225 450 1125 56 212 424 1059 57 200 400...

Page 70: ...5 42 3 6 1 5 3001 800 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 42 3 4 1 4 _ 915 825 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 42 3 2 1 4 t O 850 44 3 8 1 6 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 _ to 875 44 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 4000 900 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 1219 925 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 950 45 3 7 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 750 42 3 3 1 4 42 3 4...

Page 71: ...4 43 3 5 1 5 43 3 7 1 5 43 3 8 1 6 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 45 3 8 1 6 44 3 2 1 4 44 3 3 1 4 46 3 7 1 6 46 3 8 1 6 45 3 8 1 6 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 43 3 8 1 6 42 3 2 1 4 42 3 3 1 4 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 44 3 5 1 5 44 3 6 1 5 44 3 7 1 6 44 3 3 1 4 44 3 4 1 4 44 3 5 1 5 45...

Page 72: ...g must be properly maintained Refer to Fig 34 for field wiring information and to Fig 64 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash rapidly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode The 24 v circuit contains an automotive type ...

Page 73: ...XPLOSION HAZARD Failure to follow this warning could result in personal iniury death and or property damage Never store flammable or combustible materials on near or in contact with the furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning compounds plastic or plastic containers gasoline kerosene cigare...

Page 74: ...t and accessory wiring may need to be disconnected depend ing on their length and routing 4 If the vent and combustion air pipe passes through the blower compartment it will be necessary to remove the pipes from the blower compartment Disconnect the vent and combustion air pipe by a Loosen the clamps on the vent couplings and combustion air pipe external to the furnace b Separate the pipes from th...

Page 75: ...the manifold and remove the4screws that secure the manifold assembly tothe burner assembly and set aside Note the location ofthe green yellow wire and ground ter minal 10 Inspect the orifices inthe manifold assembly forblockages orobstructions Remove orifice and clean orreplace orifice 11 Remove the four screws that attach the topplate ofthe cas ingtothe furnace 12 Raise top plate upslightly and p...

Page 76: ...T blow into tube with tube connected to the pressure switch 9 Clean pressure switch port on collect box with a small wire Shake any water out of pressure switch tube 10 Reconnect tube to pressure switch and pressure switch port 11 Remove the relief tube from the port on the collector box and the trap 12 Clean the relief port on collect box and the trap with a small wire Shake any water out of the ...

Page 77: ...rds to gain access to screws attaching burner assembly to cell panel 6 Remove screws attaching burner assembly to cell panel See Fig 62 NOTE Burner cover manifold gas valve and burner assembly should be removed as one assembly 7 Clean heat exchanger openings with a vacuum and a soft brush See Fig 60 NOTE After cleaning inspect the heat exchangers to ensure they are free of all foreign objects that...

Page 78: ...ctor box opposite the condensate trap See Fig 59 10 Repeat Steps 5 through 8 11 If a condensate pump is used check with pump manufacturer to verify pump is safe for use with antifreeze used Allow pump to start and pump anti freeze to open drain 12 Replace main door 13 When furnace is re started flush condensate pump with clear water to check for proper operation before re starting furnace 14 Propy...

Page 79: ...WHEEL HUB SCREW LOCATION BLO HSG ASSY BRACKET BRACKET ENGAGEMENT DETAIL A SEE DETAILA _X CUTOFF BLOWER WHEEL BLOWER BRACKET_ J BLOWER HSG ASSY CAPACITOR OR POWER CHOKE WHEN USED Fig 61 Blower Assembly MOTOR BLOWER A11584 79 ...

Page 80: ...BURNER SUPT ASSY IGNITER BRACKET IGNITER BURNER ASSY __ FLAME SENSOR BELOW BURNER Fig 62 Burner Assembly FLAME ROLLOUT SWITCH A11403 80 ...

Page 81: ...V HI is energized The furnace control CPU begins a 15 sec prepurge period after the low heat pressure switch LPS closes If the 81 high heat pressure switch HPS fails to close and the low heat pressure switch LPS closes the fur nace will operate at low heat gas flow rate until the high heat pressure switch closes for a maximum of 2 minutes after ignition b Igniter Warm Up At the end of the prepurge...

Page 82: ...e connected to enable the adaptive cooling mode in response to a call for cooling See Fig 35 When ACRDJ is 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 start up the cooling unit in either low or high cooling If starting up in low cooling the furnace control CPU deter...

Page 83: ...r ON delay 45 sec in low heat and 25 sec in high heat allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the blower ON delay period at low heat or high heat airflow respectively The blower motor BLWM will revert to continuous blower airflow after the heating cycle is completed In high heat the furnace control CPU will drop the blower motor BLWM to low heat air...

Page 84: ...status codes will repeat Status codes are erased after 72 hours or can be manually erased by putting setup switch BW1 1 in the ON position and jumpering R W W1 and Y Y2 simultaneously until status code 11 is flashed When done put setup switch BW1 1 in the OFF position L Was there a previous status code other than I I t_ Does the control respond to WA_VI W2 Y1 Y Y2 and G 24V thermostat signals 7 YE...

Page 85: ...t Improper limit switch or no limit gasket Dirtyfllter or restricted duct system IGNITION PROVING FAILURE Iffl ame is not sensed during the trial for ignition period the control will repeat the ignition sequence 3 more times before lockout 14 occurs Iffl ame signal is lost during the blower on delay period blower will come on for the selected blower off delay Check the following items first before...

Page 86: ...described two steps back Does the voltage fluctuate as described in the previous step _ YES Replace the blower control module attached to the blower motor Follow the instructions with the blower control module to make sure the entire blower motor does not need to be replaced _ Turn power back on Is there115VAC at PL14 S and PL14 47 YES q s there 12 VDC at PL13 7 RED and PL13 1 GREEN 7 I Is there 1...

Page 87: ...w CFM ILK BlowerDoorInterlockSwitch SPST N O ACR Air Conditioning Relay SPST N O IND Inductor Note 7 ACRDJ Air Conditioning RelayDefeatJumper LED LightEmitting Diodefor StatusCodes BLWM Blower Motor ECM LOPS LowGas Pressure Switch SPST N O CF Continuous Fan Adjustable Airflow CFM LPS Low Heat Pressure Switch SPST N O CAP f Capacitor LS Lm tSw tch Auto Reset SPST N C COMMR Communication Relay SPDT ...

Page 88: ...s headings for dealer listing by brand name or contact CARRIER CORPORATION Consumer Relations Department P O Box 4808 Syracuse New York 13221 1 800 CARRIER Have available the model number series number and serial number located on the unit rating plate to ensure correct replacement part Model Nomenclature HEATING COOLING MODEL MOTOR WIDTH VOLTAGE MINOR SERIES AIRFLOW SIZE CFM 59TN6A 120 V 24 22 FI...