Carrier Performance 59SP5A, Installation, Start-Up, Operating And Service And Maintenance Instructions

Page 1: ...aning Heat Exchangers 70 SEQUENCE OF OPERATION 75 PARTS REPLACEMENT GUIDE 80 TABLES Loose Parts Bag 5 Minimum Clearances to Combustible Materials 8 Minimum Free Area Required 12 Minimum Space Volumes...

Page 2: ...xhaust 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 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR O...

Page 3: ...se 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...

Page 4: ...e Homes CANADA National Standard of Canada Natural Gas and Propane Installation Code NSCNGPIC CAN CSA B149 1 2010 General Installation US NFGC and the NFPA 90B For copaes contact the National Fire Pro...

Page 5: ...ed and new controls into containers before touching ungrounded objects 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage ACCESSORIES See Product Data Sheet...

Page 6: ...8 _ A_R FLOW 12_ 31 CONDENSATE DRAIN TRAP LOCATION 7 8 _ _ THERMOSTAT ENTRY _7 8 122 21 _q_ SIDE INLET 126 4 22 55 3 634 0 265 16 166S 6 _3 76 2 AIR INTAKE h I 3 4 CONN 76 2 VENT 22 2 POWER CONN 169...

Page 7: ...ed to an air distribution system Refer to Air Ducts section be provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown in Table 2 or on the furnace...

Page 8: ...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 ma...

Page 9: ...D 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 3...

Page 10: ...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...

Page 11: ...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 wi...

Page 12: ...2 5 Sq In for each two Vertical Ducts or Openings 100 000 divided by 3 000 33 3 Sq In for each Single Duct or Opening 110 000 divided by 2 000 55 0 Sq In for each two Horizontal Ducts Table 4 Minimum...

Page 13: ...ATING AIR DUCTS I 1 I I I I I I II I I I I INTERIOR HEATED SPACE VENT THROUGH ROOF _ 12 AX 305mm 0 _ 1 SQ IN PER 1000 BTUH IN DOOR OR WALL UNCONFINED SPACE 6 MIN 152mm FRONT 0 1 SQ IN PER 1000 BTUH IN...

Page 14: ...inlet of the vent elbow on the inducer Remove the plugs from the collector box and set aside Do Not Discard Plugs For Horizontal Left only Remove the middle and right plug from the ports at the botto...

Page 15: ...on front pressure switch Route tube through inducer stand offs _ Install plugs in open ports on collector box Trim excess tube Connect pressure switch tube to port on collector box _ Connect relief t...

Page 16: ...Horizontal Right Orientation Slide relief tube in stand offs to adjust length Attach condensate trap with screw to collector box Vent elbow shown in alternate orientation Tighten clamp on inlet to ve...

Page 17: ...to desired position and torque clamp on inlet 15 lb in Install plug in open ports on collector box Connect relief tube to port on collector box _ Slide relief tube in stand offs to adjust length Conn...

Page 18: ...grommet See Fig 15 7 Slide a spring clamp 1 in 25 mm down the plain end of the drain tube 8 With the bend in the tube oriented horizontally and plain end of the tube pointing away from you insert the...

Page 19: ...CH DRAIN TUBE TO CONDENSATF 7 DRAIN TRAP PULL DRAIN STUB THROUGH CASING OPEN SPRING CLAMP INSERT FIELD SUPPLIED 1 2 CPVC DRAIN PIPE CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN TUBE RIGHT SIDE DRAIN INSTA...

Page 20: ...furnace casing See Fig 24 25 26 Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air...

Page 21: ...the left hand LH or right hand RH side The furnace can be hung from floor joists rafters or trusses or installed on a non combustible platform blocks bricks or pad Platform Furnace Support Construct w...

Page 22: ...t or field supplied accessory air cleaner nmst only be connected to the bottom opening on the furnace See Fig 18 and 25 For horizontal applications the Media Cabinet or field supplied accessory air cl...

Page 23: ...AC capacity airflow 20 in Media Cabinet 4 in Block Off Plate Media Cabinet Installation Option for 4 Ton or Less A C Capacity 21 in Furnace up to 5 Ton AC Capacity 24 1 2 in Furnace up to 4 Ton AC Cap...

Page 24: ...tions on combustible flooring KGASB sub 15 1 8 19 16 6 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...

Page 25: ...anges YES NQ YES 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 UP...

Page 26: ...turn Air Configurations and Restrictions NOT PERMITTED l 0 d Fig 25 Downflow Return Air Configurations and Restrictions Al1037 NOTE RESTRICTION SAME FOR A HOR ZONAL LEFT _ T AIR 0 N HORIZONAL RETURN A...

Page 27: ...ON FOR ALLOWABLE VENT CONFIGURATIONS Fig 27 Working Platform for Attic Installation Al1154 COMBUSTION AIR PIPE SEE VENTING SECTION _ VENT ROD NOTE EXTEND IRON OUT FOR COIL o o o2 LOCATORS HEX NUT WASH...

Page 28: ...90B as tested by UL Standard 181 for Class 1 Rigid air ducts NOTE For horizontal applications the top most flange may be bent past 90 to allow the evaporator coil to hang on the flange temporarily wh...

Page 29: ...priate 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 o...

Page 30: ...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 115 v power su...

Page 31: ...e 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...

Page 32: ...60 000 13 0 80 000 13 0 100 000 16 1 120 000 16 1 Permissible limits of the voltage range at which the unit operates satisfactorily MINIMUM MAXIMUM WIRE WIRE SIZE LENGTH AWG FT M _ 14 33 10 0 14 26 8...

Page 33: ...CH ______ W HT_ JWHI L_ O _ 1 J II f_ GND T I __ 115 VFIELD AUXILIARY n _ __1 II SUPPLIED J BOX _ _ I DISCONNECT _ _N_O_T_E_I J 24 V TERMINAL WIRE BLOCK iiiiiiii_iiiiiiiii iiiii iiiii iit iiiY_Y i _ii...

Page 34: ...ATION C eO _P LIGHTDIAGNOSTIC _ r OOM _ I m 0 D TRANSFORMER 24VAC CONNECTIONS PL1 LOW VOLTAGE MAIN HARNESS CONNECTOR EAC TERMINAL 115 VAC 1 0 AMP MAX 1 c_l I I 115 VAC L2 EAC 1 _ NEUTRAL r _ _ 1 _ _ C...

Page 35: ...ditioner THERMOSTAT SINGLE STAGE SINGLE SPEED FURNACE HEAT PUMP THERMOSTAT SINGLE STAGE TWO SPEED FURNACE HEAT PUMP RVS COOLING_ N A _ HEAT STAGE 2 _ FURNACE HEAT COOL STAGE 1 COMPRESSOR FAN _ 24 VAC...

Page 36: ...rmostat for single stage compressor operation Refer to thermostat instructions 8 Configure thermostat for two stage compressor operation Refer to thermostat instructions 9 Configure thermostat for Dua...

Page 37: ...instructions d installation suivantes ainsi que l usage approprid de l apprat et ciment Tout arret feu et solin de toit utilisds avec ce systame doivent atre des matdriaux listds UL L acceptation du s...

Page 38: ...stion air requirements for this option are the same as the requirements for providing outside air for combustion for a single pipe vent system Refer to the Air For Combustion and Ventilation Section P...

Page 39: ...r to the pipe must be made as close to the furnace as reasonably possible The Maximum Vent Length for the vent and combustion air pipe when used is determined from the Maximum Equivalent Vent Length i...

Page 40: ...pter 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...

Page 41: ...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 p...

Page 42: ...628 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 Ceme...

Page 43: ...A 9 1 22 9 19 5 15 5 N A Ft 20 70 78 70 60 20 70 175 183 154 20 70 175 215 181 20 10 M 6 1 21 3 23 8 21 3 18 3 6 1 21 3 53 3 55 8 46 9 6 1 21 3 53 3 65 5 55 2 Ft 20 42 41 33 21 20 70 132 111 89 20 70...

Page 44: ...94 28 7 205 83 60 8 71 6 265 80 8 71 6 265 80 8 30 5 250 76 2 76 2 67 7 249 75 9 68 0 250 76 2 28 3 237 72 2 71 6 64 0 232 70 7 64 3 236 71 9 26 2 224 68 3 69 5 61 6 224 68 3 62 5 229 69 8 25 3 217 66...

Page 45: ...130 39 6 8001 to 9000 60 000 25 0 152 46 3 168 51 2 2438 to 80 000 10 7 111 36 8 148 45 1 156 47 5 2743 100 000 67 20 4 157 47 9 170 51 8 120 000 56 17 1 164 50 0 40 000 33 5 115 35 1 9001 to 60 000 2...

Page 46: ...apters 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 M...

Page 47: ...urnace 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 elb...

Page 48: ...ach vent pipe adapter with gasket to furnace casing _ Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling G Slide vent pipe through adapter and coupling into vent...

Page 49: ...sing _ Align notches in rubber coupling over standoffs on adapter Slide clamps over the coupling G Slide vent pipe through adapter and coupling into vent elbow _ Insert vent pipe into vent elbow _ Tor...

Page 50: ...ith 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 _ Insert vent pi...

Page 51: ...N WHEN REMAINING VENT PiPE iS INSTALLED TORQUE UPPER CLAMP TO 15 LBqN VENT PIPE FLUSH WITH ADAPTER VENT PIPE FLUSH SHOWING COUPLING Fig 43 Vent Pipe Flush with Adaptor Al1339 Point elbow down towards...

Page 52: ...h I5 kW I2 in 305 mm for appliances 500 000 Btuh 15 kW 3 ft 9 M For clearances not specified in ANSI Z223 I NFPA 54 or C A N CSA BI49 1 clearances shall be in accordance with local installation codes...

Page 53: ...w or to the side of the opening 1 ft and 100 000 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 I 8 M 3 ft 9 M Fo...

Page 54: ...e 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 fr...

Page 55: ...l components shown OVERHANG OR ROOF J 12 IN SEPARATION BETWEEN BOTTOM OF I COMBUSTION AIR AND BOTTOM OF VENT COMBUSTION AIR ELBOW PARALLEL TO WALL MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SN...

Page 56: ...m _ 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 insulat...

Page 57: ...nd flow in to open field drain 8 Remove funnel and tube from collector box and replace col lector box drain plug Purge Gas Lines If not previously done purge the lines after all connections have been...

Page 58: ...the meter b Jumper R to W c Run furnace for 3 minutes d Measure time in sec for gas meter to complete 1 revolu tion and note reading The 2 or 5 cubic feet dial provides a more accurate measurement of...

Page 59: ...the rating plate Recommended operation is at the nfid point of rise range or slightly above Adjust Thermostat Heat Anticipator When using a non electronic thermostat the thermostat heat anticipator mu...

Page 60: ...SealCap underCap PressureTap Fig 51 Gas Valve Al1153 BURNER _ ORIFICE A93059 Fig 52 Orifice Hole EXAMPLE SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AR...

Page 61: ...bustion airsupply Proper vent sizing Disconnected orobstructed pressure tubing Condensate drainage restricted orblocked Ifitopens during blower on delay period blower willcome onfortheselected blower...

Page 62: ...200 1125 1059 1000 947 900 857 818 783 750 720 692 667 643 621 600 581 563 545 529 514 500 486 474 462 450 439 429 419 409 400 391 383 375 367 SECONDS FOR 1 REVOLUTION 50 51 52 53 54 55 56 57 58 59 60...

Page 63: ...2 44 3 3 44 3 4 44 3 5 1000 44 3 0 44 3 1 44 3 2 44 3 3 775 42 3 3 42 3 4 42 3 5 42 3 6 3001 800 43 3 8 42 3 2 42 3 3 42 3 4 _ 915 825 43 3 6 43 3 7 43 3 8 42 3 2 O 850 44 3 8 43 3 5 43 3 6 43 3 7 to...

Page 64: ...2 O 725 44 3 8 43 3 4 43 3 5 43 3 6 to 750 44 3 5 44 3 7 44 3 8 43 3 4 8000 775 44 3 3 44 3 4 44 3 5 44 3 7 2438 800 44 3 1 44 3 2 44 3 3 44 3 4 825 44 2 9 44 3 0 44 3 1 44 3 2 625 42 3 4 42 3 5 42 3...

Page 65: ...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 sensin...

Page 66: ...it and discard See Fig 35 3 Verify that the Blower Heat Off Delay jumpers are set as desired See Fig 35 4 Verify that the blower and control Main doors are properly installed 5 Verify that the Status...

Page 67: ...additional lubrication These motors can be identified by the absence of oil ports on each end of the motor The following items should be performed by a qualified service technician Clean blower motor...

Page 68: ...external disconnect fuse or circuit breaker 2 Turn off gas at external shut off or gas meter 3 Remove control door and set aside 4 Turn electric switch on gas valve to OFF 5 Disconnect the gas pipe fr...

Page 69: ...e disconnected from the pressure switch is higher than the collector box opening or water will flow out of tube 4 Remove the collector box plug from the top port on the up per corner of the collector...

Page 70: ...tch with a suitable warning label Verify proper operation after servicing ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal iniury death and or property damage T...

Page 71: ...ield supplied 3 8 in 9 5 ram ID tube to the open port on the collector box 6 Insert a field supplied flmnel into the tube 7 Pour 1 quart of anti freeze solution into the flmnel tube Antifreeze should...

Page 72: ...ii Fig 58 Cleaning Heat Exchanger Cell Al1273 Burner Flame Manifold Fig 59 Burner Flame Burner Al1461 72...

Page 73: ...BLOWER W gEL SET SCREW _ _ TORQUE J _ MMET MOTOR ARM I _I SCREW SPECIAL REF SCREW BLO HSG ASSY BRA BRACKET ENGAGEMENT CUTOFF BLOWER HSG ASSY CHOKE POWER WHEN REQ D SCREW GND Fig 60 Blower Assembly MO...

Page 74: ...BURNER SUPZ ASSY IGNITER BRACKET IGNITER ii BURNER ASSY __ FLAME SENSOR BELOW BURNER Fig 61 Burner Assembly FLAME ROLLOUT SWITCH A11403 74...

Page 75: ...the blower motor BLWM is energized f Blower Off Delay When the thermostat is satisfied the R to W circuit is opened de energizing the gas valve GV stopping gas flow to the burners and de energizing t...

Page 76: ...witch again at the thermostat will shift the continuous blower speed from HEAT to COOL Repeating the procedure will shift the continuous blower speed from COOL to FAN speed The selection can be change...

Page 77: ...code by momentarily shorting the TEST TWiN terminal to Com24V terminal until the LED goes out LED will flash the status code of the previous fault or status code 11 1 short and 1 long flash if there w...

Page 78: ...e blower wheel Defective switch or connections Dirty filter or restricted duct system Improper gas input adjustment Improper limit switch or no limit gasket 34 IGNITION PROVING FAILURE If flame is not...

Page 79: ...L2 EAC 2B PL1 6 FUSE TRAN t PL1 1 NOTE 3 FURNACE TYPE _t _ I_FS E _ PLI 9_ BACKWARD COMPATIBLE _ PL1 11 PL1 7_ L o JUNCTIONTERMINAL _ FACTORYPOWERWlRING 115VAC E 0 CONTROL TERMINAL FACTORY CONTROL WI...

Page 80: ...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...