Carrier 120 Series, Installation, Start-Up, Operating And Service And Maintenance Instructions

Page 1: ...approved for use with natural or propane gas and the 58STX is also approved for use in Low NOx Air Quality Management Districts STANDARD FEATURES QuieTech noise reduction system Microprocessor based control center Adjustable heating air temperature rise Adjustable cooling airflow LED diagnostics and self test feature 4 way Multipoise furnace 13 vent applications Inner blower door Hot surface ignit...

Page 2: ... Inlet 11 Horizontal Installation 11 Suspended Furnace Support 11 Platform Furnace Support 11 Roll Out Protection 11 Bottom Return Air Inlet 11 Side Return Air Inlet 11 Filter Arrangement 11 Air Ducts 11 General Requirements 11 Ductwork Acoustical Treatment 12 Supply Air Connections 12 Return Air Connections 14 Gas Piping 15 Electrical Connections 19 115 V Wiring 19 J Box Relocation 20 Electrical ...

Page 3: ... furnaces Wear safety glasses and work gloves Have fire extinguisher available during start up and adjustment procedures and 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 GE...

Page 4: ...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 5: ... required when this furnace is installed on manufacturer s Coil Assembly Part No CD5 or CK5 or when Coil Box Part No KCAKC is used See Fig 2 for clearance to combustible construction information INTRODUCTION This Series 120 C 4 way multipoise Category I fan assisted furnace is CSA design certified A Category I fan assisted furnace is an appliance equipped with an integral mechanical means to eithe...

Page 6: ...rvicing to protect the furnace electronic control Precautions will pre vent electrostatic discharges from personnel and hand tools which are held during the procedure These 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...

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: ... will be adversely affected Never connect return air ducts to back of furnace See Fig 6 LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil 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 ...

Page 9: ...ion Method is used CARBON MONOXIDE POISONING HAZARD Failure to supply outdoor air via grilles or ducts could result in death and or personal injury Many homes require air to be supplied from outdoors for furnace combustion ventilation and dilution of flue gases The furnace combustion air supply must be provided in accordance with this instruction manual Table 2 Minimum Free Area Required for Each ...

Page 10: ... of a space if a There are no closable doors between rooms b Combining spaces on same floor level Each opening shall have free area of at least 1 in 2 1 000 Btuh 2 000 mm2 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 12 300 mm of the ceiling and the second opening shall commence within 12 300 mm of the floor Th...

Page 11: ...ir 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 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 ...

Page 12: ...ion Provide a minimum 17 3 4 X 22 piece of sheet metal for flame roll out protection in front of burner area for furnaces closer than 12 inches above the combustible deck or suspended furnaces closer than 12 in 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 r...

Page 13: ...air conditioning coil casing when used DO NOT cut main furnace casing side to attach supply air duct humidifier or other accessories All accessories MUST be connected external to furnace main casing NOTE For horizontal applications the top most flange may be bent past 90 degrees to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil ar...

Page 14: ... NOT cut main furnace casing to attach supply side air duct humidifier or other accesso ries All accessories MUST be connected external to furnace casing PLENUM OPENING C A B D FLOOR OPENING A96283 Fig 11 Floor and Plenum Opening Dimensions A04140 CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX FURNACE SHEET METAL PLENUM FLOOR OPENING COMBUSTIBLE FLOORING Fig 13 Furnace Plenum and Coil Assembly or Coil...

Page 15: ... to bottom sides left or right or a combination of bottom and side s of main furnace casing as shown in Fig 18 and 20 Bypass humidifier may be attached to unused side return air side of the furnace casing See Fig 18 and 20 Not all horizontal furnaces are approved for side return air connections See Fig 20 Fig 14 Duct Flanges A02329 UPFLOW OWNFLOW HORIZONTAL PREFERRED PERMITTED PREFERRED PREFERRED ...

Page 16: ...to avoid stress on gas control manifold and a gas leak Gas piping must be installed in accordance with national and local codes Refer to current edition of NFGC in the U S the NSCNG PIC in Canada Fig 16 Horizontal Suspension with Straps A02014 Fig 17 Typical Attic Installation A02164 30 IN MIN WORK AREA 6 MIN TYPE B VENT 17 3 4 22 SHEET METAL SEDIMENT TRAP MANUAL SHUTOFF GAS VALVE LINE CONTACT ONL...

Page 17: ...895 1730 1920 1785 1630 1790 1675 1535 1660 1565 1420 1530 1420 1275 1350 1260 1135 Both Sides or 1 Side Bottom High Med High Med Low 2530 2285 1995 2450 2215 1945 2365 2150 1900 2270 2075 1840 2165 1985 1770 2065 1890 1685 1940 1780 1600 1805 1660 1480 1670 1525 1350 1505 1360 1180 1 Side Only High Med High Med Low 2475 2260 1950 2395 2190 1910 2300 2110 1855 2200 2035 1795 2090 1940 1730 1985 18...

Page 18: ...of manual equipment shutoff valve Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada local and national plumbing and gas codes before the furnace has been connected After all connections have been made purge lines and check for leakage at furnace prior to operating furnace If pressure exceeds 0 5 psig 14 in wc gas supply pipe must be discon...

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: ... 70 2002 and any local codes or ordinances that might apply Canadian installations Make all electrical connections in accor dance with Canadian Electrical Code CSA C22 1 or authorities having jurisdiction FIRE HAZARD Failure to follow this warning could result in serious injury death or property damage Do not connect aluminum wire between disconnect switch and furnace Use only copper wire Use a se...

Page 21: ...CITY MAXIMUM WIRE LENGTH FT MAXIMUM FUSE OR CKT BKR AMPS MINIMUM WIRE GAUGE Maximum Minimum 045 08 024045 115 60 1 127 104 5 4 7 54 49 15 14 045 12 036045 115 60 1 127 104 7 0 9 50 39 15 14 070 08 024070 115 60 1 127 104 5 0 7 06 52 15 14 070 12 036070 115 60 1 127 104 6 8 9 22 40 15 14 070 16 048070 115 60 1 127 104 9 5 12 60 29 15 14 090 14 042090 115 60 1 127 104 8 2 10 83 34 15 14 090 16 04809...

Page 22: ... green ground screw 12 Complete electrical box wiring and installation Connect line voltage leads as shown in Fig 25 Use best practices NEC in U S and CSA C22 1 in Canada for wire bushings strain relief etc 13 Reinstall cover to J Box Do not pinch wires between cover and bracket POWER CORD INSTALLATION IN FURNACE J BOX NOTE Power cords must be able to handle the electrical require ments listed in ...

Page 23: ...5 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation NOTE DO NOT connect furnace control HUM terminal to HUM humidifier terminal on Thermidistat Zone Controller or simi lar device See Thermidistat Zone Controller thermostat or controller manufacturer s instructions for proper connection VENTING The furnace shall be connected to a l...

Page 24: ...proved for common venting and multistory venting with other fan assisted or draft hood equipped appliances in accordance with the NFCG or the NSCNGPIC the local building codes and furnace and vent manufacturers instructions The following information and warning must be considered in addition to the requirements defined in the NFGC and the NSCNGPIC CARBON MONOXIDE POISONING HAZARD Failure to follow...

Page 25: ...because of furnace model size capacity increments Heating load estimates can be made using approved methods available from Air Condi tioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive oversizing of the fur nace could cause the furnace and or vent to fail prematurely When a metal vent or me...

Page 26: ...lignment 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 chi...

Page 27: ...rt 2 Vent the furnace with the appropriate connector as shown in Fig 32 44 CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces 3 Orient the door to determine the correct location of the door cutout to be removed 4...

Page 28: ... operation 2 Make thermostat wire connections at the 24 v terminal block on the furance 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 opera...

Page 29: ...he page following these figures A03210 Fig 34 Downflow Application Vent Elbow Up then Left SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Fig 35 Downflow Application Vent Elbow Up SEE NOTES 1 2 4 5 6 7 8 9 10 on the page following these figures A03207 Fig 36 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 37 ...

Page 30: ... 8 9 on the page following these figures A03215 Fig 40 Horizontal Left Application Vent Elbow Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03216 Fig 41 Horizontal Left Application Vent Elbow Right SEE NOTES 1 2 4 7 8 9 on the page following these figures A03218 Fig 42 Horizontal Right Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03219...

Page 31: ...etal screws spaced approximately 180 apart 9 Secure all other single wall vent connector joints with 3 corrosion resistant screws spaced approximately 120 apart Secure Type B vent connectors per vent connector manufacturer s recommendations 10 The total height of the vent and connector shall be at least seven feet for the 154 000 Btuh gas input rate model when installed in a downflow application w...

Page 32: ...e input rate must be within 2 percent of furnace rating plate input 1 Determine the correct gas input rate In the U S A The input rating for altitudes above 2 000 ft must be reduced by 4 percent for each 1 000 ft above sea level For installa tions below 2000 ft refer to the unit rating plate For installations above 2000 ft multiply the input on the rating plate by the de rate multiplier in Table 8...

Page 33: ... 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 90 120 150 or 180 seconds cooling or heat pump 90 secon...

Page 34: ...Do not exceed tempera ture rise range specified on unit rating plate Determine the temperature rise as follows NOTE Blower access door must be installed when taking tem perature rise reading Leaving blower access door off will result in incorrect temperature measurements a Place thermometers in return and supply ducts as close to furnace as possible Be sure thermometers do not see radiant heat fro...

Page 35: ...e furnace control board See Fig 24 To change the blower off delay setting move the jumper from one set of pins on the control to the pins used for the selected blower off delay Factory off delay setting is 120 sec 8 Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow See Table 5 Air Delivery CFM With Filter See Table 9 for lead color identification Step 4 Che...

Page 36: ...s equipment other than those procedures recommended in the User s Manual ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death or property damage Before servicing disconnect all electrical power to furnace Verify proper operation after servicing ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper furnace operati...

Page 37: ...n CONTINUOUS OFF Check for 115VAC at L1 and L2 and 24VAC at SEC 1 and SEC 2 CONTINUOUS ON Control has 24VAC power RAPID FLASHING Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions LED CODE STATUS 11 NO PREVIOUS CODE Stored status code is erased automatically after 72 hours On RED LED boards stored status codes can also be erased when power 115 VAC or 24 VAC to cont...

Page 38: ...attached to the furnace such as a humidifier or electronic air cleaner Perform any service or maintenance to the accessories as recommended in the acces sory instructions CLEANING AND OR REPLACING AIR FILTER The air filter arrangement will vary depending on the application The filter is exterior to the furnace casing NOTE If the filter has an airflow direction arrow the arrow must point towards th...

Page 39: ... 0 60 0 62 0 64 Orifice No Manifold Pressure Orifice No Manifold 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 42 3 4 42 3 5 42 3 6 42 3 7 825 42 3 2 42 3 3 42 3 4 42 3 5 850 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...

Page 40: ... 5 43 2 6 43 2 7 875 43 2 3 43 2 4 43 2 5 43 2 6 900 43 2 2 43 2 3 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 Pressure U S A Only 6001 to 7000 675 43 3 4 43 3 5 43 3 6 43 3 7 700 43 3 1 43 3 3 43 3 4 43 3 5 725 ...

Page 41: ...ice purposes b Manually close blower access door switch NOTE If thermostat terminals are jumpered at the time blower access door switch is closed blower will run for 90 sec before beginning a heating or cooling cycle c Perform component self test as shown at the bottom of the SERVICE label located on the front of blower access door d Verify blower is rotating in the correct direction 19 If furnace...

Page 42: ...Orifice No Manifold Pressure Orifice No Manifold 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...

Page 43: ...2 1 43 2 1 43 2 2 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 Pressure U S A Only 6001 to 7000 675 43 3 1 43 3 2 43 3 3 43 3 4 700 43 2 9 43 3 0 43 3 1 43 3 2 725 43 2 7 43 2 8 43 2 9 43 2 9 750 43 2 5 43 2 6 43 2 7 43 2 8 775...

Page 44: ...er cell panel where collector box assembly contacts cell panel NOTE A releasing agent such as cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through R...

Page 45: ...ll remain energized until the flame is sensed or until the 2 second flame proving period begins d Flame Proving When the burner flame is proved at the flame proving sensor electrode FSE the furnace control CPU begins the blower ON delay period and continues to hold the gas valve GV open If the burner flame is not proved within two seconds the control CPU will close the gas valve GV and the control...

Page 46: ...he prepurge period then shut off for 24 seconds then come back on at HEAT speed When the W input signal disappears the furnace control begins a normal inducer post purge period and the blower switches to COOL speed after a 3 second delay If the R to W and Y and G signals disappear at the same time the blower motor BLWM will remain on for the selected blower OFF delay period If the R to W and Y sig...

Page 47: ...t 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 the control respond to W Y...

Page 48: ... 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 49: ...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 58ST 13SI Pg 48 5 05 Replaces 58ST 12SI ...