Installation, Start-Up, and Operating Instructions
Contents
1. SERES X Carrier re HEATING amp COOLING 58RAV Downflow Horizontal Induced Combustion Furnaces Visit www carrier com Installation Start Up and Operating Instructions Sizes 050 135 Series 161 NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue Index Page SAFETY CONSIDERATIONS eere 1 2 Clearances From Combustible Materials 1 Dimensional Drawing essent 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 3 ere e te EV EE vent 2 3 INTRODUCGLIION z nete orto P Ee ERO IY 3 LOCATION het e E M Ree 3 Genetal 3 Location Relative to Cooling Equipment 3 4 Hazardous Locations 4 AIR FOR COMBUSTION AND VENTILATION 4 5 Unconfined Space Confined Space outer SUPPLY AIR PLENUM INSTALLATION DOWNFLOW 5 Downflow Installation eese 5 Installation On a Combustible Floor 5 6 HORIZONTAL ATTIC _ 6 Construct a Working Platform eee 6 Install eere erre nee EE SERE 6 HORIZONTAL CRAWLSPACE INSTALLATION 6 FILTER 7 GAS PIPING noon 7 92. RANGE HEAT VALUE 0 58 ____0 60 __ 0 62 0 64 0 66 AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pressure No Pressure 42 3 2 43 3 6 43 3 4 7001 43 3 1 o 43 2 9 a to 43 2 7 5 43 2 5 8000 43 24 43 2 2 43 21 ATUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 60 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT Pressure No Pressure No Pressure No Pressure No Pressure 600 3 2 43 3 3 43 3 4 43 3 5 43 3 6 625 3 0 43 3 1 43 3 2 43 3 3 43 3 4 gt 8001 650 2 7 43 2 8 43 2 9 43 3 0 43 3 1 5 675 2 5 43 2 6 43 27 43 2 8 43 2 9 to 700 24 43 24 43 2 5 43 2 6 43 2 7 o 725 2 2 43 2 3 43 2 3 43 2 4 43 2 5 9000 750 2 0 43 21 43 2 2 43 2 3 43 2 3 775 3 6 48 3 7 43 21 43 21 43 2 2 800 3 4 48 3 5 48 3 6 48 37 43 2 0 For size 135 20 only input is 22 500 Btuh Deduct 0 1 in wc from manifold pressure shown in table Change orifice size if manifold pressure falls below 3 2 in wc on altitudes up to 2000 ft otherwise change orifice size if manifold pressure falls below 2 0 in wc 16 Table 8 Model 58RAV Orifice Size and Manifold Pressure for Correct Input Continued Tabulated Data Based on 23 000 BTUH Per Burner Derated 496 per 1000 Ft
3. 1 4 20 3 8 Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC Coil Box 12 19 20 di Non Combustible Flooring 23 19 23 5 8 19 5 8 24 1 2 Combustible Flooring Using KGASB Subbase 22 1 8 19 23 3 4 20 3 8 Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC Coil Box 22 1 2 19 23 1 2 20 Step 4 Horizontal Attic Installation A WARNING Do not install the furnace on its back safety control operation will be adversely affected Never connect return air ducts to the sides or back of the furnace Failure to follow this warning could result in fire personal injury or death The furnace can be installed horizontally on either the left hand LH or right hand RH side A typical attic installation is shown in Fig 7 CONSTRUCT A WORKING PLATFORM Construct working platform on location where all required furnace clearances are met See Table 1 and Fig 7 INSTALL FURNACE 1 Position furnace in desired location 2 Connect gas supply pipe See Fig 7 for typical piping entry 3 Install field supplied filter retainers as indicated in Fig 8 and Table 4 before connecting return air duct to furnace 4 Connect supply and return air ducts 5 Install 24 X 24 in sheet metal shield on platform in front of louvered control panel as shown in Fig 7 Step 5 Horizontal Crawlspace Installation The furnace can be installed horizontally with either the LH or RH side up In a crawlspace the furnace can ei
4. 7 800 3 7 43 3 8 42 3 2 42 3 3 42 3 4 gt 3001 825 3 5 43 3 6 43 3 7 43 3 8 42 3 2 850 3 3 43 3 4 43 3 5 43 3 6 43 3 7 to 875 3 1 43 3 2 43 3 3 43 3 4 43 3 5 o 900 2 9 43 3 0 43 3 1 43 3 2 43 3 3 4000 925 2 8 43 2 9 43 3 0 43 3 0 43 3 1 950 2 6 43 2 7 43 2 8 43 2 9 43 3 0 975 2 5 43 2 6 43 27 43 27 43 2 8 1000 2 4 43 2 4 43 2 5 43 2 6 43 2 7 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS NGE HEAT VALUE 0 60 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT Pressure No Pressure No Pressure No Pressure No Pressure 725 3 2 42 3 3 42 3 5 42 3 6 42 3 7 750 3 7 43 3 8 42 3 2 42 3 3 42 3 4 775 3 4 43 3 6 43 3 7 43 3 8 42 3 2 Z 4001 800 3 2 43 3 3 43 3 5 43 3 6 43 3 7 o 825 3 0 43 3 1 43 3 2 43 3 4 43 3 5 to 850 2 9 43 3 0 43 3 1 43 3 2 43 3 3 875 27 43 2 8 43 2 9 43 3 0 43 3 1 5000 900 2 6 43 2 6 43 2 7 43 2 8 43 2 9 925 2 4 43 2 5 43 2 6 43 2 7 43 2 8 950 2 3 43 2 4 43 2 5 43 2 5 43 2 6 For size 135 20 only input is 22 500 Btuh Deduct 0 1 in wc from manifold pressure shown in table Change orifice size if manifold pressure falls below 3 2 in wc on altitudes up to 2000 ft otherwise change orifice size if manifold pressure falls below 2 0 in wc 15 Table 8 Model 58RAV Orifice Size and Manifold Pressure for Correct Input Continued Tabulated Data Based on 23 000 BTUH Per Burner Derated 4 per 1000 Ft Above Se
5. Code CAN B149 1 and 2 M95 for proper vent sizing and installation requirements Use the enclosed Venting Tables for Category I Fan Assisted Furnaces for a quick easy reference The horizontal portion of the venting system shall maintain a minimum of 1 4 in upward slope per linear ft and it shall be rigidly supported every 5 ft or less with hangers or straps to ensure that there will be no movement after installation 10 Step 10 Start up Adjustment and Safety Check GENERAL NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control center fault indicator light will flash rapidly and furnace will not operate The furnace must have a 115 v power supply properly connected and grounded Proper polarity must be maintained for correct operation Thermostat wire connections at R W C and Y must be made at the 24 v terminal block on the control board The gas service pressure must not exceed 0 5 psig 14 in wc but must be no less than 0 16 psig 4 5 in wc Before operating the furnace check each manual reset switch for continuity If necessary press the button to reset the switch The blower compartment door must be in place to complete the 115 v circuit to the furnace CAUTION This furnace is equipped with 2 manual reset limit switches in the gas control area The switches will open and shut off power to the gas valve if a flame rollout or an overheating condition occurs in the gas cont
6. SEDIMENT TRAP Box Installed on a Combustible Floor 30 IN MIN WORK AREA A82178 Fig 7 Typical Attic Installation Step 6 Filter Arrangement A WARNING Never operate unit without a filter or with filter access door removed Failure to follow this warning could result in fire personal injury or death The 2 factory supplied filters are shipped in the blower compart ment After the return air duct has been connected to the furnace install the filters in a V formation inside the return air plenum See Fig 10 and Table 4 for horizontal applications Horizontal filter retainers must be field supplied See Fig 11 for downflow applications Step 7 Gas Piping Gas piping must be installed in accordance with national and local codes Refer to the current edition of the NFGC Canadian installations must be installed in accordance with NSC NGPIC and all authorities having jurisdiction Refer to Table 5 for recommended gas pipe sizing Risers should be used to connect to the furnace and to the meter ANGLE IRON OR pi EQUIVALENT GAS p B A ROD LOCATION USING DIMPLE LOCATORS SEE DIMENSIONAL 3 8 IN HEX NUT DWG FOR amp WASHER 4 LOCATIONS REQD PER ROD A PREFERRED ROD LOCATION B ALTERNATE ROD LOCATION B NOTES 1 A 1 In clearance minimum between top of furnace and combustible material 2 The entire l
7. additional 90 sec before reverting back to con tinuous operation on heating speed 4 Heat pump mode When installed with a heat pump the furnace control auto matically changes the timing sequence to avoid long blower off time during demand defrost cycles When the W Y or W Y G thermostat inputs are received at the same time the control changes the blower to heating speed or starts the blower if it was off and begins a heating cycle The blower remains on until the end of the prepurge period then shuts off until the end of the ignition warm up and trial for ignition periods a total of 24 sec The blower then comes back on at heating speed When the W input signal disappears the control begins the normal inducer post purge period and the blower changes to cooling speed after a l sec delay If the W Y G signals disappear at the same time the blower remains on for the selected heating blower off delay period and the inducer goes through its normal post purge period If the W Y inputs should disappear leaving the G signal input the control goes into continuous blower and the inducer remains on for the normal post purge period Anytime the control senses false flame the control locks out of the heating mode This occurs because the control cannot sense the W input due to the false flame signal and as a result sees only the Y input and goes into cooling mode blower off delay All other control functions remain in standard format
8. input Btu cu ft X cu ft hr Heating value of gas 1050 Btu cu ft Time for 1 revolution of 2 cu ft dial 2 82 sec Gas rate 88 cu ft hr from Table 9 Btu heating input 88 X 1050 92 400 Btuh In this example the orifice size and manifold pressure adjustment is within 2 percent of the furnace input rate ON AND OFF SWITCH GAS PRESSURE REGULATOR ADJUSTMENT INLET PRESSURE TAP MANIFOLD PRESSURE TAP A95618 Fig 16 Redundant Automatic Gas Control Valve 2 Set temperature rise Furnace must operate within range of temperature rise speci fied on the unit rating plate Determine the air temperature rise as follows a Place duct thermometers in return and supply ducts as near furnace as possible Be sure thermometers do not see heat exchangers so that radiant heat does not affect thermometer readings This is particularly important with straight run ducts Table 8 Model 58RAV Orifice Size and Manifold Pressure for Correct Input Tabulated Data Based on 23 000 BTUH Per Burner Derated 4 per 1000 Ft Above Sea Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS A RANGE HEAT VALUE 0 60 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT s Pressure No Pressure No Pressure No Press
9. of exhaust fans kitchen ventilation fans clothes dryers or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace Make up air MUST be provided for the ventilation devices in addition to that required by the furnace All fuel burning equipment must be supplied with air for combus tion of the fuel Sufficient air MUST be provided to ensure there will not be a negative pressure in the equipment room or space In addition a positive seal MUST be made between the furnace cabinet and the return air duct to avoid pulling air from the burner area and draft safeguard opening The requirements for combustion and ventilation air depend upon whether the furnace is located in an unconfined or confined space UNCONFINED SPACE An unconfined space must have at least 50 cu ft for each 1000 Btuh of input for all the appliances such as furnaces clothes dryer water heaters etc in the space For Example 58RAV FURNACE INPUT 7 1 2 FT CEILING 46 000 307 69 000 460 92 000 613 115 000 767 135 000 920 If the unconfined space is constructed unusually tight air for combustion and ventilation MUST come from either the outdoors or spaces freely communicating with the outdoors Combustion and ventilation openings must be sized the same as for a confined space A minimum opening with a total of at least 1 sq in per 5000 Btuh of total input rating for all equipment must be provided Return air
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12. 3 3 4 0 824 360 250 200 170 151 1 1 049 680 465 375 320 285 1 1 4 1 380 1400 950 770 660 580 1 1 2 1 610 2100 1460 1180 990 900 Cubic ft of gas per hr for gas pressures of 0 5 psig 14 in wc or less and a pressure drop of 0 5 in wc based on a 0 60 specific gravity gas Ref Table 10 2 NFPA 54 ANSI Z223 1 1996 A CAUTION Connect the gas pipe to the furnace using a backup wrench to avoid damaging gas controls A WARNING Never purge a line into a combustion chamber Never use matches candles flame or other sources of ignition to check for gas leakage Use a soap and water solution to check for gas leaks Failure to follow this warning could result in fire explosion personal injury or death Joint compounds pipe dope should be applied sparingly and only to the male threads of the joints This pipe dope must be resistant to the action of propane gas An accessible manual shutoff valve MUST be installed upstream of the furnace gas controls and within 72 in of the furnace A 1 8 in NPT plugged tapping accessible for test gage connection MUST be installed immediately upstream of the gas supply connection to the furnace and downstream of the manual shutoff valve Place a ground joint union between the gas control manifold and the manual shutoff Install a sediment trap in the riser leading to the furnace The trap can be installed by connecting a tee to the riser
13. 7 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 eee mw a 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine tem perature rise c Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise BURNER FLAME p WERE d BURNER Fig 17 Burner Flame A WARNING A89020 Disconnect the electrical power before changing the speed tap Failure to follow this warning could result in personal in
14. Above Sea Level SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE HEAT VALUE 0 88 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT Pressure No Pressure No Pressure No Pressure No Pressure 575 3 0 43 3 1 43 3 2 43 3 3 43 3 4 600 2 7 43 2 8 43 2 9 43 3 0 43 3 1 gt 9001 625 2 5 43 2 6 43 2 7 43 2 8 43 2 8 5 650 2 3 43 2 4 43 2 5 43 2 6 43 2 6 lt to 675 2 1 43 2 2 43 2 3 43 2 4 43 2 4 o 700 43 21 43 21 43 2 2 43 2 3 2 10000 725 48 3 6 48 3 7 43 21 43 21 750 48 3 4 48 3 5 48 3 6 48 3 7 775 49 3 7 49 3 8 48 34 48 3 5 For size 135 20 only input is 22 500 Btuh Deduct 0 1 in wc from manifold pressure shown in table Change orifice size if manifold pressure falls below 3 2 in wc on altitudes up to 2000 ft otherwise change orifice size if manifold pressure falls below 2 0 in wc Table 9 Gas Rate Cu Ft Hr SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 1 2 5 FOR 1 1 2 5 REVOLUTION cu ft cu ft cu ft REVOLUTION cu ft cu ft 10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 94
15. ELECTRICAL CONNECTIONS eere 9 115 v WAT reti he TER 9 10 2A v WIEIDE a e etu ee RR RE 10 A CCESSOTIES e RE Ne ER eue eH 10 AW ENTE Goes DO SR UTE PEDI REO eth gen 10 START UP ADJUSTMENT AND SAFETY CHECK 10 18 General 64 ed 10 Sequence Of Operation sse 10 13 Heating anim ean eee 10 13 Cooling Mode 13 Continuous Blower Mode 13 Heat Pump Mode 13 Start up Procedures soc cocco eret e tee ovr re ren 13 Adjustments 13 18 Set Gas Input Rates sesion sirere ener iita 13 17 Set Temperature Rise esee 14 17 Set Thermostat Heat Anticipator sseeeeee 18 Check Safety Controls esee 18 PR 18 SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified person nel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on Q CANADIAN GAS ASSOCIATION EFFICIENCY RATING CERTIFIED APPROVED R ama Table 1 Clearances From Combustible Materials In
16. K EXAMPLE 5 0 AMPS ON AMMETER 0 5 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS 80201 Fig 18 Amp Draw Check With Ammeter CHECK SAFETY CONTROLS The flame sensor gas valve and pressure switch were all checked in the Start Up Procedures section as part of normal operation 1 Check primary limit control This control shuts off the combustion control system and energizes the circulating air blower motor if the furnace overheats The preferred method of checking the limit control is to gradually block off the return air after the furnace has been operating for a period of at least 5 minutes As soon as the limit has shut off the burners the return air opening should be unblocked By using this method to check the limit control it can be established that the limit is functioning properly and operates if there is a motor failure 2 Check draft safeguard switch The purpose of this control is to permit the safe shutdown of the furnace during certain blocked vent conditions 18 a Disconnect power to furnace and remove vent connector from furnace outlet collar Be sure to allow time for vent pipe to cool down before removing b Restore power to furnace and set room thermostat above room temperature c After normal start up allow furnace to operate for 2 minutes then block flue outlet 100 percent Furnace should cycle off within 2 minutes d Remove blockage and reconnect vent pipe to furnace outlet c
17. NINH3 89 IVNIAH3 L Q3 tH VIANQ NOLLONAP OVAYE OVNSLL H3INHOJSNVHL WNINH3 NIML 9 1531 LNINOdWOO O N 1sdS HOLIMS 3unssaud 80d ISH LINDYIO 2 WGI LINDUIO 808 LINDYIO 2 HOLOSNNOO LINDHID 6 NIMULSSL Sud 91 ld 89d MS dWAL QVO TH3AO HOLOW TVNH3LNI 19588 O N LSdS 13539 OLAV HOLIMS O N 1SdS HOLIMS SHNSSIUd SVO MOT S 3002 SNLYLS 3Q0IQ ONILLIWS LHONM XO8 NOLLONNL O N 1SdS HOLIMS 4901831NI TANWd 9320v H3MO 18 O N LSdS Av 138 YOLOW 10 57 d91 qa ar dV 9 NOLLO3NNOO WAH O N LSdS AVI3H JOVAHNS HISH OWA SLL HOLIND 3OVSYNS LOH ISH 1095 AVTSY SONVHO 03395 HOLOW ON IH O N LSdd AVIS 5 HAD SHOlvH3dO INVONnO3H 3ATNASVO 93119915 GATIVLSNI 01919 H3xv3u8 HO ISNA GATIVISNI AHOLOV3 3dAL3QV18 SAILOWOLNY SSNS ind 3dO0HlO313ONIAOHd 3S4 o N 1SdS L3S3H TVNVW MS 1nO TIOH 3YWV d 318 903 NOWWO9 NOLLO3NNOO H3NV31O DINOHLO313 2 0 div S L OWA 911 NOLLO3NNOO HOLIMS SSG AHlInogIo HO
18. NOTE EAC 1 terminal is energized whenever blower operates HUM terminal is only energized when gas valve is energized START UP PROCEDURES 1 Purge gas lines After all connections have been made purge the lines and check for leaks A WARNING Never purge a line into a combustion chamber Never use matches candles flame or other sources of ignition to check for gas leakage Use a soap and water solution to check for gas leaks Failure to follow this warning could result in fire explosion personal injury or death 2 Component test The furnace control allows all components except gas valve to be run for a short period of time This feature helps diagnose a system problem in case of a component failure To initiate component test procedure short jumper the TEST 1 4 in quick connect terminal on control board adjacent to diagnostic light and the Com terminal on thermostat connection block for approximately 2 sec See Fig 13 NOTE Component test feature will not operate if any thermostat signal is present at control center Component test sequence is as follows a Momentarily jumper TEST and Com terminals until LED goes off b LED will display previous fault 4 times c Inducer motor starts and continues to run for entire com ponent test d Hot surface ignitor is energized for 15 sec then de energized e Blower motor operates on cooling speed for 10 sec then stops f Blower motor operate
19. RMER SEC 2 EN SPARE 1 BLOWER SPEED SELECTION TERMINALS SPARE 2 EAC 1 7 EAC ELECTRONIC AIR CLEANER TERMINALS 115 VAC 1 5 AMP MAX 115 VAC L1 N POWER SUPPL 115 VAC L2 NEUTRAL CONNECTION HOT SURFACE INDUCER MOTOR IGNITOR CONNECTOR CONNECTOR A95086 Fig 13 Control Board FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING NOTE2 THERMOSTAT FIVE 9 9 y TERMINALS FIELD SUPPLIED WIRE 1 FUSED DISCONNECT THREE WIRE t e e HEATING gt of 208 230 OR ONLY Ib ere e i 460 VOLT tee e e e THREE W 1 EH Num EM __ PHASE Op a e 2e e 208 230 ail GND i e ire e T Tie e YOT E 115 VOLT FUSED AUXILIARY amp r 7 PHASE DISCONNECT J BOX ai emer eg GND SWITCH CONTROL ____ 1____ l CONDENSING WHEN CHF IDE UNIT REQUIRED SANOLT TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y 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 wi
20. SS30OHdOHDIN YOLIOVdVD YOLOW NMI8 O N LSdS HOLOWH3MOT18 CO N LSdS 13530 WWANWW dIN3 183AO HOLIMS QN3931 Sv __ I Lm I d ong n L Ei a034 N3HM HOLIMS LOANNOOSIC dasn4 z 1 z ova ova 02 gt TU cduvdS l1V3H i 3uvds 1009 199135 43985 wow 19 YISH 3503 AV T3H OVIH mm e o M M P ETT xa ma oz 999 maur EE 4 L8 l 3SN 353 j IN 9 O3S 92 5 8 THM 568 LZE wt 588 035 081 293 iud osssei Ez ma aa 085 06 I mm 1101 1531 luvHoNOLO3S l A LLAVISG 240 8 d i IMS TI NO ION 71 E god u3MO18 Sud SY ssa B Z1 310N ENS a3sn NIHM 12 NOTE Ignition sequence will repeat 3 additional times before a lockout occurs Lockout automatically resets after 3 hrs or can be manually reset by turning 115v off not at thermostat for 3 sec minimum then on again f Blower on delay Forty sec after burner flame is proven the blower motor is energized on heating speed Simulta neously the humidifier and
21. UNIT SIZE 050 AND 070 096 135 DOWNFLOW In Alcove or Closet Sides Single Wall Vent 1 0 Type B 1 Double Wall Vent 0 0 Back 0 0 Top 1 1 Front Single Wall Vent et et Type B 1 Double Wall Vent 3t 3t Vent Single Wall Vent 6 Type B 1 Double Wall Vent 1 HORIZONTAL Attic Alcove or Crawlspace Sides 1 0 Back 0 0 Top Single Wall Vent 1 1 Type B 1 Double Wall Vent 1 1 Frontt Single Wall Vent 6t 6t Type B 1 Double Wall Vent 3t 3t Vent Single Wall Vent 6 6 Type B 1 Double Wall Vent 1 1 HORIZONTAL In Closet Sides 1 1 Back 3 3 Top Single Wall Vent 2 2 Type B 1 Double Wall Vent 2 2 Front Single Wall Vent 6 6 Type B 1 Double Wall Vent 3 3 Vent Single Wall Vent 6 6 Type B 1 Double Wall Vent 1 1 Indicates supply or return sides when furnace is in the horizontal position t Clearance shown is for outlet end The inlet end must maintain 6 in minimum clearance from the vent to combustible materials when using single wall vent Minimum 18 in front clearance required for alcove NOTES 1 Provide 30 in front clearance for servicing An open door in front of the furnace can meet this requirement 2 A minimum clearance of 3 in must be provided in front of the furnace for combustion air and proper operation 3 Line contact is permitted as shown in Fig 7 heating equipment observe precautions in the literature on tags and on labels attached to or shipped with the unit and other safety precautions that may apply M
22. a Level AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 60 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT Pressure No Pressure No Pressure No Pressure No Pressure 700 3 7 43 3 8 42 3 2 42 3 3 42 3 4 725 3 4 43 3 6 43 3 7 43 3 8 42 3 2 750 3 2 43 3 3 43 3 4 43 3 5 43 3 6 775 3 0 43 3 1 43 3 2 43 3 3 43 3 4 gt 5001 800 2 8 43 2 9 43 3 0 43 3 1 43 3 2 5 825 27 43 27 43 2 8 43 2 9 43 3 0 E to 850 2 5 43 2 6 43 2 7 43 2 8 43 2 8 o 875 2 4 43 2 4 43 2 5 43 2 6 43 2 7 gt 6000 900 2 2 43 2 3 43 2 4 43 2 5 43 2 5 925 21 43 2 2 43 2 3 43 2 3 43 2 4 950 3 8 43 21 43 21 43 2 2 43 2 3 975 3 6 48 3 7 43 2 0 43 21 43 2 2 1000 3 4 48 3 5 48 3 6 48 37 43 21 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 60 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT Pressure No Pressure No Pressure No Pressure No Pressure 650 3 7 43 3 8 42 3 2 42 3 3 42 3 5 675 3 4 43 3 5 42 3 2 700 3 2 43 3 3 43 3 6 6001 725 3 0 43 3 1 43 3 4 o 750 2 8 43 2 9 43 3 2 5 to 775 2 6 43 2 7 43 3 0 5 800 2 4 43 2 5 43 2 8 7000 825 2 3 43 2 4 43 2 6 850 2 2 43 2 2 43 2 5 875 2 0 43 2 1 43 2 3 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS
23. anufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Catalog No 535 850 Tab 6a 8a Printed in U S A Form 58RA 13SI Pg 1 12 96 Replaces 58RA 12SI 1 2 28 2 VENT CONNECTION y Ve DIA 20 D asy THERMOSTAT 1346 MS 1346 e WIRE ENTRY ACCESSORY 7 4 DIA HOLE POWER ENTRY 39 78 11 DIA R H GAS ENTRY Foy DIA ACCESSORY 7 8 DIA 9 1 ACCESSORY 3 134 DIA HOLE 7 10 14 GAS ENTRY i 16 146 1 TYP E Sg TYP MED 1467 OUTLET E a E wile 546 19 HA i 10 14 8 en e 1 146 16 a2 147 NOTE ADDITIONAL 74 DIA K O ARE AIRFLOW DIMPLES TO DRILL HOLES LOCATED IN THE TOP PLATE FOR HANGER BOLTS 4 PLACES AND BOTTOM PLATE IN HORIZONTAL POSITION A88324 Fig 1 Dimensional Drawing Table 2 Dimensions In UNIT SIZE A D E VENT CONN SHIP WT LB 050 08 14 3 16 12 9 16 12 11 16 4 124 050 12 14 3 16 12 9 16 12 11 16 4 127 070 08 14 3 16 12 9 16 12 11 16 4 141 070 12 14 3 16 12 9 16 12 11 16 4 145 096 12 17 1 2 15 7 8 16 4 154 096 16 17 1 2 15 7 8 16 4 154 115 16 17 1 2 15 7 8 16 4 171 115 20 21 19 3 8 19 1 2 4 181 135 20 24 1 2 22 7 8 23 5 192 Follow all safety codes In the United States follow all safety codes includi
24. at exchangers and metal vent system Some of these compounds are found in paneling and dry wall adhesives paints thinners masonry cleaning materials and many other solvents commonly used in the construction process Excessive exposure to contaminated combustion air will result in safety and performance related problems This furnace must be installed so the electrical components are protected from water Locate the furnace as close to the chimney vent and as near the center of the air distribution system as possible The furnace should be installed as level as possible When a furnace is installed so that the supply ducts carry air to areas outside the space containing the furnace the return air must also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the furnace Provide ample space for servicing and cleaning Always comply with the minimum fire protection clearances shown on the unit rating plate This furnace shall not be installed directly on carpeting tile or any combustible material other than wood flooring The furnace may be installed on combustible flooring when installed with the accessory downflow subbase which is available from your distributor or branch when required LOCATION RELATIVE TO COOLING EQUIPMENT The cooling coil must be installed parallel with or on the downstream side of the furnace to avoid condensation in the heat exchangers When installed para
25. ates At installation altitudes above 2000 ft this furnace has been approved for a 496 derate for each 1000 ft above sea level See Table 7 for derate multiplier factor Table 7 Altitude Derate Multiplier for U S A ALTITUDE 96 OF DERATE MULTIPLIER FT DERATE FACTOR FOR U S A 0 2000 0 1 00 2001 3000 8 12 0 90 3001 4000 12 16 0 86 4001 5000 16 20 0 82 5001 6000 20 24 0 78 6001 7000 24 28 0 74 7001 8000 28 32 0 70 8001 9000 32 36 0 66 9001 10 000 36 40 0 62 Derate multiplier factor is based on midpoint altitude for altitude range 14 EXAMPLE 92 000 Btuh input furnace installed at 4300 ft Furnace Input Derate Multiplier Factor 0 82 Furnace Input Rate at Installation Altitude 75 440 Rate at X Sea Level 92 000 Canada At installation altitudes from 2000 to 4500 ft this furnace must be derated 10 by an authorized Gas Conversion Station To deter mine correct input rate for altitude see example above and use 0 90 as derate multiplier factor a Turn off all other gas appliances and pilots b Start furnace and let operate for 3 minutes c Measure time in sec for gas meter test dial to complete 1 revolution d Refer to Table 9 for cu ft of gas per hr e Multiply gas rate cu ft hr X heating value Btu cu ft using natural gas heating value from local gas utility supplier EXAMPLE 0 2000 ft altitude Btu heating
26. ctrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes Do not use gas piping as an electrical ground Failure to follow this warning could result in electrical shock fire or death 24 V WIRING Make field 24 v connections at the 24 v termi nal strip See Fig 13 Connect terminal Y as shown in Fig 14 for proper operation in cooling mode Use AWG No 18 color coded wire only The 24 v circuit contains an automotive type 3 amp fuse located on the main control board Any direct shorts during installation service or maintenance could cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse of identical size ACCESSORIES 1 Electronic air cleaner EAC Two quick connect terminals marked EAC 1 and EAC 2 are provided for EAC connection See Fig 13 These terminals are energized with 115v 1 5 amp maximum during blower motor operation 2 Humidifier HUM Quick connect terminal HUM and screw terminal Com are provided for 24 v humidifier connection The terminals are energized with 24v 0 5 amp maximum after inducer motor prepurge period NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation Step 9 Venting Refer to the National or Local Installation Code such as National Fuel Gas Code NFPA No 54 1996 7223 1 1996 or the Canadian Installation
27. e NOTE is used to highlight suggestions which will result in enhanced installation reliability 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 DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CON TROL PRIOR TO DISCHARGING YOUR BODY S ELEC TROSTATIC CHARGE TO GROUND or operation 2 Firmly touch a clean unpainted metal surface of the furnace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily discharged These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances 3 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity for example DO NOT move or shuffle your feet DO NOT touch ungrounded objects etc 4 If you touch ungrounded objects recharge your body with static electricity firmly touch furnace again before touching control or wires 5 Use this procedure for installed and uninstalled ungrounded furnaces 6 Before removing a new control from its container disc
28. e structure a Each opening MUST have at least 1 sq in of free area per 1000 Btuh of the total input for all equipment within the confined space but not less than 100 sq in per opening See Fig 2 For Example 58RAV FURNACE FREE AREA PER INPUT BTUH OPENING SQ IN 46 000 100 69 000 100 92 000 100 115 000 115 135 000 138 b If the building is constructed unusually tight in addition to the 2 permanent openings that freely communicate with an unconfined space a permanent opening directly communi cating with the outdoors should be provided This opening should have a minimum free area of 1 sq in per 5000 Btuh of total input rating for all equipment in the enclosure c If the furnace is installed on a raised platform to provide a return air plenum and return air is taken directly from the hallway or space adjacent to the furnace all air for combustion must come from outdoors See Fig 3 DUCTS TO OUTDOORS 1 SQIN PER 4000 BTUH BM 12 MAX D T EUR r A RETURN vent GEMINAS BTUH AIR THROUGH FE CATEGORY Y 1SQIN P R 4000 BTUH DUCTS m T z Qo 1 SQIN PER 4000 BTUH 1SQIN E PAM qq B ELI ER BTUH 12 12 MAX C MAX 12 MAX SUPPLY AIR zi DUCT TO 1 SQIN OUTDOORS PER 4000 BTUH Minimum dimensions of 3 In NOTE Use any of the following combinations of openings A a
29. electronic air cleaner terminals HUM and Cow for humidifier EAC 1 and EAC 2 for electronic air cleaner are energized g Blower off delay When the thermostat is satisfied the circuit between R and W is broken de energizing the gas valve and stopping gas flow to the burners The blower motor and EAC remain energized for 135 sec h Post purge The inducer motor remains energized 5 sec after the burners are extinguished 2 Cooling mode When the thermostat calls for cooling R G and R Y circuits close The R Y circuit starts the outdoor condensing unit and combined R Y and R G circuits start the furnace blower motor on cooling speed The EAC 1 terminal is energized with 115v whenever the blower is operating on cooling speed When the thermostat is satisfied R G and R Y circuits are broken Furnace blower and EAC continue operating on cooling speed for an additional 90 sec 3 Continuous blower mode NOTE EAC 1 terminal is energized with 115v whenever blower is operating When the R G circuit is made the blower motor operates on heating speed During a call for heat the blower stops allowing the furnace heat exchangers to heat up more quickly then restarts at the end of the 40 sec blower on delay period The blower reverts to continuous operation after the heating cycle is completed When the thermostat calls for cooling the blower operates on cooling speed When the thermostat is satisfied the blower operates an
30. ength of furnace must be supported when furnace is used in horizontal position A96633 Fig 9 Horizontal Crawlspace Installation on Hanger Rods I Wn T 11010 HY 95235 Fig 8 Horizontal Installation on Blocks A CAUTION If a flexible connector is required or allowed by the authority having jurisdiction black iron pipe shall be installed at the gas valve and extend a minimum of 2 in outside the furnace casing A WARNING Use the proper length of pipes to avoid stress on the gas control manifold Failure to follow this warning could result in a gas leak causing fire explosion personal injury or death AIRFLOW FIELD SUPPLIED FILTER RETAINERS A82173 Fig 10 Horizontal Filter Arrangement Table 4 Filter Retainer In FURNACE FILTER SIZE CASING WIDTH AND QUANTITY 14 3 16 2 14 X 20 X 1 14 3 8 17 1 2 2 14 X 20 X 1 13 3 8 21 2 16 X 20 X 1 11 5 8 24 1 2 2 16 X 20 X 1 10 1 4 INSTALLATION POSITION OF FILTERS RETURN AIR PLENUM y y EE EIL 4 ACCESS DOOR TR TR TREO A88486 Fig 11 Downflow Filter Arrangement Table 5 Maximum Capacity of Pipe NOMINAL IRON INTERNAL LENGTH OF PIPE FT PIPE SIZE DIAMETER IN IN 10 20 30 40 50 1 2 0 622 175 120 97 82 7
31. er to furnace CHECKLIST Put away tools instruments and clean up debris Verify manual reset switches have continuity Ensure blower and control access doors are properly installed Cycle test furnace with room thermostat nA A U Ne Check operation of accessories per manufacturer s instruc tions 6 Review User s Manual with owner 7 Leave literature packet near furnace SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including Unit Familiarization Maintenance nstallation Overview Operating Sequence A large selection of product theory and skills programs is available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training A94328 Copyright 1997 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 58ra13si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations reek M PC 101 Catalog No 535 850 Printed in U S A Form 58 1351 Pg 2
32. harge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 5 before bringing the control or yourself into contact with the furnace Put all used 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 INTRODUCTION The model 58RAV Series 161 Furnaces are available in sizes 50 000 through 135 000 Btuh input capacities The design of the downflow horizontal gas fired furnace is A G A C G A certified for natural and propane gases and for installation on noncombustible flooring The furnace is factory shipped for use with natural gas The manufacturer s accessory gas conversion kit is required to convert furnace for use with propane gas These furnaces SHALL NOT be installed directly on carpeting tile or any other combustible material other than wood flooring In downflow installations the manufacturer s accessory floor base must be used when installed on combustible materials and wood flooring Special base is not 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 This furnace is for installation in alcoves attics crawlspaces basements closets or utility rooms The design of this furnace line is not A G A C G A certified for installation in mobi
33. jury d To change blower motor speed selections for heating mode remove blower motor lead from control board HEAT terminal See Fig 13 Select desired blower motor speed lead from 1 of the other terminals and relocate it to HEAT terminal See Table 10 for lead color identification Recon nect original lead on SPARE terminal Follow this same procedure for proper selection of COOL speed selection Table 10 Speed Selector 17 FACTORY COLOR SPEED ATTACHED TO Black High COOL fron Medium High SPARE Blue Medium Low HEAT Red Low SPARE White Common Com CAUTION Recheck temperature rise It must be within limits specified on unit rating plate Recommended operation is at midpoint of rise or above 3 Set thermostat heat anticipator The thermostat heat anticipator must be set to match the amp draw of the electrical components in the R W circuit Accurate amp draw readings can be obtained at thermostat subbase terminals R and W Fig 18 illustrates an easy method of obtaining the actual amp draw The amp reading should be taken after the blower motor has started See the thermostat manufacturer s instructions for adjusting the heat anticipator and for varying the heating cycle length NOTE When using an electronic thermostat set cycle rate for 3 cycles per hr THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED HOOK AROUND VOLT AMMETER oe FROM UNIT 24 VOLT TERMINAL BLOC
34. le homes recreation vehicles or outdoors Before installing the furnace refer to the current edition of the NFGC and the NFPA 90B Canadian installations must be installed in accordance NSCNGPIC and all authorities having jurisdiction For a copy of the NFGC NFPA54 Z223 1 contact International Approval Services U S Inc 8501 E Pleasant Valley Road Cleveland OH 44131 or National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 For a copy of NFPA 90B contact National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 Before installing the furnace in Canada refer to the current edition of the NSCNGPIC Contact Standards Department of Canadian Gas Association 55 Scarsdale Road Don Mills Ontario Canada M3B 2R3 A CAUTION Application of this furnace should be indoors with special attention given to vent sizing and material gas input rate air temperature rise and unit sizing Improper installation or misapplication of the furnace can require excessive servicing or cause premature component failure Installation must conform to the regulations of the serving gas supplier and the local building heating and plumbing codes in effect in the area in which the installation is made or in the absence of local codes with the requirements of the NFGC This furnace is designed for a minimum continuous return air temperature of 60 F db or intermittent operation down to 55 F db such as whe
35. leading from the furnace Connect a capped nipple into the lower end of the tee The capped nipple should extend below the level of the gas controls See Fig 12 GAS SUPPLY SEDIMENT TRAP UNION A89414 Fig 12 Typical Gas Pipe Arrangement Piping should be pressure tested in accordance with local and national plumbing and gas codes before the furnace has been attached If the pressure exceeds 0 5 psig 14 in wc the gas supply pipe must be disconnected from the furnace and capped before the pressure test If the test pressure is equal to or less than 0 5 psig 14 in wc turn off electric shutoff switch located on the gas valve before the test It is recommended that the ground joint union be loosened before pressure testing After all connections have been made purge the lines and check for gas leakage with regulated gas supply pressure Step 8 Electrical Connections 115 V WIRING Refer to the unit rating plate or Table 6 for equipment electrical requirements The control system requires an earth ground for proper operation 4 CAUTION Do not connect aluminum wire between disconnect switch and furnace Use only copper wire Make all electrical connections in accordance with the current edition of the National Electrical Code NEC ANSI NFPA 70 1996 and any local codes or ordinances that might a
36. llel with a furnace dampers or other means used to control the flow of air must prevent chilled air from entering the unit If the dampers are manually operated they must be equipped with means to prevent operation of either unit unless the damper is in the full heat or full cool position HAZARDOUS LOCATIONS When the furnace is installed in a residential garage it must be installed so that the burners and ignition source are located at least 18 in above the floor The furnace should be protected from physical damage by vehicles When a furnace is installed in public garages airplane hangars or other buildings having hazardous atmospheres the unit must be installed in accordance with the recommended good practice requirements of the National Fire Protection Association Inc Step 2 Air For Combustion and Ventilation Provisions for adequate combustion and ventilation air must be provided in accordance with Section 5 3 of the NFGC Air for Combustion and Ventilation or applicable provisions of the local building codes Canadian installations must be installed in accordance with NSC NGPIC and all authorities having jurisdiction A CAUTION Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements are found in aerosol sprays deter gents bleaches cleaning solvents salts air fresheners and other household products A CAUTION The operation
37. mp B C amp D D amp E F amp G A93388 Fig 3 Air for Combustion and Ventilation Outside Air 2 All air from outside the structure a If combustion air is taken from outdoors through vertical ducts the openings and ducts MUST have at least 1 sq in of free area per 4000 Btuh of the total input for all equipment within the confined space For Example 58RAV FURNACE FREE AREAPER ROUND PIPE INPUT BTUH OPENING SQ IN IN DIA 46 000 11 5 4 69 000 17 8 5 92 000 23 0 6 115 000 28 8 7 135 000 34 5 7 b If combustion air is taken from the outdoors through horizontal ducts the openings and ducts MUST have at least 1 sq in of free area per 2000 Btuh of the total input for all equipment within the confined space For Example 58RAV FURNACE FREE AREA PER ROUND PIPE INPUT BTUH OPENING SQ IN IN DIA 46 000 23 0 6 69 000 34 3 7 92 000 46 0 8 115 000 57 6 9 135 000 69 0 10 c When ducts are used they must be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular ducts must not be less than 3 in See Fig 3 Step 3 Supply Air Plenum Installation Downflow DOWNFLOW INSTALLATION NOTE This furnace is approved for use on combustible flooring when manufacturers accessory floor base Part No KGASB0201ALL is used Manufacturer s accessory floor base is not required when this furnace is installed
38. must not be taken from the room unless an equal or greater amount of air is supplied to the room CONFINED SPACE A confined space has volume less than 50 cu ft per 1000 Btuh of the total input ratings of all appliances installed in that space A confined space MUST have 2 permanent openings 1 within 12 in of the ceiling and the other within 12 in of the floor See Fig 2 VENT THROUGH ROOF CATEGORY 1 12 MAX 1 SQIN PER 1000 BTUH IN DOOR I I i RETURN AIR INTERIOR OR WALL HEATED UNCONFINED SPACE SPACE 6 MIN FRONT t 1 SQIN PER 1000 BTUH IN DOOR OR WALL l L12 MAX SUPPLY AIR E Minimum opening size is 100 square in with minimum dimensions of 3 In t Minimum of 3 In when type B 1 vent is used A93387 Fig 2 Air for Combustion and Ventilation Inside Air NOTE In determining the free area of an opening the blocking effect of the louvers grilles and screens must be considered If the free area of a louver or grille design is unknown assume that wood louvers have a 20 percent free area and metal louvers or grilles have a 60 percent free area Screens when used must not be smaller than 1 4 in mesh Louvers and grilles must be constructed so they cannot be closed The size of the openings depends upon whether the air comes from inside or outside the structure 1 All air from inside th
39. n used with a night setback thermostat Return air temperature must not exceed a maximum of 85 F db A WARNING Improper installation adjustment alteration service mainte nance or use can cause carbon monoxide poisoning explo sion fire electrical shock or other conditions which may cause personal injury loss of life or property damage Consult a qualified installer service agency local gas sup plier or your distributor or branch for information or assis tance The qualified installer or agency must use only factory authorized and listed kits or accessories when modi fying this product Failure to follow this warning could result in electrical shock fire personal injury or death For accessory installation details refer to the applicable installa tion literature NOTE Remove all shipping brackets and materials before oper ating the furnace Step 1 Location GENERAL 4 CAUTION Do not install furnace in a corrosive or contaminated atmo sphere Make sure all combustion and circulating air require ments are followed in addition to all local codes and ordinances 4 CAUTION Do not use this furnace during construction when adhesives sealers and or new carpets are being installed If the furnace is required during construction use clean outside air for combustion and ventilation Compounds of chlorine and fluorine when burned with combustion air form acids which cause corrosion of the he
40. ng the National Fuel Gas Code NFGC NFPA No 54 1996 ANSI Z223 1 1996 and the Installation Standards Warm Air Heating and Air Conditioning Systems NFPA 90B ANSI NFPA 90B In Canada refer to the current edition of the 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 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE National Standard of Canada CAN CGA B149 1 and 2 M95 Natural Gas and Propane Installation Codes NSCNGPIC Wear safety glasses and work gloves Have fire extinguisher available during start up and adjustment procedures and service calls A CAUTION Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will pre Recognize safety information This is the safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAU TION These words are used with the safety alert symbol DAN GER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damag
41. ollar e Wait 5 minutes and then reset draft safeguard switch 3 Check pressure switch This control proves operation of draft inducer blower a Turn off 115 v power to furnace b Remove control door and disconnect inducer motor lead 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 ignitor should NOT glow and control center diagnostic light flashes a 31 fault If hot surface ignitor glows when inducer motor is disconnected shut down furnace immediately Determine reason pressure switch did not function properly and correct condition e Turn off 115 v power to furnace f Reconnect inducer motor wires replace control door and turn on 115 v power to furnace 4 Check auxiliary limits when used a Turn off 115 v power to furnace b Remove blower access door c Disconnect red motor lead at blower speed selector Mark terminal for proper re connection d Replace blower access door e Turn on 115 v power to furnace Be sure room thermostat is calling for heat f Allow furnace to operate until auxiliary limit activates but DO NOT operate furnace longer than 4 minutes g If furnace operates for 4 minutes check replace limit switch es h Turn off 115 v power to furnace i Remove blower access door j Reconnect red motor lead reset switch and replace door k Turn on 115 v pow
42. on manufacturer s Coil Assembly Part No CD5 or CKS or Coil Box Part No KCAKC is used 1 Determine application being installed from Table 3 2 Construct hole in floor per dimensions specified in Table 3 and Fig 4 3 Construct plenum to dimensions specified in Table 3 4 If downflow subbase KGASB is used install as shown in Fig 5 If coil assembly CD5 CK5 or Coil Box KCAKC is used install as shown in Fig 6 INSTALLATION ON A COMBUSTIBLE FLOOR 1 Cut and frame hole in floor per dimensions in Installation Instructions packaged with downflow subbase 2 When completed coil assembly coil box plenum and fur nace should be installed as shown in Fig 6 c A PLENUM OPENING D A96283 Fig 4 Floor and Plenum Opening Dimensions Table 3 Opening Dimensions In FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A B C D Non Combustible Flooring 12 11 16 19 13 3 8 19 5 8 14 346 Combustible Flooring Using KGASB Subbase 11 13 16 19 13 76 20 3 8 Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC Coil Box 12 516 19 13 5 16 20 Non Combustible Flooring 16 19 16 5 8 19 5 8 17 1 2 Combustible Flooring Using KGASB Subbase 15 1 8 19 16 3 4 20 3 8 Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC Coil Box 15 1 2 19 16 1 2 20 Non Combustible Flooring 19 1 2 19 20 1 8 19 5 8 21 Combustible Flooring Using KGASB Subbase 18 5 8 19 20
43. pply For Canadian installations all electrical connections must be made in accordance with Canadian Electrical Code CSA C22 1 or authori ties having jurisdiction NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control center fault code indicator light will flash rapidly and furnace will not operate Table 6 Electrical Data MAXIMUM HERI OPERATING VOLTAGE RANGE Maximum MINIMUM MAXIMUM WIRE FUSE OR HACR PASE EIS ES UNIT AMPS WIRE GAGE LENGTH FT CKT BKR AMPS 050 08 115 60 1 127 104 6 6 14 42 15 050 12 115 60 1 127 104 8 1 14 34 15 070 08 115 60 1 127 104 67 14 42 15 070 312 115 60 1 127 104 84 14 33 15 096 12 115 60 1 127 104 9 2 14 30 15 096 16 115 60 1 127 104 10 2 14 28 15 115 16 115 60 1 127 104 10 1 14 15 115 20 115 60 1 127 104 13 3 12 20 135 20 115 60 1 127 104 14 3 12 20 Permissible limits of the voltage range at which the unit will operate satisfactorily T Time delay fuse is recommended t Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop A WARNING The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 1996 and Canadian Elec trical Code CSA C22 1 or local codes to minimize personal injury if an electrical fault should occur This may consist of ele
44. re A96415 Fig 14 Heating and Cooling Application Wiring Diagram Ignitor warm up At the end of the prepurge period the ignitor is energized for a 17 sec ignitor warm up period Ignition sequence When the ignitor warm up period is completed the gas valve opens permitting gas flow to the burners where it is ignited After 5 sec the ignitor is de energized and a 2 sec flame sensing period begins 11 d HUM terminal is energized with the gas valve See Accessories in Electrical Connections section e Flame sensing When burner flame is sensed the control begins the blower on delay period and continues holding the gas valve open If burner flame is not sensed the control closes the gas valve and repeats the ignition cycle S S6v O N3H 101 6982c Moydn uo 1 14 pesn uauM juo sjepoui uo s Sv uos n jesej ojne jojuo eAnnaesuoo Jaye 000 0 00 spuooes 06 yeay 10 spuooes gzz 10 081 Sel 06 Buneeu sef jo iewo spuooes 2 duind spuooes seb uo jewo eurej 129 9p 031009 104 0 pejoeuuoo SNU M SIY uonounf eoeuunj eui pue yams 12euuoosip eui UBEMJaq M 1eddoo juo es UO Sjrejep 10 uome jejsui ees
45. rner orifices are the correct size and do not need to be changed to obtain proper input rate 7 Check and verify burner orifice size in furnace NEVER ASSUME ORIFICE SIZE ALWAYS CHECK AND VERIFY b Adjust manifold pressure to obtain input rate 1 Remove regulator adjustment seal cap See Fig 16 2 Turn adjusting screw counterclockwise out to de crease manifold pressure or clockwise in to increase manifold pressure NOTE This furnace has been approved for a manifold pressure of 3 2 in wc to 3 8 in wc when installed at altitudes up to 2000 ft For altitudes above 2000 ft the manifold pressure can be adjusted from 2 0 in wc to 3 8 in wc A CAUTION DO NOT bottom out gas valve regulator adjusting screw This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures 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 characteristics 3 After correct manifold pressure is obtained replace gas valve regulator adjustment screw cap and verify adjusted gas input rate using method outlined in item c 4 Burner flame should be clear blue almost transparent See Fig 17 c Verify natural gas input rate by clocking gas meter NOTE High Altitude Adjustment United St
46. rol area DO NOT bypass the switches Correct inadequate combustion air supply problem and reset the switches SEQUENCE OF OPERATION CAUTION Furnace control must be grounded for proper operation or control will lockout Control is grounded through green wire routed to gas valve and burner bracket screw Using the schematic diagram shown in Fig 15 follow the sequence of operation through the different modes Read and follow the wiring diagram very carefully NOTE If there is a power interruption and any thermostat call the control will initiate a 90 sec blower only on period before starting another cycle 1 Heating mode When the thermostat calls for heat R W circuit closes The furnace control performs a self check verifies the pressure switch contacts are open and starts the inducer motor a Prepurge period As the inducer motor comes up to speed the pressure switch contacts close to begin a 15 sec prepurge period 24 V THERMOSTAT TERMINALS TEST TWIN HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX LED OPERATION amp DIAGNOSTIC LIGHT Com say W YRG HARNESS CONNECTOR ore SEC 1 3 AMP FUSE oocq DOO 24 V TRANSFO
47. s on heating speed for 10 sec then stops g Inducer motor stops 3 To operate furnace follow procedures on operating instruction label attached to furnace 4 With furnace operating set thermostat below room tempera ture and observe that furnace goes off Set thermostat above room temperature and observe that furnace restarts ADJUSTMENTS 1 Set gas input rate Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft Furnace input rate must be within 2 percent of input on furnace rating plate a Determine natural gas orifice size and manifold pressure for correct input 1 Obtain average yearly heat value at installed altitude from local gas supplier 2 Obtain average yearly specific gravity from local gas supplier 3 Verify furnace model Table 8 can only be used for model 58RAV Furnaces 4 Find installation altitude in Table 8 NOTE For Canada altitudes of 2000 to 4500 ft use U S A altitudes of 2001 to 3000 ft in Table 8 5 Find closest natural gas heat value and specific gravity in Table 8 13 6 Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation EXAMPLE 0 2000 ft altitude Heating value 1050 Btu cu ft Specific gravity 0 62 Therefore Orifice No 43 Manifold pressure 3 6 in wc Furnace is shipped with No 43 orifices In this example all main bu
48. ther be hung from the floor joist See Fig 8 or installed on suitable blocks or pad See Fig 9 The furnace can be suspended from each corner by hanger bolts 4 each 3 8 in all thread rod cut to desired length 1 X 3 8 in flat washer 3 8 in lockwasher and 3 8 in nut Dimples are provided for hole locations See Fig 1 Since horizontal crawlspace installation is very similar to the attic installation refer to Step 4 The installation of a sheet metal shield in front of the louvered control panel is covered in Step 4 For a crawlspace installation this same sheet metal shield must be installed above the louvered control panel Extend the sheet metal shield over the furnace top far enough to cover the gas pipe entry hole LUE LEM TTL ET eee FURNACE OR COIL CASING WHEN USED COMBUSTIBLE FLOORING NO DOWNFLOW t SUBBASE SHEET METAL PLENUM FLOOR OPENING 22552905 96285 FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR OPENING 40022 2DXRA A96284 Fig 5 Furnace Plenum and Subbase Installed ona Fig 6 Furnace Plenum and Coil Assembly or Coil Combustible Floor LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS STUDS OR FRAMING
49. ure No Pressure 850 3 6 41 3 7 41 3 8 40 3 6 40 3 8 875 3 8 41 8 5 41 3 6 41 3 7 41 3 8 5 900 3 5 42 37 42 3 8 41 3 5 41 3 6 S 0 925 3 4 42 8 5 42 3 6 42 3 7 42 3 8 5 950 3 2 42 3 3 42 3 4 42 3 5 42 3 6 5 to 975 E 42 3 2 42 3 3 42 3 4 T 1000 43 37 42 3 2 42 3 3 5 2000 1025 43 3 6 43 3 7 43 3 8 3 1050 5 43 3 4 43 3 5 43 3 6 1075 43 3 2 43 3 3 43 3 4 1100 44 3 5 43 3 2 43 3 3 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ORANGE HEAT VALUE 0 60 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT Pressure No Pressure No Pressure No Pressure No Pressure U S A 775 3 7 42 3 8 41 3 5 41 3 6 41 3 8 Altitudes 800 3 4 42 3 6 42 3 7 42 3 8 41 3 5 5 2001 825 3 2 42 3 3 42 3 5 42 3 6 42 3 7 S to 850 j 42 3 3 42 3 4 42 3 5 5 3000 875 2 43 3 7 42 3 2 42 3 3 g or 900 43 3 5 43 3 7 43 3 8 Canada 925 t 43 3 4 43 3 5 43 3 6 qj Altitudes 950 43 3 2 43 3 3 43 3 4 3 2000 975 43 3 0 43 3 1 43 3 2 to 1000 i 5 43 2 9 43 3 0 43 31 4500 1025 43 27 43 2 8 43 2 9 5 SPECIFIC OF NATURAL GAS ANGES HEAT VALUE 0 60 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT Pressure No Pressure No Pressure No Pressure No Pressure 750 3 4 42 3 6 42 3 7 42 3 8 41 3 5 775 3 2 42 3 3 42 3 5 42 3 6 42 3
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