Carrier 58VLR Furnace User Manual
Contents
1. MAX 85F MIN 55 A93042 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 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 heat exchangers and metal vent system Some of these compounds are found in paneling an2. 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 amp o 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 A5 80 I 160 1 400 110 33 65 164 MANIFOLD p 78i oA al 112 32 64 161 A89020 47 76 153 383 116 31 62 155 Fig 19 Burner Flame 48 75 150 375 120 Srl ales 49 73 147 367 A WARNING EXAMPLE 0 2000 ft altitude Disconnect the electrical power before changing the speed Btu heating 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 82 sec d To change blower motor speed selections for heating mode Gas rate 88 cu ft hr from Table 9 remove blower motor lead from control board HEAT Btu heating input 88 X 1050 92 400 Btuh terminal See Fig 14 Select desired blower motor speed In this example the orifice size and manifold pressure lead from 1 of the other terminals and relocate it to HEAT adjustment is within 2 percent of the furnace input terminal See Table 10 for lead color identification Recon rate nect original lead on SPARE terminal tap Failure to follow this warning could result
3. af EP Carrier SUME HEATING amp COOLING WeatherMaker 8000 58ZAV Downflow Horizontal Induced Combustion Furnaces Visit www carrier com Installation Start Up and Operating Instructions Sizes 050 135 Series 140 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 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE 5 ert pU I Rte reins INTRODUCTION Dimensional Drawing eese 2 Clearances From Combustible Materials 3 LOGCA TION 5 iei er ERR E Ores 4 Genetali x Ret e T RRR 4 Location Relative to Cooling Equipment 4 Hazardous Locations 4 AIR FOR COMBUSTION AND VENTILATION 4 5 Unconfitied Space 1 ener ede enel 4 5 Confined Spate nee RO EH E PERS 5 AIR DUCT Sis diene ie MESS Oe e metn 5 6 General Requirements eese 5 Ductwork Acoustical Treatment esee 5 Supply Air Connections eese 5 6 Return Air Connections essent 6 DOWNFLOW INSTALLATION eere 6 HORIZONTAL ATTIC INSTALLATION eere 7 Construct a Working Platform eene 7 Install Furnace eerte tr rnt nent 7 HORIZONTAL CRAWLSPACE INSTALLATION 7 FILTER ARR
4. 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 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 13 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 10 Electrical Connections 115 V WIRING Refer to the unit rating plate or Table 6 for eq
5. 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 b Igniter warm up At the end of the prepurge period the igniter is energized for a 17 sec igniter warm up period 13 c Ignition sequence When the igniter warm up period is completed the gas valve opens permitting gas flow to the burners where it is ignited After 5 sec the igniter is de energized and a 2 sec flame sensing period begins 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 NOTE Ignition sequence will repeat 3 additional times before a lockout occurs Lockout automatically resets after 3 hr or can be manually reset by turning 115v off not at thermostat for 3 sec minimum then on again f Blower on delay Forty five sec after burner flame is proven the blower motor is energized on heating speed Simultaneously terminals HUM and Com 24V for humidi fier and EAC 1 and EAC 2 for EAC are energized If jumper is on pin 6 and pin 9 the blower on delay period is 66 sec g Blower off delay When the thermostat
6. 3 8 3 1050 43 3 4 43 3 5 43 3 6 1075 B 4 43 3 2 43 3 3 43 3 4 1100 44 3 5 43 3 2 43 3 3 ALTITUDE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS HEAT VALUE 0 60 0 62 0 64 0 66 FT 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 s 2001 825 3 2 42 3 3 42 3 5 42 3 6 42 3 7 S to 850 42 3 3 42 3 4 42 3 5 S 3000 875 43 3 7 42 3 2 42 3 3 p or 900 43 3 5 43 3 7 43 3 8 S Canada 925 43 3 4 43 3 5 43 3 6 4 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 43 2 9 43 3 0 43 3 1 4500 1025 K i 43 2 7 43 2 8 43 2 9 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE 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 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 5 850 3 3 43 3 4 43 3 5 43 3 6 43 3 7 4d to 875 3 1 43 3 2 43 3 3 43 3 4 43 3 5 eo 900 2 9 43 3 0 43 3 1 43 3 2 43 3 3 2 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 2 7 43 2 7 43 2 8 1
7. ISdS Avid Lavad GEONGNI Yal JOSALOINE ONUOD uoniu I 10j speu njsseoonsun ewnoesuoo JNO Jaye 4noo0 1noxooruoniub OL 89d NO HOLONGNOO fI p HOlOW JvHQG3OnON WAI i sepou auos uo Auo spuooes Ge 1 OvAv2 NIM G 3HH Paes XW Nv g NOLLO3NNOO H3HICIADHOVAvZ WAH spuooes 06 dund 1eeu 10 Burjooo spuooes SZZ Jo 084 SEL 06 Dureeu se Aejap yo ramoig 6 O N 1SdS AV HH HOLINOI SOVSYNS LOH HISH spuooes z dund qeay 10 Buyooo spuooes qr Buljeay seb Kejep uo ievofg g OWASLL 9NIHIM CEH mI OVA SLL HOLINDI 3OWSYNS LOH ISH i SIOJOW fe UO JOU peaj MOJA 7 OvAv2 ONIHIM AHOLOV L Adds Av aH ND QOHddS HOLOWHJMO H OVIH MM RUN d OVASI ONIM AMO SMOIVESO INYONGA NASO AO bed rel An oth Dae MS E S SU deci GU Mni pus s WNIAWU31 80d danddns GSTILSNI OTAI gr xog uonounf eoeunj eu pue YAMS joeuuoosip aU ueeweg OIM Ud es ar xoq uorounf TE RULES LOIS E is uolioojes paeds desi u JYNIWHIL OIMYYNNN O 30430 LANYYALNI LNSYYNO YAMWEYE UNOHO HO ISNA end UO S fejep 40 SUORONYSU uomejjejsui ees suonpuoo eejene 104 ee suomepes peeds JO OW Mog NOLLONRIP e GHTWISNI AHOIOV JdAL Ov UN feu w 10 seuoiws peop no jeuueu 1esar ojne eua urejuoo siojoui NW T8 Jevorg pue aI Jeonpu Z AAY 9 50 10 pare eum esn peoejdei si aJ jueudinbe euio eui jo Aue OVAPZ OWASI L H3INHOJSNVUL NVHL O N LSdS I3S3H IVONVW MS pice EET SILON TN NIME S AS EINANOONCSL S CHINESE NONNO NOLLO3
8. and for installation on noncombustible flooring The furnace is factory shipped for use with natural gas A factory accessory gas conver sion kit as listed on the furnace rating plate 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 a factory accessory floor base as listed on the furnace rating plate MUST be used when installed on com bustible materials and wood flooring A factory 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 mobile homes recreation vehicles or outdoors Before installing the furnace in the United States refer to the current edition of the NFGC and the NFPA 90B For further information the NFGC and NFPA 90B are available from Na tional Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or the American Gas Association 400 N Capitol St NW Washington DC 20001 Before installing the furnace in Canada refer to the current edition of the NSCNGPIC For a copy of the NSCNGPIC contact Standard Sales CSA International 178 Rexdale Boulevard Eto bicok
9. 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 90 135 180 or 225 sec depending on the blower off time selection The furnace is factory set for a 135 sec blower off delay period h Post purge The inducer motor remains energized 5 sec after the burners are extinguished If jumper is on pin 6 and pin 9 the post purge period is 15 sec 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 45 sec blower on delay period If jumper is on pin 6 and pin 9 the blower on delay period is 66 sec The blower reverts to continuous operation after the heating cycle is completed When the thermostat calls for cooli
10. sheet metal shield must be installed above louvered control panel Extend sheet metal shield over furnace top far enough to cover gas pipe entry hole Step 8 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 return air duct has been connected to furnace install filters in a V formation inside return air plenum See Fig 11 and Table 4 for horizontal applications Horizontal filter retainers must be field supplied See Fig 12 for downflow applications Step 9 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 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 AIRFLOW FIELD SUPPLIED FILTER RETAINERS A82173 Fig 11 Horizontal Filter Arrangement Table 4 Filter Retainer In FURNACE CASING FILTER SIZE AND B WIDT
11. supplied corrosion resistant sheet metal screws located 180 apart and midway up the collar 24 V WIRING 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 Make field 24 v connections at the 24 v terminal strip See Fig 14 Connect terminal Y as shown in Fig 15 for proper operation in cooling mode Use AWG No 18 color coded wire only 11 BLOWER OFF DELAY ADJUSTMENT SWITCH f ON 24V THERMOSTAT TERMINALS LM TEST TWIN HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX LED OPERATION amp STATUS LIGHT T c Las aaalaaz BERET 1 HARNESS CONNECTOR 010 DOO T 24V TRANSFORMER SEC 2 SEC 1 NI 3 AMP FUSE i COOL HEAT SPARE 1 BLOWER SPEED SELECTION TERMINALS D SPARE 2 iol IOl Tea Ip EAC 1 BLACK 1D ey EAC ELECTRONIC AIR CLEANER x TERMINALS 11
12. this warning could result in fire Canadian installations all electrical connections must be made in accordance with Canadian Electrical Code CSA C22 1 or authori ties having jurisdiction NOTE A field supplied 115 v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control status code indicator light will flash rapidly and furnace will not operate Step 11 Venting A WARNING Refer to the national or local installation code such as NFGC in the The cabinet MUST have an uninterrupted or unbroken ground United States or the NSCNGPIC in Canada for proper vent sizing according to NEC ANSI NFPA 70 1999 and Canadian Elec and installation requirements Use the enclosed Installation In trical Code CSA C22 1 or local codes to minimize personal structions Single Stage Vent Tables for Category I Fan Assisted injury if an electrical fault should occur This may consist of Furnaces for a quick easy reference electrical 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 After fully assembling the vent connector to the furnace flue collar securely fasten the vent connector to the collar with two field
13. 000 2 4 43 2 4 43 2 5 43 2 6 43 2 7 AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 60 0 62 0 64 0 66 FT 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 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 lt to 850 2 9 43 3 0 43 3 1 43 3 2 43 3 3 2 875 2 7 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 per burner 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 t Orifices sizes shown in BOLD are factory installed 16 Table 7 Model 58ZAV Orifice Sizet and Manifold Pressure for Correct Input Continued Tabulated Data Based on 23 000 BTUH Per Burner Derated 4 percent per 1000 Ft Above Sea Level ADPEROBE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 60 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manif
14. 5 VAC 1 0 AMP MAX 1 Io ED EAC 2 WHITE SUPPLY 115 VAC L2 NEUTRAL CONNECTION HOT MEER INDUCER MOOR NNECTOR CONNECTOR A99258 Fig 14 Furnace Control FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING NOTE 2 THERMOSTAT FIVE WIRE W D TERMINALS FIELD SUPPLIED BLOWER DOOR ee i B eL 208 230 OR e i e e e 460 V e i e e e eee PHASE BL ee WBR n WH E uu Lio 4 4 I WHT e M HRA Oo e ee ee ee 2e d AT SR GND GND R Sdr im irte uet i 60j e PHASE 115 V FIELD AUXILIARY o amp M 7 e SUPPLIED _ J BOX L HB r T GND DISCONNECT Oe CONDENSING UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A98521 Fig 15 Heating and Cooling Application Wiring Diagram 12 A93053 Fig 16 EAC Terminals on Furnace Control Step 12 Start up Adjustment and Safety Check GENERAL NOTE Proper polarity must be maintained for 115 v wiring If polarity is incorrect control status indicator light will flash rapidly and furnace will not operate The furnace must have a 115 v power supply properly connected and grounded Proper polarit
15. ANGEMENT eene 8 GAS PIPING 8 10 ELECTRICAL CONNECTIONS eee 10 115 v Warmg pene etenim hr mies 10 DAN WAEITIG see e eie e RR EE EE HORE 11 ACCESSOLIES inna HET EPOD DROP 11 VENTING serne kura ete beg ee cepe eene 11 START UP ADJUSTMENT AND SAFETY CHECK 11 20 CEEA e DE A Los oom ier M R 11 13 Sequence Of Operations nons 13 Heating Mode nati tind eisai eae eb aie 13 Cooling Mode re Ue aah RR etes 13 Continuous Blower Mode eee 13 Heat Puinp Mode eret ettet tere 13 Start up Procedures cec nere ete eger roa rota 13 Adjustments ertet Reden enn 15 20 Set Gas Input Rate eere n HEP TIER ERE 15 Set Temperature Rise 18 Set Thermostat Heat Anticipator 19 Check Safety Controls 20 Checklist rtr ttt ttt ttti en 20 EFFICIENCY RATING CERTIFIED ama dh CANADIAN GAS ASSOCIATION APPROVED R O a 9001 P7 REGISTERED QUALITY SYSTEM 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 heating equipment ob
16. AS SEL Sdo1 aasn NaHW LHESION a3sn NSHM vit SON aasn NaHM m1 m3 oas os Lm m3 Cm cm oas oo J1HVHO NOLLO3 T3S AV EG 440 H3NO T8 M PEON T NO LON A 6 ILON d Eyma g d ZMS 14 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 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 should disappear leaving the G signal input the control goes into continuous blower and the inducer remains on for the normal post purge period a Determine natural gas orifice size and manifold pressure for correct input gt 1 Obtain average yearly gas heat value at installed Anytime the control senses false flame the control lock
17. DE 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 6 650 2 3 43 2 4 43 2 5 43 2 6 43 2 6 d to 675 2 1 43 2 2 43 2 3 43 2 4 43 2 4 7 700 j 43 2 1 43 2 1 43 2 2 43 2 3 10 000 725 48 3 6 48 3 7 43 2 1 43 2 1 750 48 3 4 48 3 5 48 3 6 48 3 7 775 i 49 3 7 49 3 8 48 3 4 48 3 5 For size 135 20 only input is 22 500 Btuh per burner 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 T Orifice sizes shown in BOLD are factory installed 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 s D BURNER zi N V ORIFICE A93059 A CAUTION DO NOT redrill orifices Improper drilling burrs out of round holes etc can cause excessive burner noise and misdirection of burner flames This can result in flame impingement of burners and heat exchangers causing failures 3 After correct manifold pressure is obt
18. For 1600 CFM 22 in round or 141 x 23 4 in rectangle d For airflow requirements above 1800 CFM must use entire return air opening A99288 Fig 1 Dimensional Drawing Table 1 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 4 128 070 08 14 3 16 12 9 16 12 11 16 4 129 070 12 14 3 16 12 9 16 12 11 16 4 137 096 12 17 1 2 15 7 8 16 4 146 096 16 17 1 2 15 7 8 16 4 151 115 16 17 1 2 15 7 8 16 4 159 115 20 21 19 3 8 19 1 2 4 174 115 22 21 19 3 8 19 1 2 4 176 135 20 24 1 2 22 7 8 23 5 193 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 3 After touching the chassis you may proceed to service the PROCEDURE control or connecting wires as long as you do nothing that recharges your body with static electricity for example DO A CAUTION NOT move or shuffle your feet DO NOT touch ungrounded objects etc Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to 4 If you touch ungrounded objects recharge your body with protect the furnace electronic control Precautions will pre static electricity firmly touch furnace again before touching vent electrostatic discharges from personnel and hand tools control or wires which are held during the procedure These precautions will 5 Use this procedure for installed and uninstalled ungrounded help to avoid exposing the
19. H 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 AIRFLOW 47 INSTALLATION POSITION OF FILTERS RETURN AIR PLENUM NE m dii TRI A A 4d TIR il P DOOR ITO SIN ax cM A88486 Fig 12 Downflow Filter Arrangement A WARNING Table 5 Maximum Capacity of Gas 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 73 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 anda 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 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
20. NNOO H3Nv2O HIV OINOHIOJTH ZOYI oe ON 1SdS HOLIMS 3HNSS3Hd Sud XVN dA L OWA SHL NOLLOSNNOO H3NYJTO HV OINOHLOF13 I 0V3 G3SN LON YOLOINNOO 8Od ISH LINOYIO Sd HOLMS QHVn3dVS lavad SSA G3Sn 10N noo HOLOANNOO WAI LInOHIO E d XALINOUIO ANY HOSS3OOHdOHOIN Ndo i i HOLD Sd UNOD 2s ON 184S HOLMS JHOLNHS INGACEDOO SSMA 354 z WOLO3NNOO LINOYIO 6 hd HOIOWNHJMO WATE 5 QuVvOB LINDYID G31NIHd 80d ON LSdS AVY HOLOWH3MOT8 Yma ON LSdS 13834 WNW dAG LH3AO HOLMS LIATTABVEIXDV SW 8 I QN3931 S SION o Mt A i ay z eiie NHO o Fano I pe mE LL LON E fido I I WHLNAN 1 380 NHM tlt ION e em ee E re i 4M ona n le Dad IT P az a eS reer l T 3ION phat Sa v9 diat N3HN HOLMS D aasn N3HM E OVIH ish TONOS ge a3sn N3HM Haj i e e CI Eam lt Om Tsud_ Sd91 HF3ION EIF ALON ood u u I LIION O N3HM H rH SN LON p OVASLL t 310ON l 3uvds lVaH e3uvds QNnOH9 LNAWdINOA 4 GNYdOtd 8 SVO VHn L vN TION WvHOVIG DULVINS3HOS 1O3NNOOSIQ C714 OVAGLLOL WHLAAN Es WNH S L ZENO Zi 310N zou sud zoss B 9 amp 31ON Nd NIMVISAL O
21. OCATION B ALTERNATE ROD LOCATION A B NOTES 1 A 1 In clearance minimum between top of furnace and combustible material 2 The entire length of furnace must be supported when furnace is used in horizontal position A96633 Fig 10 Horizontal Crawlspace Installation on Hanger Rods INSTALL FURNACE 1 Position furnace in desired location 2 Connect gas supply pipe See Fig 8 for typical piping entry 3 Install field supplied filter retainers as indicated in Fig 11 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 8 Step 7 Horizontal Crawlspace Installation The furnace can be installed horizontally with either the LH or RH side up In a crawlspace furnace can either be hung from floor joist see Fig 10 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 attic installation refer to Step 6 The installation of a sheet metal shield in front of louvered control panel is covered in Step 6 For a crawlspace installation this same
22. ONDITION 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 blocked vent 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 If the unconfined space is of unusually tight construction air for For Example S8ZAV FURNACE We FT 7 1 2 FT CEILING 46 000 307 69 000 460 92 000 613 115 000 767 135 000 920 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 as defined below Return air 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 is defined as a space whose volume is less than 50 cu ft per 1000 Btuh of total input
23. ained 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 19 c Verify natural gas input rate by clocking gas meter NOTE High Altitude Adjustment United States At installation altitudes above 2000 ft this furnace has been approved for a 4 percent derate for each 1000 ft above sea level See Table 8 for derate multiplier factor 18 Table 8 Altitude Derate Multiplier for U S A ALTITUDE 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 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 percent by an authorized Gas Conversion Station To determine 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
24. 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 20 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 ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER 10 a m FROM UNIT 24 V CONTROL TERMINALS EXAMPLE 5 0 AMPS ON AMMETER 0 5 AMPS FOR THERMOSTAT 10 TURNS AROUND JAWS ANTICIPATOR SETTING Fig 20 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 t
25. ative fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts 9 VENT THROUGH ROOF CATEGORY 12 MAX RETURN AIR 1 SQ IN PER 1000 BTUH IN DOOR OR WALL UNCONFINED SPACE 6 MIN FRONT t 1 SQIN PER 1000 BTUH IN DOOR OR WALL INTERIOR HEATED SPACE qu SUPPLY AIR es Minimum opening size is 100 sq in with minimum dimensions of 3 in 12 MAX t Minimum of 3 in when type B 1 vent is used A93387 DUCTS TO OUTDOORS 1 SQIN PER 4000 BTUH l EE M j I l 1 12 MAX D 12 1 SQ IN MAX mmo Pme eres E SIE hl e P I Y i 1 SQ IN PER 4000 5 BTUH A LL Q OUTDOORS Zo Qn 1 SQ IN o PER 4000 BTUH 1 SQIN E PER 2000 t B EL GE BTUH 12 12 MAX C MAX 12 MAX SUPPLY AIR Z DUCT TO 1 SQIN OUTDOORS PER 4000 BTUH Minimum dimensions of 3 in NOTE Use any of the following combinations of openings A amp B C amp D D amp E F amp G A93388 Fig 3 Confined Space Air for Combustion and Fig 4 Confined Space Air for Combustion and Ventilation from an Unconfined In
26. ce may be installed on combustible flooring in alcove or closet at minimum clearance from combustible material This furnace may be used with a Type B 1 Vent and may TOP PLENUM be vented in common with other gas fired appliances T For installation on non combustible floors only For installation on combustible flooring only when installed on special base Part No KGASB0201 ALL Coil Assembly Part No CD5 or CK5 or Coil Casing Part No KCAKC For furnaces wider than 14 25 inches 362mm may be 0 inches 18inches front clearance required for alcove Indicates supply or return sides when furnace is in the horizontal position 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 For single wall vent type 6 inches For Type B 1 vent type 3 inches TT Clearance to Back 0 inches in downflow and horizontal attic alcove amp crawlspace positions and 3 inches in horizontal closet positions Clearance in inches Vent Clearance to combustibles For Single Wall vents 6 inches For Type B 1 vent type 1 inch 322286 101 REV F LIT 99262 Fig 2 Clearances to Combustibles INTRODUCTION The model 58ZAV Series 140 Furnaces are available in sizes 46 000 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
27. control to electrostatic discharge furnaces byp tting the furnace the control and the persona the saime 6 Before removing a new control from its container discharge electrostatic potential your body s electrostatic charge to ground to protect the 1 Disconnect all power to the furnace DO NOT TOUCH THE control from damage If the control is to be installed in a CONTROL OR ANY WIRE CONNECTED TO THE CON furnace follow items 1 through 5 before bringing the control TROL PRIOR TO DISCHARGING YOUR BODY S ELEC or yourself into contact with the furnace Put all used AND TROSTATIC CHARGE TO GROUND new controls into containers before touching ungrounded 2 Firmly touch a clean unpainted metal surface of the furnace objects chassis which is close to the control Tools held in a person s 7 An ESD service kit available from commercial sources may hand during grounding will be satisfactorily discharged also be used to prevent ESD damage MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION This forced air furnace is equipped for use with natural This furnace is approved for DOWNFLOW and HORIZONTAL gas at altitudes 0 10 000 ft 0 3 050m installations An accessory kit supplied by the manufacturer shall be used to convert to propane gas use or may be required for Clearance arrows some natural gas applications do not change with This furnace is for indoor installation in a building furnace orientation constructed on site This furna
28. d 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 A WARNING Do not install the furnace on its back safety control operation will be adversely affected Failure to follow this warning could result in fire personal injury or death 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 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 parallel 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 man
29. door Space Ventilation from Outdoors Table 2 Minimum Free Area Of Combustion Air Opening Scone AIR FROM UNCON OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH FURNACE SPACE VERTICAL DUCTS HORIZONTAL DUCTS SINGLE DUCT INPUT Free Area Free Area of Round Free Area of Round Free Area of Round BTUH of Opening Opening and Duct Pipe Opening and Duct Pipe Opening and Duct Pipe Sq In Sq In In Dia Sq In In Dia Sq In In Dia 46 000 100 11 50 4 23 0 6 15 33 5 69 000 100 17 25 5 34 5 7 23 00 6 92 000 100 23 00 6 46 0 8 30 67 7 115 000 115 28 75 7 57 5 9 38 33 7 135 000 135 33 75 7 67 5 10 45 00 8 Free area shall be equal to or greater than the sum of the areas of all vent connectors in the confined space Opening area must be increased if other gas appliances in the space require combustion air Step 3 Supply Air Connections DOWNFLOW FURNACES Connect supply air duct to supply air opening on furnace The supply air duct attachment must ONLY be connected to furnace supply outlet or air conditioning coil casing when used when installed on non combustible material When installed on combus tible material supply air duct attachment must ONLY be con nected to an accessory subbase or factory approved air condition ing coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accessories MUST be connected external t
30. e 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 reconnection 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 power 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 Un A U N e Check operation of accessories per manufacturer s instruc tions an Review User s Manual with owner 7 Leave literature packet near furnace 58zav10s Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Tab 6a 8a Catalog No 535 729 Printed in U S A Form 58ZAV 10SI Pg 20 8 99 Replaces 58ZAV 9SI
31. e Toronto Ontario M9W 1R3 Canada Installation must comply with regulations of serving gas supplier and local building heating plumbing or other codes in effect in the area in which installation is made In absence of local building codes installation must conform with NFGC in the United States and the NSCNGPIC and all authorities having jurisdiction in Canada These instructions cover minimum requirements for a safe instal lation and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept pace with changing residential construction practices We require these instructions as a minimum for a safe installation 4 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 NOTE These furnaces are designed for a minimum continuous return air temperature of 60 F or intermittent operation down to 55 F such as when used with a night setback thermostat Return air temperature must not exceed a maximum of 85 F Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls FRONT RETURN AIR TTT ANTA
32. ed at altitudes up to 2000 ft energized For altitudes above 2000 ft the manifold pressure can be adjusted e Blower motor operates on cooling speed for 10 sec then from 2 0 in we to 3 8 in we stops f Blower motor operates on heating speed for 10 sec then A CAUTION stops I DO NOT bottom out gas valve regulator adjusting screw g Inducer motor stops This can result in unregulated manifold pressure and result in 3 To operate furnace follow procedures on operating instruction excess overfire and heat exchanger failures label attached to furnace 15 Table 7 Model 58ZAV Orifice Sizet and Manifold Pressure for Correct Input Tabulated Data Based on 23 000 BTUH Per Burner Derated 4 Percent per 1000 Ft Above Sea 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 850 3 6 41 3 7 41 3 8 40 3 6 40 3 8 875 3 8 41 3 5 41 3 6 41 3 7 41 3 8 S 900 3 5 42 3 7 42 3 8 41 3 5 41 3 6 B 0 925 3 4 42 3 5 42 3 6 42 3 7 42 3 8 950 3 2 42 3 8 42 3 4 42 3 5 42 3 6 Ri to 975 3 j 42 3 2 42 3 3 42 3 4 1000 43 3 7 42 3 2 42 3 8 2000 1025 j s 43 3 6 43 3 7 43
33. es In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residen tial construction practices We require these instructions as a minimum for a safe installation Manufacturer 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 535 729 Tab 6a 8a Printed in U S A Form 58ZAV 10SI Pg 1 8 99 Replaces 58ZAV 9SI 2 28 le1 VENT CONNECTION 2041 coe INLET ere 39 e of Vet DIA THERMOSTAT WIRE ENTRY x Tw 7 DIA ACCESSORY 7t DIA HOLE POWER ENTRY ACCESSORY i GAS ENTRY L d3 E hE I taer OUTLET 19r Ast 4 Miet E eo 13 9461 HM 10 Vat 8 at A 1 Vet DIA R H GAS ENTRY 16 et Tet DIA 1 TYP ACCESSORY EN TYP TiAgt a 1 Wet 742 Vet NOTE ADDITIONAL 7g DIAK O s ARE AIRFLOW DIMPLES TO DRILL HOLES FOR HANGER BOLTS 4 PLACES IN HORIZONTAL POSITION LOCATED IN THE TOP PLATE AND BOTTOM PLATE NOTE Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations for equivalent diameters a For 800 CFM 16 in round or 14 x 12 in rectangle b For 1200 CFM 20 in round or 1412 x 1912 in rectangle c
34. essure No Pressure 42 3 2 43 3 6 43 34 7001 43 3 1 o 43 2 9 4 to 43 2 7 5 43 2 5 8000 43 2 4 43 2 2 43 2 1 ALTITUDE 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 2 7 43 2 8 43 2 9 Y 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 2 9000 750 2 0 43 2 1 43 2 2 43 2 3 43 2 3 775 3 6 48 3 7 43 2 1 43 2 1 43 2 2 800 3 4 48 3 5 48 3 6 48 3 7 43 2 0 For size 135 20 only input is 22 500 Btuh per burner 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 T Orifice sizes shown in BOLD are factory installed 17 Table 7 Model 58ZAV Orifice Sizet and Manifold Pressure for Correct Input Continued Tabulated Data Based on 23 000 BTUH Per Burner Derated 4 percent per 1000 Ft Above Sea Level SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS HEAT VALUE 0 66 RANGE FT AT ALTITU
35. 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 Table 9 Gas Rate Cu Ft Hr SECONDS SIZEOF TEST DIAL sECONDS SIZE OF TEST DIAL Bennet FOR 1 1 2 5 FOR 1 1 2 5 REVOLUTION cu ft cu ft cu ft REVOLUTION cu ft cuft cu ft GAS 10 360 720 1800 50 72 144 360 PRESARE 11 327 655 1636 51 71 141 355 ADIUS IMENT 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 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 INLET 22 164 327 818 64 56 112 281 PRESSURE TAP 23 157 313 783 66 54 109 273 I BC AB 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 f A95618 26 138 277 692 72 50 100 250 Fig 18 Redundant Automatic Gas Control Valve 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 BURNER 31 116 232 581 82 44 88 220 32 113 225 563 84 43
36. he limit is functioning properly and operates if there is a motor failure 2 Check blocked vent safeguard switch The purpose of this control is to permit the safe shutdown of the furnace during certain blocked vent conditions 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 Copyright 1999 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 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 collar e Wait 5 minutes and then reset blocked vent 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 igniter should NOT glow and control diagnostic light flashes a status code 31 If hot surface igniter 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 furnac
37. in personal injury Follow this same procedure for proper selection of COOL 2 Set temperature rise speed selection Furnace must operate within range of temperature rise speci fied on the unit rating plate Determine the air temperature rise A CAUTION as follows If Model 58ZAV 115 22 is installed in 0 50 in wc or lower static pressure ductwork evaporator coil condensate blow off can occur during cooling operation When installed in this manner do not use high blower speed tap for cooling 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 b When thermometer readings stabilize subtract return air temperature from supply air temperature to determine tem Table 10 Speed Selector c Adjust air temperature rise by adjusting blower speed Black High COOL Increase blower speed to reduce temperature rise Decrease Yellow When present Medium High SPARE blower speed to increase temperature rise Blue Medium Low HEAT Red Low SPARE White Common L2 COM 19 4 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 anticipation must be set to match the
38. ing Contractors Association ACCA Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE Or consult factory The Air Systems Design Guidelines reference tables available from your local distributor The duct system should be sized to handle the required system design CFM at the design static pressure 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 Secure ductwork with proper fasteners for type of ductwork used Seal supply and return duct connections to furnace with code approved tape or duct sealer Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in clearance from combustible materials to supply air ductwork for a distance of 36 in horizontally from the furnace See NFPA 90B or local code for further requirements Step 2 Ductwork acoustical treatment Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take off may require internal acoustical lining As an altern
39. ng the blower operates on cooling speed When the thermostat is satisfied the blower operates an 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 weibeig Buni e2euanJj L Hlg 900286V 3 A34 101 698cc paesu c MS dL QVO TH3 O HOLOW IVNHSINI IJS3HOlnV 70 S y Alosseooy Jeidepy foutulur USUM pasn ss P SN JOU S SSAA UUM perpeuuco AI pl ADVAN DES ONISdS I3sdHOInV HOLMS LIN S1 pasn jou si S497 uSuw pepeuuoo e eL aNs aan iz O N ISdS HOLIMS SYNSSSHd SVO MO1 SdO1 speutue jeuuoo pinb epeds aney au sjapow eulos Z GNNOYD LNAWdINOS ct S3000 SNIWLS HO4 3QOld ONLLLINS LHOT1 Qr Aluo slepou QNnOHO Ql Se XO NOLLONAr ar Mo dn uo si 74 pesn ueuM Auo SjaPOLU MOYUMOP auos uo SI STY YAS pwj uere pasn ueuM LL RNIN ONG GG E O N LSdS HOLIMS UM TANVd SS390V H3MO 8 ni sinou say jeje ON
40. o furnace main casing HORIZONTAL FURNACES Connect supply air duct to supply air opening on furnace The supply air duct attachment must ONLY be connected to furnace supply outlet or air conditioning coil casing when used DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All accessories MUST be connected external to furnace main casing Step 4 Return Air Connections A WARNING Do not install the furnace on its back or sides Safety control operation will be adversely affected Never connect return air ducts to the back of the furnace A failure to follow this warning can cause a fire personal injury or death The return air duct must be connected to return air opening provided as shown in Fig 1 DO NOT cut into casing sides or back PLENUM OPENING D A96283 Fig 5 Floor and Plenum Opening Dimensions Table 3 Opening Dimensions In FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH A C D Non Combustible Flooring 12 11 16 13 3 8 19 5 8 14 316 Combustible Flooring Using KGASB Subbase 11 13 16 13 76 20 3 8 Combustible Flooring with CD5 or CK5 Coil Assembly or a 9 KCAKC Coil Box 12 516 13 5 16 20 Non Combustible Flooring 16 16 5 8 19 5 8 17 1 2 Combustible Flooring Using KGASB Subbase 15 1 8 16 3 4 20 3 8 Combustible Flooring with CD5 or CK5 Coil Assembly or KCAKC Coil Box i e 16 12 20 Non Combu
41. old 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 2 7 43 2 7 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 2 1 43 2 2 43 2 3 43 2 3 43 2 4 950 3 8 43 2 1 43 2 1 43 2 2 43 2 3 975 3 6 48 3 7 43 2 0 43 2 1 43 2 2 1000 3 4 48 3 5 48 3 6 48 3 7 43 2 1 anes 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 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 ALSER BE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0 58 060 0 62 0 64 0 66 FT AT ALTITUDE Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold BTU CU FT No Pressure No Pressure No Pressure No Pr
42. ows all components Specific gravity 0 62 except gas valve to be run for a short period of time Therefore Orifice No 43 This feature helps diagnose a system problem in case of a Manifold Pressure 3 6 in We component failure To initiate component test procedure short Furnace is shipped with No 43 orifices In this example jumper the TEST 3 16 in quick connect terminal on control all main burner orifices are the correct size and do not need adjacent to diagnostic light and the Cow 24V terminal on to be changed to obtain proper input rate furnace thermostat connection block for approximately 2 sec See Fig 14 7 Check and verify burner orifice size in furnace NOTE Component test feature will not operate if any thermostat NEVER ASSUME ORIFICE SIZE ALWAYS signal is present at control CHECK AND VERIFY Component test sequence is as follows b Adjust manifold pressure to obtain input rate a Momentarily jumper TEST and Com 24V terminals until 1 Remove regulator adjustment seal cap See Fig 18 LED goes off TE f 2 Turn adjusting screw counterclockwise out to de b LED will display previous status 4 times crease manifold pressure or clockwise in to increase c Inducer motor starts and continues to run for entire com manifold pressure PORES NOTE This furnace has been approved for a manifold pressure d Hot surface igniter is energized for 15 sec then de of 3 2 in wc to 3 8 in wc when install
43. panel for maximum 2 percent voltage drop 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 GAS SUPPLY Two spring clamp terminals for 12 gage maximum solid or stranded wire marked EAC 1 and EAC 2 are provided for EAC connection See Fig 14 These terminals are energized with 115v 1 5 amp maximum during blower motor opera tion To connect EAC power leads to furnace control board strip approximately 1 8 in of insulation from wire Open terminal by depressing switch arm with a screwdriver or finger and insert wire as shown in Fig 16 2 Humidifier HUM Screw terminals HUM and Com 24V are provided for 24 v humidifier connection The terminals are energized with 24v 0 5 amp maximum after inducer motor prepurge period SEDIMENT TRAP UNION A CAUTION A89414 Do not connect furnace control HUM terminal to HUM Fig 13 Typical Gas Pipe Arrangement humidifier terminal on Thermidistat Zone Controller or similar device See Thermidistat Zone Controller thermostat or controller manufacturer s instructions for proper connec tion A failure to follow
44. ratings of all appliances installed in that space A confined space MUST have provisions for supplying air for combustion ventilation and dilution of flue gases using 1 of the following methods See Fig 3 and 4 and Table 2 NOTE In determining free area of an opening the blocking effect of louvers grilles and screens must be considered If free area of 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 air comes from outside of the structure or an unconfined space inside the structure 1 All air from inside the structure requires 2 openings for structures not usually tight a Each opening MUST have at least 1 sq in of free area per 1000 Btuh of total input for all equipment within the confined space but not less than 100 sq in per opening See Fig 3 and Table 2 The minimum dimension of air openings shall not be less than 3 in b If building is constructed unusually tight a permanent opening directly communicating with the outdoors shall be provided See item 2 below c If furnace is installed on a raised platform to provide a return air plenum and return air is taken directly from hallway or space adjacent to furnace all air for combustion must come f
45. rom outdoors 2 Air from outside the structure requires 1 of the following methods a If combustion air is taken from outdoors through 2 vertical ducts the openings and ducts MUST have at least 1 sq in of free area per 4000 Btuh of total input for all equipment within the confined space See Fig 4 and Table 2 b If combustion air is taken from outdoors through 2 hori zontal ducts the openings and ducts MUST have at least 1 sq in of free area per 2000 Btuh of total input for all equipment within the confined space See Fig 4 and Table 2 c If combustion air is taken from outdoors through a single opening or duct horizontal or vertical commencing within 12 in of the top of the confined space opening and duct MUST have at least 1 sq in of free area per 3000 Btuh of the total input for all equipment within the confined space and not less than the sum of the areas of all vent connectors in the confined space See Fig 4 and Table 2 Equipment clearances to the structure shall be at least 1 in from the sides and back and 6 in from the front of the appliances 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 ducts must not be less than 3 in See Fig 4 AIR DUCTS Step 1 General Requirements The duct system should be designed and sized according to accepted national standards such as those published by Air Condition
46. s out altitude from local gas supplier of the heating mode This occurs because the control cannot sense the W input due to the false flame signal and as a result gt 2 Obtain average yearly gas specific gravity from local sees only the Y input and goes into cooling mode blower off gas supplier delay All other control functions remain in standard format 3 Verify furnace model Table 7 can only be used for NOTE EAC 1 terminal is energized whenever blower operates model 58ZAV Furnaces HUM terminal is only energized when gas valve is energized 4 Find installation altitude in Table 7 START UP PROCEDURES NOTE For Canada altitudes of 2000 to 4500 ft use U S A 1 Purge gas lines After all connections have been made purge altitudes of 2001 to 3000 ft in Table 7 the lines and check for leaks 5 Find closest natural gas heat value and specific gravity A WARNING in Table 7 6 Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation 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 EXAMPLE 0 2000 ft altitude Heating value 1050 Btu cu ft 2 Component test The furnace control all
47. serve precautions in the literature on tags and on labels attached to or shipped with the unit and other safety precautions that may apply In the United States follow all safety codes including the National Fuel Gas Code NFGC NFPA 54 1996 ANSI Z223 1 1996 and the Installation Standards Warm Air Heating and Air Condition ing Systems NFPA 90B ANSI NFPA 90B In Canada refer to the CAN CGA B149 1 and 2 M95 National Standard of Canada 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 Recognize safety information This is the safety alert symbol N When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury gt Understand the signal words DANGER WARNING CAUTION and NOTE These words are used with the safety alert symbol DANGER 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 damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation These instructions cover minimum requirements and conform to existing national standards and safety cod
48. stible Flooring 19 1 2 20 1 8 19 5 8 21 Combustible Flooring Using KGASB Subbase 18 5 8 20 1 4 20 3 8 Combustible Flooring with CD5 or CK5 Coil Assembly or 19 20 20 KCAKC Coil Box Non Combustible Flooring 23 19 5 8 24 1 2 Combustible Flooring Using KGASB Subbase 22 1 8 20 3 8 Combustible Flooring with CD5 or CK5 Coil Assembly or 22 4 2 20 KCAKC Coil Box to attach any portion of return air duct Bypass humidifier connec If coil assembly CD5 CK5 or Coil Box KCAKC is used tions should be made at ductwork or coil casing sides exterior to install as shown in Fig 7 furnace Step 6 Horizontal Attic Installation Step 5 Downflow Installation NOTE This furnace is approved for use on combustible materials A WARNING or wood flooring A factory accessory floor base as listed on the furnace rating plate MUST be used A factory accessory floor base is not required when this furnace is installed on manufactur er s Coil Assembly Part No CD5 or CKS or Coil Box Part No 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 KCAKC is used could result in fire personal injury or death 1 Determine application being installed from Table 3 The furnace can be installed horizontally on either the left hand 2 Construct hole in floor per dimensions specified in Table 3 LH or right hand RH side A typical at
49. tic installation is shown and Fig 5 in Fig 8 3 Construct plenum to dimensions specified in Table 3 CONSTRUCT A WORKING PLATFORM 4 If downflow subbase KGASB is used install as shown in Construct working platform on location where all required furnace Fig 6 clearances are met See Fig 2 and 8 m ur cU cu EE NEN T FURNACE OR COIL CASING FURNACE WHEN USED CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE VA FLOORING N ET i eee LET COMBUSTIBLE FLOORING A P d SS X N NA n seers N PLENUM PLENUM R N NI FLOOR A FLOOR H OPENING A OPENING N A960285 A96284 Fig 6 Furnace Plenum and Subbase Installed Fig 7 Furnace Plenum and Coil Assembly or on a Combustible Floor Coil Box Installed on a 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 30 IN MIN WORK AREA MANUAL SHUTOFF GAS VALVE SEDIMENT TRAP A97516 TIT WN 00 NN MUI A95235 Fig 9 Horizontal Installation on Blocks W ANGLE IRON OR pi EQUIVALENT CAS we 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 L
50. ually 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 18 IN MINIMUM TO BURNERS A93044 A WARNING When furnace is installed in a residential garage it must be installed so that burners and ignition sources are located a minimum of 18 in above floor The furnace must be located or protected to avoid physical damage by vehicles When furnace is installed in a public garage airplane hangar or other building having a hazardous atmosphere unit must be installed in accordance with requirements of 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 4 CAUTION The operation of exhaust fans kitchen ventilation fans clothes dryers or fireplaces could create a NEGATIVE PRESSURE C
51. uipment electrical requirements The control system requires an earth ground for proper operation A CAUTION Do not connect aluminum wire between disconnect switch Use the proper length of pipes to avoid stress on the gas and furnace Use only copper wire control manifold Failure to follow this warning could result in a gas leak causing fire explosion personal injury or death Make all electrical connections in accordance with the current edition of the National Electrical Code NEC ANSI NFPA 70 1999 and any local codes or ordinances that might apply For 10 Table 6 Electrical Data VOLTS unit size HERTZ CPERATING VOLTAGE RANGE MAXIMUM MINIMUM MAXIMUM WIRE use OR CKT BKR PHASE Madri Minimum UNIT AMPS WIRE GAGE LENGTH FT NES 050 08 115 60 1 127 104 6 6 14 42 15 050 12 115 60 1 127 104 81 14 34 15 070 08 115 60 1 127 104 67 14 42 15 070 12 115 60 1 127 104 84 14 33 15 096 12 115 60 1 127 104 92 14 30 15 096 16 115 60 1 127 104 102 14 28 15 115316 115 60 1 127 104 10 1 14 28 15 115 20 115 60 1 127 104 13 3 12 33 20 115 22 115 60 1 127 104 15 2 12 29 20 135 20 115 60 1 127 104 143 12 31 20 Permissible limits of the voltage range at which the unit will operate satisfactorily T Time delay type is recommended Length shown is as measured 1 way along wire path between unit and service
52. y must be maintained for correct operation Thermostat wire connections at R W C and Y must be made at the furnace 24 v terminal block on the control 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 4 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 control area DO NOT bypass the switches Correct inadequate combustion air supply problem and reset the switches SEQUENCE OF OPERATION A 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 16 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
Download Pdf Manuals
Related Search