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Carrier 58MVP Installation, Start-Up, And Operating Instructions Manual

Variable-capacity condensing gas furnace
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Installation, Start-Up, and Operating Instructions
For use by Beutler Heating and Air for Renaissance Builders
NOTE: Read the entire instruction manual before starting the
installation.
Index
SAFETY CONSIDERATIONS .....................................................3
DIMENSIONAL DRAWING........................................................2
Clearances to Combustibles......................................................3
CODES AND STANDARDS........................................................5
INTRODUCTION ..........................................................................5
APPLICATIONS............................................................................5
General ......................................................................................5
Upflow Applications.................................................................6
LOCATION..................................................................................11
General ....................................................................................11
Low-Heat Only Installation ....................................................12
AIR FOR COMBUSTION AND VENTILATION ....................13
INSTALLATION .........................................................................16
Installation In Horizontal Applications ..................................16
Air Ducts.................................................................................16
General Requirements .......................................................16
Ductwork Acoustical Treatment .......................................17
Supply-Air Connections ....................................................17
Return-Air Connections.....................................................17
Filter Arrangement..................................................................17
Bottom Closure Panel.............................................................18
Gas Piping...............................................................................18
Electrical Connections ............................................................19
115-v Wiring......................................................................19
24-v Wiring........................................................................21
Accessories ........................................................................21
Venting ....................................................................................21
Common Vent Systems................................................21
Combustion-Air and Vent Piping .....................................22
Vent Termination .........................................................29
Multiventing.......................................................................29
Condensate Drain....................................................................29
General...............................................................................29
Application.........................................................................29
Condensate Drain Protection.............................................30
General...............................................................................30
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. 535-80145
Tab 6a 8a
Variable-Capacity Condensing Gas Furnace
For Sizes 040-120, Series 180
A93040
Page
Printed in U.S.A.
As an Energy Star Partner,
Carrier Corporation has deter-
mined that this product meets
the ENERGY STAR guide-
lines for energy efficiency.
Horizontal Orientation
Select Setup Switch Positions...........................................32
Prime Condensate Trap With Water.................................33
Purge Gas Lines ................................................................34
Sequence of Operation ......................................................34
(Adaptive Mode).....................................................35
Cooling Mode...............................................................36
Thermidistat Mode .......................................................37
Super-Dehumidify Mode..............................................37
Continuous Blower Mode ............................................37
Heat Pump ....................................................................38
Component Test ...........................................................38
Adjustments .......................................................................38
Set Gas Input Rate .......................................................38
Set Temperature Rise...................................................46
Set Thermostat Heat Anticipator .................................46
Check Safety Controls.......................................................46
Check Primary Limit Control ......................................46
Check Pressure Switch.................................................46
CHECKLIST......................................................................47
Form 58MVP-15SI
Pg 1
58MVP
ama
CERTIFIED
ISO 9001:2000
REGISTERED
A04168
9-04
Replaces: None
®

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  • Page 1: Table Of Contents

    ® A93040 NOTE: Read the entire instruction manual before starting the ISO 9001:2000 installation. As an Energy Star Partner, Carrier Corporation has deter- Index Page mined that this product meets the ENERGY STAR guide- SAFETY CONSIDERATIONS .............3 lines for energy efficiency.

  • Page 3: Safety Considerations

    INSTALLATION This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m). An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications. This furnace is for indoor installation in a building constructed on site.
  • Page 4 CARBON MONOXIDE POISONING HAZARD The 58MVP Condensing Gas-Fired Furnaces are C.S.A. (formerly Failure to properly seal duct could result in death and/or AGA and CGA) design-certified for natural and propane gases personal injury.

  • Page 5: Codes And Standards

    INTRODUCTION tested by UL Standard 181 for Class I Rigid Air Ducts The model 58MVP Gas-Fired, Category IV, condensing furnace is Step 6—Gas Piping and Gas Pipe Pressure Testing available in model sizes ranging in input capacities of 40,000 to 120,000 Btuh.

  • Page 6: Upflow Applications

    FURNACE CONDENSATE DOOR TRAP FURNACE DOOR FURNACE FURNACE SIDE SIDE FIELD FIELD DRAIN DRAIN CONN CONN SIDE VIEW FRONT VIEW END VIEW FRONT VIEW HORIZONTAL ALTERNATE EXTERNAL UPFLOW APPLICATIONS APPLICATIONS SLOT FOR SCREW HORIZONTAL APPLICATION (OPTIONAL) WIRE TIE GUIDES (WHEN USED) FRONT VIEW A04170 Fig.
  • Page 7 PLUG PLUG COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE DRAIN TUBE (BLUE & WHITE STRIPED) & WHITE STRIPED) COLLECTOR BOX COLLECTOR BOX TUBE (PINK) TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (GREEN) INDUCER HOUSING (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX DRAIN TUBE) CONDENSATE...

  • Page 8: Horizontal Left (Supply-Air Discharge) Applications

    b. Extend this tube (if required) by splicing to small diameter Step 3—Horizontal Left (Supply-Air Discharge) Applications tube (factory-supplied in loose parts bag). c. Determine appropriate length, then cut and connect tube. A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace, CONDENSATE TRAP FIELD DRAIN ATTACHMENT and conditioned air is discharged to the left.

  • Page 9: Horizontal Right (Supply-Air Discharge) Applications

    2. Use smaller diameter tube (factory-supplied in loose parts bag) to extend tube disconnected in item 1. FIRE, INJURY OR DEATH HAZARD 3. Route extended tube: Failure to follow this warning could result in electrical shock, a. Behind inducer housing. fire, personal injury or death.
  • Page 10 A 3-IN. MINIMUM CLEARANCE VENT TO COMBUSTION-AIR INTAKE IS REQUIRED. COMBUSTION–AIR INTAKE A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE. 30-IN. MIN WORK AREA ⁄...

  • Page 11: Location

    2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection FIRE, INJURY OR DEATH HAZARD by splicing to small diameter tube (factory-supplied in loose Failure to follow this warning could result in electrical shock, parts bag).

  • Page 12: Low-Heat Only Installation

    HVAC system components after construction is completed. This 58MVP furnace can be installed to operate in the low-heat only heating mode when sized using the low-heat heating capacity. The furnace and its return air system shall be designed and...

  • Page 13: Furnace Location Relative To Cooling Equipment

    • Masonry acid washing materials All fuel-burning equipment must be supplied with air for fuel UNIT DAMAGE HAZARD combustion. Sufficient air must be provided to avoid negative Failure to follow this caution may result in minor property or pressure in the equipment room or space. A positive seal must be unit damage.
  • Page 14 Table 1—Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ.
  • Page 15 1 SQ IN. PER 4000 DUCTS BTUH* OUTDOORS CIRCULATING AIR VENT THROUGH ROOF DUCTS 12″ MAX 12″ 1 SQ IN. VENT PER 2000 THROUGH 12" MAX BTUH* ROOF 1 SQ IN. 1 SQ IN. 4000 PER 1000 BTUH* BTUH* IN DOOR OR WALL DUCTS UNCONFINED...

  • Page 16: Installation

    multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3 in. (80 UNIT MAY NOT OPERATE mm). Failure to follow this caution may result in intermittent unit operation. INSTALLATION The entire length of furnace MUST be supported when Step 1—Installation in Horizontal Applications furnace is used in a horizontal position to ensure proper draining.

  • Page 17: Ductwork Acoustical Treatment

    Step 3—Filter Arrangement When a furnace is installed so that the supply ducts carry air circulated by the furnace 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 FIRE, CARBON MONOXIDE AND POISONING furnace.

  • Page 18: Bottom Closure Panel

    To remove bottom closure panel, perform following: WASHABLE FILTER 1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 19.) FILTER 2. Rotate front filler panel downward to release holding tabs. RETAINER 3. Remove bottom closure panel. 4.

  • Page 19: Electrical Connections

    Table 4—Maximum Capacity of Pipe* NOMINAL ELECTRICAL SHOCK HAZARD LENGTH OF PIPE (FT) IRON INTERNAL Failure to follow this warning could result in personal injury PIPE DIAMETER or death. SIZE (IN.) (IN.) Blower access door switch opens 115-v power to furnace 0.622 control.
  • Page 20 Table 5—Electrical Data OPERATING VOLTS— MAXIMUM MINIMUM UNIT MAXIMUM WIRE MAXIMUM FUSE OR VOLTAGE RANGE HERTZ— UNIT WIRE SIZE LENGTH (FT)‡ CKT BKR AMPS** PHASE AMPS SIZE Maximum* Minimum* 040-14 115—60—1 060-14 115—60—1 080-14 115—60—1 080-20 115—60—1 13.8 100-20 115—60—1 13.8 120-20 115—60—1...

  • Page 21: 24-V Wiring

    NOTE: If modulating dampers are used, blower motor automati- cally compensates for modulating dampers. If manual disconnect The 58MVP furnaces require a dedicated (one 58MVP furnace switch is to be mounted on furnace, select a location where a drill only) sealed vent system. All air for combustion is taken from the or fastener will not contact electrical or gas components.

  • Page 22: Combustion-Air And Vent Piping

    standards. See Table 6 for approved materials for use in the U.S.A. See Table 7 for maximum pipe lengths and Fig. 40 for exterior CARBON MONOXIDE POISONING HAZARD piping arrangement. Failure to follow the steps outlined below for each appliance Vent pipe termination must be installed with adequate clearances connected to the venting system being placed into operation to building openings and equipment to comply with national and...
  • Page 23 ACRDJ PRINTED CIRCIUT BOARD TRAN PL12 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 7 8 7 8 7 8 7 8 OFF OFF OFF OFF PRINTED CIRCIUT BOARD...
  • Page 24 FUTURE COMMUNICATION CONTINUOUS FAN APPLICATIONS CONNECTOR (CF) AIRFLOW MODEL PLUG SETUP SWITCHES CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF- DELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX. ACRDJ Ð AIR CONDITIONING RELAY DISABLE JUMPER 24-V THERMOSTAT TERMINALS FLASH UPGRADE...
  • Page 25 Table 6—Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials ASTM SPECIFICATION MATERIAL PIPE FITTINGS SOLVENT CEMENT AND PRIMERS DESCRIPTION (MARKED ON MATERIAL) D1527 Pipe — — Schedule-40 D1785 Pipe — — Schedule-40 Solvent D2235 For ABS — — For ABS Cement D2241 Pipe...
  • Page 26 12 ″ MIN VENT PIPE HORIZONTAL TO ROOF VENT PIPE 12 ″ MIN VERTICAL TO ROOF NOTE: A 12-In. minimum horizontal pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. A04163 Fig.
  • Page 27 Table 7—Maximum Allowable Pipe Length (ft) NUMBER OF 90° ELBOWS PIPE DIA ALTITUDE (FT) UNIT SIZE (IN.)* 040-08 1-1/2 040-12 060-08 1-1/2 060-12 060-16 1-1/2 080-12 0 to 2000 080-16 080-20 2-1/2 100-16 2-1/2 100-20 2-1/2 120-20 3† NUMBER OF 90° ELBOWS PIPE DIA ALTITUDE (FT) UNIT SIZE...
  • Page 28 Table 7—Maximum Allowable Pipe Length (ft) (Continued) NUMBER OF 90° ELBOWS PIPE DIA ALTITUDE (FT) UNIT SIZE (IN.)* 1-1/2 040-08 040-12 060-08 1-1/2 060-12 060-16 080-12 4001 to 5000‡ 080-16 2-1/2 080-20 2-1/2 100-16 100-20 3† 120-20 4‡ no disk NUMBER OF 90°...

  • Page 29: Vent Termination

    MULTIVENTING APPLICATION When 2 or more 58MVP Furnaces are vented near each other, each The furnace, A/C, and humidifier drains may be combined and furnace must be individually vented. NEVER common vent or drained together.

  • Page 30: Condensate Drain Protection

    Table 8—Maximum Allowable Exposed Vent Pipe Length (ft) With and Without Insulation in Winter Design Temperature Ambient* WINTER DESIGN MAX PIPE FURNACE WITHOUT WITH 3/8–IN. OR TEMPERATURE DIAMETER SIZE INSULATION THICKER INSULATION† (°F) (IN.) * Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 8.
  • Page 31 25--24--65--2 AIR SUPPL Y INLET VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITED Item Clearance Descriptions Canadian Installation (1) U.S. Installation (2) Clearance above grade, veranda, porch, deck, balcony, or 12˝ (30cm) # 12˝ (30 cm) anticipated snow level Clearance to a window or door that may be opened 6˝...

  • Page 32: Select Setup Switch Positions

    Table 10—Furnace Setup Switch Description SETUP SWITCH NORMAL DESCRIPTION SWITCH NO. NAME POSITION OF USE Turn ON to retrieve up to 7 stored status codes for troubleshooting SW1-1 Status Code Recovery assistance when R thermostat lead is disconnected. Allows 2-stage operation with a single stage thermostat. Turn ON when using 2 stage thermostat to allow Low Heat opera- SW1-2 Adaptive Heat Mode...

  • Page 33: Prime Condensate Trap With Water

    CONDENSATE TRAP WIRE TIE(S) 32 o F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED HEAT TAPE (3 WRAPS MINIMUM) A93036 A93058 Fig. 34—Condensate Trap Heat Tape Fig. 32—Freeze Protection 1. Remove main furnace door and blower access panel. 2. Locate CF setup switches on furnace control. (See Fig. 25.) UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit 3.

  • Page 34: Purge Gas Lines

    AIR CONDITIONING AIRFLOW 040,060 & 080-14 080-20 & 100 120 MODEL TONS (12,000 BTU/HR) (CFM) MODEL MODEL 1-1/2 2-1/2 1050 3-1/2 1225 1400 1750 2100 X-INDICATES AN ALLOWABLE SELECTION. A/C OR CF AIRFLOW SELECTION CHART BASED ON 350 CFM/TON MODEL SIZE 040, 060, 1050...

  • Page 35: Single-Stage Thermostat And Two-Stage Heating (Adaptive Mode)

    SINGLE-STAGE THERMOSTAT AND TWO-STAGE HEATING (ADAPTIVE MODE) See Fig. 21 or 46 for thermostat connections NOTE: Low-heat-only switch, SW1-2, selects either the low- heat-only operation mode when ON, (see item 2. below) or adaptive heating mode when OFF, in response to a call for heat. (See Fig.

  • Page 36: Two-Stage Thermostat And Two-Stage Heating

    two seconds, the control CPU will close the gas valve GV-M, heat and high-heat pressure switch contacts LPS and HPS are and the furnace control CPU will repeat the ignition sequence open. for up to three more Trials-For-Ignition before going to The start-up and shutdown functions and delays described in item Ignition-Lockout.

  • Page 37: Thermidistat Mode

    The furnace control CPU can start up the cooling unit in either which means 24 vac signal is removed from the DHUM input low- or high-cooling. If starting up in low-cooling, the furnace terminal. In other words, the DHUM input logic is reversed. The control CPU determines the low-cooling on-time (from 0 to 20 DHUM input is turned ON when no dehumidify demand exists.

  • Page 38: Heat Pump

    Verify furnace model. Table 12 can only be used for model and remain OFF for 25 seconds before coming back on at heating 58MVP Furnaces. airflow. When the W/W1 input signal disappears, the furnace d. Find installation altitude in Table 12.
  • Page 39 A00277 A00275 Fig. 41—Two-Stage Furnace with Single-Speed Heat Fig. 39—Two-Stage Furnace with Single-Speed Air Pump (Dual Fuel) Conditioner A00276 A00278 Fig. 42—Two-Stage Furnace with Two-Speed Heat Fig. 40—Two-Stage Furnace with Two-Speed Air Con- ditioner Pump (Dual Fuel)
  • Page 40 A00281 Fig. 45—Two-Stage Thermostat With Two-Stage Fur- nace and Two-Speed Air Conditioner A00279 Fig. 43—Dual Fuel Thermostat with Two-Stage Furnace and Single-Speed Heat Pump See note 2 A02348 Fig. 46—Single-Stage Thermostat With Two-Stage Furnace and Two-Speed Air Conditioner A00280 Fig. 44—Dual Fuel Thermostat With Two-Stage Furnace and Two-Speed Heat Pump...
  • Page 41 Notes for Fig. 39-46: 1. Heat pump MUST have a high pressure switch for dual fuel applications. 2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure. 3. Select the ″ZONE″ position on the two-speed heat pump control. 4.
  • Page 42 ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press (ft) (Btu/cu ft) High/Low High/Low High/Low High/Low 3.5 / 1.5 3.6 / 1.5 3.8 / 1.6 3.2 / 1.3 3.8 / 1.6...
  • Page 43 ALTITUDE AVG. GAS SPECIFIC GRAVITY OF NATURAL GAS RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press Orifice Mnfld Press (ft) (Btu/cu ft) High/Low High/Low High/Low High/Low 3.8 / 1.6 3.2 / 1.4 3.4 / 1.4 3.5 / 1.5 7001...
  • Page 44 2. Adjust manifold pressure to obtain input rate. a. Remove burner enclosure front. NOTE: Manifold pressure MUST always be measured with the burner box cover REMOVED. b. Remove regulator seal caps that conceal adjustment screws for low- and high-heat gas valve regulators. (See Fig. 47.) c.
  • Page 45 Table 13—Altitude Derate Multiplier for U.S.A. Table 14—Gas Rate Cu Ft/Hr ALTITUDE % OF DERATE MULTIPLIER SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS (FT) DERATE FACTOR FOR U.S.A.* FOR 1 FOR 1 REVOLUTION REVOLUTION cu ft cu ft cu ft cu ft cu ft...

  • Page 46: Set Temperature Rise

    SET TEMPERATURE RISE 3. Return setup switch SW1-2 to OFF position and replace thermostat on subbase. Step 7—Check Safety Controls This section covers the safety controls that must be checked before UNIT DAMAGE HAZARD the installation is complete. The flame sensor, gas valve, and Failure to follow this caution may result in overheating the pressure switches were all checked in the Start-up procedure heat exchangers or condensing flue gases in heat exchanger...

  • Page 47: Checklist

    CHECKLIST 5. Turn off 115-v power to furnace. 1. Put away tools and instruments. Clean up debris. 6. Reconnect inducer motor wire harness. Reinstall furnace access door. 2. Verify flame rollout manual reset switch has continuity. 7. Turn on 115-v power to furnace. 3.
  • Page 48 Pressure Switches ________ Low-Ambient Exposed Pipes Copyright 2004 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58mvp15si Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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