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Carrier 140 Series Installation, Start-Up, And Operating Instructions Manual

Downflow/horizontal induced-combustion furnaces
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Installation, Start-Up, and Operating Instructions
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index
SAFETY CONSIDERATIONS .....................................................1
PROCEDURE ...........................................................................2
INTRODUCTION.......................................................................3-4
Dimensional Drawing ...............................................................2
Clearances From Combustible Materials .................................3
LOCATION....................................................................................4
General ......................................................................................4
Location Relative to Cooling Equipment ................................4
Hazardous Locations.................................................................4
Unconfined Space..................................................................4-5
Confined Space .........................................................................5
AIR DUCTS................................................................................5-6
General Requirements...............................................................5
Ductwork Acoustical Treatment...............................................5
Supply-Air Connections ........................................................5-6
Return-Air Connections ............................................................6
DOWNFLOW INSTALLATION ..................................................6
HORIZONTAL ATTIC INSTALLATION...................................7
Construct a Working Platform .................................................7
Install Furnace...........................................................................7
FILTER ARRANGEMENT...........................................................8
GAS PIPING.............................................................................8-10
ELECTRICAL CONNECTIONS ................................................10
115-v Wiring...........................................................................10
24-v Wiring.............................................................................11
Accessories..............................................................................11
VENTING ....................................................................................11
General...............................................................................11-13
Sequence Of Operation...........................................................13
Heating Mode..........................................................................13
Cooling Mode .........................................................................13
Continuous Blower Mode.......................................................13
Heat Pump Mode ....................................................................13
Start-up Procedures.................................................................13
Adjustments .......................................................................15-20
Set Gas Input Rate..................................................................15
Set Temperature Rise ............................................................ 18
Set Thermostat Heat Anticipator............................................19
Check Safety Controls ............................................................20
Checklist..................................................................................20
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
Downflow/Horizontal Induced-Combustion Furnaces
Sizes 050-135, Series 140
Page
Printed in U.S.A.
WeatherMaker 8000™
®
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, observe 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
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
→
Understand the signal words DANGER, WARNING, 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 codes. 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.
Form 58ZAV-10SI
Pg 1
58ZAV
ama
A PP R O VED
R
8-99
Replaces: 58ZAV-9SI
.

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  • Page 1: Table Of Contents

    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 .............1 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ®...

  • Page 2: Electrostatic Discharge (Esd) Precautions Procedure

    ⁄ † VENT CONNECTION ⁄ † DIA 20† 2† THERMOSTAT ⁄ † ⁄ ⁄ † WIRE ENTRY † INLET ⁄ † DIA ACCESSORY ⁄ † ⁄ † DIA HOLE POWER ENTRY ⁄ † ⁄ † DIA R.H. GAS ENTRY ⁄ ⁄...

  • Page 3: Introduction

    MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION This forced air furnace is equipped for use with natural This furnace is approved for DOWNFLOW and HORIZONTAL installations. gas at altitudes 0-10,000 ft (0-3,050m). 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.

  • Page 4: Location

    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.

  • Page 5: Unconfined Space

    c. If furnace is installed on a raised platform to provide a return-air plenum, and return air is taken directly from The operation of exhaust fans, kitchen ventilation fans, hallway or space adjacent to furnace, all air for combustion clothes dryers, or fireplaces could create a NEGATIVE must come from outdoors.

  • Page 6: Supply-Air Connections

    DUCTS TO OUTDOORS 1 SQ IN. PER 4000 BTUH VENT THROUGH ROOF (CATEGORY I) 12″ MAX 12″ 1 SQ IN. RETURN VENT PER 2000 THROUGH BTUH * RETURN ROOF 12″ MAX (CATEGORY I) 1 SQ IN. PER 4000 1 SQ IN. BTUH PER 1000 DUCTS...

  • Page 7: Downflow Installation

    PLENUM OPENING FLOOR OPENING A96283 Fig. 5—Floor and Plenum Opening Dimensions Table 3—Opening Dimensions (In.) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Non-Combustible Flooring 12-11/16 13-3/8 19-5/8 Combustible Flooring Using KGASB Subbase 11-13/16 13-7/16 20-3/8 14-3/16 Combustible Flooring with CD5 or CK5 Coil Assembly or 12-5/16 13-5/16 KCAKC Coil Box...
  • Page 8 FURNACE FURNACE (OR COIL CASING WHEN USED) CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING DOWNFLOW SUBBASE SHEET METAL SHEET METAL PLENUM PLENUM FLOOR FLOOR OPENING OPENING A96285 A96284 Fig. 6—Furnace, Plenum, and Subbase Installed Fig.

  • Page 9: Install Furnace

    ⁄ -IN. ROD ANGLE IRON OR EQUIVALENT ROD LOCATION USING DIMPLE LOCATORS -IN. HEX NUT (SEE DIMENSIONAL & WASHER (4) DWG FOR REQD PER ROD LOCATIONS) NOTES: 1. A 1 In. clearance minimum between top of furnace and combustible material. (A) PREFERRED ROD LOCATION 2.

  • Page 10: Electrical Connections

    Table 5—Maximum Capacity of Gas Pipe * NOMINAL IRON INTERNAL LENGTH OF PIPE (FT) PIPE SIZE DIAMETER (IN.) (IN.) 0.622 0.824 170 151 1.049 320 285 1-1/4 1.380 1400 660 580 AIRFLOW 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 12″...

  • Page 11: 24-V Wiring

    Table 6—Electrical Data VOLTS— MAXIMUM OPERATING VOLTAGE RANGE MAXIMUM MINIMUM MAXIMUM WIRE UNIT SIZE HERTZ— FUSE OR CKT BKR UNIT AMPS WIRE GAGE LENGTH FT‡ Maximum* Minimum* PHASE AMPS† 050-08 115—60—1 050-12 115—60—1 070-08 115—60—1 070-12 115—60—1 096-12 115—60—1 096-16 115—60—1 10.2 115-16...
  • Page 12 BLOWER OFF DELAY ADJUSTMENT SWITCH 24V THERMOSTAT TERMINALS TEST/TWIN HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX) LED OPERATION & STATUS LIGHT HARNESS CONNECTOR SEC-1 24V TRANSFORMER SEC-2 3-AMP FUSE SPARE 1 COOL BLOWER SPEED HEAT SELECTION TERMINALS SPARE 2 EAC 1 (BLACK) EAC-ELECTRONIC AIR CLEANER TERMINALS (115-VAC 1.0 AMP MAX) 115-VAC (L1)

  • Page 13: Start-Up, Adjustment, And Safety Check

    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.

  • Page 15: Start-Up Procedures

    until the end of the ignition warm up and trial for ignition 4. With furnace operating, set thermostat below room tempera- periods (a total of 24 sec). The blower then comes back on at ture and observe that furnace goes off. Set thermostat above heating speed.
  • Page 16 →Table 7—Model 58ZAV Orifice Size† and Manifold Pressure for Correct Input (Tabulated Data Based on 23,000 BTUH Per Burner, Derated 4 Percent per 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64 0.66...
  • Page 17 →Table 7—Model 58ZAV Orifice Size† 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 AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...
  • Page 18 →Table 7—Model 58ZAV Orifice Size† 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 AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...

  • Page 19: Set Temperature Rise

    Table 9—Gas Rate (Cu Ft/Hr) ON AND SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS OFF SWITCH FOR 1 FOR 1 REVOLUTION REVOLUTION cu ft cu ft cu ft cu ft cu ft cu ft PRESSURE 1800 REGULATOR 1636 ADJUSTMENT 1500...

  • Page 20: Set Thermostat Heat Anticipator

    7. Leave literature packet near furnace. pipe to cool down before removing. Copyright 1999 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58zav10s Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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