Carrier 58CTA Installation, Start-Up, Operating And Service And Maintenance Instructions

2-stage deluxe, induced combustion 4-way multipoise gas furnace series 140/e

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Installation and service instructions manual (58 pages)

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Page 1: Table Of Contents
58CTA/CTX 2---Stage Deluxe, Induced Combustion 4---Way Multipoise Gas Furnace Series 140/E Installation, Start---up, Operating and Service and Maintenance Instructions SAFETY CONSIDERATIONS ......
Page 2 [130.5] [130.5] 2 1/16 2 1/16 [51.6] [51.6] [43.5] [43.5] Ø7/8 Ø7/8 [22.2] [22.2] ACCESSORY (2) ACCESSORY (2) 8 5/8 8 5/8 [219] [219] 6 13/16 6 13/16 [172.3] [172.3] 5 7/8 5 7/8 1 15/16 1 15/16 [148.5] [148.5] 5 5/8 5 5/8 [49.2]...
Page 3: Safety Considerations
SAFETY CONSIDERATIONS product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, WARNING or operation. 1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate. FIRE, EXPLOSION, ELECTRICAL SHOCK, AND 2.
Page 4 gas. This furnace is not approved for installation in mobile 55_F (13_C) db such as when used with a night setback homes, recreational vehicles, or outdoors. thermostat. Return- -air temperature must not exceed 80_F (27_C) db. Failure to follow these return- -air temperature limits may These furnaces shall not be installed directly on carpeting, tile, or affect reliability of heat exchangers, motors, and controls.
Page 5: Codes And Standards
Step 7 — Electrical Connections / 27 C National Electrical Code (NEC) ANSI/NFPA 70- -2008 Step 8 — Venting NFGC; NFPA 54 / ANSI Z223.1- -2012 chapters 12 and 13 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE CAUTION / 16 C FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure.
Page 6: Location
THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE OF THE BURNER SECTION,...
Page 7: Air For Combustion And Ventilation
CAUTION WARNING FIRE, INJURY OR DEATH HAZARD PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal Improper use or installation of this furnace may cause injury, death, and/or property damage. premature component failure. This gas furnace may be used for construction heat provided that: When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18...
Page 8 S Spaces having less than 50 cubic feet per 1,000 Btuh require the CAUTION Outdoor Combustion Air Method. S Spaces having at least 50 cubic feet per 1,000 Btuh may use the FURNACE CORROSION HAZARD Indoor Combustion Air, Standard or Known Air Infiltration Method.
Page 9 1 SQ IN. CIRCULATING AIR PER 4000 VENT THROUGH ROOF DUCTS DUCTS BTUH* O UTDOORS 12" MAX (305mm) 12 ″ MAX 12 ″ (305mm) (305mm) 1 SQ IN. VENT 1 SQ IN. PER 2000 THR OUGH PER 1000 BTUH* R OOF BTUH* IN DOOR 1 SQ IN .
Page 10: Installation
Table 3 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors OTHER THAN FAN---ASSISTED TOTAL FAN---ASSISTED TOTAL (1,000s BTUH GAS INPUT RATE) (1,000s BTUH GAS INPUT RATE) Space Volume (ft.3) 0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850...
Page 11: Downflow Installation
NOTE: Side return- -air openings can be used in UPFLOW and DOWNFLOW INSTALLATION most HORIZONTAL configurations. Do not use side return- -air NOTE: For downflow applications, this furnace is approved for openings in DOWNFLOW configuration. use on combustible flooring when any one of the following 3 accessories are used: S Special Base, KGASB S Cased Coil Assembly Part No.
Page 12 Platform Furnace Support Construct working platform at location where all required furnace FURNACE (OR COIL CASING clearances are met. (See Fig. 2 and 17.) For furnaces with 1- -in. WHEN USED) (25 mm) clearance requirement on side, set furnace on non- -combustible blocks, bricks or angle iron.
Page 13 Table 4 – Opening dimensions - - In. (mm) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications on Combustible or Noncombustible Floor- 12--- 11/16 21--- 5/8 13--- 5/16 22--- 1/4 ing (KGASB subbase not required) (322) (549) (338) (565) Downflow Applications on Noncombustible Flooring (KGASB 12--- 9/16...
Page 14 " (6mm) THREADED ROD 4 REQ. OUTER DOOR A S SEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x " (19mm) SCREWS TYPICAL FOR 2 SUPPORTS 8" (203mm) MIN FOR DOOR REMOVAL 1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm) ANGLE IRON OR UNI-STRUT MAY BE USED (2) HEX NUTS, (2) WASHERS &...
Page 15: Filter Arrangement
LINE CONT A CT ONL Y PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE T OP AND TW O SIDES OF THE FURNA CE JA CKET AND BUILDING JOISTS , STUDS , OR FRAMING. ″ (451mm)OVERALL ″ (121mm) UNDER DOOR 1 ″...
Page 16 Table 5 – Air Delivery - - CFM (With Filter)* EXTERNAL STATIC PRESSURE (IN. W.C.) FURNACE RETURN---AIR SPEED SIZE INLET High 1120 1075 1020 045--- 08 / Bottom or Med --- High 024045 Side(s) Med --- Low --- --- --- --- --- --- High 1465...
Page 17: Gas Piping
Table 5 - - Air Delivery - - CFM (With Filter)* (Cont.) EXTERNAL STATIC PRESSURE (IN. W.C.) FURNACE RETURN---AIR SPEED SIZE INLET High 2090 2010 1930 1835 1710 1590 1470 1335 1025 Bottom 135--- 16/ Med --- High 1790 1755 1705 1640 1550...
Page 18 A02075 Fig. 18 - - Upflow Return Air Configurations and Restrictions A02163 Fig. 19 - - Downflow Return Air Configurations and Restrictions A02162 Fig. 20 - - Horizontal Return Air Configurations and Restrictions...
Page 19 Gas piping must be installed in accordance with national and An accessible manual equipment shutoff valve MUST be local codes. Refer to current edition of NFGC in the U.S. installed external to furnace casing and within 6 ft. of furnace. A 1/8- -in.
Page 20 FIELD 24-VOLT WIRING FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING NOTE 2 1-STAGE THERMOSTAT FIVE FIELD-SUPPLIED TERMINALS WIRE FUSED DISCONNECT THREE-WIRE 208/230- OR HEATING- 460-VOLT ONLY THREE PHASE 208/230- W/W1 VOLT NOTE 1 SINGLE Y/Y2 115-VOLT FIELD- JUNCTION PHASE SUPPLIED...
Page 21: Electrical Connections
Table 7 – Electrical Data MAXIMUM MAXIMUM OPERATING VOLTAGE VOLTS--- MINIMUM FURNACE UNIT WIRE FUSE OR RANGE HERTZ--- UNIT WIRE LENGTH CKT BKR SIZE AMPACITY# PHASE AMPS GAUGE MAX* MIN.* FT. (M)‡ AMPS† 045--- 08/024045 115--- 60--- 1 7.42 49 (14.9) 045--- 12/036045 115--- 60--- 1 9.67...
Page 22 A10141 Fig. 25 - - Field- -Supplied Electrical Box on Furnace Casing 1. Select and remove a hole knockout in the casing where the 2. Route listed power cord through 7/8- -inch (22 mm) dia- electrical box is to be installed. meter hole in J- -Box.
Page 23 See notes 2, 5, 8, 10, 11 and 12 See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13 and 15 on the page following these figures on the page following these figures A03179 A03178 Fig. 26 - - Two- -Stage Furnace with Two- -Speed Air Fig.
Page 24 See notes 2, 11, and 12 on the page following these figures See notes 1, 2, 3, 4, 12, 13, 14, 15, and 17 on the page following these figures A03182 A03183 Fig. 30 - - Dual Fuel Thermostat with Two- -Stage Furnace Fig.
Page 25 ACCESSORIES NOTE: DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidistat, Zone Controller or 1. Electronic Air Cleaner (EAC) similar device. See Thermidistatt, Zone Controller, thermostat, Connect an accessory Electronic Air Cleaner (if used) us- or controller manufacturer’s instructions for proper connection. ing 1/4- -in female quick connect terminals to the two male 1/4- -in quick- -connect terminals on the control board VENTING...
Page 26: Venting
hood equipped appliances in accordance with the NFCG, local WARNING building codes, and furnace and vent manufacturers’ instructions. The following information and warning must be considered in CARBON MONOXIDE POISONING HAZARD addition to the requirements defined in the NFGC. Failure to follow the steps outlined below for each WARNING appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or...
Page 27 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211 Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances Crown Rebuild condition: crown. Missing mortar or brick? Is chimney property lined with clay tile liner? Repair Reline...
Page 28 The Chimney Adapter Kit is a listed alternative venting system Table 9 – Minimum Allowable Input Rating of Space- -Heat- for these furnaces. See the kit instructions for complete details. ing Appliance in Thousands of BTUH per Hour This furnace is permitted to be vented into a clay tile- -lined masonry chimney that is exposed to the outdoors below the roof INTERNAL AREA OF CHIMNEY line, provided:...
Page 29 2. Adjust the gas input rate per the installation instructions. combustion- -air supply. Furnace use during construction of the Low gas input rate causes low vent gas temperatures, caus- building could cause the furnace to be exposed to halogen ing condensation and corrosion in the furnace and/or vent- compounds, causing premature failure of the furnace or venting ing system.
Page 30 SEE NOTES:1,2,3,4,5,7,8,9 SEE NOTES: 1,2,4,5,6,7,8,9,10 on the page following on the page following these figures these figures A03210 A03207 Fig. 37 - - Downflow Application- -Vent Elbow Up then Left Fig. 39 - - Downflow Application- -Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following SEE NOTES:1,2,3,4,5,7,8,9...
Page 31 SEE NOTES: 1,2,4,5,7,8,9 on the page SEE NOTES: 1,2,4,7,8,9 on the page following these figures following these figures A03213 A03215 Fig. 41 - - Horizontal Left Application - - Vent Elbow Left Fig. 44 - - Horizontal Left Application - - Vent Elbow Up SEE NOTES: 1,2,4,5,7,8,9 on the page SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures...
Page 32 SEE NOTES: 1,2,4,5,7,8,9 A02068 Fig. 47 - - Horizontal Right Application- -Vent Elbow Left VENTING NOTES FOR FIG. 35 - - 47 1. For common vent, vent connector sizing and vent material: United States- -use the NFGC. 2. Immediately increase to 5- -in. or 6- -in. (127 or 152 mm) vent connector outside furnace casing when 5- -in. (127 mm) vent connector is required, refer to Note 1 above.
Page 33: Start- -Up, Adjustment, And Safety Check
less with metal hangers or straps to ensure there is no movement CAUTION after installation. SIDEWALL VENTING CUT HAZARD This furnace is not approved for direct sidewall horizontal venting. Failure to follow this caution may result in personal injury. In the U.S.: Per section 12.4.3 of the NFPA 54 / ANSI Sheet metal parts may have sharp edges or burrs.
Page 34: Start- -Up Procedures
Table 10 – 2- -Stage Furnace Setup Switch Description SETUP SWITCH NORMAL DESCRIPTION SWITCH NO. NAME POSITION OF USE When OFF, allows 2--- stage operation with a single stage thermostat. Turn ON when using 2 stage thermostat to allow Low Heat operation SW--- 1 Adaptive Heat Mode when R to W/W1 closes and High Heat operation when R to W/W1...
Page 35 Table 11 – Altitude Derate Multiplier for U.S.A. ALTITUDE PERCENT DERATE MULTIPLIER FT. (M) OF DERATE FACTOR* 0–2000 1.00 (0--- 610) 2001–3000 8–12 0.90 (610--- 914) 3001–4000 12–16 0.86 (914--- 1219) 4001–5000 16–20 0.82 (1219--- 1524) 5001–6000 20–24 0.78 1524--- 1829) 6001–7000 24–28 0.74...
Page 36 cified on unit rating plate for high- -and low- -heat. Determine the temperature rise as follows: NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in incorrect temperature measurements. WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death.
Page 37 Table 12 – Gas Rate (cu ft. /hr) SECONDS SECONDS SIZE OF TEST DIAL SIZE OF TEST DIAL U FT. U FT. U FT. U FT. U FT. U FT. REVOLUTION REVOLUTION 1800 1636 1500 1385 1286 1200 1125 1059 1000 c.
Page 38 If clocked rate does not match required input from Step 1, WARNING increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct high heat input is achieved. Re- -install high- -heat regulator seal FIRE HAZARD cap on gas valve.
Page 39: Check Safety Controls
Table 14 – 2- -Stage Furnace Blower OFF delay Setup Switch DESIRED HEATING MODE SETUP SWITCH SETUP SWITCH BLOWER OFF DELAY (SEC.) SW---2 SW---3 guard switch did not function properly and correct condi- THERMOSTAT SUBBASE TERMINALS WITH tion. THERMOSTAT REMOVED f.
Page 40 Table 15 – Orifice Size* and Manifold Pressures (In. W.C.) for Gas Input Rate A10184...
Page 41 Table 15 - - Orifice Size and Manifold Pressures (In. W.C.) for Gas Input Rate (cont.) A10184A...
Page 42 Table 16 – Orifice Size* and Manifold Pressures (In. W.C.) for Gas Input Rate A10185...
Page 43 Table 16 - - Orifice Size* and Manifold Pressures (In. W.C.) for Gas Input Rate (cont.) A10185A...
Page 44: Service And Maintenance Procedures
SERVICE AND MAINTENANCE ELECTRICAL CONTROLS AND WIRING PROCEDURES WARNING WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal FIRE, PERSONAL INJURY AND UNIT DAMAGE injury or death. HAZARD There may be more than one electrical supply to the Failure to follow this warning could result in personal injury, furnace.
Page 45: Care And Maintenance
SERVICE If status code recall is needed, briefly remove then reconnect one main limit wire to display last stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. LED CODE STATUS CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
Page 46 A07125 Fig. 52 - - Wiring Diagram...
Page 47 Table 17 – Filter Size Information (In. / Mm) FILTER SIZE FURNACE CASING WIDTH SIDE BOTTOM FILTER TYPE RETURN RETURN 16 x25 x 3/4 14 x25 x 3/4 14 ---1/2 (368) Washable* (406 x635 x 19) (356 x635 x 19) 16 x25 x 3/4 16 x25 x 3/4 17 ---1/2 (445)
Page 48 problem exists which needs to be corrected, such as improper CAUTION adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken UNIT DAMAGE HAZARD to correct the problem.
Page 49: Sequence Of Operation
striking with ball- -peen hammer. TIGHTNESS IS VERY IMPORTANT. NOTE: The materials needed in item 9 can usually be purchased 1-7/8 at local hardware stores. (47.6 mm) (1.) Attach variable- -speed, reversible drill to the end of spring cable (end opposite brush). (2.) Insert brush end of cable into the outlet opening of cell and slowly rotate with drill.
Page 50 control CPU, transformer TRAN, inducer motor IDM, blower control CPU selects high- -heat operation, the high- -heat motor BLWM, hot- -surface igniter HSI, and gas valve GV. gas valve solenoid GV- -HI is also energized. 1. Two- -Stage Heating (Adaptive mode) with Single- - d.
Page 51 The start up and shut down functions and delays described in wall thermostat “calls cooling”, closing item 1. above apply to the 2- -stage heating mode as well, except R- -to- -G- -and- -Y circuits. The R- -to- -Y1 circuit starts the outdoor for switching from low- - to high- -Heat and vice versa.
Page 52: Wiring Diagrams
from COOL to HI HEAT for a maximum of 10 minutes NOTE: If the blower- -off delay is set to the maximum, the before reverting back to COOL speed. If there is still a adjustable continuous- -fan feature is locked (i.e., fan speed cannot demand for dehumidification after 20 minutes, the fur- be changed from its current setting).
Page 53 A02107A Fig. 56 - - Troubleshooting Guide - - 2- -Speed...
Page 54 A05001...
Page 55: Parts Replacement Information Guide
Consumer Relations Department P.O. Box 4808 Syracuse, New York 13221- -4808 1- -800- -CARRIER Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part. Example of Model Number COOLING...
Page 56 Catalog No:58CT ---12SI Printed in U.S.A. Edition Date: 08/13 Copyright 2013 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Replaces:58CT- -11SI Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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Carrier 58CTA Installation, Start-Up, Operating And Service And Maintenance Instructions

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