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

4-way multipoise fixed-capacity condensing for sizes 040—120 series 110
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Installation, Start-Up, and Operating Instructions
NOTE: Read the entire instruction manual
before starting the installation.
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issue.
A93040
Index
DIMENSIONAL DRAWING........................................................2
SAFETY CONSIDERATIONS .....................................................3
Clearances to Combustibles......................................................3
INTRODUCTION ..........................................................................4
APPLICATIONS ......................................................................4-11
General ......................................................................................4
Upflow Applications..............................................................4-7
Downflow Applications.........................................................7-8
LOCATION ............................................................................11-13
General...............................................................................11-12
Hazardous Locations...............................................................13
General ....................................................................................13
Unconfined Space ...................................................................13
Confined Space..................................................................13-15
INSTALLATION....................................................................15-19
Leveling Legs (If Desired) .....................................................15
Installation On a Concrete Slab .............................................15
Applications) ................................................................15-16
Installation In Horizontal Applications ..................................16
Filter Arrangement..................................................................16
Bottom Closure Panel.............................................................16
Gas Piping..........................................................................17-19
ELECTRICAL CONNECTIONS...........................................19-20
115-v Wiring......................................................................19-20
24-v Wiring.............................................................................20
Accessories..............................................................................20
VENTING ...............................................................................20-29
Common Vent Systems................................................20-22
Combustion-Air and/or Vent Piping.................................22-25
Vent Termination...............................................................25-28
Multiventing ............................................................................29
CONDENSATE DRAIN ........................................................29-30
General ....................................................................................29
Application.........................................................................29-30
Condensate Drain Protection ..................................................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. 535-748
Tab 6a 8a
For Sizes 040-120 Series 110
Page
Printed in U.S.A.
4-Way Multipoise Fixed-Capacity
Condensing Gas Furnace
®
As an ENERGY STAR®
Partner, Carrier Corpora-
tion has determined that
this product meets the EN-
REGISTERED QUALITY SYSTEM
ERGY STAR® guidelines
for energy efficiency.
HORIZONTAL
LEFT
AIRFLOW
Fig. 1-Multipoise Orientations
SEQUENCE OF OPERATION..............................................30-32
Heating Mode..........................................................................31
Cooling Mode .........................................................................31
Continuous Blower Mode.......................................................31
Heat Pump Mode ....................................................................31
Component Test.................................................................31-32
START-UP PROCEDURES ..................................................32-38
General ....................................................................................32
Prime Condensate Trap With Water ......................................32
Purge Gas Lines......................................................................32
Adjustments .......................................................................32-38
Set Gas Input Rate ............................................................32-37
Set Temperature Rise..............................................................37
Blower Off Delay (Heat Mode) .............................................37
Set Thermostat Heat Anticipator............................................37
CHECK SAFETY CONTROLS..................................................38
Check Primary Limit Control.................................................38
Check Pressure Switch ...........................................................38
CHECKLIST...........................................................................38-39
Form 58MSA-3SI
Pg 1
58MSA
ama
A PP R O VED
R
AIRFLOW
UPFLOW
HORIZONTAL
RIGHT
DOWNFLOW
AIRFLOW
AIRFLOW
A93041
5-99
Replaces: 58MSA-2SI

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  • Page 1: Table Of Contents

    ® A PP R O VED A93040 Index Page As an ENERGY STAR® Partner, Carrier Corpora- DIMENSIONAL DRAWING............2 tion has determined that SAFETY CONSIDERATIONS .............3 this product meets the EN- REGISTERED QUALITY SYSTEM ERGY STAR® guidelines Clearances to Combustibles............3 for energy efficiency.

  • Page 3: Safety Considerations

    SAFETY CONSIDERATIONS identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight Installing and servicing heating equipment can be hazardous due to suggestions which will result in enhanced installation, reliability, gas and electrical components.

  • Page 4: Introduction

    We require these The 58MSA Multipoise Condensing Gas-Fired Furnaces are instructions as a minimum for a safe installation. A.G.A./C.G.A. certified for natural and propane gases and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages.
  • Page 5 FURNACE BLOWER SHELF CONDENSATE DOOR TRAP FURNACE CONDENSATE DOOR FURNACE TRAP (INSIDE) FURNACE SIDE SIDE FIELD FIELD DRAIN DRAIN CONN CONN ALTERNATE DRAIN TUBE LOCATION SIDE VIEW FRONT VIEW END VIEW FRONT VIEW CONDENSATE TRAP DRAIN TUBE LOCATION HORIZONTAL DOWNFLOW AND ALTERNATE UPFLOW APPLICATIONS APPLICATIONS EXTERNAL UPFLOW APPLICATIONS...
  • Page 6 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 COLLECTOR BOX TUBE (GREEN) TUBE (GREEN) COLLECTOR BOX INDUCER HOUSING DRAIN TUBE (BLUE) (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX...

  • Page 7: Downflow Applications

    NOTE: See Fig. 5 or 6 or tube routing label on main furnace door 1. Remove 3 tubes connected to condensate trap. to check for proper connections. 2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. UPPER COLLECTOR BOX AND INDUCER HOUSING (UN- USED) DRAIN CONNECTIONS 3.

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

    (a.) Install drain tube coupling (factory-supplied in 2. Use smaller diameter tube (factory-supplied in loose parts loose parts bag) into collector box drain tube bag) to extend collector box pressure tube (green label) which (blue and white striped label) which was previ- was previously connected to condensate trap relief port ously plugged.
  • Page 9 PLUG COLLECTOR BOX AUXILIARY "J" BOX DRAIN TUBE RELOCATED HERE (BLUE AND WHITE STRIPED) CONDENSATE COLLECTOR BOX TRAP TUBE (GREEN) INDUCER HOUSING COLLECTOR DRAIN TUBE (VIOLET) BOX EXTENSION COLLECTOR BOX DRAIN TUBE DRAIN TUBE (BLUE) COLLECTOR BOX EXTENSION TUBE DRAIN TUBE COUPLING COLLECTOR BOX TUBE (PINK) RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 040, 060, AND 080 HEATING INPUT FURNACES...

  • Page 10: Horizontal Right (Supply-Air Discharge) Applications

    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

    COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE PLUG COLLECTOR BOX TUBE (PINK) CONDENSATE TRAP COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX EXTENSION TUBE A93303 Fig. 11—Horizontal Right Tube Configuration f.
  • Page 12 FRONT LEVEL (0″) FRONT FRONT LEVEL (0″) ″ MAX ⁄ ″ MAX ⁄ UPFLOW OR DOWNFLOW HORIZONTAL BACK A93025 NOTE: For proper furnace operation, install furnace so that it is level or pitched forward within 1/2 in. to ensure proper condensate FRONT drainage from secondary heat exchangers.

  • Page 13: Furnace Location Relative To Cooling Equipment

    An unconfined space must have at least 50 cu ft for each 1000 Btuh of total input for all the appliances (such as furnaces, clothes dryers, water heaters, etc.) in the space. For Example: MINIMUM FLOOR AREA FOR UNCONFINED SPACE 58MSA Furnace Minimum Sq Ft With Input Btuh 7-1/2 Ft Ceiling 40,000...
  • Page 14 Ventilation from an Unconfined Space Ventilation from Outdoors For Example: For Example: COMBUSTION AIR FROM UNCONFINED SPACE COMBUSTION AIR FROM OUTDOORS THROUGH VERTICAL DUCTS 58MSA Furnace Free Area per Opening Input Btuh (Sq In.) 58MSA Furnace Free Area per Opening Round Pipe Input Btuh (Sq In.)

  • Page 15: Installation

    3. 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. 13.) INSTALLATION Step 1—Leveling Legs (If Desired) When furnace is used in upflow position with side inlet(s), leveling HOLE IN...

  • Page 16: Installation In Horizontal Applications

    Do not bend duct flanges inward as shown in Fig. 17. This The entire length of furnace MUST be supported when will affect airflow across heat exchangers and may cause furnace is used in a horizontal position to ensure proper limited cycling or premature heat exchanger failure.

  • Page 17: Gas Piping

    COMBUSTION-AIR A 3-IN. MINIMUM INTAKE CLEARANCE TO COMBUSTION-AIR INTAKE IS REQUIRED. VENT ⁄ -IN. ROD ANGLE ″ ⁄ IRON OR EQUIVALENT ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX DRAIN (A) ROD LOCATION USING DIMPLE LOCATORS -IN. MAX -IN. HEX NUT (SEE DIMENSIONAL ALTERNATE SUPPORT &...
  • Page 18 ⁄ -IN. WIDE ⁄ -IN. WIDE CASINGS ONLY: CASINGS ONLY: CUT AND FOLD Use proper length of pipe to avoid stress on gas control INSTALL FIELD-SUPPLIED FACTORY-PROVIDED manifold. Failure to follow this warning could result in a gas FILTER FILLER STRIP FILTERS AS SHOWN UNDER FILTER.

  • Page 19: Electrical Connections

    FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 THERMOSTAT FIVE FIELD-SUPPLIED TERMINALS WIRE DISCONNECT THREE-WIRE 208/230- OR HEATING- 460-V ONLY THREE PHASE 208/230-V SINGLE PHASE AUXILIARY 115-V J-BOX FIELD-SUPPLIED NOTE 1 CONTROL DISCONNECT CONDENSING UNIT...

  • Page 20: 24-V Wiring

    2. Rotate J-box 180° and attach box to right side, using holes VENTING provided. The 58MSA Furnaces require a dedicated, (one 58MSA furnace only) sealed vent system. All air for combustion is taken from the area adjacent to furnace, and all flue products are discharged to outside atmosphere.

  • Page 22: Combustion-Air And/Or Vent Piping

    24-V THERMOSTAT TERMINALS TEST/TWIN HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX) LED OPERATION & DIAGNOSTIC LIGHT HARNESS CONNECTOR SEC-1 24-V TRANSFORMER SEC-2 3-AMP FUSE SPARE-1 COOL BLOWER SPEED HEAT SELECTION TERMINALS SPARE-2 EAC-1 EAC-ELECTRONIC AIR CLEANER TERMINALS (115-VAC 1.5 AMP MAX) 115-VAC (L1) EAC-2 POWER SUPPLY...
  • Page 23 NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and FIELD-SUPPLIED 1 combustion-air pipe connection. 1 combustion-air pipe connection. 2-IN. DIAMETER FIELD-SUPPLIED PVC 90° ELBOW 2-IN. DIAMETER PVC PIPE FLOW COMBUSTION- COMBUSTION- VENT VENT VENT VENT COMBUSTION- COMBUSTION- FLOW...
  • Page 24 HOUSING COMBUSTION–AIR PLUG EXAMPLE: INTAKE HOUSING ″ ID TUBE An 080-12 size furnace located in Indianapolis, elevation BURNER 650 ft above sea level, could be installed in an application requiring 3 elbows and 32 ft of vent pipe. Table 4 indicates this application would allow a 2-in.

  • Page 25: Vent Termination

    12″ MIN 12″ MIN VENT PIPE VENT PIPE HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL VENT PIPE 12″ MIN 12″ MIN VENT PIPE VERTICAL TO ROOF VERTICAL TO SIDEWALL NOTE: A 12-In. minimum offset 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.
  • Page 26 Table 4—Maximum Allowable Vent Pipe Length (Ft) NUMBER OF 90° ELBOWS VENT PIPE ALTITUDE (FT) UNIT SIZE DIAMETER (IN.) 040-08 1-1/2 040-12 1-1/2 060-08 060-16 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 NUMBER OF 90° ELBOWS VENT PIPE ALTITUDE (FT) UNIT SIZE...
  • Page 27 Table 4—Maximum Allowable Vent Pipe Length (Ft) (Continued) NUMBER OF 90° ELBOWS VENT PIPE ALTITUDE (FT) UNIT SIZE DIAMETER (IN.) 1-1/2 040-08 040-12 1-1/2 060-08 060-16 080-12 5001 to 6000† 080-16 2-1/2 080-20 2-1/2 100-16 100-20 120-20 NUMBER OF 90° ELBOWS VENT PIPE ALTITUDE (FT) UNIT SIZE...
  • Page 28 Table 4—Maximum Allowable Vent Pipe Length (Ft) (Continued) NUMBER OF 90° ELBOWS VENT PIPE ALTITUDE (FT) UNIT SIZE DIAMETER (IN.) 1-1/2 040-08 040-12 060-08 060-16 080-12 9001 to 10,000† 080-16 2-1/2 080-20 2-1/2 100-16 100-20 120-20 * Wide radius elbow. †...

  • Page 29: Multiventing

    ‡ 36 in. to electric meter in Canada only. OVERHANG OR ROOF NOTES: 1. If installing 2 adjacent 58MSA Furnaces, refer to Multiventing and Vent Terminations section for proper vent configurations. 2. When locating vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recirculation of the appliance’s own flue products or the flue products of adjacent vents.

  • Page 30: Condensate Drain Protection

    Outdoor draining of the furnace is permissible if allowed by local codes. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining. Caution should be taken to prevent draining where slippery conditions may cause personal injuries. Excessive condensate draining may cause saturated soil conditions which may result in damage to plants.

  • Page 31: Heating Mode

    Step 1—Heating Mode Step 4—Heat Pump Mode When installed with a heat pump, furnace control automatically When wall thermostat "calls for heat," R-W circuit closes. Furnace control performs a self-check, verifies pressure switch contacts are changes blower on delay timing sequence to avoid no blower open, and starts inducer motor.

  • Page 32: Start-Up Procedures

    Proper polarity must be maintained for correct operation. c. Verify furnace model. Table 7 can only be used for model 58MSA furnaces. NOTE: Proper polarity must be maintained for 115-v wiring. If d. Find installation altitude in Table 7.
  • Page 33 A99118 A99119 → Fig. 38—Inducer Housing Drain Tube → Fig. 39—Filling Condensate Trap ON AND EXAMPLE: (0—2000 altitude) OFF SWITCH Heating value = 1050 Btu/cu ft Specific gravity = 0.62 PRESSURE Therefore: Orifice No. 45 REGULATOR Manifold pressure 3.6-in. wc ADJUSTMENT * Furnace is shipped with No.
  • Page 34 Table 7—Model 58MSA Orifice Size and Manifold Pressure for Correct Input (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62...
  • Page 35 Table 7—Model 58MSA Orifice Size and Manifold Pressure for Correct Input (Continued) (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60...
  • Page 36 → Table 7—Model 58MSA Orifice Size and Manifold Pressure for Correct Input (Continued) (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58...

  • Page 37: Set Temperature Rise

    NOTE: If orifice hole appears damaged or it is suspected to have Table 8—Altitude Derate Multiplier for U.S.A. been redrilled, check orifice hole with a numbered drill bit of ALTITUDE % OF DERATE MULTIPLIER correct size. Never redrill an orifice. A burr-free and squarely (FT) DERATE FACTOR FOR U.S.A*...

  • Page 38: Blower Off Delay (Heat Mode)

    Table 9—Gas Rate (Cu Ft/Hr) BLOWER OFF DELAY (HEAT MODE) The main blower off time delay period is factory-set at 135 sec and SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS is not field-adjustable. FOR 1 FOR 1 REVOLUTION REVOLUTION cu ft...

  • Page 39: Checklist

    5. Turn off 115-v power to furnace. 6. Reconnect inducer motor leads, reinstall main furnace door, and turn on 115-v power supply. CHECKLIST 1. Put away tools and instruments. Clean up debris. 2. Verify manual reset switch has continuity. 3. Verify that blower and control access doors are properly installed.
  • Page 40 Primary Limit ________ Pressure Switch Copyright 1999 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58msa3si 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.

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