Page 1: Table Of Contents
58CTW/CTY Variable---Speed, ECM Induced---Combustion 2---Stage Deluxe 4---Way Multipoise Gas Furnace Series 100 Installation, Start---up, Operating and Service and Maintenance Instructions SAFETY CONSIDERATIONS ......
Page 2: Safety Considerations
SAFETY CONSIDERATIONS to identify hazards which may result in minor personal injury or product and property damage. NOTE is used to highlight WARNING suggestions which will result in enhanced installation, reliability, or operation. 1. Use only with type of gas approved for this furnace. Refer FIRE, EXPLOSION, ELECTRICAL SHOCK, AND to the furnace rating plate.
Page 3 A10269 Fig. 1 - - Clearances to Combustibles...
Page 4: Introduction
INTRODUCTION only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington, DC 20001 (www.AGA.org.) . The Series 100 4- -way multipoise Category I fan- -assisted furnace Combustion and Ventilation Air is CSA (formerly A.G.A. and C.G.A.) design- -certified. A Section 9.3 NFPA 54/ANSI Z223.1- -2012, Air for Combustion Category I fan- -assisted furnace is an appliance equipped with an and Ventilation .
Page 5: Location
[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 6 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 CAUTION PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may result in premature furnace component failure. This gas furnace may be used for heating buildings under construction provided that: - -The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions.
Page 8: Air For Combustion And Ventilation
Table 1 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS FURNACE (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ.
Page 9: Outdoor Combustion Air Method
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: Combination Of Indoor And Outdoor Air
Infiltration rates greater than 0.60 ACH shall not be used. The plates and floors, between wall- -ceiling joints, between minimum required volume of the space varies with the number of wall panels, at penetrations for plumbing, electrical ACH and shall be determined per Table 2 or Equations 1 and 2. and gas lines, etc.
Page 11: Leveling Legs (If Desired)
NOTE: It is recommended that the perforated supply- -air duct 5/ 16  (8mm) flanges be completely folded over or removed from furnace when installing the furnace on a factory- -supplied cased coil or coil box. (8mm) To remove the supply- -air duct flange, use wide duct pliers or 5/ 16 ...
Page 12: Roll- -Out Protection
FURNACE (OR COIL CASING WHEN USED) COMBUSTIBLE PLENUM FLOORING OPENING DOWNFLOW SUBBASE FLOOR SHEET METAL OPENING PLENUM FLOOR OPENING A96285 A96283 Fig. 12 - - Furnace, Plenum, and Subbase Installed on a Fig. 11 - - Floor and Plenum Opening Dimensions Combustible Floor Roll- -Out Protection Provide a minimum 17- -3/4- -in.
Page 13: Filter Arrangement
Table 3 – Opening Dimensions - - In. (mm) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH IN. (mm) 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)
Page 14: Supply Air Connections
shall be accessible when the furnace is installed and shall be of temporarily while the remaining attachment and sealing of the such a size that the heat exchanger can be viewed for possible coil are performed. openings using light assistance or a probe can be inserted for Downflow Furnaces sampling the air stream.
Page 15 " (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 16 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 17 DOWNFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS A02163 Fig. 19 - - Downflow Return Air Configurations and Restrictions A02162 Fig. 20 - - Horizontal Return Air Configurations and Restrictions...
Page 18 Table 4 – Air Delivery - - CFM (With Filter)* COOLING AND HEATING AIR DELIVERY - CFM (Bottom Return With Filter) (SW1-5 and SW2-2 set to OFF, except as indicated. See notes 1 and 2.) Cooling Switch Settings External Static Pressure (ESP) Unit Size SW2-8 SW2-7...
Page 19 Table 4 - - Air Delivery - - CFM (With Filter)* (CONTINUED) Cooling Switch Settings External Static Pressure (ESP) Unit Size SW2-8 SW2-7 SW2-6 110-22/ 066110 2055 2000 1950 1900 1840 1790 1740 1675 1625 1565 See note 4 1060 See note 4 1250 1180...
Page 20: Return Air Connections
Return Air Connections NOTE: In the state of Massachusetts: 1. Gas supply connections MUST be performed by a li- WARNING censed plumber or gas fitter. 2. When flexible connectors are used, the maximum length shall not exceed 36 in. (915 mm). FIRE HAZARD 3.
Page 21: Electrical Connection
joint union between furnace gas control valve and exterior ELECTRICAL CONNECTIONS manual equipment gas shutoff valve. WARNING A 1/8- -in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual ELECTRICAL SHOCK, FIRE OR EXPLOSION equipment shutoff valve.
Page 22 Table 6 – Electrical Data OPERATING VOLTAGE VOLTS - MAX WIRE MAX. FUSE MAX. UNIT UNIT MIN. WIRE RANGE * HERTZ - LENGTH FT OR CKT. BKR FURNACE SIZE AMPS AMPACITY GAUGE PHASE (M)‡ AMPS † Max. Min. 045--- 12/036045 115-60-1 10.85 070--- 16/048070...
Page 23: Accessories
8. Remove cover from furnace J- -Box. 3. Secure power cord to J- -Box bracket with a strain relief bushing or a connector approved for the type of cord used. 9. Route field ground wire through holes in electrical box and casing, and into furnace J- -Box.
Page 24 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 25: Venting
VENTING General Venting Requirements The furnace shall be connected to a listed factory built chimney Follow all safety codes for proper vent sizing and installation or vent, or a clay- -tile lined masonry or concrete chimney. Venting requirements, including local building codes, the National Fuel into an unlined masonry chimney or concrete chimney is Gas Code NFPA 54/ANSI Z223.1- -2012 (NFGC), Parts 12 and prohibited.
Page 26 See notes 1, 2, 4, 6, 7, 9, 10, 11, and 15 on the page following these figures A00275 A03180 Fig. 27 - - Two- -Stage Furnace with Single- -Speed Fig. 29 - - Two- -Stage Furnace with Single- -Speed Heat Pump Air Conditioner (Dual Fuel) See notes 2, 5, 8, 10, 11 and 12...
Page 27 See notes 1, 2, 4, 11, 14, 15, and 16 on the page following these figures See notes 2, 11, and 12 on the page following these figures A03181 A03183 Fig. 31 - - Dual- -Fuel Thermostat with Two- -Stage Furnace Fig.
Page 28 NOTES FOR FIGURES 27 - - 34 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. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two- -speed heat pump control. Heat pumps having date codes 1601E and later do not have or require a “ZONE”...
Page 29 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 30 Masonry Chimney Requirement Relining with a listed metal liner or Type- -B vent is considered to be a vent- -in- -a- -chase. NOTE: These furnaces are CSA design- -certified for use in If a metal liner or Type- -B vent is used to line a chimney, no other exterior tile- -lined masonry chimneys with a factory accessory appliance shall be vented into the annular space between the Chimney Adapter Kit.
Page 31 Table 8 – Minimum Allowable Input Rating of Additional Venting Requirements Space- -Heating Appliance in Thousands of Btuh per Hour A 4- -in. (102 mm) round vent elbow is supplied with the furnace. A 5- -in. (127 mm) or 6- - in. (152 mm) vent connector may be INTERNAL AREA OF CHIMNEY required for some model furnaces.
Page 32 SEE NOTES: 1,2,4,7,8,9 SEE NOTES:1,2,3,4,5,7,8,9 on the page following on the page following these figures these figures A03208 A03210 Fig. 36 - - Upflow Application - - Vent Elbow Up Fig. 38 - - Downflow Application - - Vent Elbow Up then Left SEE NOTES: 1,2,4,5,7,8,9 SEE NOTES: 1,2,3,4,7,8,9 on the page following...
Page 33 SEE NOTES: 1,2,4,7,8,9 on the page following these figures A03213 Fig. 42 - - Horizontal Left Application - - Vent Elbow Left SEE NOTES: 1,2,4,5,6,7,8,9,10 on the page following these figures A03207 Fig. 40 - - Downflow Application - - Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03214...
Page 34 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 following these figures A03215 A03219 Fig. 45 - - Horizontal Left Application - - Vent Elbow Up Fig. 47 - - Horizontal Right Application - - Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 SEE NOTES: 1,2,4,5,7,8,9 on the page...
Page 35: Start- -Up, Adjustment, And Safety Check
Caution!! For the following applications, use the minimum vertical heights as specified below. For all other applications, follow exclusively the National Fuel Gas Code. MIN. VENT MIN. VERTICAL VENT FURNACE VENT ORIENTATION FURNACE INPUT DIAMETER HEIGHT ORIENTATION (BTUH/HR) IN. (mm)* FT.
Page 36: Start- -Up Procedures
Start- -Up Procedures WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.
Page 37 Furnace Setup Switch Description SETUP NORMAL SWITCH NAME DESCRIPTION OF USE SWITCH POSITION Turn ON to retrieve up to 7 stored status codes for troubleshooting SW1-1 Status Code Recovery assistance when R thermostat lead is disconnected. When SW1-2 is OFF allows two-stage operation with a single stage Low Heat Only thermostat.
Page 38: Adjustments
A14310 Fig. 54 - - Service Label Adjustments c. Find installation altitude in Table 12. d. Find closest natural gas heat value and specific gravity WARNING in Table 12. e. Follow heat value and specific gravity lines to point of intersection to find orifice size and low- -and high- -heat FIRE HAZARD manifold pressure settings for proper operation.
Page 39 d. Run furnace for 3 minutes in low- -heat operation. EXAMPLE 1: 0–2000 ft. (0- -610 M) altitude For 22,000 Btuh per burner application use Table 12. e. Measure time (in sec) for gas meter to complete 1 Heating value = 1000 Btuh/cu ft. revolution and note reading.
Page 40 the range specified on furnace rating plate. If temperat- Table 10 – Blower Off Delay Setup Switch ure rise is outside this range, proceed as follows: SETUP SWITCH (SW --- 7 AND --- 8) DESIRED HEATING MODE (1.) Check gas input for low- - and high- -heat opera- POSITION BLOWER OFF DELAY (SEC.) tion.
Page 41 A14327 Fig. 55 - - Wiring Diagram...
Page 42 Table 11 – Gas Rate (CU ft./hr) SECONDS G SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 REVOLUTION FOR 1 REVOLUTION 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1800 1636 1500...
Page 43 Table 12 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Tabulated Data Based on 22,000 Btuh High- -Heat/14,500 Btuh for Low- -Heat per Burner, Derated 4 Percent for Each 1000 Ft. (305 M) Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG.
Page 44 Table 12 - - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con’t.) (Tabulated Data Based on 22,000 Btuh High- -Heat/14,500 Btuh for Low- -Heat per Burner, Derated 4 Percent for Each 1000 Ft. Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG.
Page 45: Check Safety Controls
Check Safety Controls SW1- -7 and SW1- -8 for the blower OFF DELAY are set as desired per Table 10. The flame sensor, gas valve, and pressure switch were all checked 3. Verify that blower and burner access doors are properly in- in the Start- -up procedure section as part of normal operation.
Page 46: General
General NOTE: The Status Codes cannot be retrieved by disconnecting the limit switch or draft safeguard switch. To retrieve Status These instructions are written as if the furnace is installed in an Codes, follow the procedure below. upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of 2.
Page 47: Care And Maintenance
CARE AND MAINTENANCE have furnace and burner serviced by a qualified service agency. WARNING 5. Inspect the vent pipe/vent system before each heating sea- son for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a FIRE OR EXPLOSION HAZARD qualified service agency.
Page 48 Table 13 – Filter Size Information - - In. (mm) FILTER SIZE FURNACE CASING WIDTH SIDE BOTTOM FILTER TYPE RETURN RETURN 16 X 25 X 3/4 14 X 25 X 3/4 14 ---1/2 (368) Washable* (406 X 635 X 19) (356 X 635 X 19) 16 X 25 X 3/4 16 X 25 X 3/4...
Page 49 9. Using field- -provided 25- -caliber rifle cleaning brush, 36- -in. (914 mm) long, 1/4- -in. (6 mm) diameter steel spring cable, a variable speed, follows: a. Remove metal screw fitting from wire brush to allow insertion into cable. b. Insert the twisted wire end of brush into end of spring cable, and crimp tight with crimping tool or crimp by striking with ball- -peen hammer.
Page 50: Sequence Of Operation
13. Reconnect wires to the following components (Use con- a single- -stage thermostat because the furnace control CPU nection diagram on wiring label, if wires were not marked includes a programmed adaptive sequence of controlled for reconnection locations.): operation, which selects low- -heat or high- -heat operation. This selection is based upon the stored history of the length of a.
Page 51 repeat the ignition sequence for up to three more Tri- high- -heat pressure switch relay HPSR is de- -energized als- -For- -Ignition before going to Ignition- -Lockout. to close the NC contact. When sufficient pressure is Lockout will be reset automatically after three hours, available the high- -heat pressure switch HPS closes, or by momentarily interrupting 115 vac power to the and the high- -heat gas valve solenoid GV- -HI is ener-...
Page 52 which is the true on- -board CF selection as shown in Fig. 53. b. High cooling- -When the R- -to- -G- -and Y/Y2 circuit is closed and there is a demand for dehumidification, the If the furnace control CPU switches from low- -cooling to furnace blower motor BLWM will drop the blower high- -cooling, the furnace control CPU will energize the air airflow to 90 percent of high- -cooling airflow.
Page 53: Wiring Diagram
6. Heat pump expired. See Fig. 29 - - 32 for thermostat connections. The component test sequence is as follows: When installed with a heat pump, the furnace control auto- a. The furnace control CPU turns the inducer motor ON matically changes the timing sequence to avoid long at high- -heat speed and keeps it ON through step c.
Page 54 A14311A Fig. 59 - - Troubleshooting Guide...
Page 55 A14311B Fig. 59 - - Troubleshooting Guide (Continued)
Page 56: Parts Replacement Information Guide
-authorized replacement parts, kits, or accessories when modifying this product. Edition Date: 06/14 Catalog No: 58CTW---03SI Copyright 2014 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Replaces: 58CTW- -02SI Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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