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Carrier 120/C Series Installation, Start-Up, Operating And Service And Maintenance Instructions

Single-stage deluxe induced-combustion 4-way multipoise furnace
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Installation, Start-up, Operating, and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
→
Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1-2002©,
with permission of National Fire Protection Association, Quincy, MA 02269 and
American Gas Association, Washington DC 20001. This reprinted material is not the
complete and official position of the NFPA or ANSI on the referenced subject, which
is represented only by the standard in its entirety.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS .....................................................2
INTRODUCTION ..........................................................................3
CODES AND STANDARDS........................................................3
Safety.........................................................................................3
General Installation...................................................................5
Combustion and Ventilation Air ..............................................5
Duct Systems ............................................................................5
Acoustical Lining and Fibrous Glass Duct..............................5
Gas Piping and Gas Pipe Pressure Testing..............................5
Electrical Connections ..............................................................5
PROCEDURE ................................................................................5
LOCATION....................................................................................5
General ......................................................................................5
Location Relative to Cooling Equipment ................................7
AIR FOR COMBUSTION AND VENTILATION ......................7
INSTALLATION .........................................................................10
Upflow Installation .................................................................10
Bottom Return Air Inlet ....................................................10
Side Return Air Inlet.........................................................10
Leveling Legs (If Desired)................................................10
Downflow Installation ............................................................10
Bottom Return Air Inlet ....................................................11
Horizontal Installation ............................................................12
Suspended Unit Support....................................................12
Platform Unit Support .......................................................12
Roll-Out Protection............................................................12
Bottom Return Air Inlet ....................................................13
Side Return Air Inlet.........................................................13
Filter Arrangement..................................................................13
Air Ducts.................................................................................13
General Requirements .......................................................13
Ductwork Acoustical Treatment .......................................13
Supply Air Connections ....................................................13
Return Air Connections.....................................................14
Gas Piping...............................................................................17
Electrical Connections ............................................................19
115-V Wiring.....................................................................19
J-Box Relocation ...............................................................20
Electrical Connection to J-Box .........................................20
Power Cord Installation.....................................................21
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
Tab 6a 8a
4-Way Multipoise Furnace
Series 120/C
Venting ....................................................................................21
General ....................................................................................33
Start-Up Procedures ................................................................33
Adjustments.............................................................................34
Check Safety Controls ............................................................36
Checklist..................................................................................37
Introduction .............................................................................40
Care and Maintenance ............................................................44
Sequence of Operation............................................................48
Wiring Diagrams.....................................................................50
Troubleshooting ......................................................................50
Printed in U.S.A.
Single-Stage Deluxe
Induced-Combustion
Cancels: II 311A-45-5
BX Cable Installation ........................................................21
24-V Wiring.......................................................................21
Accessories ........................................................................21
General Venting Requirements .........................................23
Masonry Chimney Requirements......................................23
Appliance Application Requirements ...............................27
Additional Venting Requirements.....................................29
Sidewall Venting ...............................................................29
General...............................................................................40
Electrical Controls and Wiring .........................................40
Cleaning and/or Replacing Air Filter ...............................44
Blower Motor and Wheel..................................................44
Cleaning Heat Exchanger..................................................45
Pg 1
II 311A-45-6
4-06
4-06

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  • Page 1: Table Of Contents

    Single-Stage Deluxe Induced-Combustion 4-Way Multipoise Furnace Cancels: II 311A-45-5 II 311A-45-6 4-06 Installation, Start-up, Operating, and Service and Maintenance Instructions Series 120/C NOTE: Read the entire instruction manual before starting the installation. This symbol → indicates a change since the last issue. →...

  • Page 2: Safety Considerations

    28-7/8" 26-1/8" (FLUE COLLAR) 25-1/4" 2-7/16" 22-9/16" AIRFLOW 1-5/16" 13/16" 19" JUNCTION BOX 13/16" 1-1/8" LOCATION OUTLET 4-13/16" 5-15/16" 1/2" DIA. K.O.THERMOSTAT 9-5/8" WIRE ENTRY 11/16" 7/8" DIA 8-9/16" 1-3/4" DIA.RIGHT HAND 7-3/4" ACCESSORY GAS ENTRY 1/2" DIA THERMOSTAT 11-1/2" WIRE ENTRY 3-15/16"...

  • Page 3: Introduction

    Table 1—Dimensions (IN.) FILTER C.L. TOP AND FLUE MEDIA SUPPLY-AIR RETURN-AIR FURNACE SIZE BOTTOM COLLAR* SHIP WT (LB) CABINET CABINET WIDTH WIDTH WIDTH FLUE COLLAR (IN.) SIZE (IN.) (IN.) (IN.) (IN.) 045-08/024045 14-3/16 12-9/16 12-11/16 9-5/16 045-12/036045 14-3/16 12-9/16 12-11/16 9-5/16 070-08/024070 14-3/16...
  • Page 4 INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES This forced air furnace is equipped for use with This furnace is approved for UPFLOW, DOWNFLOW, and HORIZONTAL installations. natural gas at altitudes 0-10,000 ft (0-3,050m). accessory kit, supplied...

  • Page 5: General Installation

    ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause prema- ture furnace component failure. Electrostatic discharge can affect electronic components. Follow the Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace electronic control.
  • 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 BURNER SECTION, AND...

  • Page 7: Location Relative To Cooling Equipment

    PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may cause 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 Table 2–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 9 1 SQ IN. PER 4000 CIRCULATING AIR DUCTS VENT THROUGH ROOF BTUH* DUCTS OUTDOORS 12″ MAX 12″ 12" MAX 1 SQ IN. VENT PER 2000 THROUGH BTUH* ROOF 1 SQ IN. 1 SQ IN. PER 1000 BTUH* IN DOOR 4000 OR WALL BTUH* UNCONFINED...

  • Page 10: Installation

    ″ ⁄ ″ ⁄ ″ ⁄ ″ ⁄ ″ ⁄ A02098 Fig. 9—Removing Bottom Closure Panel ″ ⁄ ″ ⁄ ″ ⁄ free area of at least 1-in. /4,000 Btuh of total input rating for A89014 all gas appliances in the space. Fig.

  • Page 11: Bottom Return Air Inlet

    FURNACE (OR COIL CASING WHEN USED) PLENUM COMBUSTIBLE OPENING FLOORING DOWNFLOW FLOOR SUBBASE OPENING SHEET METAL PLENUM FLOOR OPENING A96283 Fig. 11—Floor and Plenum Opening Dimensions Fig. 12—Furnace, Plenum, and Subbase Installed on a Combustible Floor A96285 FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX...

  • Page 12: Horizontal Installation

    Table 4—Opening Dimensions (In.) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications on Combustible or Noncombustible 12-11/16 21-5/8 13-5/16 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring 12-9/16 13-3/16 19-5/8 (KGASB subbase not required) 14–3/16 Downflow applications on combustible flooring (KGASB 11-13/16 13-7/16...

  • Page 13: Bottom Return Air Inlet

    UPFLOW OWNFLOW HORIZONTAL 90˚ 90˚ PREFERRED PREFERRED PREFERRED PREFERRED PREFERRED PREFERRED 120˚ 120˚ 120˚ PERMITTED PERMITTED PERMITTED A02329 Fig. 14—Duct Flanges Bottom Return Air Inlet American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guide- These furnaces are shipped with bottom closure panel installed in lines reference tables available from your local distributor.

  • Page 14: Return Air Connections

    " THREADED ROD 4 REQ. OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x " SCREWS TYPICAL FOR 2 SUPPORTS 8" MIN FOR DOOR REMOVAL 1" SQUARE, 1 " x 1 " x " ANGLE IRON OR UNI-STRUT MAY BE USED (2) HEX NUTS, (2) WASHERS &...
  • Page 15 METHOD 2 USE (4) #8 x 3/4 SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES. METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).
  • Page 16 Table 5—Air Delivery - CFM (With Filter)* EXTERNAL STATIC PRESSURE (IN. WC) FURNACE RETURN-AIR SPEED SIZE INLET Bottom High 1085 1035 024045 Med-High Side(s) Med-Low High 1440 1375 1305 1240 1160 1070 Bottom Med-High 1360 1300 1240 1175 1115 1040 036045 Med-Low 1250...

  • Page 17: Gas Piping

    Table 5—Air Delivery - CFM (With Filter)* (Continued) EXTERNAL STATIC PRESSURE (IN. WC) FURNACE RETURN-AIR SPEED SIZE INLET High 2090 2010 1930 1835 1710 1590 1470 1335 1025 Bottom Med-High 1790 1755 1705 1640 1550 1465 1360 1210 048135 Med-Low 1545 1525 1500...
  • 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: Electrical Connections

    The gas supply pressure shall be within the maximum and Table 6—Maximum Capacity of Pipe* minimum inlet supply pressures marked on the rating plate with NOMINAL the furnace burners ON and OFF. LENGTH OF PIPE (FT) IRON INTERNAL ELECTRICAL CONNECTIONS PIPE DIAMETER SIZE...

  • Page 20: J-Box Relocation

    Table 7—Electrical Data OPERATING VOLTS- MAXIMUM MAXIMUM UNIT MAXIMUM MINIMUM VOLTAGE RANGE FURNACE SIZE HERTZ- FUSE OR CKT BKR UNIT AMPS AMPACITY# WIRE LENGTH (FT)‡ WIRE GAUGE PHASE AMPS† Maximum* Minimum* 045-08/024045 115-60-1 7.54 045-12/036045 115-60-1 9.50 070-08/024070 115-60-1 7.06 070-12/036070 115-60-1 9.22...

  • Page 21: Power Cord Installation

    4. Secure field ground wire to green ground screw on J-Box bracket. 5. Connect line voltage leads as shown in Fig. 25. 6. Reinstall cover to J-Box. Do not pinch wires between cover and bracket. BX CABLE INSTALLATION IN FURNACE J-BOX 1.
  • Page 22 TWINNING AND/OR COMPONENT TEST BLOWER OFF-DELAY TERMINAL BLOWER OFF-DELAY HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) 24-V THERMOSTAT TERMINALS TRANSFORMER 24-VAC CONNECTIONS TEST/TWIN 0.5 AMP@24VAC 3-AMP FUSE FUSE 3-AMP SEC-2 SEC-1 LED OPERATION & EAC-2 DIAGNOSTIC LIGHT PL1-LOW VOLTAGE MAIN HARNESS CONNECTOR 115-VAC(L2)NEUTRAL CONNECTIONS COOL...

  • Page 23: General Venting Requirements

    The following information and warning must be considered in addition to the requirements defined in the NFGC and the CARBON MONOXIDE POISONING HAZARD NSCNGPIC. Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
  • Page 24 See notes 2,5,7, and 10 on the page following these figures. See notes 1, 2, 4, 6, 7, 9, 10 and 12 on the A04215 page following these figures. Fig. 26–Single-Stage Furnace with Single-Speed A04217 Air Conditioner Fig. 28–Single-Stage Furnace with Single-Speed Heat Pump (Dual Fuel) See notes 1, 2, 3, 4, 6, 8, 9, 10 and 12 on the See notes 2,5,8, and 10 on the page following these figures.
  • Page 25 HUMIDFIER HUMIDFIER (24VAC) (24VAC) See notes 1, 2, 3, 4, 11, 12, and 14 on the page following these figures. See notes 1, 2, 4, 11, 12, and 13 on the page following these figures. A04220 A04219 Fig. 31–Dual Fuel Thermostat with Single-Stage Fig.
  • Page 26 Notes For Figures 26-32 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. Outdoor Air Temperature Sensor must be attached in all dual fuel applications. 4.

  • Page 27: Appliance Application Requirements

    Canada (and U.S.A.)-This furnace is permitted to be vented into Table B—Minimum Alowable Input Rating of a clay tile-lined masonry chimney that is exposed to the outdoors Space-Heating Appliance in below the roof line, provided: Thousands of BTU per Hour 1.
  • Page 28 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 in the U.S.A. or to the Canadian installation Code CSA-B149.1 in Canada. Crown Rebuild condition: crown.

  • Page 29: Additional Venting Requirements

    To prevent condensation in the furnace and vent system, the following precautions must be observed: CUT HAZARD 1. The return-air temperature must be at least 60°F db except for Failure to follow this caution may result in personal injury. brief periods of time during warm-up from setback at no lower Sheet metal parts may have sharp edges or burrs.
  • Page 30 SEE NOTES: 1,2,4,5,7,8,9 SEE NOTES: 1,2,4,7,8,9 on the page following on the page following these figures these figures A03208 A03211 Fig. 34—Upflow Application-Vent Elbow Up Fig. 37—Downflow Application-Vent Elbow Up SEE NOTES: 1,2,4,5,6,7,8,9,10 SEE NOTES: 1,2,3,4,7,8,9 on the page following these figures on the pages following these figures A03209...
  • Page 31 SEE NOTES: 1,2,4,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03213 Fig. 40—Horizontal Left Application-Vent Elbow Left A03215 Fig. 42—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 A03214 A03216...
  • Page 32 SEE NOTES: 1,2,4,5,7,8,9 A02068 Fig. 46—Horizontal Right Application-Vent Elbow Left Venting Notes for Figures 34-46 1. For common vent, vent connector sizing and vent material: United States--use the NFGC Canada--use the NSCNGPIC 2. Immediately increase to 5-inch or 6-inch vent connector outside furnace casing when 5-inch vent connector is required, refer to Note 1 above. 3.

  • Page 33: Start-Up, Adjustment, And Safety Check

    A04131 Fig. 51—Remove Knockout with Hammer START-UP, ADJUSTMENT, AND SAFETY CHECK Step 1—General A04128 Fig. 48—Rounded End of Knockout FIRE HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. This furnace is equipped with manual reset limit switches in the gas control area.

  • Page 34: Adjustments

    Step 3—Adjustments ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, or death. FIRE HAZARD Blower access door switch opens 115-v power to control. No Failure to follow this warning could result in injury, death component operation can occur unless switch is closed. and/or property damage.
  • Page 35 REGULATOR Table 8–Altitude Derate Multipler for U.S.A. SEAL CAP ALTITUDE PERCENT DERATE MULTIPLIER REGULATOR (FT) OF DERATE FACTOR* ADJUSTMENT SCREW 0–2000 1.00 ON/OFF SWITCH 2001–3000 8–12 0.90 3001–4000 12–16 0.86 4001–5000 16–20 0.82 REGULATOR SPRING 1/2˝ NPT INLET 5001–6000 20–24 0.78 6001–7000 24–28...

  • Page 36: Check Safety Controls

    Table 9—Speed Selection COLOR SPEED AS SHIPPED White Common Black High COOL Yellow† Med-High SPARE Blue Med-Low HEAT Low* SPARE * Continuous-blower speed-as shipped default † Not available on 1/5 HP motors. BURNER ORIFICE A93059 k. Turn gas valve ON/OFF switch to ON. Fig.

  • Page 37: Checklist

    THERMOSTAT SUBBASE Table 10–GAS RATE (CU FT/HR) TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS MUST BE OUT OF CIRCUIT.) FOR 1 FOR 1 REVOLUTION REVOLUTION Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft...
  • Page 38 Table 11—Orifice Size* and Manifold Pressure For Gas Input Rate (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE Orifice...
  • Page 39 Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...

  • Page 40: Service And Maintenance Procedures

    Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...
  • Page 41 Table 12—Orifice Size* and Manifold Pressure For Gas Input Rate (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE Orifice...
  • Page 42 Table 12—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...
  • Page 43 Table 12—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...

  • Page 44: Care And Maintenance

    Step 2—Care and Maintenance Table 13—Filter Size Information (IN.) FILTER SIZE FURNACE FILTER CASING WIDTH TYPE Side Return Bottom Return FIRE OR EXPLOSION HAZARD 14-1/2 16 X 25 X 1 14 X 25 X 1 Cleanable* Failure to follow this warning could result in personal injury, 17-1/2 16 X 25 X 1 16 X 25 X 1...

  • Page 45: Cleaning Heat Exchanger

    To ensure long life and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually. UNIT DAMAGE HAZARD The inducer and blower motors are pre-lubricated and require no Failure to follow this caution may result in shortened heat additional lubrication.
  • Page 46 PRINTED CIRCIUT BOARD PRINTED CIRCIUT BOARD...
  • Page 47 9/32˝ 1-7/8” 5/16˝ A05026 Fig. 58—Igniter Position-Top View (1.) Attach variable-speed, reversible drill to the end of A05025 spring cable (end opposite brush). Fig. 57—Igniter Position-Side View (2.) Insert brush end of cable into the outlet opening of cell quality combustion air, incorrect size or damaged manifold ori- and slowly rotate with drill.

  • Page 48: Sequence Of Operation

    circuit. The furnace control performs a self-check, verifies the pressure switch contacts PRS are open, and starts the inducer motor IDM. a. Inducer Prepurge Period- As the inducer motor IDM comes up to speed, the pressure switch contacts PRS close to begin a 15-second prepurge period.
  • Page 49 2. Cooling Mode after 20 minutes, the furnace control CPU will drop the The thermostat “calls for cooling.” blower speed back to HEAT speed. This alternating 10- minute cycle will continue as long as there is a call for a. Single-Speed Cooling cooling.

  • Page 50: Wiring Diagrams

    blower motor BLWM will remain on for the selected blower- selected blower-OFF delay period then switch to continuous- OFF delay period then switch to continuous-blower speed. blower speed. When the R-to-W-and-Y/Y2, R-to-W-and-Y/Y2-and-G, R-to- W-and-Y1-and-Y/Y2, or R-to-W-and-Y1-and-Y/Y2-and-G Step 4—Wiring Diagrams circuits are energized the furnace control CPU will switch to Refer to Fig.
  • Page 52 Copyright 2006 Carrier Corporation 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 Printed in U.S.A. Pg 52 4-06 Tab 6a 8a...

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