Carrier 59CU5A Installation, Start-Up, Operating And Service And Maintenance Instructions
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Carrier 59CU5A Installation, Start-Up, Operating And Service And Maintenance Instructions

Single-stage, upflow/horizontal communicating, variable speed ecm, ultra low nox, 35-in tall condensing gas furnace
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59CU5A
Single-Stage, Upflow/Horizontal Communicating,
Variable Speed ECM, Ultra Low NOx, 35-in Tall
Condensing Gas Furnace
NOTE: Read the entire instruction manual before starting the installation.
Approved for installations up to 5,400 feet (1646 meters)

TABLE OF CONTENTS

Required Notice for Massachusetts Installations . . . . . . . . . . . . . . . . 2
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 1 - Minimum Clearances to Combustible Materials for All Units
5
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2 - Loose Parts Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CODES AND STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCE-
DURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 3 - Minimum Free Area Required for Each Combustion Air
Opening or Duct to Outdoors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 4 - Minimum Space Volumes for 100% Combustion, Ventila-
tion and Dilution Air from Outdoors . . . . . . . . . . . . . . . . . . . . . . 10
CONDENSATE TRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Condensate Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 5 - Condensate Trap Configurations . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 6 - Evaporator Coil Spacer or Shield Requirements. . . . . 16
AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 7 - Air Filter Selection and Duct Sizing - In. (mm) . . . . . 21
Table 8 - Opening Dimensions - In. (mm) . . . . . . . . . . . . . . . . . 21
Table 9 - Filter Media Pressure Drop (Clean) Versus Airflow - In.
W.C. (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 10 - Filter Media Pressure Drop (Clean) Versus Face Velocity-
In. W.C. (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 11 - Air Delivery - CFM (With Filter) . . . . . . . . . . . . . . . 22
GAS PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 12 - Maximum Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 24
Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1E, 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.
Installation, Start-up, Operating and
Service and Maintenance Instructions
ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 13 - Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
NOTES FOR THERMOSTATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 14 - Vent Termination Kit for Direct Vent (2-pipe) Systems32
Table 15 - Hanger Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Notes for Venting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 16 - Approved Combustion-Air and Vent Pipe, Fitting and Ce-
ment Materials (U.S.A. Installations) . . . . . . . . . . . . . . . . . . . . . 41
Table 17 - Maximum Allowable Exposed Vent Length in Uncondi-
tioned Space - Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 18 - Maximum Equivalent Vent Length - Ft. . . . . . . . . . . 42
Table 19 - Deductions from Maximum Equivalent Vent Length - Ft.
(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Table 20 - Altitude Derate Multiplier for USA. . . . . . . . . . . . . . 50
Table 21 - Blower Off Delay Setup Switch . . . . . . . . . . . . . . . . 51
Table 22 - Gas Rate (CU ft./hr). . . . . . . . . . . . . . . . . . . . . . . . . . 52
Table 23 - Gas Valve Outlet Pressure for Gas Heat Values at Altitude
- 60,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 24 - Gas Valve Outlet Pressure for Gas Heat Values at Altitude
- 80,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 25 - Gas Valve Outlet Pressure for Gas Heat Values at Altitude
- 100,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
WINTERIZATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SERVICE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . . . . . 69
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
A200352

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  • Page 1: Table Of Contents

    59CU5A Single-Stage, Upflow/Horizontal Communicating, Variable Speed ECM, Ultra Low NOx, 35-in Tall Condensing Gas Furnace Installation, Start-up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the installation. Approved for installations up to 5,400 feet (1646 meters) TABLE OF CONTENTS Required Notice for Massachusetts Installations .

  • Page 2: Required Notice For Massachusetts Installations

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Required Notice for Massachusetts Installations IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA-54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: a.
  • Page 3 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions A190253 SHIP WT. FURNACE SIZE CABINET WIDTH OUTLET WIDTH BOTTOM INLET WIDTH AIR INTAKE LB (KG) 060C17--16 17-1/2 (445) 15-7/8 (403) 16 (406) 8-3/4 (222) 149.6 (67.9) 080C21--20 21 (533) 19-3/8 (492)

  • Page 4: Safety Considerations

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions WARNING CAUTION CARBON MONOXIDE POISONING HAZARD FURNACE RELIABILITY HAZARD Failure to follow this warning could result in personal injury and/or Faulure to follow this caution may result in unit component damage.

  • Page 5: Introduction

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions 4. Combustion products must be discharged outdoors. Connect this NOTICE furnace to an approved vent system only, as specified in the “Venting” section of these instructions. Important Installation and Start-up Procedures 5.

  • Page 6: Codes And Standards

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions load estimates and select the furnace. Excessive oversizing of the Table 2 – Loose Parts Bag furnace may cause the furnace and/or vent to fail prematurely, customer DESCRIPTION discomfort and/or vent freezing.

  • Page 7: Dure

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE CAUTION FURNACE RELIABILITY HAZARD Failure to follow this caution may result in unit component damage. Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the 6-3/8”...

  • Page 8: Air For Combustion And Ventilation

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Location Relative to Cooling Equipment WARNING The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When CARBON MONOXIDE POISONING / COMPONENT...
  • Page 9 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions WARNING WARNING CARBON MONOXIDE POISONING HAZARD CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death. Failure to follow this warning could result in personal injury or death.
  • Page 10 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions 2. An attic or crawlspace may be considered a space that freely between wall-ceiling joints, between wall panels, at penetrations communicates with the outdoors provided there are adequate for plumbing, electrical and gas lines, etc.

  • Page 11: Condensate Trap

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions NOTICE The condensate trap extends below the underside of the casing in the horizontal position. A minimum of 6⅜-in. of physical clearance is required and 1-in. of additional clearance is recommended between the casing side and the furnace platform for the trap to extend out of the casing in the horizontal position.
  • Page 12 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions • There is an air gap at the point where the two drain lines meet or • All condensate piping is at least 3/4” PVC and there is a relief tee at the top of condensate drain piping as shown , see Fig.

  • Page 13: Installation

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Table 5 – Condensate Trap Configurations 2. Remove two of the factory-installed drain plugs from collector box. Orientation specific drain plugs, see Fig. Installation Configuration Part Upflow 3. Check that all pre-installed gaskets on trap components are present,...
  • Page 14 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions A200077 Fig. 19 – Example of Tube Connection A200065 Fig. 16 – Upflow - Offset of Condensate Drain Upflow Specific Steps – Standard Installation NOTICE 1. Install trap adapter to the collector box using provided machine screw, see Fig.
  • Page 15 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Alternate Horizontal Option - 2. Install the grommet in the casing when required for direct-vent horizontal applications. Remote Trap Installation Specific Steps 3. Allow for 6-3/8” (162 mm) of clearance underneath the furnace for 1.
  • Page 16 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions 8. Allow at least 1/4-in. per foot (20 mm per meter) of slope down and A---COIL SHIELD away from the furnace in horizontal sections of drain line. 16-- 1/2 3-- 3/4 Representative drawing only, some models may vary.
  • Page 17 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Cabinet Size Dimension “B” PERFORATED 17-in. 17-1/2-in. DISCHARGE DUCT FLANGE 21-in. 21-in. Fig. 26 – Dimensions of 8-in. Tall Metal Spacer NOTE: The allowable use of the 8-in. spacer demonstration, see Table 6 Fig.
  • Page 18 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions NOTICE Upflow installations utilizing the right side air return opening should follow the Upflow Specific Steps - Offset Installation to ensure the full opening is available for return ductwork. Leveling Legs (If Desired) In upflow position with side return inlet(s), leveling legs may be used, Fig.
  • Page 19 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions WARNING FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury, death, or property damage. Do not install the furnace on its back or hang furnace with control compartment facing downward.

  • Page 20: Air Ducts

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions duct must be connected to ONLY the furnace supply-outlet-air duct return use in the horizontal position, see Fig. 29. If both side and bottom flanges or air conditioning coil casing (when used). DO NOT cut main openings are used, see Fig.

  • Page 21: Pa)

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Ductwork Acoustical Treatment American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines NOTE: Metal duct systems that do not have a 90 degree elbow and 10 reference tables available from your local distributor.
  • Page 22 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Table 10 – Filter Media Pressure Drop (Clean) Versus Face Velocity- In. W.C. (Pa) Representative After-Market Filter Media* Factory-Accessory Face Velocity Washable Fiberglass* Pleated* (m/s) (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in.

  • Page 23: Gas Piping

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Air Delivery - CFM (With Filter) continued Unit Size: Clg/CF Switch settings External Static Pressure (ESP) 100C21-22 Clg Switches: SW2-3 SW2-2 SW2-1 Clg Default: 1765 1775 1790 1805 1810 1820 1820...
  • Page 24 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions pipe pressure test. After all connections have been made, purge lines and In the state of Massachusetts: NOTICE check for leakage at furnace prior to operating furnace. The gas supply pressure shall be within the maximum and minimum 1.

  • Page 25: Electrical Connections

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions CAUTION SUPPLY FURNACE MAY NOT OPERATE HAZARD FRONT Failure to follow this caution may result in intermittent furnace MANUAL SHUT OFF operation. VALVE (REQUIRED) Furnace control must be grounded for proper operation or else control will lock out.
  • Page 26 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions The J-Box mounting bracket and green ground screw is used as a grounding point for all line voltage wiring options. The J-Box cover may be omitted when electrical connections are made inside an external electrical box mounted external to the casing.
  • Page 27 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions ACCESSORIES 3. Secure power cord to J-Box bracket with a strain relief bushing or a connector approved for the type of cord used. 1. Electronic Air Cleaner (EAC) 4. Pull furnace power wires through 1/2-in. (12 mm) diameter hole in Connect an accessory Electronic Air Cleaner (if used) using 1/4-in.
  • Page 28 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip A11157 Fig. 40 – Field-supplied Isolation Relay for Humidifiers with Internal Power Supply...
  • Page 29 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions COMMUNICATION CONTINUOUS FAN OUTDOOR SW4 SETUP CONNECTOR (CF) AIRFLOW AIR TEMP SWITCHES SETUP SWITCHES CONNECTOR MODEL PLUG PL8 - PRESSURE CONNECTOR TRANSDUCER CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF- DELAY AIR CONDITIONING...
  • Page 30 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions THERMOSTAT THERMOSTAT A190367 See notes 1, 2, 4, 6, 7, 9, 10, 14 Fig. 43 – 1-Speed Variable Furnace with Single-Speed A190368 Fig. 45 – 1-Speed Variable Furnace with Single-Speed Heat Pump...

  • Page 31: Notes For Thermostats

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions NOTES FOR THERMOSTATS VENTING WARNING CARBON MONOXIDE POISONING HAZARD 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 32 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions need to be re-sized. Vent systems or vent connectors of other appliances Table 14 – Vent Termination Kit for Direct Vent (2-pipe) Systems must be sized to the minimum size as determined using appropriate table...
  • Page 33 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions 3. Termination or termination kit should be positioned where vent WARNING vapors will not damage plants/shrubs, air conditioning equipment or utility meters. CARBON MONOXIDE POISONING HAZARD 4. Do not locate termination directly into prevailing winds.
  • Page 34 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions with outside diameters of approximately 60 mm (2-3/8 inches). Any pipe diameter change should be made outside furnace casing in vertical pipe. Any change in diameter to the pipe must be made as close to the furnace as reasonably possible, see Fig.
  • Page 35 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions ADDITIONAL INFORMATION FOR EXAMPLE FOR NOTICE UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. POLYPROPYLENE VENTING SYSTEMS Polypropylene venting systems include flexible vent pipe. These flexi- ble vent pipes have a different equivalent vent length than straight sec- tions of PVC/ABS DWV vent pipe.
  • Page 36 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions MAY NOT be used for venting the furnace. Try the next larger diameter pipe NOTE: If the calculated Total Equivalent Vent Lengths results in Slope vent pipe back to the different diameter pipes for the vent and combustion air, select the larger furnace at least ¼”...
  • Page 37 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions can pass through the vent pipe adapter; it cannot pass through the inlet 4. Complete the vent and combustion air pipe installation by pipe adapter. connecting the concentric vent or by installing the required termination elbows, see Fig.
  • Page 38 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Table 15 – Hanger Spacing Material Diameter PVC Sch 40 SDR 21 & 26 CPVC Polypropylene 1 1/2-in. 3-ft. 2 1/2-ft. 3-ft. 3-ft. 3.25-ft. 38-mm 914-mm 762-mm 914-mm 914-mm 1000 mm 2-in.
  • Page 39 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Loosely assemble concentric vent/combustion termination NOTICE components together using instructions in kit. Slide assembled kit with rain shield REMOVED through hole in wall or RECOMMENDED SUPPORT FOR VENT roof flashing. TERMINATIONS...

  • Page 40: Notes For Venting Options

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Any other unused knockout may be used for combustion air connection. Requires Accessory Vent Kit See Product Data for Current Kit Number UPFLOW VERTICAL VENT HORIZONTAL LEFT-RIGHT VENT CONFIGURATION A11310A Fig. 56 – Upflow Configurations (Appearance may vary) A11329A Fig.
  • Page 41 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Table 16 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A. Installations) MATERIALS 1. All pipe, fittings, primers*, and solvents* must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards or ULC S636 where required by code.
  • Page 42 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Table 18 – Maximum Equivalent Vent Length - Ft. NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 19 Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application.
  • Page 43 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Venting System Length Calculations The Total Equivalent Vent Length (TEVL) for EACH combustion air or vent pipe equals the length of the venting system, plus the equivalent length of elbows used in the venting system, see Table Standard vent terminations or factory accessory concentric vent terminations count for zero deduction.
  • Page 44 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions No operable windows, doors or Clearance distances for intakes of any type within the items greater than 3 feet shaded areas of Wall A and B. (1 meter ) away from the...
  • Page 45 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions A12326 Fig. 60 – Direct Vent Termination Clearance NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations.
  • Page 46 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions A12325 Fig. 61 – Ventilated Combustion Air and Non-Direct Vent Termination Clearance NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations.
  • Page 47 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions ¾ in. (222mm) for 3 in. (76mm) ¾ in. (172mm) for 2 in. (51mm) 12 in. (305mm) min. separation between bottom of combustion air and bottom of vent (Typ.) A13305 Fig. 62 – Combustion Air and Vent Pipe Termination for Direct Vent (2-Pipe) System...

  • Page 48: Start-Up, Adjustment, And Safety Check

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Ventilated Combustion Air intake pipe Pipe hangar 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE highest level of insulation ATTIC A10497 Fig. 64 – Vent Terminations for Ventilated Combustion Air...
  • Page 49 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Prime Condensate Trap with Water switch configurations. To set these setup switches for the appropriate requirement: CAUTION 1. Remove blower door. 2. Locate setup switches on furnace control. UNIT OPERATION HAZARD 3.
  • Page 50 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions m.Remove manometer from the inlet pressure tap of the gas valve. n. Tighten set screw on inlet tower pressure tap with 3/32−in. hex wrench, or if 1/8−in. NPT plug was removed, apply pipe dope sparingly to end of plug and re−install in the gas valve...
  • Page 51 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions c. Measure time (in seconds) for gas meter to complete 1 revolution (4.) Ensure setup switch SW1-4. See Fig. 42 for switch location. and note reading. The 2 or 5 cubic feet dial provides a more (5.) Make sure proper model plug is installed.
  • Page 52 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Set Thermostat Heat Anticipator b. Gradually block off return air with a piece of cardboard or sheet metal until the limit trips. 1. Mechanical thermostat - Set thermostat heat anticipator to match c.
  • Page 53 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Table 23 – Gas Valve Outlet Pressure for Gas Heat Values at Table 24 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude - 60,000 Altitude - 80,000 (Tabulated Data Based on 60,000 BTUH Input for 0-ft (0m) to...

  • Page 54: Service And Maintenance

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions General Table 25 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude - 100,000 These instructions are written as if the furnace is installed in an upflow (Tabulated Data Based on 100,000 BTUH Input for 0-ft (0m) to application.
  • Page 55 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Electrical Controls and Wiring is the number of short flashes, the second digit is the number of long flashes. WARNING For an explanation of status codes, refer to service booklet located on blower access door (see Fig.
  • Page 56 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Component Self-Test CAUTION To initiate the component test sequence, shut OFF the room thermostat or disconnect the “R” thermostat lead. Reset power and then put setup CUT HAZARD switch “SW1-6” in the ON position to start the component test sequence.
  • Page 57 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Blower Motor and Wheel Maintenance CAUTION WARNING UNIT DAMAGE HAZARD ELECTRICAL SHOCK HAZARD Failure to follow this caution may result in shortened heat exchanger Failure to follow this warning could result in personal injury or death.
  • Page 58 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Cleaning Flame Sensor GROMMET MOTOR SHAFT FLAT MOTOR ARM The following items must be performed by a qualified service SCREW technician. If the Flame Sensor develops an accumulation of light dirt or...
  • Page 59 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Flushing Collector Box and Drainage System WARNING WARNING FIRE OR EXPLOSION HAZARD ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage.
  • Page 60 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Cleaning Heat Exchangers The following items must be performed by a qualified service technician. Primary Heat Exchangers IMPORTANT: It is not recommended to clean the heat exchanger as part of annual maintenance.

  • Page 61: Winterization

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions WINTERIZATION 90-second blower-on period, the furnace will respond to the thermostat normally. CAUTION NOTE: If BTS happens to be open as well, the inducer will operate during the 90s. If the BTS does not reset during this time, a permanent lockout will result and power must be cycled to reset.
  • Page 62 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions selection at blower-OFF delay switches). The furnace control c. Two-Stage Thermostat and Two-Speed Cooling CPU is factory-set for a 120-second blower-OFF delay. Fig. 42 and thermostat wiring for connections 2. Cooling mode NOTE: The air conditioning relay disable jumper ACRDJ must be The thermostat “calls for cooling”.
  • Page 63 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions b. When the R-to-Y/Y2 circuit is closed, R-to-G circuit is open, and from the factory setting to the next highest CF selection airflow as there is a demand for dehumidification, the furnace blower motor shown in Fig.
  • Page 64 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions A190174 Fig. 75 – Troubleshooting Guide Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 65 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions A11326B Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 66 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions Troubleshooting Guide (Continued) A11326C Troubleshooting Guide (Continued) Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 67 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions 346011-2 rev A A200312 Fig. 76 – Wiring Diagram Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

  • Page 68: Service Guide

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions SERVICE GUIDE LED CODES STATUS CONTINUOUS OFF Check for 115VAC at L1 and N, and 24VAC at SEC-1 and SEC-2 CONTINUOUS ON Control has 24VAC power. RAPID FLASHING Line voltage (115VAC) polarity reversed. Check for poor or no ground (GND).

  • Page 69: Parts Replacement Information Guide

    59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Blower door Burner Bottom plate Flame sensor Control door Gas valve Door knob assembly Hot surface igniter Top filler plate Manifold Orifice...
  • Page 70 59CU5A: Installation, Start-up, Operating and Service and Maintenance Instructions © 2020 Carrier. All rights reserved. Edition Date: 08/20 Catalog No: 59CU5A-01SI Replaces: NEW Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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