Carrier 120 Series Operating Instructions Manual
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Carrier 120 Series Operating Instructions Manual

Carrier 120 Series Operating Instructions Manual

Condensing gas furnace
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59MN7A
Modulating 4---Way Multipoise
Condensing Gas Furnace
Series 120
Installation, Start---up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
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24- -V Wiring
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Use of the AHRI Certified
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manufacturer's participation in the program. For
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go to www.ahridirectory.org.
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Portions of the text and tables are reprinted from NFPA 54/ANSI
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Z223.1- -2012E, with permission of National Fire Protection
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Association, Quincy, MA 02269 and American Gas Association,
Washington DC 20001. This reprinted material is not the complete
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and official position of the NFPA or ANSI on the referenced
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subject, which is represented only by the standard in its entirety.
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  • Page 1: Table Of Contents

    59MN7A Modulating 4---Way Multipoise Condensing Gas Furnace Series 120 Installation, Start---up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the Checklist ........installation.
  • Page 2 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. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...

  • Page 3: Safety Considerations

    SAFETY CONSIDERATIONS CAUTION WARNING CUT HAZARD Failure to follow this caution may result in personal injury. FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and Failure to follow this warning could result in dangerous gloves when handling parts, and servicing furnaces.

  • Page 4: Introduction

    13. These furnaces SHALL NOT be installed directly on carpet- S CANADA: National Standard of Canada, Natural Gas and ing, combustible tile, or any other combustible material oth- Propane Installation Code (NSCNGPIC) CAN/CSA er than wood flooring. In downflow installations, factory B149.1- -2010 accessory floor base MUST be used when installed on com- General Installation...

  • Page 5: Electrostatic Discharge (Esd) Precautions

    ELECTROSTATIC DISCHARGE (ESD) LOCATION PRECAUTIONS PROCEDURE CAUTION CAUTION PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD FURNACE RELIABILITY HAZARD Improper use or installation of this furnace may result in Failure to follow this caution may result in unit component premature furnace component failure. This gas furnace may damage.
  • Page 6 General made between the furnace cabinet and the return- -air duct to prevent pulling air from the burner area. These furnaces are shipped with materials to assist in proper furnace installation. These materials are shipped in the main WARNING blower compartment. See Table 1 for loose parts bag contents. This furnace must: FIRE, INJURY OR DEATH HAZARD S be installed so the electrical components are protected from...

  • Page 7: Loose Parts Bag Contents

    Table 1 – Factory- -Supplied Installation Parts DESCRIPTION QUANTITY Air Intake Pipe Flange Vent Pipe Flange Coupling Flange Gaskets Sharp Tip Screws (Vent and Inlet Flanges) Vent Pipe Coupling Vent Pipe Coupling Clamps Rubber Drain Elbow Drain Tube Clamps 1/2---in. CPVC to 3/4---in. PVC Pipe Adapter Gas Line Grommet Junction Box Cover Junction Box Base...
  • Page 8 A12267 59MN7 SHIP WT. BOTTOM LB (KG) FURNACE SIZE CABINET WIDTH OUTLET WIDTH AIR INTAKE INLET WIDTH 060--- 14 154.0 (69.3) 17--- 1/2 (445) 15--- 7/8 (403) 16 (406) 8--- 3/4 (222) 080--- 14 164.0 (73.8) 060--- 20 158.5 (72.0) 080--- 20 21 (533) 19--- 3/8 (492)
  • Page 9 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 CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE OF THE BURNER SECTION, BURNER SECTION, AND...

  • Page 10: Air For Combustion And Ventilation

    AIR FOR COMBUSTION AND Outdoor Combustion Air Method VENTILATION 1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent hori- Introduction zontal or vertical duct(s) or opening(s) directly communicat- Direct Vent (2- - pipe) Applications ing with the outdoors or spaces that freely communicate with the outdoors.

  • Page 11: Minimum Free Area Required

    Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO OPENINGS OR TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING VERTICAL DUCTS (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) FURNACE (1 SQ. IN./4,000 BTUH) (1,100 SQ.

  • Page 12: Condensate Trap

    CONDENSATE TRAP NOTICE Condensate Trap- -Upflow Orientation When the furnace is installed in the upflow position, it is not The field- -supplied, accessory horizontal drain trap grommet is necessary to relocate the condensate trap or associated tubing. ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. Refer to Fig.
  • Page 13 Remove pressure switch tube from pressure switch port. Remove relief tube from relief port on condensate trap. Remove tube from Remove trap from relief port. collector box. Loosen clamp on inlet Remove middle and bottom plugs. to vent elbow. DO NOT DISCARD. Trim excess tube.
  • Page 14 Remove plug from collector box. DO NOT DISCARD. If alternate vent position is required, loosen clamp on inlet of vent elbow. Remove trap from collector box. Unconverted Factory Trap Configuration As Viewed in the Horizontal Right Orientation Slide relief tube in stand-offs to adjust length.
  • Page 15 Remove trap from collector box. If alternate vent position is required, loosen clamp Remove relief tube on vent elbow inlet. from relief port on condensate trap. Remove pressure switch tube from port on collector box. Remove relief tube from port on collector box.

  • Page 16: Condensate Drain

    CONDENSATE DRAIN CONNECTION For Right Side Condensate Drain: 1. Remove the 7/8- -in. knock- -out from the right side of the CAUTION casing. See Fig. 11 for suggested knockout removal tech- nique. 2. Remove the pre- -formed rubber drain elbow and two spring FROZEN AND BURST WATER PIPE HAZARD clamps from the loose parts bag.
  • Page 17 7. After inserting the Z- -pipe through the casing, slide a spring 2. To allow for servicing the trap, the condensate drain elbow clamp over each end of the Z- -pipe. in the loose parts bag can be used to make a coupler to allow for future service of the condensate trap and drain 8.
  • Page 18 INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAP PULL DRAIN STUB THROUGH CASING CAUTION OPEN SPRING CLAMP CUT HAZARD INSERT FACTORY SUPPLIED 1/2 IN. CPVC TO 3/4 IN. PVC ADAPTER OR 1/2 IN. CPVC PIPE Failure to follow this caution may result in personal injury. *CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN TUBE Sheet metal parts may have sharp edges or burrs.

  • Page 19: Installation

    Supply Air Connections NOTE: Trap grommet is required only for direct-vent applications. For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream.

  • Page 20: Downflow

    4. Adjust outside nut to provide desired height, and tighten in- bottom return air is used in downflow applications. To remove side nut to secure arrangement. bottom closure panel, perform the following: 5. Reinstall bottom closure panel if removed. 1. Tilt or raise furnace and remove 4 screws holding bottom plate.

  • Page 21: Filter Arrangement

    accessible when the furnace is installed and shall be of such a size For horizontal applications, the Media Cabinet (or field supplied that the heat exchanger can be viewed for possible openings using accessory air cleaner) for all models can be connected to the light assistance or a probe can be inserted for sampling the air bottom opening on the furnace.
  • Page 22 Table 5 – Filter Media Pressure Drop (Clean) Versus Airflow - - In. W.C. (Pa) Representative After-Market Filter Media* 14 x 25 Filter Factory-Accessory Factory-Accessory (356 x 635 mm) Washable Media* Fiberglass* Pleated* (1-in. / 2.5 cm) (4-in. / 10 cm) (1-in.

  • Page 23: Filter Size Information

    Table 6 – 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. / 5 cm) (1-in. / 2.5 cm) (2-in.
  • Page 24 4-in. Block Off 21-in. Furnace 14-3/16 and 17-1/2-in. Plate Furnace 4-Ton or less, AC capacity airflow 1/2-in. Screws 20-in. Media Cabinet 16-in. Media Cabinet Media Cabinet Installation Media Cabinet Installation Option for Side Return 4-Ton or Less A/C Capacity 21- or 24-1/2-in. 21-in.

  • Page 25: Opening Dimensions

    FURNACE FURNACE (OR COIL CASING WHEN USED) APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING PLENUM OPENING DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR SHEET METAL PLENUM OPENING FLOOR FLOOR OPENING OPENING A10491 Fig. 18 - - Installation on Combustible Flooring Table 8 –...
  • Page 26 UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT 90° 90° FLANGE 120° 120° 120° A10493 Fig. 19 - - Duct Flanges 5/ 16 (8mm) (8mm) 5/ 16 (44mm) (44mm) (8mm) BOTTOM CLOSURE PANEL (8mm) 5/ 16 (44mm) 3/ 4 3/ 4 (44mm) BOTTOM PLATE A89014 A11092...
  • Page 27 ANY COMBINATION OF 1, 2, OR 3 PERMITTED. A11036 A11037 Fig. 23 - - Upflow Return Air Configurations and Restrictions Fig. 24 - - Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig. 25 - - Horizontal Return Air Configurations and Restrictions...
  • Page 28 COMBUSTION - AIR PIPE (SEE VENTING SECTION) 30 IN. (762 mm) MIN. WORK AREA 2-IN. (51 mm) ROLLOUT PROTECTION REQUIRED Install 12” x 22” (305 x 559 mm) sheet metal in front of burner compartment area. A11154 Fig. 26 - - Working Platform for Attic Installation NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.

  • Page 29: Air Ducts

    AIR DUCTS NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. NOTICE Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended. Many states, provinces and localities are considering or have Maintain a 1- -in.

  • Page 30: Air Delivery Cfm

    Table 9 – Cooling and Heating Air Delivery - - CFM (Bottom Return With Filter) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2 SWx-1 060-14 Clg Default:...
  • Page 31 Table 9 - - Cooling and Heating Air Delivery - - CFM (Bottom Return With Filter) (Continued) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2 SWx-1 080-14 Clg Default: 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005 CF Default:...
  • Page 32 Table 9 - - Cooling and Heating Air Delivery - - CFM (Bottom Return With Filter) (Continued) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2 SWx-1 100-22 Clg Default: 1820 1825 1840 1845 1840 1835 1825 1805 1780 1770 CF Default:...

  • Page 33: Gas Piping

    GAS PIPING WARNING WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could result in personal FIRE OR EXPLOSION HAZARD injury, death, and/or property damage. Failure to follow this warning could result in personal If local codes allow the use of a flexible gas appliance injury, death, and/or property damage.

  • Page 34: Electrical Connections

    ELECTRICAL CONNECTIONS Table 10 – Maximum Capacity of Pipe NOMINAL LENGTH OF PIPE --- FT (M) IRON PIPE WARNING SIZE (3.0) (6.0) (9.1) (12.1) (15.2) IN. (MM) 1/2 (13) ELECTRICAL SHOCK, FIRE OR EXPLOSION 3/4 (19) HAZARD 1 ( 25) Failure to follow safety warnings exactly could result in 1-1/4 (32) 1400...

  • Page 35: 115- -V Wiring

    115- -V Wiring 1. Fasten a field-supplied external electrical box to the outside of the casing by driving two field-supplied screws from in- Furnace must have a 115-v power supply properly connected and side electrical box into casing. See Fig. 31. grounded.

  • Page 36: Accessories

    operation. Use only AWG No. 18, color- -coded, copper thermostat 2. Humidifier (HUM) wire. The HUM terminal is a 24 VAC output, energized when the blower NOTE: Use AWG No. 18 color-coded copper thermostat wire for is operating during a call for heat. lengths up to 100 ft.
  • Page 37 GROUND NEUTRAL LINE VOLTAGE ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY ALUMINUM WIRE A12226 A11146 Fig. 30 - - Installing J- -Box (When Used) Fig. 31 - - Field- -Supplied Electrical Box on Furnace Casing Appearance May Vary...
  • Page 38 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. 32 - - Field- -supplied Isolation Relay for Humidifiers with Internal Power Supply W/W1 Y/Y2 A11401 Fig.
  • Page 39 COMMUNICATION CONTINUOUS FAN OUTDOOR SW4 SETUP (CF) AIRFLOW AIR TEMP SWITCHES CONNECTOR SETUP SWITCHES CONNECTOR MODEL PLUG PL8 - MODULATING CONNECTOR GAS VALVE CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF- DELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.
  • Page 40 THERMOSTAT THERMOSTAT See notes 2, 5, 7, 10, 11, 16, and 17 See notes 1, 2, 4, 6, 7, 9, 10, 11, 15, 16, and 17 Modulating and 2-Stage Furnace with Single-Speed Heat Pump Modulating and 2-Stage Furnace with Single-Speed Air Conditioner THERMOSTAT THERMOSTAT See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13, 15, 16, and 17...

  • Page 41: Venting

    NOTES FOR THERMOSTAT WIRING DIAGRAMS 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 with date code 1601E and later do not have or require a “ZONE”...

  • Page 42: Materials

    Other gas appliances with their own venting system may also use WARNING the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code and the vent or liner manufacturer’s installation instructions. Care must CARBON MONOXIDE POISONING HAZARD be taken to prevent the exhaust gases from one appliance from Failure to follow the steps outlined below for each appliance...

  • Page 43: Locating Vent Termination

    Table 12 – Vent Termination Kit for Direct Vent (2- -pipe) WARNING Systems DIRECT VENT DIAM. OF COMBUS- TERMINATION (2--- PIPE) TION AIR AND VENT SYSTEM CARBON MONOXIDE POISONING HAZARD TERMINATION KIT PIPES --- IN. (mm) 2 ---in. (51 mm) Single Penetration of 1, 1 ---1/2, 2, or 2 ---1/2 Failure to follow the instructions outlined below for each...

  • Page 44: Size The Vent And Combustion Air Pipes

    4. Termination or termination kit should be positioned where it stream and contaminate the incoming combustion air for the will not be damaged by or subjected to foreign objects such furnace. as stones, balls, etc. Refer to Fig. 49 for terminations approved for use in Alberta and 5.

  • Page 45: Combustion Air And Vent Piping Insulation Guidelines

    9. If the Total Vent Length is longer than the Maximum In any configuration, it will be necessary to add the equivalent length of the tee (15 feet/5 M) to the Total Equivalent Vent Length Equivalent Vent Length for the diameter of pipe chosen, of the venting system.
  • Page 46 Install the Vent and Combustion Air Pipes 4. Slide the end of the rubber vent coupling with notches in it over the standoffs on the vent pipe adapter. With the furnace installed in the required position, remove the 5. Insert a length of vent pipe through the coupling into the desired knockouts from the casing.

  • Page 47: Installing The Vent Termination

    termination elbows as shown in Fig. 47, 48 and 49. diameter (127 mm) flashing for a 3-inch (80 mm ND) concentric For Ventilated Combustion Air Termination, See Fig. 50. vent kit. For two-pipe or single pipe vent systems, a flashing for each pipe of the required diameter will be necessary.

  • Page 48: Combustion- -Air Vent Pipe, Fitting & Cement Material

    NOTE: Do not allow insulation or other materials to accumulate this instruction. inside of pipe assembly when installing it through hole. 1. Cut two holes, one for each pipe, of appropriate size for pipe size being used. 4. Locate assembly through sidewall with rain shield posi- tioned no more than 1- -in.

  • Page 49: Maximum Allowable Exposed Vent Lengths Insulation

    Table 14 – Maximum Allowable Exposed Vent Lengths Insulation Table - - Ft. / M Maximum Length of Uninsulated and Insulated Vent Pipe-Ft (M) No Insulation 3/8-in. (9.5 mm) 1/2-in. (12.7 mm) Modulating Pipe Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Winter Design Furnace High...

  • Page 50: Maximum Equivalent Vent Length

    NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 16 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 15 – Maximum Equivalent Vent Length - - Ft. (M) 0 to 4500 Ft.

  • Page 51: Venting System Length Calculations

    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 from Table 16. Standard vent terminations or factory accessory concentric vent terminations count for zero deduction. See vent system manufacturer’s data for equivalent lengths of flexible vent pipe or other termination systems.
  • Page 52 NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 16 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 17 – Maximum Equivalent Vent Length - - Ft. (M) 4501 to 10,000 Ft.
  • Page 53 Attach gaskets to vent pipe and Vent Coupling and Adapter combustion air adapters. A13074 Fig. 36 - - Vent Coupling and Adapter with Gaskets VENT ELBOW CLAMP TORQUE 15 LB-IN. INDUCER OUTLET VENT PIPE CLAMP TORQUE 15 LB-IN. MODULATING INDUCER ASSEMBLY VENT ELBOW A11286 Fig.
  • Page 54 Rotate vent elbow to required position. Any other unused knockout may be used for combustion air connection. Rotate vent elbow to required position. & UPFLOW LEFT CONFIGURATION DOWNFLOW LEFT CONFIGURATION A11309A A11311A Rotate vent elbow to required position. Any other unused Any other unused knockout may be used knockout may be used...
  • Page 55 ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL LEFT ---VERTICAL VENT CONFIGURATION HORIZONTAL RIGHT ---VERTICAL VENT CONFIGURATION A11327A A11337 Alternate combustion air connection. Rotate vent elbow to required position. Vent Pipe Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT ---LEFT VENT CONFIGURATION HORIZONAL LEFT ---LEFT VENT CONFIGURATION A11328A A11336...
  • Page 56 NOTES FOR VENTING OPTIONS 1. Attach vent pipe adapter with gasket to furnace casing. 2. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. 3. Slide vent pipe through adapter and coupling into vent elbow. 4.
  • Page 57 A12326 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. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony...
  • Page 58 A12325 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. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony or...
  • Page 59 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. 47 - - Combustion Air and Vent Pipe Termination for Direct Vent (2- -Pipe) System Roof Termination (Preferred) Vent Maintain 12 in...
  • Page 60 OPTIONAL TERMINATION BRACKET FOR 2-PIPE TERMINATIONS OPTIONAL 12 IN. (305 MM) MIN. BRACKET SEPARATION BETWEEN COUPLING BOTTOM OFCOMBUSTION 12 IN. (305 MM) MIN. SEPARATION AIR AND BOTTOM OF VENT. BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT. MAINTAIN 12 IN. (305 MM) CLEARANCE ABOVE HIGHEST ANTICIPATED 12-IN.
  • Page 61 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. 50 - - Vent Terminations for Ventilated Combustion Air...
  • Page 62 EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. A12220 Fig. 51 - - Sample Inlet Air Pipe Connection for Polypropylene Venting Systems TO CODE APPROVED DRAIN OR CONDENSATE PUMP Representative drawing only, some models may vary in appearance L12F028 Fig.

  • Page 63: Start- -Up, Adjustment, And Safety Check

    START- -UP, ADJUSTMENT, AND SAFETY Setup Switches (SW1) CHECK The furnace control has 8 setup switches that may be set to meet the application requirements. Refer to Fig. 57 and the Adjustments NOTICE section for setup switch configurations. To set these setup switches for the appropriate requirement: 1.

  • Page 64: Prime Condensate Trap

    Adjustments 4. Replace blower door. Prime Condensate Trap with Water CAUTION WARNING FURNACE DAMAGE HAZARD CARBON MONOXIDE POISONING HAZARD Failure to follow this caution could result in reduced furnace life. Failure to follow these warnings could result in personal injury DO NOT push or force gas valve adjusting screw.
  • Page 65 In Canada, the input rating must be reduced by 5 percent for NOTE: To convert gas manifold Table pressures to Pascals, altitudes of 2000 ft. (609.6M) to 4500 ft. (1371.6M) above sea multiply the in. w.c. value by 249.1 Pa/in. w.c. (1 in. w.c. = 249.1 level.
  • Page 66 Clocking The Meter 1. Make sure the gas supply is turned off to the furnace and at the electric switch on the gas valve. Verify natural gas input rate by clocking meter. 2. Remove the 1/8 inch NPT plug from the outlet pressure tap NOTE: Contact your HVAC distributor or gas supplier for metric on the gas valve.
  • Page 67 4. Check the position of setup switch SW1- -3. When set to CAUTION ON, airflow is raised 18% for Minimum Heat and for Intermediate Heat. Factory default position is OFF. 5. Turn 115 VAC power on. FURNACE DAMAGE HAZARD 6. Re- -check Minimum Heat Temperature Rise Failure to follow this caution may result in: S Overheating the heat exchangers or condensing flue gases To lock the furnace in Intermediate Heat:...

  • Page 68: Check Safety Controls

    R- -W/W1 circuit. Accurate amp. draw readings can be CAUTION obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat anticipator should NOT be in the circuit while measuring current. FURNACE OVERHEATING HAZARD a. Set SW1- -2 switch on furnace control board to ON. Failure to follow this caution may result in reduced furnace b.
  • Page 69 MODULATING ON/OFF Switch Min/Max Heat Adust (Under Cap) Turn screw 1 click per second to adjust rate. Clockwise to increase rate, counter clockwise to decrease rate. Inlet Pressure Tap BURNER ORIFICE 1/2” NPT Outlet Manifold Pressure Tap A10496 A93059 Fig. 53 - - Gas Valve Fig.
  • Page 70 338307-201 Rev. F A11594 Fig. 56 - - Service Label Information...
  • Page 71 A11623 Fig. 56 - - Furnace Setup Switches and Description...
  • Page 72 Furnace Setup Switch Description Turn ON to retrieve up to 7 stored status codes for SW1-1 Status Code Recovery troubleshooting assistance when R thermostat lead is disconnected. When SW1-2 and SW4-2 are OFF allows Modulating operation Minimum Heat Only with a single stage thermostat. Turn ON SW1-2 when using (Adaptive Heat Mode two-stage thermostat to allow Minimum Heat operation when SW1-2...

  • Page 73: Altitude Derate Multiplier For U.s.a

    Table 18 – Altitude Derate Multiplier for U.S.A.* Table 19 – Blower Off Delay Setup Switch PERCENT DERATE SETUP SWITCH ALTITUDE MULTIPLIER (SW1---7 AND ---8) DESIRED HEATING MODE DERATE FACTOR* POSITION BLOWER OFF DELAY (SEC.) 0–2000 0---610 1.00 SW1--- 7 SW1--- 8 2001–3000 610---914...
  • Page 74 Table 21 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate To Be Used with Modulating Furnaces Except 59MN7A060V21- -20 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
  • Page 75 Table 21- - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) To Be Used with Modulating Furnaces Except 59MN7A060V21- -20 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...

  • Page 76: Orifice Size And Manifold Pressure

    Table 22 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate To Be Used with Modulating Furnaces 59MN7A060V21- -20 Only (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
  • Page 77 Table 22 - - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) To Be Used with Modulating Furnaces 59MN7A060V21- -20 Only (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...

  • Page 78: Service And Maintenance Procedures

    SERVICE AND MAINTENANCE Electrical Controls and Wiring PROCEDURES WARNING Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be ELECTRICAL SHOCK HAZARD performed by trained service personnel. A qualified service person should inspect the furnace once a year.
  • Page 79 Care and Maintenance 2. Turn Setup Switch, SW1- -1 “ON.” 3. Manually close blower door switch. WARNING 4. Control will flash up to 7 Status Codes. 5. The last Status Code, or 8th Code, will be Code 11. FIRE OR EXPLOSION HAZARD 6.
  • Page 80 3. Check electrical connections for tightness and controls for The inducer and blower motors are pre- -lubricated and require no proper operation each heating season. Service as necessary. additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor. 4.
  • Page 81 13. Reinstall blower assembly in furnace. Refer to Fig. 63. 14. Reinstall 2 screws securing blower assembly to blower 1. Disconnect power at external disconnect, fuse or circuit deck. breaker. 15. Reconnect blower leads to furnace control. Refer to furnace 2.
  • Page 82 Flushing Collector Box and Drainage System NOTE: Use propane-resistant pipe dope to prevent leaks. Do not use Teflon tape. WARNING 13. Install the gas pipe to the gas valve. WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury, FIRE OR EXPLOSION HAZARD death, and/or property damage.

  • Page 83: Cleaning Heat Exchangers

    3. Align the condensate trap with the drain opening on the col- WARNING lector box and secure the trap with the screw 4. Attach the relief hose to the relief port on the condensate trap and collector box. ELECTRICAL SHOCK, FIRE OR EXPLOSION 5.
  • Page 84 9. Remove the middle unused rubber plug from the port on the WARNING collector box opposite the condensate trap. See Fig. 60. 10. Repeat Steps 5 through 8. FIRE OR EXPLOSION HAZARD 11. If a condensate pump is used, check with pump manufacturer to verify pump is safe for use with antifreeze Failure to follow this warning could result in personal used.
  • Page 85 1-1/4-in. (31.8) 2-1/2-in. (64.4) A11405 A11273 Fig. 58 - - Igniter Position - - Top View Fig. 61 - - Cleaning Heat Exchanger Cell Burner Flame 2 − in. 50 mm Burner 3/8 − in. 9.6 mm 3/16 − in. 4.6 mm Manifold 3/32 −...
  • Page 86 GROMMET MOTOR SHAFT FLAT MOTOR ARM SCREW SET SCREW MOTOR WHEEL HUB SEE DETAIL SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT DETAIL CUTOFF, BLOWER WHEEL, BLOWER BLOWER HSG ASSY BRACKET CAPACITOR OR POWER CHOKE (WHEN USED) MOTOR, BLOWER SCREW (GND) A11584 Fig.
  • Page 87 A11290A Fig. 65 - - Troubleshooting Guide...
  • Page 88 A11290B...
  • Page 89 A11290C...

  • Page 90: Sequence Of Operation

    SEQUENCE OF OPERATION This selection is based upon the stored history of the length of previous gas-heating periods of the single-stage thermostat. CAUTION The furnace will start up in either intermediate-, or maximum-heat. The furnace will transition and operate at minimum-heat or the calculated modulating rate after starting and operating for 45 UNIT OPERATION HAZARD seconds at intermediate-heat.
  • Page 91 CPU will repeat the ignition sequence for up to three more inducer motor RPM. The blower motor BLWM will trans- Trials-For-Ignition before going to Ignition-Lockout. Lock- ition to the maximum-heat airflow five seconds after the out will be reset automatically after three hours, or by mo- furnace control CPU switches from a medium range input mentarily interrupting 115 vac power to the furnace, or by to maximum-heat.
  • Page 92 inducer motor speed gets within 15% of the required inter- NOTE: The air conditioning relay disable jumper ACRDJ must be mediate-heat RPM the furnace control CPU will start a 5 connected to enable the adaptive cooling mode in response to a call second blower airflow change delay.
  • Page 93 DHUM. When there is a dehumidify demand, the DHUM input is motor BLWM will remain ON until the main burners ignite then activated, which means 24 vac signal is removed from the DHUM shut OFF and remain OFF for the blower-ON delay (45 seconds in input terminal.
  • Page 94 338307--- 201 REV. F A13334 Fig. 66 - - Wiring Diagram...

  • Page 95: Parts Replacement Guide

    CARRIER CORPORATION Consumer Relations Department P.O. Box 4808 Syracuse, New York 13221 1- -800- -CARRIER Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part. Model Nomenclature COOLING HEATING...
  • Page 96 Catalog No:59MN7A ---07SI Copyright 2013 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 11/13 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: 59MN7A--- 06SI...

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