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

4-way multipoise fixed-capacity direct-vent condensing gas furnace, series 140 (limited)
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Installation, Start-Up, and Operating Instructions
For Sizes 040-140, Series 140 (LIMITED)
DIMENSIONAL DRAWING........................................................2
SAFETY CONSIDERATIONS .....................................................3
Clearances to Combustibles......................................................3
INTRODUCTION ..........................................................................4
APPLICATIONS ......................................................................5-12
General ......................................................................................5
Upflow Applications..............................................................5-7
Downflow Applications.........................................................7-8
LOCATION ............................................................................12-13
General ....................................................................................12
Hazardous Locations...............................................................13
INSTALLATION....................................................................13-17
Leveling Legs (If Desired) .....................................................13
Installation In Horizontal Applications ..................................15
Filter Arrangement..................................................................16
Bottom Closure Panel.............................................................16
Gas Piping..........................................................................16-17
AIR DUCTS............................................................................17-18
General Requirements.............................................................17
Ductwork Acoustical Treatment.............................................18
Supply Air Connections..........................................................18
Return Air Connections ..........................................................18
ELECTRICAL CONNECTIONS...........................................18-19
115-v Wiring......................................................................18-19
24-v Wiring.............................................................................19
Accessories..............................................................................19
DIRECT VENTING ...............................................................19-29
Common Vent Systems................................................19-21
Combustion-Air and Vent Piping .....................................21-27
Kit Installation ...................................................................28
Multiventing and Vent Termination.......................................28
CONDENSATE DRAIN ........................................................30-32
General ....................................................................................30
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-758
Tab 6a 8a
4-Way Multipoise Fixed-Capacity
Direct-Vent Condensing Gas Furnace
A93040
As an ENERGY STAR®
Partner, Carrier Corpora-
tion has determined that
Page
this product meets the EN-
ERGY STAR® guidelines
for energy efficiency.
AIRFLOW
Application ..............................................................................30
Condensate Drain Protection ..................................................32
SEQUENCE OF OPERATION..............................................32-34
Heating Mode..........................................................................32
Cooling Mode .........................................................................32
Continuous Blower Mode.......................................................33
Heat Pump Mode ....................................................................33
Component Test ......................................................................33
START-UP PROCEDURES ..................................................34-42
General ....................................................................................34
Prime Condensate Trap With Water ......................................34
Purge Gas Lines......................................................................34
Adjustments .......................................................................35-42
Set Gas Input Rate ............................................................35-41
Set Temperature Rise ........................................................41-42
Blower Off Delay (Heat Mode) .............................................42
Set Thermostat Heat Anticipator............................................42
CHECK SAFETY CONTROLS..................................................42
Check Primary Limit Control.................................................42
Check Pressure Switch ...........................................................42
CHECKLIST ................................................................................43
Printed in U.S.A.
Form 58MCA-7SI
ama
REGISTERED QUALITY SYSTEM
AIRFLOW
UPFLOW
HORIZONTAL
LEFT
DOWNFLOW
AIRFLOW
Fig. 1-Multipoise Orientations
Pg 1
58MCA
CERTIFIED
HORIZONTAL
RIGHT
AIRFLOW
A93041
1-00
Replaces: New

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  • Page 1: Table Of Contents

    For Sizes 040-140, Series 140 (LIMITED) CERTIFIED A93040 NOTE: Read the entire instruction manual before starting the As an ENERGY STAR® installation. Partner, Carrier Corpora- tion has determined that Index Page this product meets the EN- REGISTERED QUALITY SYSTEM ERGY STAR® guidelines for energy efficiency.

  • Page 3: Safety Considerations

    SAFETY CONSIDERATIONS In Canada, refer to the current edition of the CAN/CGA-B149.1- and .2-M95 National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC). Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified person- Wear safety glasses and work gloves.

  • Page 4: Electrostatic Discharge (Esd) Precautions

    In some instances, these instructions exceed certain local codes propane gas. The 58MCA 040 through 120 size units are and ordinances, especially those that may not have kept pace with A.G.A./C.G.A.

  • Page 5: Applications

    FURNACE BLOWER SHELF CONDENSATE DOOR TRAP FURNACE CONDENSATE DOOR FURNACE TRAP (INSIDE) FURNACE SIDE SIDE FIELD FIELD DRAIN DRAIN CONN CONN ALTERNATE DRAIN TUBE LOCATION SIDE VIEW FRONT VIEW END VIEW FRONT VIEW CONDENSATE TRAP DRAIN TUBE LOCATION HORIZONTAL DOWNFLOW AND ALTERNATE UPFLOW APPLICATIONS APPLICATIONS EXTERNAL UPFLOW APPLICATIONS...
  • Page 6 PLUG COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) PLUG COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) INDUCER HOUSING (MOLDED) DRAIN COLLECTOR BOX TUBE (BEHIND TUBE (PINK) COLLECTOR BOX DRAIN TUBE) COLLECTOR BOX COLLECTOR BOX TUBE (GREEN)

  • Page 7: Downflow Applications

    CONDENSATE TRAP TUBING (ALTERNATE UPFLOW NOTE: See Fig. 5 or 6 or tube routing label on main furnace door ORIENTATION) to check for proper connections. NOTE: See Fig. 6 or tube routing label on main furnace door to UPPER COLLECTOR BOX AND INDUCER HOUSING (UN- confirm location of these tubes.

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

    1. Remove 3 tubes connected to condensate trap. (2.) Condensate Trap Located on Right Side of Casing 2. Remove trap from blower shelf by gently pushing tabs inward (a.) Route inducer housing drain tube (violet label) and rotating trap. directly from inducer housing to condensate trap as shown in Fig.
  • Page 9 CONDENSATE TRAP LOCATION d. Clamp tube to prevent any condensate leakage. The condensate trap must be removed from the factory-installed 2. Inducer Housing Drain Tube blower shelf location and relocated in selected application location a. Remove and discard LOWER (molded) inducer housing as shown in Fig.

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

    COMBUSTION – AIR INTAKE VENT A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE. 30 MIN WORK AREA ⁄ MANUAL SHUTOFF ACCESS OPENING GAS VALVE FOR TRAP DRAIN...
  • Page 11 COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE PLUG COLLECTOR BOX TUBE (PINK) CONDENSATE TRAP COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX EXTENSION TUBE A93303 Fig. 11—Horizontal Right Tube Configuration 4.

  • Page 12: Location

    6. Route this extended tube (pink label) to condensate trap relief port connection. 7. Determine appropriate length, cut, and connect tube. 8. Clamp tube to relief port connection. CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain Protection section for recommenda- tions and procedures.

  • Page 13: Furnace Location Relative To Cooling Equipment

    INSTALLATION Step 1—Leveling Legs (If Desired) When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 12.) Install field-supplied, corrosion-resistant 5/16-in. machine bolts and nuts. ⁄ 32 F MINIMUM INSTALLED AMBIENT OR FREEZE ⁄...
  • Page 14 PLENUM OPENING FLOOR OPENING A96283 Fig. 13—Floor and Plenum Opening Dimensions FURNACE FURNACE (OR COIL CASING WHEN USED) CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING DOWNFLOW SUBBASE SHEET METAL PLENUM SHEET METAL PLENUM FLOOR FLOOR OPENING OPENING...

  • Page 15: Installation In Horizontal Applications

    duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 16.) Do not bend duct flanges inward as shown in Fig. 16. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure.

  • Page 16: Filter Arrangement

    ⁄ -IN. WIDE ⁄ -IN. WIDE CASINGS ONLY: CASINGS ONLY: CUT AND FOLD The entire length of furnace MUST be supported when INSTALL FIELD-SUPPLIED FACTORY-PROVIDED furnace is used in a horizontal position to ensure proper FILTER FILLER STRIP FILTERS AS SHOWN draining.

  • Page 17: Air Ducts

    SUPPLY MANUAL SHUTOFF VALVE (REQUIRED) SEDIMENT TRAP UNION BOTTOM CLOSURE PANEL FRONT FILLER PANEL A93324 A93047 Fig. 21—Typical Gas Pipe Arrangement Fig. 20—Removing Bottom Closure Panel If a flexible connector is required or allowed by authority Gas valve shutoff switch MUST be facing forward or tilted having jurisdiction, black iron pipe shall be installed at gas upward.

  • Page 18: Ductwork Acoustical Treatment

    Step 4—Return Air Connections through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor UPFLOW FURNACES barrier is recommended. The return-air duct must be connected to bottom , sides (left or Maintain a 1-in. clearance from combustible materials to supply air right), or a combination of bottom and side(s) of main furnace ductwork for a distance of 36 in.

  • Page 19: 24-V Wiring

    DIRECT VENTING J-Box Relocation The 58MCA Furnaces require a dedicated (one 58MCA furnace 1. Remove 2 screws holding auxiliary J-box. (See Fig. 23.) only) direct-vent system. In a direct-vent system, all air for 2.
  • Page 20 TRAN COOL HEAT...

  • Page 21: Combustion-Air And Vent Piping

    Table 4—Electrical Data OPERATING VOLTS— MAX WIRE MAX FUSE UNIT UNIT VOLTAGE RANGE HERTZ— UNIT WIRE LENGTH OR CKT BKR SIZE AMPACITY† PHASE AMPS SIZE (FT)‡ AMPS** Max* Min* 040-08 115—60—1 040-12 115—60—1 10.0 060-08 115—60—1 060-12 115—60—1 060-16 115—60—1 12.8 080-12 115—60—1...
  • Page 22 † 18 in. above roof surface in Canada. ‡ 36 in. to electric meter in Canada only. NOTES: FURNACE 1. If installing 2 adjacent 58MCA Furnaces, refer to Multivent- ing and Vent Terminations section for proper vent configura- tions. 2. When locating combustion-air and vent terminations, consid-...
  • Page 23 NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and 1 combustion-air pipe connection. 1 combustion-air pipe connection. EXAMPLE: An 080-12 size furnace located in Indianapolis, elevation FLOW 650 ft above sea level, could be installed in an application COMBUSTION- COMBUSTION- VENT...
  • Page 24 12 MIN 12 MIN VENT PIPE VENT PIPE COMBUSTION-AIR PIPE COMBUSTION-AIR PIPE HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL COMBUSTION-AIR PIPE VENT PIPE COMBUSTION-AIR PIPE 12 MIN 12 MIN VENT PIPE VERTICAL TO ROOF VERTICAL TO SIDEWALL NOTE: A 12 In. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems.
  • Page 25 Table 6—Maximum Allowable Pipe Length (Ft) NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE UNIT SIZE TYPE (IN.)* 040-08 2 Pipe or 2-In. 1-1/2 040-12 Concentric 060-08 1-1/2 2 Pipe or 2-In. 060-12 Concentric 060-16 1-1/2 080-12 2 Pipe or 2-In. 080-16 Concentric 080-20...
  • Page 26 Table 6—Maximum Allowable Pipe Length (Ft) Continued NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE UNIT SIZE TYPE (IN.)* 1-1/2 040-08 2 Pipe or 2-In. 040-12 Concentric 060-08 1-1/2 2 Pipe or 2-In. 060-12 Concentric 060-16 080-12 2 Pipe or 2-In. 080-16 Concentric 2-1/2...
  • Page 27 Table 6—Maximum Allowable Pipe Length (Ft) Continued NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE UNIT SIZE TYPE (IN.)* 1-1/2 040-08 2 Pipe or 2-In. 040-12 Concentric 060-08 1-1/2 2 Pipe or 2-In. 060-12 Concentric 060-16 080-12 2 Pipe or 2-In. 8001 to 080-16 Concentric...

  • Page 28: Concentric Vent And Combustion-Air Termination Kit Installation

    Step 4—Multiventing and Vent Terminations affected by wind eddy (such as inside building corners) or When 2 or more 58MCA Furnaces are vented near each other, each allow recirculation of flue gases, airborne leaves, or light furnace must be individually vented. NEVER common vent or snow.
  • Page 29 ROOF 18 MAXIMUM BRACKET COUPLING COMBUSTION VERTICAL SEPARATION VENT BETWEEN COMBUSTION AIR AND VENT 8 3 / 4 FOR 3 KIT 6 3 / 4 FOR 2 KIT MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. A87224 Fig.

  • Page 30: Condensate Drain

    Table 7—Maximum Allowable Exposed Vent Pipe Length (Ft) With and Without Insulation in Winter Design Temperature Ambient* WINTER DESIGN MAX PIPE UNIT WITHOUT WITH 3/8-IN. OR TEMPERATURE DIAMETER SIZE INSULATION THICKER INSULATION† (°F) (IN.) 2-1/2 2-1/2 2-1/2 * Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 6.
  • Page 31 A96128 Fig. 35—Rooftop Termination (Dimension "A" is Touching or 2-In. Maximum Separation) 1 MAXIMUM VENT (TYP) VENT COMBUSTION AIR VENT COMBUSTION VENT A93056 A93057 Fig. 36—Concentric Vent and Combustion-Air Fig. 37—Concentric Vent and Combustion-Air Roof Termination Side Termination (Dimension "A" is Touching or 2-In. Maximum Sepa- (Dimension "A"...

  • Page 32: Condensate Drain Protection

    CONDENSATE TRAP WIRE TIE(S) OPEN STAND PIPE FOR A/C OR HUMIDIFIER DRAIN HEAT TAPE (3 WRAPS MINIMUM) A93036 TO OPEN Fig. 41—Condensate Trap Heat Tape DRAIN Step 1—Heating Mode When wall thermostat calls for heat, R-W circuit closes. Furnace control performs a self-check, verifies pressure switch contacts are open, and starts inducer motor.

  • Page 33: Continuous Blower Mode

    When thermostat is satisfied, R-G and R-Y circuits are opened, 3. Hot surface ignitor is energized for 15 sec, then de-energized. furnace blower continues operating on cooling speed for an 4. Main blower operates at HEAT speed for 10 sec, then turns additional 90 sec.

  • Page 34: Start-Up Procedures

    A99118 A99119 Fig. 42—Inducer Housing Drain Tube Fig. 43—Filling Condensate Trap Step 2—Prime Condensate Trap with Water 6. After component test is completed and furnace is operating properly, release blower access panel door switch, replace blower access panel, and replace main furnace door. START-UP PROCEDURES Condensate trap must be PRIMED or proper draining may not occur.

  • Page 35: Adjustments

    58MCA furnaces with heating sizes of 040 through 120. d. Replace gas valve regulator adjustment screw cap. Table 9 can only be used for model 58MCA furnaces with e. Replace burner enclosure front and verify adjusted gas a 140 heating size.
  • Page 36 Table 8—Model 58MCA Orifice Size and Manifold Pressure for Correct Input For Use with 040 through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) * SPECIFIC GRAVITY OF NATURAL GAS...
  • Page 37 Table 8—Model 58MCA Orifice Size and Manifold Pressure for Correct Input (Continued) For Use with 040 through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) * SPECIFIC GRAVITY OF NATURAL GAS...
  • Page 38 Table 8—Model 58MCA Orifice Size and Manifold Pressure for Correct Input (Continued) For Use with 040 through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) * SPECIFIC GRAVITY OF NATURAL GAS...
  • Page 39 Table 9—Model 58MCA Orifice Size and Manifold Pressure for Correct Input For Use with 140 Size Furnaces Only (Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) * SPECIFIC GRAVITY OF NATURAL GAS...
  • Page 40 Table 9—Model 58MCA Orifice Size and Manifold Pressure for Correct Input (Continued) For Use with 140 Size Furnaces Only (Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) * SPECIFIC GRAVITY OF NATURAL GAS...

  • Page 41: Set Temperature Rise

    Table 10—Altitude Derate Multiplier for U.S.A. ON AND ALTITUDE % OF DERATE MULTIPLIER OFF SWITCH (FT) DERATE FACTOR FOR U.S.A.* 0—2000 1.00 2001—3000 4—6 0.95 PRESSURE REGULATOR 3001—4000 6—8 0.93 ADJUSTMENT 4001—5000 8—10 0.91 5001—6000 10—12 0.89 BURNER 6001—7000 12—14 0.87 ENCLOSURE 7001—8000...

  • Page 42: Blower Off Delay (Heat Mode)

    SET THERMOSTAT HEAT ANTICIPATOR Thermostat heat anticipator must be set to match amp draw of Disconnect 115-v electrical power before changing speed tap. components in R-W circuit. Accurate amp draw measurements can Failure to follow this warning could result in personal injury. be obtained at thermostat subbase terminals R and W.

  • Page 43: Checklist

    CHECKLIST 4. Cycle test furnace with room thermostat. 1. Put away tools and instruments. Clean up debris. 5. Check operation of accessories per manufacturer’s instruc- tions. 2. Verify manual reset switch has continuity. 6. Review User’s Guide with owner. 3. Verify that blower and control access doors are properly installed.
  • Page 44 Pressure Switch ________ Low-Ambient Exposed Pipes Copyright 2000 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58mca7si Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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