Carrier Infinity ICS 58MVC Installation Instructions Manual

Direct vent 4-way multipoise condensing gas furnace with idealcomfortt idealhumidity

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Installation Instructions

PAGE

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As an ENERGY STAR® Partner,

Carrier Corporation has deter-

mined that this product meets

the ENERGY STAR® guidelines

for energy efficiency.

HORIZONTAL

AIRFLOW

. .

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit damage.

Improper installation or misapplication of furnace may

require excessive servicing or cause premature component

failure. This furnace can be vented as either a direct vent

(2- -pipe) furnace or as an optional ventilated combustion air

Application.

A direct vent system shall be installed in accordance with

the direct vent (2- -pipe) procedures in the Combustion Air

and Vent Pipe Systems section within this instruction. For

optional ventilated combustion air applications, refer to the

ventilated combustion air option procedures in the same

section.

Application of this furnace should be indoors with special

attention given to vent sizing and material, gas input rate,

air temperature rise, unit leveling, and unit sizing.

ama

ISO 9001:2000

REGISTERED

AIRFLOW

UPFLOW

HORIZONTAL

LEFT

RIGHT

DOWNFLOW

AIRFLOW

Fig. 1 - - Furnace Orientation

CAUTION

CERTIFIED

AIRFLOW

A93041

Table of Contents

Summary of Contents for Carrier Infinity ICS 58MVC

Page 1 Vent components supplied with the furnace and components in As an ENERGY STAR® Partner, factory authorized vent kits may be used with ULC- -S636 Carrier Corporation has deter- mined that this product meets certified vent systems. the ENERGY STAR® guidelines The ULC- -S636 certified plastic components, and specified for energy efficiency.
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 CAUTION CUT HAZARD Failure to follow this caution may result in personal injury. FURNACE RELIABILITY HAZARD Sheet metal parts may have sharp edges or burrs. Use care Improper installation or misapplication of furnace may and wear appropriate protective clothing and gloves when require excessive servicing or cause premature component handling parts.
Page 4 " ⁄ ⁄ " ⁄ " " ⁄ AIRFLOW " ⁄ " ⁄ " ⁄ ⁄ " " ⁄ 19" ⁄ " " " 2-IN. COMBUSTION- " CONDENSATE DRAIN ⁄ AIR CONN OUTLET OUTLET TRAP LOCATION (DOWNFLOW & CONDENSATE DRAIN HORIZONTAL LEFT) 2-IN.
Page 5 debris from all HVAC system components after In a direct- -vent system, all air for combustion is taken directly construction is completed. from the outside atmosphere and all flue products are discharged to the outside atmosphere. See furnace and factory accessory After construction is complete, verify furnace operating termination kit instructions for proper installation.
Page 6: Codes And Standards
CODES AND STANDARDS Installer Packet Includes: Installation, Start--- up, and Operating Instructions Follow all national and local codes and standards in addition Service and Maintenance Instructions to these instructions. The installation must comply with regulations of the serving gas supplier, local building, heating, User’s Information Manual plumbing, and other codes.
Page 7: Electrostatic Discharge (Esd) Precautions
drain and pressure tubes are connected as shown in Fig. 7. See The use of copper tubing for gas piping is not approved appropriate application instructions for these procedures. by the state of Massachusetts. Electrical Connections CAUTION US: National Electrical Code (NEC) ANSI/NFPA 70- -2005.
Page 8 FURNACE BLOWER SHELF CONDENSATE DOOR TRAP FURNACE CONDENSATE DOOR FURNACE TRAP (INSIDE) FURNACE SIDE SIDE (124mm) (146mm) (146mm) FIELD FIELD (667mm) (19mm) DRAIN DRAIN (667mm) (38mm) CONN CONN ALTERNATE DRAIN TUBE LOCATION SIDE VIEW FRONT VIEW END VIEW FRONT VIEW CONDENSATE TRAP DRAIN TUBE LOCATION HORIZONTAL...
Page 9 PLUG COLLECTOR BOX PLUG DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX DRAIN TUBE (BLUE & COLLECTOR BOX WHITE STRIPED) TUBE (PINK) INDUCER HOUSING (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX COLLECTOR BOX TUBE (PINK) DRAIN TUBE) COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX COLLECTOR BOX TUBE (GREEN...
Page 10: Downflow
COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) PLUG COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE) TUBE (GREEN) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (PINK) PLUG COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE & DRAIN TUBE (BLUE & WHITE STRIPED) WHITE STRIPED) COLLECTOR BOX...
Page 11: Horizontal Left
b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to condensate trap. PLUG COLLECTOR BOX AUXILIARY “J” BOX DRAIN TUBE (BLUE & WHITE STRIPED) CONDENSATE COLLECTOR BOX TRAP TUBE (GREEN) INDUCER HOUSING COLLECTOR BOX (MOLDED) DRAIN TUBE EXTENSION TUBE (VIOLET) COLLECTOR BOX...
Page 12 COMBUSTION – AIR A 3-IN. MINIMUM CLEARANCE VENT INTAKE TO COMBUSTION-AIR INTAKE VENT IS REQUIRED. COMBUSTION–AIR INTAKE A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE TO REDUCE EXCESSIVE...
Page 13: Horizontal Right
1. Disconnect collector box pressure tube (pink label) Condensate Trap Location attached to High Pressure Switch. PLUG 2. Use smaller diameter tube (factory- -suppled in loose pars COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE) TUBE (GREEN) bag) to extend tube disconnected in Item 1. COLLECTOR BOX TUBE (PINK) 3.
Page 14: Location
Condensate Trap Tubing Condensate Trap Freeze Protection NOTE: See Fig. 14 or tube routing label on main furnace door Refer condensate Drain Protection section recommendations and procedures. to check for proper connections. Construct a Working Platform 1. Collector Box DrainTube Construct working platform where all required furnace clearances a.
Page 15 WARNING FRONT FIRE OR DEATH HAZARD Failure to follow this warning could result in property damage, personal injury, or death. Do not install furnace on its back. (See Fig. 16.) Safety control operation will be adversely affected. Never connect return- -air ducts to back of furnace. BACK The furnace and its return air system shall be designed and installed so that negative pressure created by the air circulating...
Page 16: Installation
Hazardous Locations 4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement. WARNING NOTE: Bottom closure must be used when leveling legs are used. See Bottom Closure Panel section. FIRE, EXPLOSION, INJURY OR DEATH Installation in Upflow or Downflow Applications HAZARD NOTE: For downflow applications, this furnace is approved for Improper location or inadequate protection could result in...
Page 17 FURNACE FACTORY SUPPLIED CASED COIL OR COIL BOX COMBUSTIBLE FLOORING PLENUM OPENING SHEET METAL FLOOR PLENUM OPENING FLOOR OPENING A96283 A07586 Fig. 19 - - Floor and Plenum Opening Dimensions Fig. 21 - - Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor FURNACE PERFORATED...
Page 18 -IN. ROD ANGLE ″ IRON OR EQUIVALENT ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX DRAIN (A) ROD LOCATION USING DIMPLE LOCATORS -IN. MAX -IN. HEX NUT (SEE DIMENSIONAL ALTERNATE SUPPORT & WASHER (4) DWG FOR LOCATION FROM BACK LOCATIONS) REQD PER ROD NOTES: 1.
Page 19: Air Ducts
Table 1 – Opening Dimensions (in./mm) APPLICATION FURNACE PLENUM OPENING FLOOR OPENING (APPROVED FACTORY SUPPLIED CASED COILS AND COIL BOX: CASING CD5, CKR, CAPVP, CARVP, CAPMP, CARMP, CNPVP, CNRVP, AND WIDTH KCAKC) 16 in./ 24- -1/8 in./ 16- -5/8 in./ 24- -3/4 in./ Upflow Applications on Combustible or Noncombustible Flooring (KGASB subbase not required)
Page 20 humidifier, or other accessories. All accessories MUST be CAUTION connected external to furnace main casing. Return Air Connections CUT HAZARD WARNING Failure to follow this caution may result in personal injury. Use care when cutting support rods in filters to protect FIRE HAZARD against flying pieces and sharp rod ends.
Page 21 NOTE: Remove and discard bottom closure panel when bottom WASHABLE FILTER inlet is used. Bottom Closure Panel These furnaces are shipped with bottom closure panel installed in FILTER bottom return- -air opening. This panel MUST be in place when RETAINER side return air is used.
Page 22 BOTTOM CLOSURE PANEL FRONT FILLER PANEL A93047 Fig. 26 - - Removing Bottom Closure Panel SUPPLY MANUAL SHUTOFF VALVE (REQUIRED) SEDIMENT TRAP UNION A93324 Fig. 27 - - Typical Gas Pipe Arrangement COMBUSTION-AIR PIPE GROMMET UNUSED 1-3/4 -IN. DIAMETER GAS COMBUSTION CONN.
Page 23 Table 3 – Maximum Capacity of Pipe* WARNING NOMINAL LENGTH OF PIPE (FT/M) INTERNAL IRON UNIT MAY NOT OPERATE DIAMETER PIPE (IN.) SIZE Failure to follow this caution may result in intermittent 12.2 15.2 (IN.) unit operation. 0.622 Furnace control must be grounded for proper operation 0.824 or control will lock out.
Page 24 FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-, 208/230-, 460-V WIRING NOTE 5 THERMOSTAT FIVE TERMINALS FIELD-SUPPLIED WIRE DISCONNECT THREE-WIRE HEATING 208/230- OR ONLY 460-V THREE PHASE W/W1 115-V NOTE SINGLE PHASE 208/230-V SINGLE AUXILIARY PHASE 115-V J-BOX...
Page 25 Install power entry hole filler plugs (factory- -supplied in loose 24- -v wiring parts bag) in unused power entry holes. (See Fig. 31.) Make field 24- -v thermostat connections at 24- -v terminal block on furnace control. Y wire from thermostat MUST be connected to Y/Y2 terminal on control, as shown in Fig.
Page 26: Air For Combustion And Ventilation
Combustion- -Air and Vent Pipe Systems properly insulated and supported combustion- -air (when For additional venting information contact www.Carrier.com. applicable) and vent pipes. Each furnace must have its own set of General combustion- -air and vent pipes and be terminated individually, as shown in Fig.
Page 27 Table 5 – Approved Combustion- -Air and Vent Pipe, Fitting and Cement Materials ASTM SOLVENT SPECIFICATION MATERIAL PIPE FITTINGS DESCRIPTION CEMENT (MARKED ON AND PRIMERS MATERIAL) D1527 Pipe — — Schedule40 D1785 Pipe — — Schedule40 D2235 For ABS — —...
Page 28 USER INTERFACE CONTINUOUS FAN SW4 SETUP OR ADVANCED (CF) AIRFLOW SWITCHES PRODUCT SETUP SWITCHES MODEL PLUG CONNECTOR MONITOR CONNECTOR CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF- DELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX. ACRDJ – AIR CONDITIONING RELAY DISABLE JUMPER...
Page 29 12 inches (30 cm) for applieances >10,000 Btuh(3 kW) and < 100,000 Btuh(30kW), 36 inches (91cm) for appliances > 100,000 Btuh(30kW) A06675 Fig. 34 - - Direct Vent Termination Clearance...
Page 30 A05013 Fig. 35 - - Ventilated Combustion Air Vent Termination Clearance...
Page 31 Roof T e rmination (Preferred) At least 36 in. Concentric Vent and Combustion Air Roof Termination (preferred) Vertical separation between combustion At least air and vent 36 in. Maintain 12 8 3/4 in. for 3 in. kit min. clearance above 18 in.
Page 32: Combustion Air Pipe
NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and 1 combustion-air pipe connection. 1 combustion-air pipe connection. FLOW COMBUSTION- COMBUSTION- FURNACE VENT VENT VENT VENT NOT IN HORIZONTAL SECTION COMBUSTION- COMBUSTION- PIPE DIAMETER TRANSITION IN FLOW VERTICAL SECTION UPFLOW...
Page 33 COMBUSTION AIR CAUTION INTAKE HOUSING 3/8" ID TUBE BURNER UNIT CORROSION HAZARD Failure to follow this caution may result in reduced furnace component life. Air for combustion must not be contaminated by halogen 3/16" compounds, which include fluoride, chloride, bromide, and DRILL COMBUSTION iodide.
Page 34: Vent Pipe
VENT PIPE Crawlspace terminations require the open end of the combustion air intake pipe to point downward. Maintain 3 inches (76.2mm) General of clearance below the floor joist insulation and 12 inches Furnace vent connection must be attached as shown in Fig. 39. (304.8mm) above the grade.
Page 35 (304.8mm) minimum A06672 Fig. 41 - - Attic Termination (76.2 mm) minimum (304.8 mm) minimum A06673 Fig. 42 - - Crawlspace Termination...
Page 36 3” (76.2mm) minimum (304.8mm) minimum A06674 Fig. 43 - - Crawlspace Termination...
Page 37: Vent Termination
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 (304.8mm) 12 ″ MIN VENT PIPE (304.8mm) VERTICAL TO ROOF VERTICAL TO SIDEWALL NOTE: A 12-in.
Page 38 Vent Termination Kit (Direct Vent/2- -Pipe System Only) NOTE: Always refer to the instructions in termination kit for the latest version. Combustion air and vent pipes MUST terminate outside structure. A factory accessory termination kit must be installed as shown in Table 8.
Page 39 Table 6 – Maximum Allowable Exposed Vent Pipe Length (Ft / M) with Insulation in Winter Design Temperature Ambient* WINTER DESIGN WINTER DESIGN MAXIMUM PIPE MAXIMUM PIPE INSULATION THICKNESS† UNIT SIZE TEMPERATURE DIAMETER (IN.) 20_F / - -6.7_C 30 / 9.1 55 / 16.8 61 / 18.6 70 / 21.3...
Page 40 Table 7 – Maximum Allowable Pipe Length (Ft / M) Direct Vent (2- -Pipe Only) NUMBER OF 90_ ELBOWS UNIT SIZE Termination Pipe Dia ALTITUDE (BTUH) Type (IN.)* 2 Pipe or 2--- In. 1--- 1/2 50 / 15.2 45 / 13.7 40 / 12.9 35 / 10.7 30 / 9.1...
Page 41 Table 9 — Maximum Allowable Pipe Length (Ft / M) (Continued) Direct Vent (2- -Pipe Only) NUMBER OF 90_ ELBOWS UNIT SIZE ALTITUDE Termination Pipe Dia (BTUH) Type (IN.)* 2 Pipe or 2--- In. 1--- 1/2 35 / 10.7 30 / 9.1 25 / 7.6 20 / 6.1 15 / 4.6...
Page 42: Condensate Drain
Table 8 – Vent Termination Kit for Direct Vent / 2- -Pipe System DIRECT VENT (2 PIPE) TERMINATION DIAMETER OF COMBUSTION AIR TERMINATION SYSTEM AND VENT PIPES (IN INCHES) 2in. Concentric Vent Kit Single Penetration of Wall or Roof 1, 1- -1/2, 2, or 2- -1/2 3in.
Page 43: Start- -Up, Adjustments, And Safety Check
2. Locate heat tape between sides of condensate trap back. continuous fan airflow or low- -cooling airflow to be adjusted. To (See Fig. 46.) set desired continuous fan airflow or low- -cooling airflow: 3. Use wire ties to secure heat tape in place. Wire ties can be 1.
Page 44 2. Locate setup switch SW4 on furnace control. (See Fig. 33.) 3. See Table 5 for setup switch description. (See Fig. 40 and Fig. 49.) 4. Replace main furnace door and blower access panel. Prime Condensate Trap with Water CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in intermittent unit operation or performance satisfaction.
Page 45 A06677 Fig. 49 - - Wiring Diagram...
Page 46 A99118 A01050 Fig. 50 - - Inducer Housing Drain Tube Fig. 51 - - Filling Condensate Trap Table 9 – Furnace Setup Switch Description SETUP SWITCH NORMAL SWITCH NAME DESCRIPTION OF USE POSITION Turn ON to retrieve up to 7 stored status codes for troubleshooting SW1- -1 Status Code Recovery assistance when R thermostat lead is disconnected.
Page 47 Purge Gas Lines The furnace will start up in either medium- -, or high- -heat. The furnace will operate in low- -heat after starting and operating for 1 If not previously done, purge the lines after all connections have minute at medium- -heat before transitioning to low- -heat. The been made and check for leaks.
Page 48 and operate the inducer motor IDM at full speed until Switching from High- - to Medium- - or Low- -Heat — flame is no longer proved. The furnace control CPU will not switch from high- -heat to medium- - or low- -heat while the thermostat R to W cir- 5.
Page 49 The wall thermostat ”calls for heat”, closing the R to W1 circuit The wall thermostat “calls for cooling”, closing the R to G and- - for medium- -heat or closing the R to W1- -and- -W2 circuits for Y circuits. The R to Y1 circuit starts the outdoor unit on high- -heat.
Page 50 2. High cooling – When the R to G- -and Y/Y2 circuit is When the R to G circuit is opened, the blower motor BLWM will closed and there is a demand for dehumidification, the continue operating for an additional 5 seconds, if no other furnace blower motor BLWM will drop the blower airflow function requires blower motor BLWM operation.
Page 51 A06678 A06680 Fig. 52 - - Step- -Modulating Furnace with Single- -Speed Air Fig. 54 - - Step Modulating Furnace with Single- -Speed Heat Conditioning Pump (Dual Fuel) A06679 Fig. 53 - - Step Modulating Furnace with Two- -Speed Air A06681 Fig.
Page 52 A06682 A06684 Fig. 56 - - Step Modulating Furnace with Single- -Speed Heat Fig. 58 - - Two- -Stage Thermostat with Step Modulating Pump Furnace and Two- -Speed Air Conditioner A06683 A06685 Fig. 57 - - Dual Fuel thermostat with Step- -Modulating Fig.
Page 53 NOTE: Reference Fig. 52- -59: NOTE: For Canadian altitudes of 2000 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 10. 1. Heat pump MUST have a high pressure switch for dual fuel applications. e. Find closest natural gas heat value and specific gravity in Table 10.
Page 54 NOTE: DO NOT set medium- -heat manifold pressure less than NOTE: Be sure all pressure tubing, combustion- -air and vent 1.3- - in. wc or more than 1.7- -in. wc for natural gas. pipes, and burner enclosure front are in place when checking input by clocking gas meter.
Page 55 Table 10 – Orifice Size* and Manifold Pressures for Gas Input Rate (Tabulated Data Based on 20,000 BTUH High Heat / 13,000 Btuh Med- -Heat / 8,000 Btuh Low- -Heat per Burner, Derated 2% / 1000 Ft. Above Sea Level) A07253...
Page 56 Orifice Size* and Manifold Pressures for Gas Input Rate (Tabulated Data Based on 20,000 BTUH High Heat / 13,000 Btuh Med- -Heat / 8,000 Btuh Low- -Heat per Burner, Derated 2% / 1000 Ft. Above Sea Level) A07254...
Page 57 o. Wait for blower off- -delay to finish then reset 115- -v CAUTION power to furnace. p. Jumper R and W/W1 thermostat connections on control to start furnace. UNIT DAMAGE HAZARD q. Wait for the blower to turn ON then repeat items i through Failure to follow this caution may result in component l for low- -heat operation.
Page 58 Table 12 – Gas Rate cu Ft/Hr SECONDS SIZE OF TEST DIAL SECONDS SIZE OF TEST DIAL FOR 1 FOR 1 REVOLUTION cu ft cu ft cu ft REVOLUTION cu ft cu ft cu ft 1800 1636 1500 1385 1286 1200 1125 1059...
Page 59: Checklist
NOTE: When using an electronic thermostat, set cycle rate for 3 2. Remove control access door and disconnect inducer motor 12- -pin wire harness at inducer motor. cycles per hr. 3. Turn on 115- -v power to furnace. 3. Return setup switch SW1- -2 to OFF position and replace thermostat on subbase.
Page 60 Catalog No: 58MVC ---2SI Printed in U.S.A. Edition Date: 09/07 Copyright 2007 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Replaces: New Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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Carrier Infinity ICS 58MVC Installation Instructions Manual

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