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

4-way multipoise fixed-capacity direct-vent condensing gas furnace sizes 040-140, series 170
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Installation, Start-Up, and Operating Instructions
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
Index
DIMENSIONAL DRAWING........................................................2
SAFETY CONSIDERATIONS .....................................................3
Clearances to Combustibles......................................................4
INTRODUCTION ..........................................................................5
APPLICATIONS ......................................................................6-12
General ......................................................................................6
Upflow Applications..............................................................6-7
Downflow Applications.........................................................7-9
LOCATION ............................................................................12-13
General ....................................................................................12
Hazardous Locations...............................................................13
INSTALLATION....................................................................13-14
Leveling Legs (If Desired)................................................13-14
Installation In Horizontal Applications ..................................14
AIR DUCTS............................................................................14-19
General ....................................................................................14
Ductwork Acoustical Treatment.............................................16
Supply Air Connections ....................................................16-17
Return Air Connections ..........................................................17
Filter Arrangement..................................................................17
Bottom Closure Panel.............................................................18
Gas Piping..........................................................................18-19
ELECTRICAL CONNECTIONS...........................................19-20
115-v Wiring......................................................................19-20
24-v Wiring.............................................................................20
Accessories..............................................................................20
DIRECT VENTING ...............................................................20-30
Common Vent Systems.....................................................23
Combustion-Air and Vent Piping .....................................23-29
Kit Installation..............................................................29-30
Multiventing and Vent Termination.......................................30
CONDENSATE DRAIN ........................................................30-34
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. 535-80091
Tab 6a 8a
Direct-Vent Condensing Gas Furnace
For Sizes 040-140, Series 170
A93040
Page
Printed in U.S.A.
4-Way Multipoise Fixed-Capacity
As an ENERGY STAR®
Partner, Carrier Corpora-
tion has determined that
this product meets the EN-
REGISTERED QUALITY SYSTEM
ERGY STAR® guidelines
for energy efficiency.
HORIZONTAL
LEFT
AIRFLOW
Fig. 1-Multipoise Orientations
General...............................................................................30-32
Application ..............................................................................32
Condensate Drain Protection.............................................32-34
SEQUENCE OF OPERATION..............................................34-36
Heating Mode..........................................................................34
Cooling Mode ....................................................................34-35
Continuous Blower Mode.......................................................35
Heat Pump Mode ....................................................................35
Component Test.................................................................35-36
START-UP PROCEDURES ..................................................36-44
General ....................................................................................36
Prime Condensate Trap With Water ......................................36
Purge Gas Lines......................................................................36
Adjustments .......................................................................36-44
Set Gas Input Rate ............................................................36-44
Set Temperature Rise..............................................................44
Blower Off Delay (Heat Mode) .............................................44
Set Thermostat Heat Anticipator............................................44
CHECK SAFETY CONTROLS..................................................44
Check Primary Limit Control.................................................44
Check Pressure Switch ...........................................................44
CHECKLIST ................................................................................45
Form 58MCA-10SI
Pg 1
58MCA
ama
CERTIFIED
AIRFLOW
UPFLOW
HORIZONTAL
RIGHT
DOWNFLOW
AIRFLOW
AIRFLOW
A93041
12-02
Replaces: 58MCA-9SI

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  • Page 1: Table Of Contents

    A93040 NOTE: Read the entire instruction manual before starting the installation. As an ENERGY STAR® Partner, Carrier Corpora- This symbol → indicates a change since the last issue. tion has determined that this product meets the EN- REGISTERED QUALITY SYSTEM ERGY STAR®...

  • Page 3: Safety Considerations

    Box Part No. KCAKC is used. Improper installation, adjustment, alteration, service, mainte- The 58MCA 040 through 120 size units are CSA design-certified nance, or use can cause carbon monoxide poisoning, explo- for use in manufactured (mobile) homes when factory accessory sion, fire, electrical shock, or other conditions which may conversion kit is used.

  • Page 4: Clearances To Combustibles

    INSTALLATION This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m). An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications. This furnace is for indoor installation in a building constructed on site.

  • Page 5: Electrostatic Discharge (Esd) Precautions

    CHARGING YOUR BODY’S ELECTROSTATIC CHARGE INTRODUCTION TO GROUND. The model 58MCA 4-way multipoise, Gas-Fired, Category IV, 2. Firmly touch a clean, unpainted, metal surface of the furnace direct-vent condensing furnace is available in model sizes ranging chassis which is close to the control. Tools held in a person’s in input capacities of 40,000 to 138,000 Btuh.

  • Page 6: Applications

    APPLICATIONS Local codes may require a drain pan under entire furnace and PLUG condensate trap when a condensing furnace is used in an attic application or over a finished ceiling. COLLECTOR BOX DRAIN TUBE (BLUE Step 1—General & WHITE STRIPED) COLLECTOR BOX Some assembly and modifications are required for furnaces TUBE (PINK)

  • Page 7: Downflow Applications

    NOTE: Failure to use CPVC elbows may allow drain to kink and CONDENSATE TRAP FIELD DRAIN ATTACHMENT prevent draining. Refer to Condensate Drain section for recommendations and f. Connect larger diameter drain tube and clamp (factory- procedures. supplied in loose parts bag) to condensate trap and clamp PRESSURE SWITCH TUBING securely.
  • Page 8 COLLECTOR BOX DRAIN TUBE (BLUE) PLUG PLUG COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE) EXTENSION TUBE COLLECTOR BOX COLLECTOR BOX TUBE (PINK) TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE EXTENSION TUBE &...

  • Page 9: Horizontal Left (Supply-Air Discharge) Applications

    PLUG COLLECTOR BOX AUXILIARY "J" BOX DRAIN TUBE (BLUE AND WHITE STRIPED) CONDENSATE COLLECTOR BOX TRAP TUBE (GREEN) INDUCER HOUSING COLLECTOR DRAIN TUBE (VIOLET) BOX EXTENSION COLLECTOR BOX DRAIN TUBE DRAIN TUBE (BLUE) COLLECTOR BOX EXTENSION TUBE DRAIN TUBE COUPLING COLLECTOR BOX TUBE (PINK) RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 040, 060, AND 080 HEATING INPUT FURNACES...

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

    CONDENSATE TRAP TUBING CONSTRUCT A WORKING PLATFORM Construct working platform where all required furnace clearances NOTE: See Fig. 10 or tube routing label on main furnace door to are met. (See Fig. 3 and 11.) check for proper connections. 1. Collector Box Drain Tube a.
  • Page 11 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. WORK AREA ″ ⁄ MANUAL SHUTOFF ACCESS OPENING GAS VALVE FOR TRAP DRAIN...

  • Page 12: Location

    b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was previously connected to condensate trap. c. Connect LOWER collector box drain tube (blue and white striped label) to condensate trap. Tube does not need to be LEVEL (0″) cut.

  • Page 13: Furnace Location Relative To Cooling Equipment

    entering furnace. If dampers are manually operated, they must be equipped with a means to prevent operation of either unit unless This gas furnace may be used for construction heat provided damper is in full-heat or full-cool position. that: -The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation instructions.

  • Page 14: Installation In Upflow And Downflow Applications

    ″ ⁄ Do not bend duct flanges inward as shown in Fig. 21. This will affect airflow across heat exchangers and may cause limit ″ ⁄ cycling or premature heat exchanger failure. Remove duct ″ flange completely or bend it inward a minimum of 210° as ⁄...
  • Page 15 PLENUM OPENING FLOOR OPENING A96283 Fig. 18—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 16: Ductwork Acoustical Treatment

    if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both PERFORATED DISCHARGE DUCT acoustical lining and fibrous ductwork shall comply with NFPA FLANGE 90B as tested by UL Standard 181 for Class 1 Rigid air ducts. Step 3—Supply Air Connections UPFLOW FURNACES Connect supply-air duct to 3/4-in.

  • Page 17: Return Air Connections

    supply/outlet or air conditioning coil casing (when used). DO NOT Table 2—Filter Information cut main furnace casing to attach supply side air duct, humidifier, FURNACE FILTER SIZE (IN.)* FILTER TYPE or other accessories. All accessories MUST be connected external CASING FRAMED Side Return Bottom Return...

  • Page 18: Bottom Closure Panel

    Use proper length of pipe to avoid stress on gas control manifold. Failure to follow this warning could result in a gas leak resulting in fire, explosion, personal injury, or death. Table 3—Maximum Capacity of Pipe* NOMINAL LENGTH OF PIPE (FT) IRON INTERNAL PIPE...

  • Page 19: Electrical Connections

    → FIRE OR EXPLOSION HAZARD Blower access panel door switch opens 115-v power to Failure to follow the safety warnings exactly could result in control center. No component operation can occur. Do not serious injury, death or property damage. bypass or close switch with panel removed. Failure to follow Never test for gas leaks with an open flame.

  • Page 20: 24-V Wiring

    DIRECT VENTING thermostat MUST be connected to Y terminal on furnace control The 58MCA Furnaces require a dedicated (one 58MCA furnace center, as shown in Fig. 27. The 24-v terminal block is marked for only) direct-vent system. In a direct-vent system, all air for easy connection of field wiring.
  • Page 21 PRINTED CIRCIUT BOARD PRINTED CIRCIUT BOARD...
  • Page 22 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 23: Removal Of Existing Furnaces From Common Vent Systems

    Step 1—Removal of Existing Furnaces from In Canada, construct all combustion-air and vent pipes for this unit Common Vent Systems of CSA or ULC listed schedule-40 PVC, PVC-DWV or ABS- → DWV pipe and pipe cement. SDR pipe is NOT approved in When an existing Category I furnace is removed or replaced, the Canada.
  • Page 24 be taken to prevent the exhaust gases from one appliance from contaminating the combustion air of other gas appliances. FURNACE Combustion air must not be taken from inside structure because inside air is frequently contaminated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, NOT IN cleaning solvents, salts, air fresheners, adhesives, paint, and...
  • Page 25 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.
  • Page 26 NOTE: Moisture in combustion-air intake may be result of EXAMPLE: improper termination. Ensure combustion-air intake pipe termina- An 080-12 size furnace located in Indianapolis, elevation tion is similar to that shown in Fig. 36, 37, 38, 39, and 40 so it will 650 ft above sea level, could be installed in an application not be susceptible to areas where light snow or other sources of requiring 3 elbows and 32 ft of vent pipe, along with 5...
  • Page 27 Table 7—Maximum Allowable Pipe Length (ft) NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE (FT) 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 28 Table 7—Maximum Allowable Pipe Length (ft) (Continued) NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE (FT) 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 29: Concentric Vent And Combustion-Air Termination Kit Installation

    Table 7—Maximum Allowable Pipe Length (ft) (Continued) NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE (FT) 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 8001 to 9000‡...

  • Page 30: Multiventing And Vent Termination

    (such as inside building corners) or Step 4—Multiventing and Vent Terminations allow recirculation of flue gases, airborne leaves, or light When 2 or more 58MCA Furnaces are vented near each other, each snow. furnace must be individually vented. NEVER common vent or d.
  • Page 31 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.

  • Page 32: Application

    → Table 8—Maximum Allowable Exposed Vent Pipe Length (ft) With and Without Insulation in Winter Design Temperature Ambient* WINTER DESIGN MAX PIPE FURNACE WITHOUT WITH 3/8–IN. OR TEMPERATURE DIAMETER SIZE INSULATION THICKER INSULATION† (°F) (IN.) * 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 7.
  • Page 33 A96128 Fig. 41—Rooftop Termination (Dimension "A" is Touching or 2-In. Maximum Separation) 1″ MAXIMUM VENT (TYP) VENT COMBUSTION AIR VENT COMBUSTION VENT A93057 A93056 Fig. 43—Concentric Vent and Combustion-Air Fig. 42—Concentric Vent and Combustion-Air Side Termination Roof Termination (Dimension "A" is Touching or 2-In. (Dimension "A"...

  • Page 34: Sequence Of Operation

    long as no faults are detected. After the 90-second period, the furnace will respond to the thermostat normally. The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot-surface igniter HSI, and gas valve GV.

  • Page 35: Continuous Blower Mode

    The thermostat closes the R-to-G-and-Y circuits. The R-to-Y circuit starts the outdoor unit, and the R-to-G and Y circuits start the furnace blower motor BLWM on COOL speed. The electronic air cleaner terminal EAC-1 is energized with 115 vac when the blower motor BLWM is operating. When the thermostat is satisfied, the R-to-G-and-Y circuits are opened.

  • Page 36: Component Test

    Verify furnace model. Table 9 can only be used for model 58MCA furnaces with heating sizes of 040 through 120. Table 10 can only be used for model 58MCA furnaces with a heating size of 140. d. Find installation altitude in Table 9 or 10.
  • Page 37 e. Find closest natural gas heat value and specific gravity on Table 9 or 10. DO NOT bottom out gas valve regulator adjusting screw. f. Follow heat value and specific gravity lines to point of This can result in unregulated manifold pressure and result in intersection to find orifice size and manifold pressure excess overfire and heat exchanger failures.
  • Page 38 Table 9—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 39 Table 9—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 40 Table 9—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 41 Table 10—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 42 Table 10—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 43 Table 11—Altitude Derate Multiplier for U.S.A. ALTITUDE % OF DERATE MULTIPLIER (FT) DERATE FACTOR 0—2000 1.00 2001—3000 4—6 0.95 3001—4000 6—8 0.93 4001—5000 8—10 0.91 5001—6000 10—12 0.89 6001—7000 12—14 0.87 7001—8000 14—16 0.85 8001—9000 16—18 0.83 9001—10,000 18—20 0.81 BURNER ORIFICE * Derate multiplier factor is based on midpoint altitude for altitude range.

  • Page 44: Start-Up Procedures

    Table 14—Blower Off Delay Setup Position EXAMPLE: (0—2000 ft altitude) PINS 1 AND 2 2 AND 3 3 AND 4 4 AND 5 Furnace input from rating plate is 100,000 Btuh. Time (in sec) Btu heating input = Btu/cu ft X cu ft/hr SET THERMOSTAT HEAT ANTICIPATOR Heating value of gas = 975 Btu/cu ft →...

  • Page 45: Checklist

    CHECKLIST—INSTALLATION LOAD CALCULATION Condensate Drain ____________ Heating Load (Btuh) ________ Unit Level or Pitched Forward ____________ Cooling Load (Btuh) Internal Tubing Connections Free of Kinks ________ and Traps ____________ Furnace Model Selection External Drain Connection Leak Tight and COMBUSTION AIR AND VENT PIPING ________ Sloped Termination Location...
  • Page 48 Copyright 2003 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58mca10si Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 Tab 6a 8a PC 101 Catalog No.

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