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

4-way multipoise fixed-capacity condensing gas furnace for sizes 040—120 series 140
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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 last
issue.
A93040
Index
DIMENSIONAL DRAWING........................................................3
SAFETY CONSIDERATIONS .....................................................2
Clearances to Combustibles......................................................4
CODES AND STANDARDS ....................................................2-5
INTRODUCTION ..........................................................................5
APPLICATIONS ......................................................................6-12
General ......................................................................................6
Upflow Applications..............................................................6-7
Downflow Applications.........................................................7-9
LOCATION ............................................................................12-14
General ....................................................................................12
Hazardous Locations...............................................................14
General ....................................................................................14
Unconfined Space ...................................................................14
Confined Space .......................................................................15
INSTALLATION....................................................................15-17
Leveling Legs (If Desired) .....................................................15
Installation In Horizontal Applications.............................15-17
AIR DUCTS............................................................................17-21
General ....................................................................................17
Ductwork Acoustical Treatment.............................................17
Supply Air Connections..........................................................17
Return Air Connections ..........................................................17
Filter Arrangement..................................................................19
Bottom Closure Panel.............................................................19
Gas Piping..........................................................................19-21
ELECTRICAL CONNECTIONS...........................................21-25
115-v Wiring......................................................................21-22
24-v Wiring.............................................................................24
Accessories ........................................................................24-25
VENTING ...............................................................................25-30
Common Vent Systems.....................................................25
Combustion-Air and Vent Piping .....................................25-29
Vent Termination...............................................................29-30
Multiventing ............................................................................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. 535-80113
Tab 6a 8a
For Sizes 040-120 Series 140
Page
Printed in U.S.A.
4-Way Multipoise Fixed-Capacity
Condensing Gas Furnace
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
CONDENSATE DRAIN ........................................................30-32
General ....................................................................................30
Application ..............................................................................32
Condensate Drain Protection ..................................................32
SEQUENCE OF OPERATION..............................................33-36
Heating Mode ....................................................................33-34
Cooling Mode .........................................................................34
Continuous Blower Mode.......................................................35
Heat Pump Mode ....................................................................35
Component Test.................................................................35-36
START-UP PROCEDURES ..................................................36-42
General ....................................................................................36
Prime Condensate Trap With Water ......................................36
Purge Gas Lines......................................................................36
Adjustments .......................................................................36-42
Set Gas Input Rate ............................................................36-41
Set Temperature Rise..............................................................42
Blower Off Delay (Heat Mode) .............................................42
Set Thermostat Heat Anticipator............................................42
CHECK SAFETY CONTROLS ............................................42-43
Form 58MSA-7SI
Pg 1
58MSA
ama
CERTIFIED
AIRFLOW
UPFLOW
HORIZONTAL
RIGHT
DOWNFLOW
AIRFLOW
AIRFLOW
A93041
10-03
Replaces: 58MSA-6SI

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  • Page 1: Table Of Contents

    This symbol → indicates a change since last issue. CERTIFIED A93040 Index Page As an ENERGY STAR® Partner, Carrier Corpora- DIMENSIONAL DRAWING............3 tion has determined that SAFETY CONSIDERATIONS .............2 this product meets the EN- REGISTERED QUALITY SYSTEM ERGY STAR® guidelines Clearances to Combustibles............4...

  • Page 2: Safety Considerations

    NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. The 58MSA Multipoise Condensing Gas-Fired Furnaces are CSA design-certified for natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets,...

  • 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

    1. Disconnect all power to the furnace. Multiple disconnects may INTRODUCTION be required. DO NOT TOUCH THE CONTROL OR ANY The model 58MSA 4-way multipoise, Gas-Fired, Category IV, WIRE CONNECTED TO THE CONTROL PRIOR TO DIS- condensing furnaces are available in model sizes ranging in gas CHARGING YOUR BODY’S ELECTROSTATIC CHARGE...

  • Page 6: Applications

    PLUG PLUG COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE DRAIN TUBE (BLUE & WHITE STRIPED) & WHITE STRIPED) COLLECTOR BOX COLLECTOR BOX TUBE (PINK) TUBE (PINK) COLLECTOR BOX COLLECTOR BOX TUBE (GREEN) TUBE (GREEN) COLLECTOR BOX INDUCER HOUSING DRAIN TUBE (BLUE) (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX...

  • Page 7: Downflow Applications

    c. Install drain tube coupling grommet (factory-supplied in d. Clamp tube to prevent any condensate leakage. loose parts bag) in selected casing hole. 3. Relief Port Tube d. Slide drain tube coupling (factory-supplied in loose parts a. Connect relief port tube (green label) to condensate trap. bag) through grommet ensuring long end of coupling faces b.
  • 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

    3. Relief Port Tube 5. Route this extended tube (pink label) to condensate trap relief port connection. Refer to Pressure Switch Tubing section for connection 6. Determine appropriate length, cut, and connect tube. procedure. 7. Clamp tube to relief port connection. CONDENSATE TRAP FIELD DRAIN ATTACHMENT CONDENSATE TRAP FREEZE PROTECTION Refer to Condensate Drain section for recommendations and...

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

    3. Route extended tube: a. Behind inducer housing. Casing hole filler cap must be installed in blower shelf hole b. Between blower shelf and inducer housing. when condensate trap is relocated. Failure to follow this c. Behind inducer motor bracket. warning could result in electrical shock, fire, personal injury d.
  • Page 11 A 3-IN. MINIMUM CLEARANCE VENT TO COMBUSTION-AIR INTAKE IS REQUIRED. COMBUSTION–AIR INTAKE 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-IN. MIN WORK AREA ″...

  • Page 12: Location

    COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE PLUG COLLECTOR BOX TUBE (PINK) AUXILARY “J” BOX RELOCATED HERE CONDENSATE TRAP COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX EXTENSION TUBE A00214 Fig.

  • Page 13: Furnace Location Relative To Cooling Equipment

    This gas furnace may be used for construction heat provided that: -The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to LEVEL (0″) FRONT FRONT ⁄ ″ these installation instructions. A return air duct is provided, ⁄...

  • Page 14: Hazardous Locations

    FRONT BACK FRONT 18-IN. MINIMUM TO BURNERS A93043 A93044 Fig. 16—Installation in a Garage Fig. 14—Prohibit Installation on Back Canadian installations must be in accordance with Section 7.2 of the Air Supply Determination for Central Heating Furnaces, If this furnace is installed in a n unconditioned space where Boilers, and Hot Water Heaters, and 7.3, Air Supply Openings and ambient temperatures may be 32°F or lower, freeze protection Ducts, of the NSCNGPIC and all authorities having jurisdiction.

  • Page 15: Confined Space

    For Example: For Example: MINIMUM FLOOR AREA FOR UNCONFINED SPACE COMBUSTION AIR FROM OUTDOORS THROUGH VERTICAL DUCTS 58MSA Furnace Minimum Sq Ft With Input Btuh 7-1/2 Ft Ceiling 58MSA Furnace Free Area per Opening Round Pipe Input Btuh (Sq In.) (In.

  • Page 16: Installation In Horizontal Applications

    1 SQ IN. PER 4000 DUCTS BTUH * OUTDOORS SUPPLY VENT THROUGH ROOF OR SIDEWALL 12 ″ MAX 12″ 1 SQ IN. VENT PER 2000 THROUGH SUPPLY BTUH * ROOF 12″ MAX 1 SQ IN. SIDEWALL PER 4000 BTUH * 1 SQ IN.

  • Page 17: Air Ducts

    acoustical lining. As an alternative, fibrous ductwork may be used ″ ⁄ if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both ″ acoustical lining and fibrous ductwork shall comply with NFPA ⁄...
  • Page 18 PLENUM OPENING FLOOR OPENING A96283 Fig. 20—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 19: Filter Arrangement

    Bottom return-air opening may be used with all 4 orientations. Filter may need to be cut to fit some furnace widths. Install filter PERFORATED DISCHARGE DUCT as shown in Fig. 26. FLANGE Step 6—Bottom Closure Panel These furnaces are shipped with bottom enclosure panel installed in bottom return-air opening.
  • Page 20 COMBUSTION-AIR A 3-IN. MINIMUM INTAKE CLEARANCE TO COMBUSTION-AIR INTAKE IS REQUIRED. VENT ⁄ -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 &...

  • Page 21: Electrical Connections

    21-IN. WIDE ⁄ -IN. WIDE CASINGS ONLY: CASINGS ONLY: SUPPORT RODS (3) SUPPLY INSTALL FIELD-SUPPLIED EXTEND 1/4" ON EACH MANUAL FILTER FILLER STRIP SIDE OF FILTER AND SHUTOFF UNDER FILTER. REST ON CASING FLANGE VALVE (REQUIRED) SEDIMENT 3 ″ TRAP UNION ″...
  • Page 22 ELECTRIC ALTERNATE DISCONNECT FIELD SWITCH FACTORY LOCATION INSTALLED COPPER LOCATION WIRE ONLY ALUMINUM WIRE A93033 Fig. 29—Disconnect Switch and Furnace rating plate. Also, check to be sure that service provided by power supply is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 4 for equipment electrical specifi- cations.
  • Page 23 PRINTED CIRCIUT BOARD PRINTED CIRCIUT BOARD...

  • Page 24: 24-V Wiring

    Table 4—Electrical Data OPERATING VOLTS— UNIT UNIT MAX WIRE MAX FUSE OR VOLTAGE RANGE HERTZ— UNIT WIRE SIZE AMPACITY† LENGTH (FT)‡ CKT BKR AMPS** PHASE AMPS SIZE 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 25: Venting

    GENERAL during blower operation. VENTING The 58MSA Furnaces require a dedicated, (one 58MSA furnace Solvent cements are combustible. Keep away from heat, only) sealed vent system. All air for combustion is taken from the sparks, and open flame. Use only in well-ventilated areas.
  • Page 26 TWINNING AND/OR COMPONENT TEST BLOWER OFF-DELAY TERMINAL J2 JUMPER BLOWER OFF-DELAY HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) 24-V THERMOSTAT TERMINALS TRANSFORMER 24-VAC CONNECTIONS TEST/TWIN 0.5 AMP@24VAC 3-AMP FUSE FUSE 3-AMP SEC-2 SEC-1 LED OPERATION & EAC-2 DIAGNOSTIC LIGHT PL1-LOW VOLTAGE MAIN HARNESS CONNECTOR 115-VAC(L2)NEUTRAL CONNECTIONS...
  • Page 27 NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and FIELD-SUPPLIED 1 combustion-air pipe connection. 1 combustion-air pipe connection. 2-IN. DIAMETER FIELD-SUPPLIED PVC 90° ELBOW 2-IN. DIAMETER FLOW PVC PIPE COMBUSTION- COMBUSTION- VENT VENT VENT VENT COMBUSTION- COMBUSTION- FLOW...
  • Page 28 VENT PIPE EXAMPLE: NOTE: Furnace vent pipe connections are sized for 2-in. pipe. An 080-12 size furnace located in Indianapolis, elevation Any vent pipe size change should be made outside furnace casing 650 ft above sea level, could be installed in an application in vertical pipe.

  • Page 29: Vent Termination

    12 ″ MIN 12 ″ MIN VENT PIPE VENT PIPE HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL VENT 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 30: Multiventing

    The field drain connection (condensate trap or drain tube coupling) is sized for 1/2-in. CPVC, 1/2-in. PVC, or 5/8-in. ID tube When 2 or more 58MSA Furnaces are vented near each other, each connection. furnace must be individually vented. NEVER common vent or Drain pipe and fittings must conform to ANSI standards and breach vent 58MSA furnaces.
  • Page 31 Table 6—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 4001 to 5000‡...

  • Page 32: Application

    Table 6—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 8001 to 9000‡...

  • Page 33: Sequence Of Operation

    Table 7—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 34 → Table 8—Vent Pipe Termination Clearances CLEARANCE (FT) LOCATION U.S.A. Canada Above grade level or above 1† anticipated snow level ROOF Dryer / Water heater vent Plumbing vent stack Any mechanical fresh air in- See Note 4 See Note 6 take For furnaces with an input ca- VENT...

  • Page 35: Cooling Mode

    long as the blower motor BLWM is energized. During ″a call for heat,″ the blower BLWM will stop during igniter warm-up (17 seconds), ignition (7 seconds), and blower-ON delay (66 seconds), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at HEAT speed.

  • Page 36: Start-Up Procedures

    Verify furnace model. Table 9 can only be used for model 3. Natural gas service pressure must not exceed 0.5 psig (14-in. 58MSA furnaces. wc), but must be no less than 0.16 psig (4.5-in. wc). d. Find installation altitude in Table 9.
  • Page 37 A99118 A99119 Fig. 44—Inducer Housing Drain Cap Fig. 45—Filling Condensate Trap a. Remove burner enclosure front. NOTE: This furnace has been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft. b.
  • Page 38 Table 9—Model 58MSA Orifice Size and Manifold Pressure for Correct Input (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62...
  • Page 39 Table 9—Model 58MSA Orifice Size and Manifold Pressure for Correct Input Continued (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60...
  • Page 40 Table 9—Model 58MSA Orifice Size and Manifold Pressure for Correct Input Continued (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60...
  • Page 41 multiplier factor. EXAMPLE: 100,000 Btuh input furnace installed at 4300 ft. Derate Furnace Input Rate Furnace Input Rate Multiplier at Installation at Sea Level Factor Altitude 100,000 0.91 91,000 Canada At installation altitudes from 2001 to 4500 ft, this furnace must be derated 5% by an authorized Gas Conversion Station.

  • Page 42: Set Temperature Rise

    BLOWER OFF DELAY (HEAT MODE) EXAMPLE: (0—2000 ft altitude) The blower off delay has 4 adjustable settings from 90 sec to 180 Furnace input from rating plate is 100,000 Btuh. sec. (See Table 13.) The blower off delay jumpers are located on Btu heating input = Btu/cu ft X cu ft/hr the furnace control board.
  • Page 43 Step 2—Check Pressure Switch 5. Turn off 115-v power to furnace. 6. Reconnect inducer motor leads, reinstall main furnace door, This control proves operation of draft inducer. Check switch operation as follows: and turn on 115-v power supply. 1. Turn off 115-v power to furnace. CHECKLIST 1.
  • Page 44 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 ________ Sloped VENT PIPING ________ Condensate Trap Primed before Start-Up...
  • Page 45 SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials.
  • Page 48 Copyright 2003 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58msa7si 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. 535-80113 Printed in U.S.A.

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