Carrier 58MXA Installation, Start-Up, And Operating Instructions Manual
Deluxe 4–way multipoise fixed-capacity
direct vent condensing gas furnace
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- Installation, start-up, and operating instructions manual (52 pages) ,
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Table of Contents
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Installation, Start-Up, and Operating Instructions
NOTE: Read the entire instruction manual before starting the
installation.
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TABLE OF CONTENTS
SAFETY CONSIDERATIONS .....................................................2
INTRODUCTION ..........................................................................3
CODES AND STANDARDS........................................................3
APPLICATIONS............................................................................5
General ......................................................................................5
Upflow Applications.................................................................5
Orientation) ..........................................................................6
Orientation) ..........................................................................6
Orientation) ..........................................................................7
Orientation) ..........................................................................7
Condensate Trap Field Drain Attachment ..........................7
Pressure Switch Tubing.......................................................8
(Unused) Drain Connections...............................................8
Condensate Trap Freeze Protection ....................................8
Downflow Applications ............................................................8
Condensate Trap Location ..................................................8
Condensate Trap Tubing .....................................................8
Condensate Trap Field Drain Attachment ..........................9
Pressure Switch Tubing.......................................................9
Condensate Trap Freeze Protection ....................................9
Applications ..............................................................................9
Condensate Trap Location ..................................................9
Condensate Trap Tubing .....................................................9
Condensate Trap Field Drain Attachments ......................10
Pressure Switch Tubing.....................................................10
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. 535-80114
Tab 6a 8a
Deluxe 4-Way Multipoise Fixed-Capacity
Direct Vent Condensing Gas Furnace
Sizes 040-140, Series 170
A93040
Printed in U.S.A.
Condensate Trap Freeze Protection ..................................10
Construct a Working Platform ..........................................10
Applications ............................................................................11
Condensate Trap Location ................................................11
Condensate Trap Tubing ...................................................11
Condensate Trap Field Drain Attachment ........................12
Pressure Switch Tubing.....................................................12
Condensate Trap Freeze Protection ..................................12
Construct a Working Platform ..........................................12
LOCATION..................................................................................13
General ....................................................................................13
Equipment ...............................................................................14
Hazardous Locations...............................................................14
INSTALLATION .........................................................................14
Leveling Legs (If Desired) .....................................................14
Applications ............................................................................14
Installation in Horizontal Applications ..................................16
Air Ducts.................................................................................16
General Requirements .......................................................16
Ductwork Acoustical Treatment .......................................16
Supply Air Connections ....................................................17
Return Air Connections.....................................................17
Filter Arrangement..................................................................18
Bottom Closure Panel.............................................................18
Gas Piping...............................................................................19
Electrical Connections ............................................................20
115-v Wiring.....................................................................20
24-v Wiring.......................................................................20
Accessories ........................................................................20
Direct Venting.........................................................................21
Vent Systems .....................................................................21
Combustion-Air and Vent Piping .....................................24
Vent Extension Pipe ..........................................................28
Termination Kit Installation ..............................................30
Multiventing and Vent Terminations................................32
Condensate Drain....................................................................33
General...............................................................................33
Application.........................................................................33
Condensation Drain Protection .........................................34
Sequence of Operation............................................................34
Heating Mode ....................................................................35
Cooling Mode ....................................................................38
Thermidistat Mode ............................................................38
Continuous Blower Mode .................................................39
Heat Pump Mode...............................................................39
Component Test.................................................................39
START-UP PROCEDURES........................................................40
General ....................................................................................40
Prime Condensate Trap With Water ......................................40
Form 58MXA-15SI
Pg 1
58MXA
11-03
Replaces: 58MXA-14SI
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Summary of Contents for Carrier 58MXA
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Page 1: Table Of Contents
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. 535–80114 Printed in U.S.A. Form 58MXA-15SI Pg 1 11-03 Replaces: 58MXA-14SI Tab 6a 8a... -
Page 2: Safety Considerations
SAFETY CONSIDERATIONS reliability, or operation. The 58MXA Multipoise Condensing Gas-Fired Furnaces are C.S.A. (formerly AGA and CGA) design-certified for natural and Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air propane gases (see furnace rating plate) and for installation in temperature rise, unit leveling, and unit sizing. -
Page 3: Introduction
In the United States and Canada, follow all codes and standards for Box Part No. KCAKC is used. the following: The 58MXA 040 through 120 size units are C.S.A. (formerly AGA Step 1—Safety and CGA) design-certified for use in manufactured (mobile) •... -
Page 5: Applications
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 6: Condensate Trap Location (Factory-Shipped Orientation)
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 EXTERNAL UPFLOW APPLICATIONS APPLICATIONS... -
Page 7: Condensate Trap Location (Alternate Upflow Orientation)
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 8: Pressure Switch Tubing
COLLECTOR BOX DRAIN TUBE (BLUE) PLUG PLUG COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE EXTENSION TUBE &... -
Page 9: Condensate Trap Field Drain Attachment
b. Install removed clamp and plug into UPPER collector box applications. This tube MUST be disconnected and used for the drain tube (blue label) which was connected to condensate condensate trap relief port tube. The other collector box pressure trap. tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure c. -
Page 10: Condensate Trap Field Drain Attachments
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 11: 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. WORK AREA ″ ⁄ MANUAL SHUTOFF ACCESS OPENING GAS VALVE FOR TRAP DRAIN... -
Page 12: Condensate Trap Field Drain Attachment
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: Location
NOTE: For upflow/downflow applications install furnace so that it is level or pitched forward within 1/2-in. for proper furnace → The condensate trap MUST be installed below furnace. See operation. For horizontal applications pitch 1/4-in. minimum to Fig. 5 for dimensions. The drain connection to condensate 1/2-in. -
Page 14: Furnace Location Relative To Cooling Equipment
32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED 18-IN. MINIMUM TO BURNERS A93044 Fig. 16—Installation in a Garage ″ ⁄ A93058 Fig. 15—Freeze Protection ″ ⁄ ″ ⁄ → If furnace is installed in an unconditioned space where the ambient temperatures may be 32°F or lower, freeze protection measures must be taken. - Page 15 Table 1—Opening Dimensions (in.) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications 24–1/8 16–5/8 24–3/4 Downflow Applications on Non-Combustible Flooring 15-7/8 16-1/2 19-5/8 Downflow Applications on Combustible Flooring Using KGASB Subbase 15-1/8 16-3/4 20-3/8 Furnace with or without CD5 or CK5 Coil Assembly or 17-1/2 KCAKC Coil Box Downflow Applications on Combustible Flooring NOT Using...
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Page 16: Installation In Horizontal Applications
FURNACE PERFORATED DISCHARGE DUCT FLANGE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM 210° FLOOR OPENING A93029 Fig. 21—Duct Flanges Step 4—Air Ducts A96284 GENERAL REQUIREMENTS The duct system should be designed and sized according to Fig. -
Page 17: Supply Air Connections
⁄ -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 REQD PER ROD LOCATIONS) NOTES:... -
Page 18: Filter Arrangement
WASHABLE Table 2—Filter Information FILTER AIR FILTER LOCATED IN BLOWER COMPARTMENT FURNACE FILTER SIZE (IN.) FILTER FILTER CASING TYPE RETAINER Side Return Bottom Return WIDTH (IN.) 17–1/2 (1) 16 X 25 X 1† (1) 16 X 25 X 1† Cleanable (1) 16 X 25 X 1* (1) 20 X 25 X 1†... -
Page 19: Gas Piping
Table 3—Maximum Capacity of Pipe* NOMINAL LENGTH OF PIPE (FT) IRON INTERNAL PIPE DIAMETER SIZE (IN.) (IN.) 0.622 0.824 1.049 1-1/4 1.380 1400 1-1/2 1.610 2100 1460 1180 * Cubic ft of gas per hr for gas pressures of 0.5 psig (14–in. wc) or less and a pressure drop of 0.5–in wc (based on a 0.60 specific gravity gas). -
Page 20: Electrical Connections
→ SUPPLY Do not connect aluminum wire between disconnect switch MANUAL and furnace. Use only copper wire. (See Fig. 28.) Failure to SHUTOFF follow this caution will result in minor unit operation or VALVE (REQUIRED) performance satisfaction. SEDIMENT TRAP UNION The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2002 and Canadian Elec- trical Code CSA C22.1 or local codes to minimize personal... -
Page 21: Direct Venting
EAC terminals may be added if humidifier operation is desired during all blower operation. Step 9—Direct Venting ALTERNATE FIELD The 58MXA furnaces require a dedicated (one 58MXA furnace FACTORY LOCATION only) direct-vent system. In a direct-vent system, all air for INSTALLED... - Page 22 PRINTED CIRCIUT BOARD PRINTED CIRCIUT BOARD...
- Page 23 TWINNING AND/OR COMPONENT TEST BLOWER OFF-DELAY TERMINAL 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 COOL...
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Page 24: Combustion-Air And Vent Piping
CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance FURNACE connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are NOT IN... - Page 25 NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and 1 combustion-air pipe connection. 1 combustion-air pipe connection. Combustion air must not be taken from inside structure FLOW because inside air is frequently contaminated by halogens, COMBUSTION- COMBUSTION- VENT...
- Page 26 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 27 NOTE: Moisture in combustion-air intake may be result of EXAMPLE: An 080-12 size furnace located in Indianapo- improper termination. Ensure combustion-air intake pipe termina- lis, elevation 650 ft above sea level, could be installed in an tion is similar to that shown in Fig. 36, 37, 38, 39, and 40 so it will application requiring 3 elbows and 32 ft of vent pipe, along not be susceptible to areas where light snow or other sources of with 5 elbows and 34 ft of combustion-air pipe.
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Page 28: Vent Extension Pipe
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 29 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...
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Page 30: 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 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.
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Page 32: Multiventing And Vent Terminations
COMBUSTION-AIR WHICHEVER IS MULTIVENTING AND VENT TERMINATIONS GREATER. When 2 or more 58MXA Furnaces are vented near each other, A87225 each furnace must be individually vented. NEVER common vent Fig. 39—Sidewall Termination of 12 in. or More or breach vent 58MXA furnaces. When 2 or more 58MXA... -
Page 33: Condensate Drain
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 34: Condensation Drain Protection
A96128 Fig. 41—Rooftop Termination (Dimension “A” is Touching or 2-in. Maximum Separation) Outdoor draining of the furnace is permissible if allowed by local codes. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining. VENT VENT Caution should be taken to prevent draining where slippery conditions may cause personal injuries. -
Page 35: Heating Mode
VENT OPEN STAND PIPE FOR A/C OR COMBUSTION AIR HUMIDIFIER DRAIN COMBUSTION AIR A96129 TO OPEN Fig. 44—Raised Sidewall Termination When Wall DRAIN Penetration is 12 in. or Less Above Snow or Grade (Dimension “A” is Touching or 2-in. Maximum Separation) A94054 Fig. - Page 36 A00268 Fig. 48–Single-Stage Furnace with Single-Speed A00270 Air Conditioner Fig. 50–Single-Stage Furnace with Single-Speed Heat Pump (Dual Fuel) A00271 Fig. 51–Single-Stage Furnace with Two-Speed Heat Pump (Dual Fuel) A00269 Fig. 49–Single Stage Furnace with Two-Speed Air Conditioner...
- Page 37 HUMIDFIER HUMIDFIER (24VAC) (24VAC) A02103 A02102 Fig. 53–Dual Fuel Thermostat with Single-Stage Fig. 52–Dual Fuel Thermostat with Single-Stage Furnace and Two-Speed Heat Pump Furnace and Single-Speed Heat Pump HUMIDFIER (24VAC) A02161 Fig. 54–Two-Stage Thermostat with Single-Stage Furnace and Two-Speed Air Conditioner...
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Page 38: Cooling Mode
Notes For Figure 48-54 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. Select the “ZONE” position on the two-speed heat pump control. 4. -
Page 39: Continuous Blower Mode
after 20 minutes, the furnace control CPU will drop the (same speed as FAN). If the R to W-and-Y1-and-G signals blower speed back to HEAT speed. This alternating 10- disappear at the same time, the blower motor BLWM will minute cycle will continue as long as there is a call for remain on for the selected blower-OFF delay period. -
Page 40: Start-Up Procedures
5. Reconnect R lead to furnace control, remove tape from blower door switch, and re-install blower door. 6. Operate furnace per instruction on outer door. 7. Verify furnace shut down by lowering thermostat setting below room temperature. 8. Verify that furnace restarts by raising thermostat setting above room temperature. - Page 41 (1000’s Btuh) of 040 through 120. Table 10 can only be transparent. (See Fig. 59.) used for model 58MXA furnaces with a heating size of 140. h. Remove jumper from R and W. d. Find installation altitude in Table 9 or 10.
- Page 42 Table 9—Model 58MXA Orifice Size and Manifold Pressure for Correct Input For Use with 040 through 120 Size Furnaces Only (Tabulated Data is Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) * SPECIFIC GRAVITY OF NATURAL GAS...
- Page 43 TABLE 9—Model 58MXA 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 Percent for Each 1000 ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS...
- Page 44 Table 9—Model 58MXA 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 45 Table 10—Model 58MXA 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 46 Table 10—Model 58MXA 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 47 BURNER FLAME EXAMPLE: BURNER 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 Table 11–Altitude Derate Multipler for U.S.A. ALTITUDE PERCENT DERATE MULTIPLIER (FT) OF DERATE FACTOR*...
- Page 48 Table 12—Gas Rate (cu ft/hr) Table 13—Speed Selector FACTORY- SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS COLOR SPEED SHIPPED FOR 1 FOR 1 REVOLUTION REVOLUTION CONNECTION Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft Black High Cool...
- Page 49 THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED HOOK-AROUND VOLT/AMMETER R Y W G 10 TURNS FROM UNIT 24-VOLT TERMINAL BLOCK EXAMPLE: 5.0 AMPS ON AMMETER = 0.5 AMPS FOR THERMOSTAT SETTING 10 TURNS AROUND JAWS A80201 Fig. 60—Amp Draw Check with Ammeter 3.
- Page 50 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 COMBUSTION AIR AND VENT PIPING ________ Condensate Trap Primed before Start-Up...
- Page 52 Copyright 2003 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58mxa15si 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. 535–80114 Printed in U.S.A.