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) ..........................................................................5
Orientation) ..........................................................................6
Orientation) ..........................................................................6
Orientation) ..........................................................................7
Condensate Trap Field Drain Attachment ..........................7
Pressure Switch Tubing.......................................................7
(Unused) Drain Connections...............................................7
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. 535-80085
Tab 6a 8a
Deluxe 4-Way Multipoise Fixed-Capacity
Direct Vent Condensing Gas Furnace
Sizes 040-140, Series 160
A93040
Printed in U.S.A.
Condensate Trap Freeze Protection ..................................10
Construct a Working Platform ..........................................10
Applications ............................................................................10
Condensate Trap Location ................................................11
Condensate Trap Tubing ...................................................11
Condensate Trap Field Drain Attachment ........................11
Pressure Switch Tubing.....................................................11
Condensate Trap Freeze Protection ..................................12
Construct a Working Platform ..........................................12
LOCATION..................................................................................12
General ....................................................................................12
Equipment ...............................................................................13
Hazardous Locations...............................................................13
INSTALLATION .........................................................................13
Leveling Legs (If Desired) .....................................................13
Applications ............................................................................14
Installation in Horizontal Applications ..................................15
Air Ducts.................................................................................16
General Requirements .......................................................16
Ductwork Acoustical Treatment .......................................16
Supply Air Connections ....................................................16
Return Air Connections.....................................................17
Filter Arrangement..................................................................17
Bottom Closure Panel.............................................................17
Gas Piping...............................................................................18
Electrical Connections ............................................................19
115-v Wiring.....................................................................19
24-v Wiring.......................................................................19
Accessories ........................................................................20
Direct Venting.........................................................................20
Vent Systems .....................................................................20
Combustion-Air and Vent Piping .....................................21
Termination Kit Installation ..............................................26
Multiventing and Vent Terminations................................31
Condensate Drain....................................................................31
General...............................................................................31
Application.........................................................................31
Condensation Drain Protection .........................................31
Sequence of Operation............................................................33
Heating Mode ....................................................................33
Cooling Mode ....................................................................34
Thermidistat Mode ............................................................34
Continuous Blower Mode .................................................37
Heat Pump Mode...............................................................37
Component Test.................................................................38
START-UP PROCEDURES........................................................38
General ....................................................................................38
Prime Condensate Trap With Water ......................................38
Form 58MXA-13SI
Pg 1
58MXA
7-02
Replaces: 58MXA-12SI
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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. 535–80085 Printed in U.S.A. Form 58MXA-13SI Pg 1 7-02 Replaces: 58MXA-12SI Tab 6a 8a... -
Page 2: Safety Considerations
SAFETY CONSIDERATIONS highlight suggestions which will result in enhanced installation, reliability, or operation. The 58MXA Multipoise Condensing Gas-Fired Furnaces are Application of this furnace should be indoors with special C.S.A. design-certified for natural and propane gases (see furnace attention given to vent sizing and material, gas input rate, air rating plate) and for installation in alcoves, attics, basements, temperature rise, unit leveling, and unit sizing. -
Page 3: Introduction
Box Part No. KCAKC is used. is used. Step 2—General Installation → The 58MXA 040 through 120 size units are C.S.A. (A.G.A. and • US: NFGC and the NFPA 90B. For copies, contact the National C.G.A.) design-certified for use in manufactured (mobile) homes Fire Protection Association Inc., Batterymarch Park, Quincy,... - Page 4 ⁄ ⁄ " " ⁄ ⁄ " " AIRFLOW ⁄ ⁄ " " ⁄ " ⁄ " ⁄ " ⁄ ⁄ ⁄ 19" " " " 2-IN. COMBUSTION- ⁄ " CONDENSATE DRAIN AIR CONN OUTLET OUTLET TRAP LOCATION (DOWNFLOW & CONDENSATE DRAIN HORIZONTAL LEFT) 2-IN.
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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 Tubing (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 APPLICATIONS EXTERNAL UPFLOW APPLICATIONS... -
Page 7: Condensate Trap Tubing (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: Condensate Trap Freeze Protection
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
(c.) Route extended collector box drain tube directly 6. Determine appropriate length, cut, and connect tube. from collector box drain to condensate trap as 7. Clamp tube to relief port connection. shown in Fig. 9. CONDENSATE TRAP FREEZE PROTECTION (d.) Determine appropriate length and cut. Refer to Condensate Drain Protection section for recommenda- (e.) Connect to condensate trap. -
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: Condensate Trap Location
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 Freeze Protection
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
LEVEL (0″) FRONT FRONT ⁄ ″ ⁄ ″ MAX ⁄ ″ MAX UPFLOW OR DOWNFLOW HORIZONTAL 32°F MINIMUM INSTALLED A02146 AMBIENT OR FREEZE → PROTECTION REQUIRED Fig. 13—Furnace Location for Proper Condensate Drainage → NOTE: For upflow/downflow applications install furnace so that it is level or pitched forward within 1/2-in. -
Page 14: Installation In Upflow And Downflow Applications
″ ⁄ ″ ⁄ ″ ⁄ PLENUM OPENING ″ ⁄ FLOOR OPENING ″ ⁄ ″ ⁄ ″ ⁄ ″ ⁄ A96283 A89014 Fig. 18—Floor and Plenum Opening Dimensions Fig. 17—Leveling Legs 1. Position furnace on its back. Locate and drill a 5/16–in. FURNACE diameter hole in each bottom corner of furnace. -
Page 15: Installation In Horizontal Applications
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... -
Page 16: Air Ducts
⁄ -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:... -
Page 17: Return Air Connections
to furnace supply-/outlet-air duct flanges or air conditioning coil Table 2—Filter Information casing (when used). DO NOT cut main furnace casing to attach AIR FILTER LOCATED IN BLOWER COMPARTMENT supply side air duct, humidifier, or other accessories. All accesso- FURNACE ries MUST be connected external to furnace main casing. -
Page 18: Gas Piping
⁄ -IN. WIDE Table 3—Maximum Capacity of Pipe* CASINGS ONLY: INSTALL FIELD-SUPPLIED NOMINAL FILTER FILLER STRIP LENGTH OF PIPE (FT) UNDER FILTER. IRON INTERNAL PIPE DIAMETER SIZE (IN.) 3 ″ (IN.) 0.622 ″ 0.824 1.049 1 ″ 1-1/4 1.380 1400 1-1/2 1.610 2100... -
Page 19: Electrical Connections
SUPPLY Furnace control must be grounded for proper operation or MANUAL control will lock out. Control is grounded through SHUTOFF green/yellow wire routed to gas valve and burner box screw. VALVE (REQUIRED) 115–V WIRING SEDIMENT Before proceeding with electrical connections, make certain that TRAP UNION voltage, frequency, and phase correspond to that specified on unit... -
Page 20: Accessories
115-v (1.0-amp maximum) during blower Fig. 29—Relocating J-Box motor operation. Step 9—Direct Venting The 58MXA furnaces require a dedicated (one 58MXA furnace → only) direct-vent system. In a direct-vent system, all air for DO NOT connect furnace control HUM terminal to HUM combustion is taken directly from outside atmosphere, and all flue (humidifier) terminal on Thermidistat™, Zone Controller or... -
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 TO 115VAC FIELD DISCONNECT SCHEMATIC DIAGRAM (WHEN USED) BLOWER OFF DELAY LGPS NOTE #2 (NATURAL GAS & PROPANE) JUMPER SELECT EQUIPMENT GROUND DHUM CAP-1 MED LO NOTE #11 HEAT MED HI START SPARE-1 NOTE #10 HI/LO BLWR COOL EAC-2 Y/Y2 TEST/TWIN BLWM EAC-1...
- 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...
- Page 24 † 18 in. above roof surface in Canada. NOTES: with 5 elbows). Therefore, 2-1/2 in. diameter pipe must be 1. If installing 2 adjacent 58MXA furnaces, refer to Multiventing and Vent used for both vent and combustion-air pipes since larger Terminations section for proper vent configurations.
- 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.
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Page 26: Concentric Vent And Combustion-Air Termination Kit Installation
NOTE: Moisture in combustion-air intake may be result of VENT EXTENSION PIPE improper termination. Ensure combustion-air intake pipe is similar Furnaces with 100,000 Btuh and larger inputs are supplied with a to that shown in Fig. 36, 37, 38, 39, and 40 so it will not be PVC vent extension pipe (2-in. - 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 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 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 31: Multiventing And Vent Terminations
MULTIVENTING AND VENT TERMINATIONS an open or vented drain as close to the respective equipment as When 2 or more 58MXA Furnaces are vented near each other, possible to prevent siphoning of the equipment’s drain. each furnace must be individually vented. NEVER common vent See Fig. - Page 32 Table 8—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.) * 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.
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Page 33: Sequence Of Operation
VENT VENT VENT COMBUSTION COMBUSTION AIR COMBUSTION AIR A93056 Fig. 42—Concentric Vent and Combustion-Air Roof Termination (Dimension “A” is Touching or A96129 2-in. Maximum Separation) Fig. 44—Sidewall Termination of 12 in. of Less (Dimension “A” is Touching or 2-in. Maximum Separation) 1″... -
Page 34: Cooling Mode
e. Blower-On Delay- If the burner flame is proven, the blower motor is energized on HEAT speed 66 seconds (004 through 120 sizes) or 45 seconds (140 size) after the gas valve GV is energized. Simultaneously, the electronic air cleaner terminal EAC-1 is energized and remains energized as long as the blower motor BLWM is energized. - Page 35 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 36 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 37: Continuous Blower 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 38: Component Test
START-UP PROCEDURES W-and-Y1-and-Y/Y2, or R to W-and-Y1-and-Y/Y2-and-G circuits are energized the furnace control CPU will switch to Step 1—General or turn on the blower motor BLWM at HEAT speed, and 1. Furnace must have a 115-v power supply properly connected begin a heating cycle. - Page 39 Verify furnace model and size. Table 9 can only be used for model 58MXA furnaces with heating sizes of 040 through 120. Table 10 can only be used for model 58MXA furnaces with a 140,000 Btuh input. d. Find installation altitude in Table 9 or 10.
- Page 40 Table 9—Model 58MXA 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 41 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 42 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 43 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 44 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 45 EXAMPLE: (0-2000 ft altitude) Furnace input from rating plate is 100,000 Btuh. Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 975 Btu/cu ft Time for 1 revolution of 2-cu ft dial = 70 sec Gas rate = 103 cu ft/hr (from Table 12) Btu heating input = 103 X 975 = 100,425 Btuh.
- Page 46 THERMOSTAT SUBBASE Table 12—Gas Rate (cu ft/hr) TERMINALS WITH THERMOSTAT REMOVED SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS HOOK-AROUND FOR 1 FOR 1 VOLT/AMMETER REVOLUTION REVOLUTION Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft 1800 1636 R Y W G...
- Page 47 CHECKLIST—INSTALLATION LOAD CALCULATION Condensate Drain _______ Heating Load (Btuh) _______ Unit Level or Pitched Forward Internal Tubing Connections Free _______ Cooling Load (Btuh) _______ of Kinks and Traps External Drain Connection Leak _______ Furnace Model Selection _______ Tight and Sloped Condensate Trap Primed before _______ COMBUSTION AND VENT PIPING...
- Page 48 Copyright 2002 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58mxa13si 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. 535–80085 Printed in U.S.A.