Carrier 59TP6B Installation Manual

Page 2 - Required Notice for Massachusetts Installations; IMPORTANT; NFPA 54 as adopted by the Board and

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 102) Revise 10.8.3 by adding the following additional requirements: a. For all side wall horizontally vented g...

Page 3 - SAFETY CONSIDERATIONS; WARNING

3 SAFETY CONSIDERATIONS FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation, personal injury, death, or property damage.Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon ...

Page 4 - NOTICE; INTRODUCTION

4 8. A gas--fired furnace for installation in a residential garage must be installed as specified in the warning box in the “Location” section. 9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION sectio...

Page 5 - CAUTION; ACCESSORIES

5 CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions. The installation must comply with regulations of the serving gas supplier, local building, heating,plumbing, and other codes. In absence of local codes, the installation must comply with the na...

Page 6 - LOCATION; General

6 LOCATION PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD Improper use or installation of this furnace may result in premature furnace component failure. Unless otherwise prohibited, this gas furnace may be used for heating buildings under construction provided that: --The furnace is permanently inst...

Page 7 - FIRE, INJURY OR DEATH HAZARD; FIRE HAZARD; Location Relative to Cooling Equipment

7 THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED ABOVE THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED DOWNWARD THE BLOWER I...

Page 9 - Introduction; Ventilated Combustion Air Applications; Outdoor Combustion Air Method

9 AIR FOR COMBUSTION AND VENTILATION Introduction Direct Vent (2--pipe) Applications When the furnace is installed as a direct vent (2-pipe) furnace, nospecial provisions for air for combustion are required. However, other gas appliances installed in the space with the furnace mayrequire outside air...

Page 10 - Indoor Combustion Air; Standard Method; National Fuel; ACH; Volume; ACH; Combination of Indoor and Outdoor Air

10 Indoor Combustion Air E NFPA & AGA Standard and Known--Air--Infiltration Rate Methods Indoor air is permitted for combustion, ventilation, and dilution, if the Standard or Known--Air--Infiltration Method is used. CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in ...

Page 11 - EXAMPLES: Determining Free Area; Outdoors

11 Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors FURNACE INPUT (BTUH) TWO HORIZONTAL DUCTS (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) SINGLE DUCT OR OPENING (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) TWO OPENINGS OR VERTICAL DUCTS (1 SQ. IN./4,000 BTUH) (550 SQ. ...

Page 12 - CONDENSATE TRAP; To Relocate the Condensate Trap:

12 CONDENSATE TRAP Condensate Trap -- Upflow Orientation When the furnace is installed in the upflow position, it is notnecessary to relocate the condensate trap or associated tubing. Refer to Fig. 8 for upflow condensate trap information. Refer toCondensate Drain section for information how to inst...

Page 16 - CONDENSATE DRAIN CONNECTION; FROZEN AND BURST WATER PIPE HAZARD; PROPERTY DAMAGE HAZARD; Upflow/Downflow Orientation; For Right Side Condensate Drain:; TIP FROM CONTRACTORS

16 CONDENSATE DRAIN CONNECTION FROZEN AND BURST WATER PIPE HAZARD Failure to protect against the risk of freezing may result in property damage.Special precautions MUST be made if installing furnace in an area which may drop below freezing. This can cause improper operation or damage to equipment. I...

Page 17 - CUT HAZARD; For Left Side Condensate Drain Connection:; DO NOT DISCARD THE FORMED GROMMET; Horizontal Orientation

17 CUT HAZARD Failure to follow this caution may result in personal injury.Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts, and servicing furnaces. CAUTION ! L12F019B Fig. 12 -- Knockout Removal For Lef...

Page 19 - ï ï

19 Air gap here Open standpipe LQKLJK PLQLPXP for coil or humidifier drain TEE (1/2” CPVC to 3/4” PVC adapter from loose parts bag.) To open drain &RLORUKXPLGLILHUGUDLQZKHQXVHG + + + Condensing Furnace - - - - - ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄ Evapora...

Page 20 - INSTALLATION; Upflow Installation; Supply Air Connections

20 INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAP PULL DRAIN STUB THROUGH CASING OPEN SPRING CLAMPINSERT FACTORY ï SUPPLIED 1/2 ï IN. CPVC TO 3/4 ï IN. PVC ADAPTER OR 1/2 ï IN. CPVC PIPE *CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN TUBE A11342A Fig. 15 -- Formed Rubber Drain Gr...

Page 21 - Downflow Installation; Return Air Connections

21 Return Air Connections FIRE HAZARD A failure to follow this warning could cause personal injury, death and/or property damage.Never connect return--air ducts to the back of the furnace. Follow instructions below. ! WARNING The return--air duct must be connected to bottom, sides (left orright), or...

Page 22 - Horizontal Installation; Platform Furnace Support; Filter Arrangement

22 Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return--air opening. Remove and discard this panel whenbottom return air is used. To remove bottom closure panel see Fig. 23 and 24. Horizontal Installation NOTE: The furnace must be pitched forward a...

Page 23 - Table; Filter and Return Duct Sizing

23 Refer to the instructions supplied with Media Cabinet or accessoryair filter for assembly and other details.See Table 7 for filter size details. Filter and Return Duct Sizing Pressure drop must be taken into account when sizing filters, filterracks, IAQ devices, and associated system ductwork. Se...

Page 24 - Air Filter Located in Filter Cabinet

24 Table 6 – Filter Media Pressure Drop (Clean) Versus Face Velocity-- In. W.C. (Pa) Face Velocity Factory-Accessory Washable Representative After-Market Filter Media* Fiberglass* Pleated* FPM (m/s) (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) 200 (1) 0.04 (10) 0....

Page 25 - Media Cabinet Installation Option for

25 14-3/16 and 17-1/2-in. Furnace 16-in. Media Cabinet 21-in. Furnace 4-Ton or less, AC capacity airflow 20-in. Media Cabinet 4-in.Block OffPlate 1/2-in. Screws 20- or 24-in. Medi a Cabinet Bottom Return Plenum 21- or 24-1/2-in. Furnace Up to 5-Ton ACcapacity airflow 45 ° Transition 20- or 24-in. Me...

Page 27 - closure panel to the furnace casing and remove the

27 UPFLOW DOWNFLOW HORIZONTAL YES NO NO YES YES YES NO 120 ° MIN YES 120 ° MIN YES 120 ° MIN 90 ° 90 ° PERFORATEDDISCHARGE DUCTFLANGE A10493 Fig. 22 -- Duct Flanges 1 Lay furnace on the back or side2 Remove the two (2) screws that secure the bottom closure panel to the furnace casing and remove the ...

Page 28 - and Restrictions

28 LEVEL 0-IN. (0 MM) TO1/2-IN. (13 MM) MAX UPFLOW ORDOWNFLOW HORIZONTAL MIN 1/4-IN. (6 MM) TO1/2-IN. (13 MM) MAX A11237 Fig. 25 -- Furnace Pitch Requirements ANY COMBINATION OF 1, 2, OR 3 PERMITTED. A11036 Fig. 26 -- Upflow Return Air Configurations and Restrictions A11037 Fig. 27 -- Downflow Retur...

Page 30 - AIR DUCTS; General Requirements; The Air; Return Duct Sizing

30 AIR DUCTS Many states, provinces and localities are considering or have implemented standards and/or restrictions on duct sizing practices, ductwork leakage, and/or ductwork thermal, airflow and electrical efficiencies. CONSULT LOCAL CODE OFFICIALS for ductwork design and performance requirements...

Page 31 - Table 9 – Cooling

31 Table 9 – Cooling 4 and Heating Air Delivery -- CFM (Bottom Return 5 with Filter) (SW1 --- 5 and SW4 --- 3 set to OFF, except as indicated. See notes 1 and 2.) Unit Size: 040V14 --- 10 Clg/CF Switch settings External Static Pressure (ESP) Clg Switches: SW2 --- 8 SW2 --- 7 SW2 --- 6 0.1 0.2 0.3 0....

Page 32 - with Filter) continued

32 Table 9 -- Cooling 4 and Heating Air Delivery -- CFM (Bottom Return 5 with Filter) continued (SW1 --- 5 and SW4 --- 3 set to OFF, except as indicated. See notes 1 and 2.) Unit Size: 060V14 --- 12 Clg/CF Switch settings External Static Pressure (ESP) Clg Switches: SW2 --- 8 SW2 --- 7 SW2 --- 6 0.1...

Page 35 - GAS PIPING

35 Table 9 -- Cooling 4 and Heating Air Delivery -- CFM (Bottom Return 5 with Filter) -- NOTES 1. Nominal 350 CFM/ton cooling airflow is delivered with SW1 --- 5 and SW4 --- 3 set to OFF. Set both SW1 --- 5 to ON for nominal 400CFM/ton (+15% airflow) Set SW4 --- 3 to ON for nominal 325 CFM/ton ( ---...

Page 36 - FURNACE DAMAGE HAZARD; Gas Pipe Grommet; NOTE: Top plate may be field drilled for alternate gas and

36 FURNACE DAMAGE HAZARD Failure to follow this caution may result in furnace damage.Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls and burner misalignment. CAUTION ! An accessible manual equipment shutoff valve MUST be installed external to furnace casing and withi...

Page 37 - ELECTRICAL CONNECTIONS

37 ELECTRICAL CONNECTIONS ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings could result in dangerous operation, serious injury, death or property damage.Improper servicing could result in dangerous operation, serious injury, death or property damage. -- Before servicing, ...

Page 38 - FIRE OR ELECTRICAL SHOCK HAZARD; External Electrical Box on Furnace Casing

38 J--Box Installation FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death, or property damage.High voltage field connections must be located in J--Box with furnace, or in field supplied external disconnect mounted to furnace.If field--supplied manua...

Page 39 - Power Cord Installation in Furnace J--Box; Thermostats; Accessories

39 7. Install the green ground screw to the J--Box bracket and attach both ground wires to the green ground screw. 8. Connect any code required external disconnect(s) to field power wiring. 9. Connect field power and neutral leads to furnace power leads inside the external electrical box as shown in...

Page 40 - Table 11 – Electrical Data

40 Table 11 – Electrical Data FURNACE SIZE VOLTS --- HERTZ --- PHASE OPERATING VOLTAGE RANGE* MAXIMUM UNIT AMPS UNIT AMPACITY# MINIMUM WIRE SIZE AWG MAXIMUM WIRE LENGTH FT (M) } MAXIMUM FUSE OR CKT BKR AMPS { Maximum* Minimum* 040V14 --- 10 115 --- 60 --- 1 127 104 7.0 9.7 14 38 (11.7) 15 040V17 ---...

Page 43 - Special Venting Requirements for Installations in; must; The special vent; Consignes spéciales pour l’installation de

43 NOTES FOR THERMOSTAT WIRING DIAGRAMS 1. Heat pump MUST have a high pressure switch for HYBRID HEAT r dual fuel applications. 2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.3. If the heat pump date code is 1501E or earlier, select the “ZONE” ...

Page 44 - CARBON MONOXIDE POISONING HAZARD; USA

44 CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance 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 be...

Page 45 - Venting Systems; RECOMMENDED SUPPORT FOR

45 Table 12 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (USA Installations) MATERIALS USA 1. All pipe, fittings, primers*, and solvents* must conform to American National Standards Institute (ANSI) standards and American Society for Testing and Materials (ASTM) standards or...

Page 46 - Ventilated Combustion Air Systems; Locating the Vent Termination

46 Table 13 – Vent Termination Kit for Direct Vent (2--pipe) Systems Vent and Combustion Air Pipe Diameters Approved Two- Pipe Termination Fittings Allowable Concentric Vent Kit 1 1/2--in. (38 mm) 2--in. (51 mm) 2 1/2--in. (64 mm) 3--in. (76--mm) 4--in. (102 mm) 1 1/2--in. (38 mm) No Yes No No No 2-...

Page 47 - Ventilated Combustion Air; Size the Vent and Combustion Air Pipes

47 prevailing winds. The roof location is preferred since the vent andcombustion air system is less susceptible to damage or contamination. The termination is usually located away fromadjacent structures or other obstacles such as inside corners, windows, doors or other appliances. It is less prone ...

Page 48 - Recommended Combustion Air Inlet Moisture Trap; shorter

48 Length in Table 16 minus the number of fittings multiplied by the deduction for each type of fitting used from Table 17. OPTIONAL CONFIGURATION FOR COMBUSTION AIR INLET PIPE In applications where there is a risk of excessive moisture entering the combustion air inlet pipe, a moisture trap may be ...

Page 49 - Near Furnace Vent Connections

49 Total Equivalent Vent Length using the next smaller diameter. If the Maximum Equivalent Vent Length is still longer than the longer TEVL of the vent pipe or combustion air pipe, then that diameter of pipe selected may be used. When installing vent systems pipe lengths of 10 ft. (3 M) or less, use...

Page 50 - See “Notes for Venting Options”

50 1 2 3 4 6 7 5 5 Rotate vent elbow torequired position. Any other unusedknockout may be usedfor combustion airconnection. & UPFLOW LEFT CONFIGURATION A11309A 1 2 3 4 5 6 7 5 Rotate vent elbow torequired position. Any other unusedknockout may be usedfor combustion airconnection. UPFLOW RIGHT CO...

Page 51 - Requires Accessory Vent Kit; Requires Internal Vent Kit

51 HORIZONTAL LEFT --- VERTICAL VENT CONFIGURATION A11327A 6 4 Alternate combustion airconnection. Rotate ventelbow torequired position. 4 5 Vent Pipe HORIZONAL LEFT --- LEFT VENT CONFIGURATION A11328A Requires Accessory Vent Kit See Product Data for Current Kit Number HORIZONTAL LEFT --- RIGHT VENT...

Page 52 - NOTES FOR VENTING OPTIONS; Vent Coupling and Adapter

52 NOTES FOR VENTING OPTIONS 1. Attach vent pipe adapter with gasket to furnace casing.2. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.3. Slide vent pipe through adapter and coupling into vent elbow.4. Insert vent pipe into vent elbow.5. Torque all clamp...

Page 54 - Optional Installation of the Vent Pipe; VENT PIPE FLUSH SHOWING COUPLING

54 mm) per linear ft.(1-in (25 mm) per 4 ft.(1.2 M)) with nosags between hangers is required. See Caution Box below. FURNACE RELIABILITY HAZARD Failure to follow this caution may result in nuisance short cycling, frozen vent termination, and/or no heat.Slope the vent and combustion air piping downwa...

Page 55 - Installing the Vent Termination; Roof Terminations; Inducer Outlet Restrictor

55 Installing the Vent Termination Roof Terminations A roof termination of any type will require a 4-in. (102 mm) flashing for a 2 in. (50 mm ND) concentric vent or a 5--in. diameter(127 mm) flashing for a 3-in. (80 mm ND) concentric vent kit. For two-pipe or single pipe vent systems, a flashing for...

Page 58 - Venting System Length Calculations; EACH; Example 1

58 Venting System Length Calculations The Total Equivalent Vent Length (TEVL) for EACH combustion air or vent pipe equals the length of the venting system, plus the equivalent length of elbows used in the venting system from Table 17.Standard vent terminations or factory accessory concentric vent te...

Page 59 - Inside Corner Terminations; Inside corner vent terminations are permitted provided that:

59 A190032 Fig. 51 -- Inside Corner Termination Inside Corner Terminations Inside corner vent terminations are permitted provided that: S Only two exterior walls come together to form an angle of 90 degrees to 135 degrees. There are no other exterior walls attached to either wall to form an alcove. ...

Page 66 - CHECK; Setup Switches

66 START--UP, ADJUSTMENT, AND SAFETY CHECK Important Installation and Start--up Procedures Failure to follow this procedure may result in a nuisance smoke or odor complaint.The manifold pressure, gas rate by meter clocking, temperature rise and operation must be checked after installation. Minor smo...

Page 67 - UNIT OPERATION HAZARD; Purge Gas Lines; FIRE OR EXPLOSION HAZARD; Adjustments

67 UNIT OPERATION HAZARD Failure to follow this caution may result in intermittent unit operation or performance satisfaction.Condensate trap must be PRIMED or proper draining may not occur. The condensate trap has two internal chambers which can ONLY be primed by pouring water into the inducer drai...

Page 68 - EXAMPLE 1; Adjust Manifold Pressure

68 In the USA, the input rating for altitudes above 2000 ft. (609.6M)must be reduced by 2 percent for each 1000 ft. (304.8M) above sea level. Refer to Table 18. The natural gas manifold pressures in Table 21 adjust for BOTH altitude and natural gas heating value. In Canada, the input rating must be ...

Page 69 - Burner Flame; Clocking the Meter; Adjust Temperature Rise

69 j. Move setup switch SW1--2 to OFF position after complet- ing low--heat adjustment. k. Leave manometer or similar device connected and proceed to Step 2. 2. Adjust manifold pressure to obtain high fire input rate See Fig. 32. a. Jumper R to W/W1 and W2 thermostat connections on fur- nace control...

Page 71 - Check Safety Controls; NOT; Checklist; OFF

71 b. Remove thermostat from subbase or from wall. c. Connect an amp. meter as shown in Fig. 63 across the R and W subbase terminals or R and W wires at wall. d. Record amp. draw across terminals when furnace is in low heat and after blower starts. e. Set heat anticipator on thermostat per thermosta...

Page 77 - Troubleshooting

77 SERVICE AND MAINTENANCE PROCEDURES Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. A qualified service personshould inspect the furnace once a year. FIRE, INJURY OR DEATH H...

Page 78 - Care and Maintenance

78 b. Look into blower door indicator for current LED status. c. Remove blower door. NOTE : The Status Codes cannot be retrieved by disconnecting the limit switch. To retrieve Status Codes, follow the procedurebelow. 2. Turn Setup Switch, SW1--1 “ON.”3. Manually close blower door switch.4. Control w...

Page 79 - Cleaning and/or Replacing Air Filter; CARBON MONOXIDE POISONING AND FIRE; ELECTRICAL SHOCK, FIRE OR EXPLOSION; Blower Motor and Wheel Maintenance

79 4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have furnace and burner serviced by a qualified service agency. 5. Inspect the vent pipe/vent system before each heating sea- son for water leakage, sagging pipes or broken fittings...

Page 81 - Cleaning Burners and Flame Sensor

81 b. Connect vent connector to vent elbow. 17. Turn on electrical supply. Manually close blower door switch. Use a piece of tape to hold switch closed. Check forproper rotation and speed changes between heating andcooling by jumpering R to G and R to Y/Y2 on furnace control thermostat terminals. If...

Page 82 - Servicing Hot Surface Igniter; Cleaning Condensate Drain and Trap

82 FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death, and/or property damage.Never purge a gas line into a combustion chamber. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of le...

Page 83 - Checking Heat Pad Operation (If Applicable); Cleaning Heat Exchangers; Primary Heat Exchangers; ELECTRICAL SHOCK AND FIRE HAZARD

83 gasket is included in the service kit or obtain one from your localdistributor. 1. Disconnect power at external disconnect, fuse or circuit breaker. 2. Turn off gas at external shut-off or gas meter.3. Remove control door and set aside.4. Turn electric switch on gas valve to OFF.5. Disconnect ext...

Page 84 - Secondary Heat Exchangers; WINTERIZATION; UNIT AND PROPERTY DAMAGE HAZARD; UNIT COMPONENT DAMAGE HAZARD

84 3. Disconnect wires or connectors to flame rollout switch, gas valve, igniter, and flame sensor. 4. Using backup wrench, disconnect gas supply pipe from fur- nace gas control valve. 5. Remove two screws attaching top filler plate and rotate up- wards to gain access to screws attaching burner asse...

Page 85 - SEQUENCE OF OPERATION

85 SEQUENCE OF OPERATION NOTE : Furnace control must be grounded for proper operation or else control will lock out. Control is grounded throughgreen/yellow wire routed to gas valve and burner box screw. Usingthe schematic diagram in Fig. 73, follow the sequence of operationthrough the different mod...

Page 91 - PARTS REPLACEMENT INFORMATION GUIDE; Consumer Relations Department

91 PARTS REPLACEMENT INFORMATION GUIDE Casing Group Blower doorBottom plateControl doorDoor knob assemblyTop filler plate Electrical Group 3--Amp fuseCircuit boardControl boxDoor switchJunction boxLimit switch(es)Transformer Blower Group Blower housingBlower motorBlower wheelCut--off platePower chok...