Carrier 59MN7A Installation, Start-Up, Operating And Service And Maintenance Instructions

Modulating 4-way multipoise condensing gas furnace series 200

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Installation, start-up, operating and service and maintenance instructions (86 pages)

Operating instructions manual (96 pages)

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Page 1: Table Of Contents
59MN7A Modulating 4---Way Multipoise Condensing Gas Furnace Series 200 Installation, Start---up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the Checklist ........
Page 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 10 2) Revise 10.8.3 by adding the following additional requirements: a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...
Page 3: Safety Considerations
SAFETY CONSIDERATIONS CAUTION WARNING CUT HAZARD Failure to follow this caution may result in personal injury. FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and Failure to follow this warning could result in dangerous gloves when handling parts, and servicing furnaces.
Page 4: Introduction
13. These furnaces SHALL NOT be installed directly on carpet- S CANADA: Part 8 of the CAN/CSA B149.1- -2010, Venting ing, combustible tile, or any other combustible material oth- Systems and Air Supply for Appliances er than wood flooring. In downflow installations, factory Duct Systems accessory floor base MUST be used when installed on com- S US and CANADA: Air Conditioning Contractors Association...
Page 5: Accessories
General surface of the furnace again before touching control or wires. These furnaces are shipped with materials to assist in proper 5. Use this procedure for installed and uninstalled (ungroun- furnace installation. These materials are shipped in the main ded) furnaces. blower compartment.
Page 6 pressure in the equipment room or space. A positive seal must be WARNING made between the furnace cabinet and the return- -air duct to prevent pulling air from the burner area. FIRE HAZARD WARNING Failure to follow this warning could result in personal injury, death and/or property damage.
Page 7 A12267 59MN7 SHIP WT. BOTTOM LB (KG) FURNACE SIZE CABINET WIDTH OUTLET WIDTH AIR INTAKE INLET WIDTH 060--- 14 154.0 (69.3) 17--- 1/2 (445) 15--- 7/8 (403) 16 (406) 8--- 3/4 (222) 080--- 14 164.0 (73.8) 060--- 20 158.5 (72.0) 080--- 20 21 (533) 19--- 3/8 (492)
Page 8 THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE OF THE BURNER SECTION, BURNER SECTION, AND...
Page 9: Air For Combustion And Ventilation
AIR FOR COMBUSTION AND Outdoor Combustion Air Method VENTILATION 1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent hori- Introduction zontal or vertical duct(s) or opening(s) directly communicat- Direct Vent (2- - pipe) Applications ing with the outdoors or spaces that freely communicate with the outdoors.
Page 10 Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO OPENINGS OR TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING VERTICAL DUCTS (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) FURNACE (1 SQ. IN./4,000 BTUH) (1,100 SQ.
Page 11: Condensate Trap
CONDENSATE TRAP NOTICE Condensate Trap- -Upflow Orientation When the furnace is installed in the upflow position, it is not The field- -supplied, accessory horizontal drain trap grommet is necessary to relocate the condensate trap or associated tubing. ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. Refer to Fig.
Page 12 Remove pressure switch tube from pressure switch port. Remove relief tube from relief port on condensate trap. Remove tube from Remove trap from relief port. collector box. Loosen clamp on inlet Remove middle and bottom plugs. to vent elbow. DO NOT DISCARD. Trim excess tube.
Page 13 Remove plug from collector box. DO NOT DISCARD. If alternate vent position is required, loosen clamp on inlet of vent elbow. Remove trap from collector box. Unconverted Factory Trap Configuration As Viewed in the Horizontal Right Orientation Slide relief tube in stand-offs to adjust length.
Page 14 Remove trap from collector box. If alternate vent position is required, loosen clamp Remove relief tube on vent elbow inlet. from relief port on condensate trap. Remove pressure switch tube from port on collector box. Remove relief tube from port on collector box.
Page 15: (Downflow). (Note: When The Inducer Housing Has Been
CONDENSATE DRAIN CONNECTION 4. From inside the casing, insert the formed grommet end of the elbow through the 7/8- -in. knockout in the casing. CAUTION 5. Pull the grommet through the casing from the outside until it is seated in the knockout 6.
Page 16: Horizontal
the other side of the casing should be facing the front of the 7. The remaining drain line can be constructed from field- - furnace. supplied 1/2- -in. CPVC or 3/4- -in. PVC pipe, in compliance with local building codes. A factory- -supplied 1/2- -in. 11.
Page 17: Condensate Drain
INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAP PULL DRAIN STUB THROUGH CASING NOTE: Trap grommet is required only for direct-vent applications. Remove knockout. Install grommet before relocating condensate OPEN SPRING CLAMP trap. INSERT FACTORY SUPPLIED 1/2 IN. CPVC TO 3/4 IN.
Page 18: Installation
INSTALLATION Leveling Legs (If Desired) In upflow position with side return inlet(s), leveling legs may be NOTICE used. See Fig. 20. Install field- -supplied, 5/16 x 1- -1/2 in. (8 x 38 mm) (max) corrosion- -resistant machine bolts, washers and nuts. NOTE: Bottom closure must be used when leveling legs are used.
Page 19 Return Air Connections Suspended Furnace Support The furnace must be supported under the entire length of the WARNING furnace with threaded rod and angle iron. See Fig. 27. Secure angle iron to bottom of furnace as shown. Roll- - Out Protection FIRE HAZARD Provide a minimum 12- -in.
Page 20 There are no provisions for an internal filter rack in these furnaces. An external filter is required. The furnace is shipped with a factory-supplied Media Filter Cabinet. The Media Filter Cabinet uses either a standard 1- -in. (25 mm) filter or 4- -in. (102 mm) wide Media Filter which can be purchased separately.
Page 21 Table 5 – Filter Media Pressure Drop (Clean) Versus Airflow - - In. W.C. (Pa) Representative After-Market Filter Media* 14 x 25 Filter Factory-Accessory Factory-Accessory (356 x 635 mm) Washable Media* Fiberglass* Pleated* (1-in. / 2.5 cm) (4-in. / 10 cm) (1-in.
Page 22 Table 7 – Air Filter Selection and Duct Sizing - - In. (mm) FILTER SIZE FURNACE CASING WIDTH FILTER TYPE SIDE RETURN BOTTOM RETURN 16 x 25 x 3/4 16 x 25 x 3/4 17---1/2 (445) Washable* (406 x 635 x 19) (406 x 635 x 19) 16 x 25 x 3/4 20 x 25 x 3/4...
Page 23 4-in. Block Off 21-in. Furnace 14-3/16 and 17-1/2-in. Plate Furnace 4-Ton or less, AC capacity airflow 1/2-in. Screws 20-in. Media Cabinet 16-in. Media Cabinet Media Cabinet Installation Media Cabinet Installation Option for Side Return 4-Ton or Less A/C Capacity 21- or 24-1/2-in. 21-in.
Page 24 FURNACE FURNACE (OR COIL CASING WHEN USED) APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING PLENUM OPENING DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR SHEET METAL PLENUM OPENING FLOOR FLOOR OPENING OPENING A10491 Fig. 18 - - Installation on Combustible Flooring Table 8 –...
Page 25: Upflow
UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT 90° 90° FLANGE 120° 120° 120° A10493 Fig. 19 - - Duct Flanges ″ 5/ 16 (8mm) (8mm) ″ 5/ 16 ″ (44mm) ″ (44mm) (8mm) ″ BOTTOM CLOSURE PANEL (8mm) 5/ 16 ″ (44mm) 3/ 4 ″...
Page 26 ANY COMBINATION OF 1, 2, OR 3 PERMITTED. A11036 A11037 Fig. 23 - - Upflow Return Air Configurations and Restrictions Fig. 24 - - Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig. 25 - - Horizontal Return Air Configurations and Restrictions...
Page 27 COMBUSTION - AIR PIPE (SEE VENTING SECTION) 30 IN. (762 mm) MIN. WORK AREA 2-IN. (51 mm) ROLLOUT PROTECTION REQUIRED Install 12” x 22” (305 x 559 mm) sheet metal in front of burner compartment area. A11154 Fig. 26 - - Working Platform for Attic Installation NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.
Page 28: Air Ducts
AIR DUCTS NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. NOTICE Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended. Many states, provinces and localities are considering or have Maintain a 1- -in.
Page 29 Table 9 – Cooling and Heating Air Delivery - - CFM (Bottom Return With Filter) (SW1-5 and SW4-3 set to OFF, except as indicated. See notes 1 and 2) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2 SWx-1 060-14 Clg Default:...
Page 30 Table 9 - - Cooling and Heating Air Delivery - - CFM (Bottom Return With Filter) (Continued) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2 SWx-1 080-14 Clg Default: 1055 1065 1080 1075 1065 1050 1045 1035 1025 1005 CF Default:...
Page 31 Table 9 - - Cooling and Heating Air Delivery - - CFM (Bottom Return With Filter) (Continued) Clg/CF Switch Settings External Static Pressure (ESP) Unit Size SWx-3 SWx-2 SWx-1 100-22 Clg Default: 1820 1825 1840 1845 1840 1835 1825 1805 1780 1770 CF Default:...
Page 32: Gas Piping
GAS PIPING WARNING WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could result in personal FIRE OR EXPLOSION HAZARD injury, death, and/or property damage. Failure to follow this warning could result in personal If local codes allow the use of a flexible gas appliance injury, death, and/or property damage.
Page 33: Electrical Connections
Table 10 – Maximum Capacity of Pipe Field- -supplied wiring shall conform with the limitations of 63_F (33_C) rise. NOMINAL LENGTH OF PIPE --- FT (M) IRON PIPE SIZE WARNING (3.0) (6.0) (9.1) (12.1) (15.2) IN. (MM) 1/2 (13) 3/4 (19) ELECTRICAL SHOCK AND FIRE HAZARD 1 ( 25) Failure to follow this warning could result in personal...
Page 34: J- -Box Installation
J- -Box Installation 3. Secure power cord to J- -Box bracket with a strain relief bushing or a connector approved for the type of cord used. WARNING 4. Pull furnace power wires through 1/2- -in. (12 mm) diameter hole in J- -Box. If necessary, loosen power wires from strain—relief wire- -tie on furnace wiring harness.
Page 35: Alternate Power Supplies
2. Humidifier (HUM) nicating User Interface. It is not required when the furnace is controlled by a standard type thermostat. Refer to the in- The HUM terminal is a 24 VAC output, energized when the blower structions supplied with the User Interface for complete de- is operating during a call for heat.
Page 36 GROUND NEUTRAL LINE VOLTAGE ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY ALUMINUM WIRE A12226 A11146 Fig. 30 - - Installing J- -Box (When Used) Fig. 31 - - Field- -Supplied Electrical Box on Furnace Casing Appearance May Vary...
Page 37 To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip A11157 Fig. 32 - - Field- -supplied Isolation Relay for Humidifiers with Internal Power Supply W/W1 Y/Y2 A11401 Fig.
Page 38 COMMUNICATION CONTINUOUS FAN OUTDOOR SW4 SETUP (CF) AIRFLOW AIR TEMP SWITCHES CONNECTOR SETUP SWITCHES CONNECTOR MODEL PLUG PL8 - MODULATING CONNECTOR GAS VALVE CONNECTOR SW1 SETUP SWITCHES AND BLOWER OFF- DELAY AIR CONDITIONING (A/C) AIRFLOW SETUP SWITCHES HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.
Page 39 THERMOSTAT THERMOSTAT See notes 2, 5, 7, 10, 11, 16, and 17 See notes 1, 2, 4, 6, 7, 9, 10, 11, 15, 16, and 17 Modulating and 2-Stage Furnace with Single-Speed Heat Pump Modulating and 2-Stage Furnace with Single-Speed Air Conditioner THERMOSTAT THERMOSTAT See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13, 15, 16, and 17...
Page 40: Venting
NOTES FOR THERMOSTAT WIRING DIAGRAMS 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. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two speed heat pump control. Heat pumps with date code 1601E and later do not have or require a “ZONE”...
Page 41: Materials
Other gas appliances with their own venting system may also use WARNING the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code and the vent or liner manufacturer’s installation instructions. Care must CARBON MONOXIDE POISONING HAZARD be taken to prevent the exhaust gases from one appliance from Failure to follow the steps outlined below for each appliance...
Page 42: Locating Vent Termination
Table 12 – Vent Termination Kit for Direct Vent (2- -pipe) WARNING Systems DIRECT VENT DIAM. OF COMBUS- TERMINATION (2--- PIPE) TION AIR AND VENT SYSTEM CARBON MONOXIDE POISONING HAZARD TERMINATION KIT PIPES --- IN. (mm) 2 ---in. (51 mm) Single Penetration of 1, 1 ---1/2, 2, or 2 ---1/2 Failure to follow the instructions outlined below for each...
Page 43: Size The Vent And Combustion Air Pipes
4. Termination or termination kit should be positioned where it away by use of an elbow or tee, certified to ULC S636 from the will not be damaged by or subjected to foreign objects such adjacent property line must be used. See Fig. 48. as stones, balls, etc.
Page 44: Combustion Air And Vent Piping Insulation Guidelines
9. If the Total Vent Length is longer than the Maximum In any configuration, it will be necessary to add the equivalent length of the tee (15 feet/5 M) to the Total Equivalent Vent Length Equivalent Vent Length for the diameter of pipe chosen, of the venting system.
Page 45 Install the Vent and Combustion Air Pipes 4. Slide the end of the rubber vent coupling with notches in it over the standoffs on the vent pipe adapter. With the furnace installed in the required position, remove the 5. Insert a length of vent pipe through the coupling into the desired knockouts from the casing.
Page 46: Installing The Vent Termination
termination elbows as shown in Fig. 46, 47 and 48. diameter (127 mm) flashing for a 3-inch (80 mm ND) concentric For Ventilated Combustion Air Termination, See Fig. 49. vent kit. For two-pipe or single pipe vent systems, a flashing for each pipe of the required diameter will be necessary.
Page 47 NOTE: Do not allow insulation or other materials to accumulate this instruction. inside of pipe assembly when installing it through hole. 1. Cut two holes, one for each pipe, of appropriate size for pipe size being used. 4. Locate assembly through sidewall with rain shield posi- tioned no more than 1- -in.
Page 48 Table 14 – Maximum Allowable Exposed Vent Lengths Insulation Table - - Ft. / M Maximum Length of Uninsulated and Insulated Vent Pipe-Ft (M) No Insulation 3/8-in. (9.5 mm) 1/2-in. (12.7 mm) Modulating Pipe Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Winter Design Furnace High...
Page 49 NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 16 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 15 – Maximum Equivalent Vent Length - - Ft. (M) 0 to 4500 Ft.
Page 50: Venting System Length Calculations
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 16. Standard vent terminations or factory accessory concentric vent terminations count for zero deduction. See vent system manufacturer’s data for equivalent lengths of flexible vent pipe or other termination systems.
Page 51 NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 16 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 17 – Maximum Equivalent Vent Length - - Ft. (M) 4501 to 10,000 Ft.
Page 52 Attach gaskets to vent pipe and Vent Coupling and Adapter combustion air adapters. A11314 Fig. 36 - - Vent Coupling and Adapter with Gaskets VENT ELBOW CLAMP TORQUE 15 LB-IN. INDUCER OUTLET VENT PIPE CLAMP TORQUE 15 LB-IN. MODULATING INDUCER ASSEMBLY VENT ELBOW A11286 Fig.
Page 53 Any other unused knockout may be used for combustion air Any other unused connection. knockout may be used Rotate vent elbow to for combustion air required position. connection. Rotate vent elbow to & required position. A11308 A11309 Any other unused knockout may be used for combustion air connection.
Page 54 Rotate vent elbow to required position. Rotate vent elbow to required position. Any other unused knockout may be used for combustion air connection. A11311 A11312 A11313 Downflow Vertical Requires Accessory Internal Vent Kit. See Product Data for current kit number. Attach vent pipe adapter with gasket to furnace casing.
Page 55: Horizontal Left
HORIZONTAL LEFT - HORIZONTAL LEFT - VERTICAL VENT CONFIGURATION LEFT VENT CONFIGURATION HORIZONTAL LEFT - RIGHT VENT CONFIGURATION* *Requires Accessory Internal Vent Kit See Product Data for Current Kit Number Attach vent pipe adapter with gasket to furnace casing. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. Slide vent pipe through adapter and coupling into vent elbow.
Page 56 HORIZONTAL RIGHT - HORIZONTAL RIGHT - VERTICAL VENT CONFIGURATION LEFT VENT CONFIGURATION* *Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT - RIGHT VENT CONFIGURATION Attach vent pipe adapter with gasket to furnace casing. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. Slide vent pipe through adapter and coupling into vent elbow.
Page 57 ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND-OFF ON ADAPTER. TORQUE LOWER CLAMP 15 LB-IN. WHEN REMAINING VENT PIPE ADAPTER WITH GASKET VENT PIPE IS INSTALLED, TORQUE INSTALLED ON FURNACE VENT UPPER CLAMP TO 15 LB-IN. PIPE IS CUT FLUSH WITH TOP OF ADAPTER.
Page 58 A12326 NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony...
Page 59 A12325 NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony or...
Page 60 Roof Termination (Preferred) Note: 36 in. separation between pairs of inlets only required for direct vent systems Note: Vertical separation between At least 36 in. “A” denotes 0 To 2 in. (51mm) combustion air and vent (914mm) Between the first 2 vents Third 8 ¾...
Page 61 OPTIONAL TERMINATION BRACKET FOR 2-PIPE TERMINATIONS OPTIONAL BRACKET 12-IN. COUPLING (305 MM) 12 IN. (305 MM) SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT. MAINTAIN 12 IN. (305 MM) CLEARANCE ABOVE HIGHEST ANTICIPATED 12-IN. (305 MM) SNOW LEVEL OR GRADE, ABOVE ANTICIPATED WHICHEVER IS GREATER.
Page 62 Ventilated Combustion Air intake pipe Pipe hangar 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE highest level of insulation ATTIC A10497 Fig. 49 - - Vent Terminations for Ventilated Combustion Air...
Page 63 EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. A12220 Fig. 50 - - Sample Inlet Air Pipe Connection for Polypropylene Venting Systems TO CODE APPROVED DRAIN OR CONDENSATE PUMP Representative drawing only, some models may vary in appearance L12F028 Fig.
Page 64: Start- -Up, Adjustment, And Safety Check
START- -UP, ADJUSTMENT, AND SAFETY NOTE: If modulating dampers are used, blower motor automatically compensates for modulating dampers. CHECK Air Conditioning (A/C) Setup Switches (SW2) General The air conditioning setup switches are used to match furnace 1. Furnace must have a 115-v power supply properly connec- airflow to required cooling airflow or high stage cooling airflow ted and grounded.
Page 65: Purge Gas Lines
CAUTION WARNING FIRE HAZARD UNIT OPERATION HAZARD Failure to follow this warning could result in personal Failure to follow this caution may result in intermittent unit injury, death and/or property damage. operation or performance satisfaction. DO NOT push or force gas valve adjusting screw. This can Condensate trap must be PRIMED or proper draining may result in damage to the adjustment screw resulting in not occur.
Page 66 provided in the furnace installation instructions to match the 2. Remove the 1/8 in. NPT plug from the inlet pressure tap on required orifice to the manifold pressure to the heat content and the gas valve. specific gravity of the gas. 3.
Page 67 8. After the main burners ignite and the blower starts, confirm 4. Measure time (in sec) for gas meter to complete one Maximum Heat manifold pressure is correct, based on the revolution and note reading. The 2 or 5 cubic feet dial manifold pressure tables in the installation instructions.
Page 68 When setup switch SW1- -4 is ON, operation will be near the high 4. Check the position of setup switch SW1- -3. When set to end of the rise range for improved comfort. ON, airflow is raised 18% for Minimum Heat and for Intermediate Heat.
Page 69: Check Safety Controls
Descriptions. Depending on the model size, the cooling airflow e. Set heat anticipator on thermostat per thermostat can be adjusted from 1.5 to 6 tons based on 350 CFM ton. instructions and install on subbase or wall. NOTE: 6 ton airflow will truncate at 2200 CFM on applicable f.
Page 70: Burner Orifice
MODULATING ON/OFF Switch Min/Max Heat Adust (Under Cap) Turn screw 1 click per second to adjust rate. Clockwise to increase rate, counter clockwise to decrease rate. Inlet Pressure Tap BURNER ORIFICE 1/2” NPT Outlet Manifold Pressure Tap A10496 A93059 Fig. 52 - - Gas Valve Fig.
Page 71 338307-201 Rev. F A11594 Fig. 55 - - Service Label Information...
Page 72 A11623 Fig. 56 - - Furnace Setup Switches and Description...
Page 73 Furnace Setup Switch Description Turn ON to retrieve up to 7 stored status codes for SW1-1 Status Code Recovery troubleshooting assistance when R thermostat lead is disconnected. When SW1-2 and SW4-2 are OFF allows Modulating operation Minimum Heat Only with a single stage thermostat. Turn ON SW1-2 when using (Adaptive Heat Mode two-stage thermostat to allow Minimum Heat operation when SW1-2...
Page 74 Table 18 – Altitude Derate Multiplier for U.S.A.* Table 19 – Blower Off Delay Setup Switch PERCENT DERATE SETUP SWITCH ALTITUDE MULTIPLIER (SW1---7 AND ---8) DESIRED HEATING MODE DERATE FACTOR* POSITION BLOWER OFF DELAY (SEC.) 0–2000 0---610 1.00 SW1--- 7 SW1--- 8 2001–3000 610---914...
Page 75 Table 21 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate To Be Used with Modulating Furnaces Except 59MN7A060V21- -20 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
Page 76 Table 21- - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) To Be Used with Modulating Furnaces Except 59MN7A060V21- -20 MODULATING FURNACE (TABULATED DATA BASED ON 20,000 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
Page 77 Table 22 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate To Be Used with Modulating Furnaces 59MN7A060V21- -20 Only (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
Page 78 Table 22 - - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) To Be Used with Modulating Furnaces 59MN7A060V21- -20 Only (TABULATED DATA BASED ON 20,200 BTUH MAX-HEAT / 8,000 BTUH MIN-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE...
Page 79: Service And Maintenance Procedures
SERVICE AND MAINTENANCE Electrical Controls and Wiring PROCEDURES WARNING WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury FIRE, INJURY OR DEATH HAZARD or death. Failure to follow this warning could result in personal There may be more than one electrical supply to the furnace. injury, death and/or property damage.
Page 80 Care and Maintenance 2. Turn Setup Switch, SW1- -1 “ON.” 3. Manually close blower door switch. WARNING 4. Control will flash up to 7 Status Codes. 5. The last Status Code, or 8th Code, will be Code 11. FIRE OR EXPLOSION HAZARD 6.
Page 81 3. Check electrical connections for tightness and controls for The inducer and blower motors are pre- -lubricated and require no proper operation each heating season. Service as necessary. additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor. 4.
Page 82 13. Reinstall blower assembly in furnace. Refer to Fig. 63. 14. Reinstall 2 screws securing blower assembly to blower 1. Disconnect power at external disconnect, fuse or circuit deck. breaker. 15. Reconnect blower leads to furnace control. Refer to furnace 2.
Page 83 Flushing Collector Box and Drainage System NOTE: Use propane-resistant pipe dope to prevent leaks. Do not use Teflon tape. WARNING 13. Install the gas pipe to the gas valve. WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury, FIRE OR EXPLOSION HAZARD death, and/or property damage.
Page 84: Cleaning Heat Exchangers
3. Align the condensate trap with the drain opening on the col- WARNING lector box and secure the trap with the screw 4. Attach the relief hose to the relief port on the condensate trap and collector box. ELECTRICAL SHOCK, FIRE OR EXPLOSION 5.
Page 85 3. Remove furnace control door. WARNING 4. Remove the top unused rubber plug from the port on the collector box opposite the condensate trap. See Fig. 59. FIRE OR EXPLOSION HAZARD 5. Connect a field supplied 3/8- -in. (9.5- -mm) ID tube to the open port on the collector box Failure to follow this warning could result in personal injury, death, and/or property damage.
Page 86: Burner Flame
A11392 A11273 Fig. 59 - - Priming Condensate Trap Fig. 60 - - Cleaning Heat Exchanger Cell (Appearance May Vary) Burner Flame Burner Manifold A11461 Fig. 61 - - Burner Flame...
Page 87 GROMMET MOTOR SHAFT FLAT MOTOR ARM SCREW SET SCREW MOTOR WHEEL HUB SEE DETAIL SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT DETAIL CUTOFF, BLOWER WHEEL, BLOWER BLOWER HSG ASSY BRACKET CAPACITOR OR POWER CHOKE (WHEN USED) MOTOR, BLOWER SCREW (GND) A11584 Fig.
Page 88 IGNITER BURNER SUPT. ASSY BRACKET, IGNITER BURNER ASSY FLAME ROLLOUT SWITCH FLAME SENSOR (BELOW BURNER) A11403 Fig. 63 - - Burner Assembly...
Page 89 A11290A Fig. 64 - - Troubleshooting Guide...
Page 90 A11290B...
Page 91 A11290C...
Page 92: Sequence Of Operation
SEQUENCE OF OPERATION This selection is based upon the stored history of the length of previous gas-heating periods of the single-stage thermostat. CAUTION The furnace will start up in either intermediate-, or maximum-heat. The furnace will transition and operate at minimum-heat or the calculated modulating rate after starting and operating for 45 UNIT OPERATION HAZARD seconds at intermediate-heat.
Page 93 CPU will repeat the ignition sequence for up to three more inducer motor RPM. The blower motor BLWM will trans- Trials-For-Ignition before going to Ignition-Lockout. Lock- ition to the maximum-heat airflow five seconds after the out will be reset automatically after three hours, or by mo- furnace control CPU switches from a medium range input mentarily interrupting 115 vac power to the furnace, or by to maximum-heat.
Page 94 inducer motor speed gets within 15% of the required inter- NOTE: The air conditioning relay disable jumper ACRDJ must be mediate-heat RPM the furnace control CPU will start a 5 connected to enable the adaptive cooling mode in response to a call second blower airflow change delay.
Page 95 DHUM. When there is a dehumidify demand, the DHUM input is motor BLWM will remain ON until the main burners ignite then activated, which means 24 vac signal is removed from the DHUM shut OFF and remain OFF for the blower-ON delay (45 seconds in input terminal.
Page 96 338307-201 Rev. F A11595 Fig. 65 - - Wiring Diagram...
Page 97 CARRIER CORPORATION Consumer Relations Department P.O. Box 4808 Syracuse, New York 13221 1- -800- -CARRIER Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part. Model Nomenclature COOLING HEATING...
Page 98 Catalog No:59MN7A ---05SI Copyright 2012 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 06/12 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: 59MN7A--- 04SI...

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59tp6a series 2