Carrier 580PB User Manual
58ED,PB
HEATING A COOLING
Horizontal Gas-Fired Furnaces
Installation, Start-Up and Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS
GENERAL .................................................................1
INSTALLATION ....................................................2-13
Step 1 — Select Location ...........................................2
Step 2 — Provide Air For Combustion and
Ventilation..............................................................3
Step 3 — Assemble Furnace ......................................3
• DRAFT HOOD
Step 4 — Size Ductwork
Step 5 — Vent Furnace ..............................................4
• MASONRY CHIMNEY
• TYPE B-1 VENT
• ATTIC INSTALLATION
Step 6 — Connect Gas Piping
• BURNER ORIFICES
Step 7 — Make Electrical Connections
Step 8 — Install Filters
.............................................
Step 9 — Reverse Components
(if required) ........................................................ 11-13
START-UP AND ADJUSTMENT ........................13-15
SERVICE AND MAINTENANCE
SAFETY CONSIDERATIONS
These instructions are intended for use by qualified
personnel who have been trained in installing this type of
furnace. Installation of this furnace by an unqualified
person may lead to equipment damage and/or a
hazardous condition which may lead to personal injury
GENERAL
This furnace is designed for use with either natural or
liquefied petroleum (propane) gases and has been design
certified by the American Gas Association It is shipped
as a packaged unit, complete with burners and controls,
and requires only a line voltage ( 115-v) connection to the
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1
4
5
6
II
15-17
Fig. 1 — Furnace Dimensions
(Modei 58ED Shown)
junction box and a thermostat hookup as shown in the
wiring diagram. The design of the furnace is such that
the burners, controls and flue outlet can be assembled
on the same side to facilitate servicing for installations
where only limited access to the unit is available. (See
Step 9 — Reverse Components.) The 58ED furnace
(with intermittent electronic ignition) is shown in Fig. I.
This furnace has been designed to interface with splitsystem cooling equipment (approved by UL) to provide
year-round air conditioning. The blower is sized for
both heating and cooling. Table I provides physical
data and dimensions of the furnaces, and Table 2 pro
vides airflow data.
The furnace installation must conform with local
building codes or, in the absence of local codes, with the
National Fuel Gas Code, NFPA54-I984/ANSI Z223.I-
I984 For complete information on installation standards
consult the National Fuel Gas Code, obtainable at a
nominal cost from the National Fire Protection Associa
tion, Inc., Batterymarch Park, Quincy MA 02269 or the
Table 1 — Physical Data and Dimensions
SIZE 58ED/PB FURNACE
INPUT (1000 Btuh)*
HEATING CAPACITY (1000 Btuh)t
Non-Weatherized
Indoor
TEMPERATURE RISE (F)
DIMENSIONS (ft-ln.)
NUMBER OF BURNERS
SHIPPING WEIGHT (lb)
‘Ratings shown are for elevations up to 2000 ft above sea level.
For elevations above 2000 ft, deduct 4% of input capacity for
each 1000 ft above sea level
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations.
Book|1 |4 PC101 Catalog No 535-834 Printed in U S A Form 58ED,PB-1SI Pg 1 6-85 Replaces: 58PB-1 SI
Tab |6a|8a
Length A
Width B
Duct Opening C
Vent Diameter D
E
F
G
OSO
50
38
39
35-65
4-6
1- V/2
0-11 Ye 0-11 Ye 1-ЗУв
0-4
1- 8%
0- 8%
1-4
1- 9У4 1- 9'/4
1- 7%
2
155
For replacement items use Carrier Specified Parts.
075 100
75 100 125 140
56
58 77
40-70 40-70
4-6
1- VÁ
0-4 0-5
1- 8У4 1-8У4
0- 8% 0-6У8
1-4
1- 7У4 1-7У4 1- 5У4
3
165 190
fDetermined as per U S Government standard tests
75
4-6
1-5
1-4
1-9У4
4
125
94 105
96
40-70
4-8
1- 8Уг 2-0
1- 6Ув 1-10Ув
0-5 0-6
1- 8У4
0- 9У2 0- 9Уг
1- 5У4
1-11 '/4
5
230 250
140
108
40-70
4-8
1- 7У4
1- 5У4
1-11 '/4
1- 5'/4
6
58ED,PB
HEATING A COOLING
American Gas Association, 1515 Wilson Boulevard,
Arlington, VA 22209.
A WARNING
The furnace cabinet must have an uninterrupted or
unbroken electrical ground to minimize personal
injury if an electrical fault should occur. The unit
must also be electrically grounded in accordance
with local codes, with the National Electrical Codes
ANSl/NFPA No. 70-1984 or the latest edition. Do
not use gas piping as an electrical ground.
INSTALLATION
Step 1 — Select Location — This furnace may be
located in an attic, basement crawl space, alcove or
suspended from the ceiling of a utility room or basement.
As shown in Table 3, the minimum clearances, or greater,
must be provided between the furnace and adjacent
construction.
A WARNING
Failure to comply with all the recommended clear
ances will result in a fire hazard.
If a furnace is to be installed in a residential garage, it
must be installed so the burners and the ignition source
are located not less than 18 in. above the floor and the
furnace must be located or protected to avoid physical
damage by vehicles.
The furnace should be located as close to the chimney
as possible in order to keep vent connections as short and
direct as possible. The furnace should also be located as
near to the center of the air distribution as possible, and
should be mounted level.
Horizontal Gas-Fired Furnaces
Since this furnace is suitable for attic installation, it
must not be installed directly on carpeting, tile or other
combustible material. Line contact is only permissible
between lines formed by the intersection of the furnace
top and two sides and the building joists, studs or
framing. See Fig. 2
A clearance of at least 30 in. should be provided at the
front of the furnace for combustion air and servicing.
For attic installations, the passageway and service area
adjacent to the furnace should have a floor installed.
The areas adjacent to the combustion air openings must
be covered with fireproof board or sheet metal extending
a minimum of 12 in. from the furnace. See Fig. 2.
If the furnace is to be installed in a crawl space, consult
local codes. Use of a concrete pad one to 2 in. thick is
recommended.
If the furnace is to be suspended from the ceiling, it is
necessary to use steel pipe straps around each end of the
furnace. These straps should be attached to the furnace
with sheet metal screws and bolted to the rafters. The
furnace may also be suspended by an angle iron frame
bolted to the rafters.
A WARNING
Do not place combustible material on or against
the draft hood.
A WARNING
The furnace is not watertight and is not designated
for outdoor installation.
Table 2 — Blower Data (Direct Drive)
FURNACE 58ED/PB
SERiES (15th Digit
of Model No.)
BLOWER SIZE (in)
DXW
MOTOR HP (PSC)
SPEED TAP
WIRE COLOR
BLOWER RPM
EXTERNAL STATIC
PRESSURE (in wg)
A
10x4 10x4
%
Hi
Lo
Red BIk
830 1070
20 50
930
765
050
B c
10x6 10x6
Va
Lo Hi
Red BIk
1080 700 920 1020
760
50 20
20
1220 790 1165
735
075 100
A B c A B c C
10x6 10x6
'/3 %
Lo Lo
Red Red BIk Blu BIk Blu Red
Va
Hi Med Hi
790
20 50 20 50 20 20
1130 995 1260 1090
'/3
Med Lo
1060 820 860
10x8
10x8 10x8
Va
'4
Hi
Med Hi Med
BIk Blu
990 730 1050
50 20 50
AIRFLOW (Cfm)
1290 1090 1530 1360 2010 I860
1310
'/3
BIk Blu
840 1070
20 50 20 50
Hi
BIk
125 140
D B c
12 X 9
'h
Med Hi
Blu BIk
12x9 12 X 12 12x12
3/4
Med Hi
820
Blu BIk Blu BIk Blu
920
1000
20 50 20 50 20
1810
2115
’/2
Med
1070 970
2100 1930
3/4
Hi Med
980 780
2350 2100
A WARNING
When operating furnace in heating mode, the static pressure
and the temperature rise (outlet air temperature minus room
temperature) must be within those limits specified on the
AGA rating plate.
Book|1 |4 PC101 Catalog No 535-834 Printed in U S A Form 58ED.PB-1 SI Pg 2 6-85 Replaces: 58PB-1 SI
Tab I6al8a
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without Incurring obligations.
For replacement Items use Carrier Specified Parts
58ED,PB
HEATING A COOLING
Table 3 — Alcove Clearances (In.)
TOP
8 6
’With draft hood in front of furnace
tWith draft hood on back of furnace
SIDES
BACK
8*
18t
DRAFT
HOOD
Line
Contact
SINGLE
WALL VENT
6
Step 2 — Provide Air For Combustion and
Ventilation — For an unconfined space (more than
50 cu ft of volume per 1,000 Btu of aggregate input rating
of all appliances installed in that space) such as a base
ment or attic, infiltration air is normally adequate to
provide air for combustion, ventilation and dilution of
flue gases. Adjoining rooms may be included if there are
no doors between the rooms
For a confined space, where air is taken from an
interior space, 2 permanent openings of equal area are
required. One opening must be within 12 in. of the ceiling
and the other must be within 12 in. of the floor. Each
opening must have a free area of at least 1 sq in. per
1000 Btu of total input rating but not less than 100 sq
inches.
If the outside air is supplied to a confined space, then
the 2 openings must be equal and located as above and
the free area of each must be:
Horizontal Gas-Fired Furnaces
A CAUTION
Whenever this furnace is installed in an area along
with one or more gas appliances, the total Btu input
of all appliances must be included when determining
the free area requirements for combustion and
ventilation air openings.
When ducts are used, they must be of the same cross-
sectional area as the free area of the openings to which
they connect. The minimum dimension of rectangular
air ducts must not be less than 3 inches.
The free area through a design of louver or grille
should be used in calculating the size opening required
to provide the free area specified. If the design and free
area is not known, it may be assumed that wood louvers
have 20-25% free area and metal louvers and grilles have
60-75% free area. Screens used must not be smaller than
1/4 in. mesh and louvers shall be fixed in the open posi
tion or interlocked with the equipment so that they are
opened automatically during equipment operation.
A WARNING
Do not block the combustion air openings in the
furnace. Any blockage will result in improper com
bustion and may result in a fire hazard or unsafe
condition
1. Onesqin. per 4,000 Btu of total input rating when
the air is directly communicated from the outdoors.
2. One sq in. per 4,000 Btu of total input rating when
the air is brought in through vertical ducts.
3 One sq in. per 2,000 Btu of total input rating when the
air is transferred through horizontal ducts.
LINE CONTACT ONLY
PERMISSIBLE BETWEEN
TOP CORNERS OF FURNACE
AND BUILDING JOISTS.
STUDS OR FRAMING.
KEEP ALL INSULATING
MATERIAL CLEAR OF
FURNACE. INSULATING
MATERIALS MAY BE
COMBUSTIBLE.
METAL EXTENDING 12 IN, FROM
UNDER COMBUSTION CHAMBER
Fig. 2 — Attic Installation Showing Point Contact
A CAUTION
For an attic installation, keep insulation 12 in. or
more away from any furnace openings. Some types
of insulating materials may be combustible.
Step 3 — Assemble Furnace — The burner and
controls are shipped in place and the furnace high- and
low-voltage wiring is complete to facilitate the installa
tion. Low-voltage wiring to the field-supplied thermostat
is necessary to complete the unit wiring (see Step 7 —
Make Electrical Connections).
In order to accommodate all the possible field installa
tions that may exist, the unit is designed so that the gas
valve, controls and draft hood assembly may be
assembled on either side of the furnace. Refer to Com
ponent Reversal section for details. After reversal (if
required), return to this section.
A CAUTION
Remove cardboard shipping insert from eye of the
blower scroll before energizing blower.
DRAFT HOOD — In order to save shipping space the
draft hood is shipped disassembled (on models 125 and
140 the left panel is spotwelded in place). Remove the
draft hood components from the blower compartment
(on some models the panels might be packed outside the
furnace jacket). On the models 50, 75 and 100 there will
Book|1 |4 PC101 Catalog No 535-834 PrintedinUSA Form 58ED.PB-1 SI Pg 3 6-85 Replaces: 58PB-1SI
Tab l6a|8a
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations.
For replacement items use Carrier Specified Parts
r
58ED,PB
HEATING & COOLING
be a wrapper, 2 panels (one marked with an “R”, the
other marked with an “L”) and a hardware package.
Refer to Fig 3 to assemble the draft hood. Depending
on the model, one or both panels are slid into the proper
location in order to line up the 4 mounting holes. Secure
the panel(s) with the screws provided
After completing the draft hood assembly, it is
advisable to check the overall size with Table 4.
Install the draft hood over the selected flue opening by
placing it on top of the draft hood clip and securing it to
the furnace jacket with screws provided. Adhere to the
necessary clearances as shown in Table 3.
Table 4 — Draft Hood Dimensions (in.)
FURNACE
58ED/PB
050
075
100
125
140
LENGTH
16
16
16 10
17'/4
17'/4
HEIGHT
10
10
10
10
DEPTH
8
8
8
8
8
PIPE DIA.
4
4
5
5
6
Step 4 — Size Ductwork— Proper ductwork sizing
is necessary to ensure satisfactory heating operation
Ductwork should be in accordance with the latest editions
of NFPA-90A (Air Conditioning Systems) and NFPA-
90 B(Warm Air Heating and Air Conditioning Systems).
Follow these recommendations when installingductwork:
1. Install locking-type dampers in all branch or indi
vidual ducts to balance out system. Dampers should
be adjusted to impose the proper static pressure at
the outlet of the furnace.
2 Noncombustible flexible duct connectors are recom
mended to connect both the supply and return ducts
to the furnace
3 In cases where the return air grille is located close to
the fan inlet, there should be at least one 90 degree air
turn between fan and inlet grille. Further reduction
in sound can be accomplished by installing acoustical
air turning vanes and/ or lining the inside of duct with
acoustical material.
Horizontal Gas-Fired Furnaces
When installing the furnace with cooling equipment
for year-round operation, the following recommenda
tions should be followed for series or parallel airflow:
1. In series airflow applications, the coil is mounted
after the furnace in an enclosure in the supply air-
stream. The furnace blower is used for both heating
and cooling airflow.
A WARNING
The coil must be installed on the air discharge
side of the furnace. U nder no circumstance should
the airflow be such that cooled, conditioned air
can pass over the furnace heat exchanger. This
causes condensation in the heat exchanger and
possibly early failure due to rust.
2. In parallel flow installation, dampers must be pro
vided to direct air over the furnace heat exchanger
when heat is desired and over the cooling coil when
cooling is desired.
IMPORTANT: The dampers should be adequate
to prevent cooled air from entering the furnace,
and if manually operated, must be equipped with
means to prevent operation of either the cooling
unit or furnace unless the damper is in the
full cool or heat position.
Step 5 — Vent Furnace — This furnace must be
A CAUTION
Air openings in burner cover, return air grilles, and
warm air registers must not be obstructed.
A WARNING
When supply ducts carry air circulated by the furnace
to areas outside the spaces containing the furnace,
return air shall also be handled by a duct sealed to
the furnace casing and terminating outside the space
containing the furnace.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book|1 14 PCiOl Catalog No 535-834 Printed in U S A Form 58ED,PB-1SI Pg4 6-85 Replaces: 58PB-1SI
Tab l6al8a
For replacement items use Carrier Specified Parts.
vented to the outside and in accordance with local codes
or requirements of the local utility. In the absence of local
codes, venting should conform to the requirements of
the National Fuel Gas Code (NFPA 54-1984/ANSI
Z223.1-1984 Part 7).
For additional venting information, refer to ANSI/
NFPA 211 Chimneys, Fireplaces, Vents and Solid Fuel
Burning Appliances.
This furnace must not be vented into a solid fuel
burning chimney. The chimney must be checked for
deterioration. Correct the condition before venting
the furnace into the chimney. The chimney must be
properly lined and sized per National Fuel Gas Code
(ANSI Z223.1-1984/NFPA-54, 1984).
58ED,PB
HEATING A COOLING
MASONRY CHIMNEY — This furnace can be vented
into an existing masonry chimney. Normal connections
to a chimney are made using single wall pipe; however,
single wall pipe is not approved to pass through any attic,
inside wall or concealed space or through any floor. For
further information, consult venting section of National
Fuel Gas Code.
TYPE B-1 VENT — The furnace is also approved for
use with a Type B-1 vent that terminates through the roof
(horizontal venting through an outside wall is not
approved). The vent must be terminated with a listed
cap or roof assembly. This venting must be installed in
accordance with the vent manufacturer’s instructions
and be in accordance with all local codes.
ATTIC INSTALLATION — Attic and/or National Fuel
Gas installations require the use of Type B or Type L vent
material The following requirements are provided for
venting system;
1. Ensure the chimney flue is clear of any dirt or debris.
2. Ensure the chimney is not serving an open fireplace.
3. Never reduce the pipe size below the outlet size of
the furnace.
GAS
SUPPLY
Horizontal Gas-Fired Furnaces
4. All pipe should be supported using the proper clamps
and/ or straps
5. All horizontal runs of pipe must have an upward
slope of 1/4 in. per foot.
6. All runs of pipe should be as short as possible with
as few turns as possible.
7. Seams must be tightly joined and checked for leaks.
8 The flue pipe must not extend into the chimney,
but be flush with the inside chimney wall.
9. The chimney or gas vent must extend 3 ft above the
highest point where it passes through a roof of a
building and at least 2 ft higher than any portion of a
building within a horizontal distance of 10 feet. It
shall also extend at least 5 ft above the highest
connected equipment flue collar.
10 Check local codes for any variance.
Step 6 — Connect Gas Piping — Install gas piping
to provide a supply of gas sufficient to meet the maximum
demand without undue loss of pressure between the gas
meter and the furnace. The gas line to the furnace should
be a separate line direct from the meter, unless the
existing gas line is of ample capacity. Refer to Table 5
for sizing gas piping.
Use a joint compound (pipe dope) resistant to the
action of liquefied petroleum gases or to any other
chemical constituents of the gases to be conducted
through the piping.
Before any system of gas piping is finally put into
service, it should be carefully tested to determine if it is
gas tight. The piping must withstand a pressure of 6 in. Hg
for a period of 10 minutes or as required by local
authority.
note:
LOCATE MANUAL SHUTOFF VALVE AS REQUIRED
BY THE LOCAL AUTHORITY OR CODE IN THE
ABSENCE OF SUCH A CODE, LOCATE THE
MANUAL MAIN
FROM THE FLOOR
FIELD SUPPLIED MAIN
MANUAL SHUTOFF VALVE
FURNACE
GAS VALVE -
Tl
CD
r'l
PIPE CAP MINIMUM OF I IN. FROM
FLOOR TO PERMIT REMOVAL
GAS PIPE LAYOUT AFTER REVERSING COMPONENTS
(SEE NOTE)
r
Lj
Fig. 4 — Gas Pipe Layout
A WARNING
The furnace and its individual shutoff valve must be
disconnected from the gas supply system during any
pressure testing of that system at test pressures in
excess of 1 / 2 psig. The furnace must be isolated from
the gas supply piping system at pressures equal to or
less than 1/2 psig.
GAS
SUPPLY
The recommended method for installing the gas piping
to the furnace is shown in Fig. 4. Also shown is correct
piping if the gas valve and controls have been reversed
in the field.
Table 5 — Gas Pipe Sizing (Cu Ft of Gas per Hour)'*
)
PIPE (ft)
10
20
30
40
50
75
100
150
* Based on gas pressures of 0 5 psig or less and pressure drop of
0 3 in wg and 0 60 specific gravity gas
DIAMETER OF PIPE — IPS (in.)
Vr % 1 IV4
132
278
92
190
73
152
63
130
—
115
—
—
_
520 1050
350 730
285 590
245 500
215 440
93 175 360
150 305
79
64 120 250
IV2
1600
1100
890
760
670
545
460
380
Manufacturer reserves the right to discontinue, or change at any time, specitications or designs without notice and without incurring obligations.
Book|1 |4 PC101 Catalog No 535-834 PrintedinUSA Form 58ED.PB-1SI Pg5 6-85 Replaces; 58PB-1 SI
Tab l6a|8a
For replacement items use Carrier Specified Parts
58ED,PB
HEATING & COOLING
Support all gas piping independent of the furnace. For
propane gas, a tank regulator is required to reduce supply
pressure to 12-13in.wg. For manifold pressure, see
Table 6.
Check all piping for leaks using soapy water and a
brush.
A CAUTION
Never use an open flame when testing for gas leaks!
Use a soap and water solution
A 1/8 in. NPT plugged tap accessible for test gage
connection must be installed immediately upstream of
the gas supply connection to the furnace if one is not
supplied on gas valve.
BURNER ORIFICES — The furnace is supplied with
standard orifices for the gas shown on the rating plate.
Table 6 shows combinations of heating values and
specific gravities for various fuels, from which proper
input may be obtained
Regardless of the type of gas used, when installation is
at an elevation of 2000 ft or more above sea level, orifices
may need to be changed, depending on local gas value.
For operation at elevations above 2000 ft, input ratings
should be reduced at the rates of 4% for each 1000 ft
above sea level. To change orifices, remove the burner
removal cover on the gas valve side of unit. Remove
manifold locking device and slide the manifold tray back
until each burner is clear of heat exchanger tube. See
Fig. 5 Pull the manifold tray forward until burners are
clear of furnace. Remove the locking device from each
burner and pull each burner back off the orifice.
A CAUTION
Take care when removing the pilot burner not to
damage the pilot gas line.
Horizontal Gas-Fired Furnaces
Fig. 5 — Burners Removed From Furnace
After securing the manifold assembly, replace all other
components and/or wiring, being sure that all connec
tions and screws are tightened.
A WARNING
If it is necessary to adjust the manifold pressure
more than 0.3 in. wg, the orifices must be changed
A WARNING
Never set the furnace input rate above that shown
on rating plate.
Use the following formula to determine the furnace
input rate:
After removing orifices, ensure the new orifiees are
Input (Btuh) = Heating Value of Gas (Btu/cu ft)
seated properly and tightened. Replace burners correctly
and secure with the locking device before replacing and
securing the manifold assembly.
X 7200 sec/2 hr
Time in sec for 2 cu ft of gas
Example. If the heating value of natural gas is 1015
_______
______
Btu/cu ft and it takes 75 seconds to burn 2cuft of gas,
A CAUTION
The manifold must be properly positioned in order
to engage the locking mechanism
then:
Input (Btuh) = 1015 Btu/cu ft X 7200 sec/2 hr
75 sec/2 cu ft
Input = 97,440 Btuh
When checking rate, make sure all other gas appliances
are shut off except for pilot burners.
Table 6 — Burner Orifices
Step 7 — Make Electrical Connections — The
control system depends on the correct polarity of the
TYPE OF GAS
(Heating Value — SP GR)
BTU PER CU FT
NATURAL — MANIFOLD PRESS. 3.5 in. wg
800 — 0.6
900 — 0.6
1000 — 0.6
1100 — 0.6
PROPANE — MANIFOLD PRESS. 10 in. wg
2500 — 1.53
Book|1 |4 PC101 Catalog No 535-834 Printed in U S A Form 58ED.PB-1 SI Pg6 6-85 Replaces: 58PB-1SI
Tab l6al8a
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
ORIFICE SIZE
(Drill No.)
43
44
45
46
54
For replacement items use Carrier Specified Parts
power supply. Connect field power wiring and field
ground wire as shown in Fig. 6 and 7.
A WARNING
The unit cabinet must have a separate uninterrupted
or unbroken electrical ground to minimize personal
injury if an electrical fault should occur.
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