Carrier 58PAV User Manual

58PAV

HEATING A COOLING

Upflow Induced-Combustion Furnaces

Installation, Start-Up, and Operating Instructions

Sizes 035-125,

NOTE: Before beginning the installation, READ THESE

INSTRUCTIONS CAREFULLY AND COMPLETELY.

SAFETY CONSIDERATIONS

Installation and servicing of heating equipment can be haz
ardous due to gas and electrical components. Only trained
and qualified personnel should install, repair, or service
heating equipment.

Untrained personnel can perform basic maintenance func
tions such as cleaning and replacing air filters. All other
operations must be performed by trained service personnel.
When working on heating equipment, observe precautions
in the literature, tags, and labels attached to or shipped

with the unit and other safety precautions that may apply.
Follow all safety codes. In the United States, follow all

safety codes including the National Fuel Gas Code NFPA
No. 54-1988/ANSI Z223.1-1988. In Canada, refer to the cur
rent edition of the National Standard of Canada CAN/CGA­B149.1- and .2-M86 Natural Gas and Propane Gas Installa
tion Codes. Wear safety glasses and work gloves. Have fire
extinguisher available duriag startup and adjustment pro
cedures and service calls.

Recognize safety information: This is the safety-alert symognize

A. VI

bol A. When you see this symbol on the furnace and in
instructions or manuals, be alert to the potential for per
sonal injury.

Understand the signal word—DANGER, WARNING, or
CAUTION. These words are used with the safety-alert sym
bol. DANGER identifies the most serious hazards which

will result in severe personal injury or death. WARNING

signifies a hazard that could result in personal injury or
death. CAUTION is used to identify unsafe practices, which
would result in minor personal injury or product and prop
erty damage.

Table 1—Minimum Clearances From

Combustible Materials (In Ins.)

Size
Sides—Single-Wall Vent 1 0

Type B-1 Double-Wall Vent
Back
Top of Plenum
Vent Connector—Single-Wall Vent

Type B-1 Double-Wall
Vent

Front—Single-Wall Vent

Type B-1 Double-Wall Vent
Service

NOTES:

1. Provide 30-in. front clearance for servicing. An open door in front of the
furnace can meet this requirement.

2. A minimum clearance of 3 ins. must be provided in front of the furnace
for combustion air and proper operation.

035 and 055 075 thru 125

0 0
0 0
1 1
6 6

1 1
6 6

3 ■ 3

30 30

These instructions cover minimum requirements and con
form to existing national standards and safety codes. In
some instances, these instructions exceed certain local
codes and ordinances, especially those that may not have
kept up with changing residentieil construction practices.

We require these instructions as a minimum for a safe

installation.

INTRODUCTION

The design of the upflow gas-fired furnace is A.G.A./CGA
certified for natural and propane gas and for instaUation on
combustible flooring, in alcoves, attics, basements, closets,
or utility rooms. The design of this furnace line is not
A.G.A./CGA certified for installation in mobile homes, rec
reation vehicles, or outdoors.

Before instalhng the furnace, refer to the current edition of
the National Fuel Gas Code NFPA No. 54-1988/ANSI
Z223.1-1988. Canadian installations must be installed in
accordance with CAN/CGA.B149 Installation Codes and aU
authorities having jurisdiction. For further information, the
National Fuel Gas Code is available from National Fire
Protection Association Inc. Batterymarch Park, Quincy,
MA 02269, American Gas Association, 1515 Wilson Boule
vard, Arlington, VA 22209, or from Literature Distribution.

Installation must conform to the regulations of the serving
gas supplier and the local building, heating, and plumbing
codes in effect in the area in which the installation is made,
or in the absence of local codes, with the requirements of the
National Fuel Gas Code.

A CAUTION

Application of this furnace should be indoors with spe
cial attention given to vent sizing and material, gas
input rate, air temperature rise, and unit sizing.
Improper installation or misapplication of the furnace
can require excessive servicing or cause premature
component failure.

This furnace is designed for a minimum continuous return
air temperature of 60 degrees F DB or an intermittent oper
ation down to 55 degrees F DB such as when used with a
thermostat night setback. Return air temperature must not
exceed a maximum of 85 degrees F DB.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations.

Book] 1 I 4 PC 101 Catalog No. 565-913 Printed in U.S.A. Form58PA-1SI Pg 1 5-90 Replaces: New
Tab 16a i 8a

RETURN AIR.

Fig. 1 —Dimensional Drawing

A WARNING

Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poison
ing, explosion, fire, electrical shock, or other conditions
which may cause personal injury or property damage.
Consult a qualified installer, service agency, local gas
supplier or your distributor or branch for information
or assistance. The qualified installer or agency must use
only factory authorized and fisted kits or accessories
when modifying this product. A failure to foUow this
warning can cause electrical shock, fire, personal injury,
or death.

For accessory installation details, refer to the applicable
instruction literature.

NOTE: Remove aU shipping brackets and materials before
operating the furnace.

I. LOCATION
A. General

A CAUTION

Do not install furnace in a corrosive or contaminated
atmosphere. Make sure all combustion and circulating
air requirements are adhered to, in addition to eiU local
codes and ordinances.

Do not use this furnace during construction when adhe
sives, sealers, and/or new carpets are being installed. If
the fm-nace is required during construction, use clean
outside air for combustion and ventilation. Compounds
of chlorine and fluorine when burned with combustion
air form acids which will cause corrosion of the heat

exchangers and metal vent system. Some of these com
pounds are: paneling and dry waU adhesives, paints,
thinners, masonry cleaning materials, and many other
solvents commonly used in the construction process.

Locate the furnace close to the chimney/vent and as near
the center of the air distribution system as possible. The
furnace should be installed as level as possible.

When a furnace is installed so that the supply ducts carry
air to areas outside the space containing the furnace, the
return air must also be handled by a duct(s) sealed to the
furnace casing and terminating outside the space containing
the furnace.

Provide ample space for servicing and cleaning. Always
comply with the minimum fire protection clearemces shown
on the unit rating plate. This furnace shall not be installed
directly on carpeting, tüe, or any combustible material other
than wood flooring.

Table 2—Dimensions (In Ins.)

Vent Conn

Size
035-EC
035-GC 14-3/16 12-9/16

055-EC 14-3/16 12-9/16
055-GC 14-3/16 12-9/16
075-GC 17-1/2 15-7/8
075-JC 21
090-GC
090-JC 21
090-LC 24-1/2 22-7/8 23
110-JC
110-LC 24-1/2 22-7/8 23
125-LC

A D

14-3/16 12-9/16

17-1/2

21

24-1/2

19-3/8
15-7/8
19-3/8

19-3/8
22-7/8

E
12-11/16
12-11/16
12-11/16
12-11/16

16

19-1/2

16

19-1/2
19-1/2

23

4
4
4 126
4 128
4 143
4 147
4 153
4 159
4 176
5
5
5 196

B. Location With Respect to Cooling Equipment

The coofing coil must be installed parallel with, or on the
downstream side of, the furnace to avoid condensation in
the heat exchangers. When installed parallel with a furnace,
dampers or other means used to control the flow of air must
prevent chilled air from entering the unit. If the dampers
are manually operated, they must be equipped with means
to prevent operation of either unit unless the damper is in
the full-heat or fuU-cool position.

C. Hazardous Locations

When the furnace is installed in a residential garage, it must
be installed so that the burners and ignition source are
located no less them 18-ins. above the floor. Also, the fur
nace should be protected from physical damage by vehicles.

When a furnace is installed in public garages, airplane han
gars, or other buildings having hazardous atmospheres, the
unit must be installed in accordance with the recommended
good practice requirements of the National Fire Protection
Association, Inc.

II. AIR FOR COMBUSTION AND VENTILATION

Provisions for adequate combustion and ventilation air
must be provided in accordance with Section 5.3, Air for
Combustion and Ventilation, of the National Fuel Gas Code,
ANSI Z223.1-1988, or applicable provisions of the local
building codes.

Canadian installations must be installed in accordance with
CAN/CGA.B149 Installation Codes, and aU authorities hav
ing jurisdiction.

Ship. Wt

116
118

171
186

A CAUTION

Air for combustion must not be contaminated by halo
gen compounds, which include fluoride, chloride, bro
mide and iodide.

These elements are found in aerosol sprays, detergents,
bleaches, cleaning solvents, salts, air fresheners, and
other household products.

AU fuel burning equipment must be supplied with air for
combustion of the fuel. Sufficient air MUST be provided to
insure there wfll not be a negative pressure in the equipment
room or space. In addition, a positive seal MUST be made
between the furnace cabinet and the return-air duct puUing
air from the burner area and draft safeguard opening.

A CAUTION

The operation of exhaust fans, kitchen ventilation fans,
clothes dryers, or fireplaces could create a negative
pressure condition at the furnace. Make up air must be
provided for the ventilation devices, in addition to that
required by the furnace.

WA

Combustion air requirements are determined by whether
the fiunace is in an UNCONFINED or CONFINED space.
A confined space is a space whose volume is less than 50
cubic ft per 1000 Btu per hour of the total output rating for
aU appliances installed in that space.

I

A. Unconfined Space

An unconfined space must have at least 50 cubic ft for each
1000 Btuh of input for all the appliances (i.e. furnaces,
clothes dryer, water heaters, etc.) in the space.

For Example:

Minimum Sq Ft

58PAV Furnace

Input Btuh

with

7-1/2 Ft Ceiling

1. All air from inside the structure
Each opening MUST have at least 1 square in. of free
area per 1000 Btuh of the total input for all equipment
within the confined space, but not less than 100 square
ins. per opening. See Fig. 2.

For Example:

58PAV Furnace

Input Btuh

Free Area per Opening

(square ins.)
44,000 100
66,000 100
88,000 100

110,000 110
132,000

132

154,000 154
44,000 293
66,000

88,000 587

110,000
132,000
154,000

If the unconfined space is of unusually tight construction,
air for combustion and ventilation MUST come from either
the outdoors or spaces freely communicating with the out
doors. Combustion and ventilation openings must be sized
the same as for a confined space. A minimum opening hav
ing a total of not less than 1 square in. per 5000 Btuh of
total input rating for all equipment must be provided.
Return air must not be taken from the room, unless an equal
or greater eimount of air is supplied to the room.

B. Confined Space

A confined space MUST have two permanent openings, one
within 12-ins. of the ceiLing, and the other within 12-ins. of
the floor. See Fig. 2.

NOTE: In deterniining the free area of an opening, the
blocking effect of the louvers, grilles and screens must be
considered. If the free area of a louver or grille design is
unknown, it may be assumed that wood louvers have a 20
percent free area and metal louvers or grilles have a 60 per
cent free area. Screens, when used, must not be smaller than
1/4-in. mesh. Louvers and grilles must be constructed so
they cannot be closed.

The size of the openings depend upon whether the air comes
from inside or outside of the structure.

SUPPLY

AIR

r~Hn

VENT TO ROOF

12 MAX

440

733
880

1026

If the building is of unusually tight construction, a perma
nent opening directly communicating with the outdoors
shall be provided. This opening shall have a minimum free
area of 1 square in. per 5000 Btuh of total input rating for
all equipment in the enclosure.

If the furnace is installed on a raised platform to provide a
return air plenum, and return air is taken directly from the
hallway or space adjacent to the furnace, aU air for combus
tion must come from outdoors.

2. All air from outdoors
a. If combustion air is taken from outdoors through

vertical ducts, the openings and ducts MUST have
at least one square inch of free area per 4000 Btuh
of the total input for aU equipment within the con
fined space. See Fig. 3.

For Example:

58PAV Furnace

input Btuh

44,000
66,000

88,000
110,000
132,000
154,000

Free Area per Opening

(square ins.)

11.0 4

16.5 5

22.0 6

27.5 6

33.0 7

38.5 7

Round Pipe

(ins. dia)

b. If combustion air is taken from the outdoors through

horizontal ducts, the openings and ducts MUST have
at least one square in. of free area per 2000 Btuh of the

1 so INCH PER
4000 BTUH

I'. ".I

T TO ROOF

MAX 12

1 SQ INCH PERT
2000 BTUH

DUCTS
TO ROOF-

SUPPLY D

AIR

A A VENT

^ 1 SQ INCH

PER 1000

I BTUH*

INTERIOR
HEATED
SPACE

-6 MIN

(FRONT)

♦Minimum opening size is 100 square ins.
tMinimum of 3 ins. when type-B vent is used.

Fig. 2

A89012

DUCTS TO
OUTS DE

1 SQ INCH PER

2000 BTUH ^

MAX 12

A

RETURN AIR

USE ANY OF THE FOLLOWING
COMBINATIONS OF OPENINGS:
A&B C&D D&E

j

Fig-3

,^PER 4000

DUCT
TO OUTSIDE

i

2 MAX

1 SQ INCH

BTUH

A89013

total input for all equipment within the confined space.

For Example:

58PAV Furnace

Input Btuh

44,000
66,000

88,000 44.0
110,000
132,000 66.0
154,000

Free Area per Opening

(square ins.)

22.0

33.0

55.0

77.0

Round Pipe

(ins. dia)

6
7
8

9
10
10

When ducts are used, they must be of the same cross sec
tional area as the free area of the openings to which they
connect. The minimum dimension of rectangular ducts must
not be less than 3-ins. See Fig. 3.

The front bracket(s) are installed on the bottom front plate
as shown in Fig. 5, once the bottom enclosure has been
removed. Rotate filter supports 180 degrees so filter will
rest on support emd reinstall. (Do not reinstall in 17-1/2-in.
casing.) Install the filter retaining rod (small U-shaped end)
in the rear bracket, and the front of the filter retainer rod as

shown in Fig. 5. Two sets of hardware are needed for fur
naces in 24-1/2-in. casings using one filter for bottom return.
All hardware is provided for filter installation.

A WARNING

Never operate unit without a filter or with filter access
door removed. A failure to follow this warning can
cause a fire, personal injury, or death.

A WARNING

Do not install the furnace on its back; safety control
operation will be adversely affected. Never connect
return-air ducts to the back of the furnace. A failure to
follow this warning can cause a fire, personal injury, or
death.

III. FILTER ARRANGEMENT

The factory-supphed filter(s) is shipped in the blower com
partment. Deterrnine location for the filter and move filter
retaining hardware, if necessary, before attaching the
return-air duct. After the return-air duct has been connected
to the furnace, install the filter(s) inside the furnace blower
compartment. See Fig. 4 for side return apphcation and Fig.
5 for bottom return application.

A bottom closure panel is factory-installed in the bottom of
the furnace. When bottom return inlet is desired, remove
and discard the enclosure panel.

Filter retaining brackets, supports, and retainers are fac
tory assembled and shipped installed for side return appUca­tion, with one set of all required hardware provided. See Fig.

4. For bottom return appHcations, remove the brackets
(front and back) and supports from each side. The back
bracket(s) are installed in the rear of the furnace casing
(dimples are provided to mark mounting screw locations).

Table 3—Filter Information

Furnace

Casing Width

14-3/16

17-1/2

21

24-1/2

*Filter can be field-modified by cutting to the desired size. Aiternate sizes

can be ordered from your Distributor or Deaier.

fFactory provided with the furnace.

Side Return Bottom Return

(1)16x25x1
(1)16x25x1
(1)16x25x1
(2)16x25x1

Fiiter Size* Fiiter

(1)14x25x1t
(1)16x25x1t
(1)20 x 25x1t
(1)24 x 25x1t

Type

Cleanable
Cleanable
Cleanable
Cleanable

Fig. 4—Side Filter Arrangement

Fig. 5—Bottom Filter Arrangement

IV. LEVELING LEGS (If Required)

When the furnace is used with side inlet(s), and leveling legs
are required, refer to Fig. 6, and install field-supplied
corrosion-resistant 5/16-in. machine bolts and nuts.

NOTE; The maximum length of the bolt should not exceed
1-1/2 ins.

1. Lay furnace on its back, locate and drill 5/16-in. diame
ter hole in each bottom corner of furnace as shown in
Fig. 6.

2. Install nut on bolt and install bolt and nut in hole.
(Install flat washer if desired.)

3. Install another nut on other side of furnace base.
(Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and
tighten inside nut to secure arrangement.

V. GAS PIPING

Gas piping must be installed in accordance with national
and local codes. Refer to the current edition of the National
Fuel Gas Code. Canada installations must be installed in
accordance with CAN/CGA.B149 Installation Codes, and all
authorities having jurisdiction.

The gas supply line should be a separate line running
directly from the gas meter to the furnace, if possible. Refer
to Table 4 for the recommended gas pipe size. Risers must
be used to connect to the furnace and the meter.

Table 4—Maximum Capacity of Pipe*

Nominal

Iron Pipe

Size
Ins.

1/2
3/4

1
1-1/4
1-1/2

*Cubic ft of gas per hour, for gas pressures of 0.5 psig (14 ins. wc) or less,

and a pressure drop of 0.5 in. wc (based on a 0.60 specific gravity gas).
Ref; Table C-4 NFPA 54-1988.

Internal

Diameter

Ins.

0.622 175

0.824

1.049 680

1.380 1400

1.610 2100 1460 1180 990 900

10 20 30 40 50
360 250 200 170

Length of Pipe, Ft

120
465

950 770 660 580

97

82 73

375 320

151
285

Fig. 7—Typical Gas Pipe Arrangement

made, purge the lines and check for leakage with regulated
gas supply pressure.

Install a sediment trap in the riser leading to the furnace.
The trap can be installed by connecting a tee to the riser
leading from the furnace. Connect a capped nipple into the
lower end of the tee. The capped nipple should extend below
the level of the gas controls. See Fig. 7.

Apply joint compound (pipe dope) sparingly and only to the
male threads of each joint. The compound must be resistant
to the action of propane gas.

A WARNING

Never purge a line into a combustion chamber. Never
use matches, candles, flame, or other sources of ignition
for the purpose of checking leakage. Use a soap-and­water solution to check for leakage. A failure to follow
this warning can cause a fire, explosion, personal
injury, or death.

An accessible manual shut-off valve shall be installed
upstream of the furnace gas controls and within 6 ft of the
furnace. A 1/8-in. NPT plugged tapping, accessible for test
gauge connection, must be installed immediately upstream
of the gas supply connection to the furnace and downstream

of the manual shut-off valve. Place ground joint union
between the gas control manifold and the manual shut-off
valve.

A WARNING

Use the proper length of pipes to avoid stress on the

gas control manifold. A failure to follow this warning
can cause a gas leak resulting in a fire, explosion, per
sonal injury, or death.

A CAUTION

If a flexible connector is required or allowed by the
authority having jurisdiction, black iron pipe shall be
installed at the gas valve and extend a minimum of 2­ins. outside the furnace casing.

Piping should be pressure-tested in accordance with local

and national plumbing and gas codes before the furnace has
been attached. If the pressure exceeds 0.5 psig (14 in. wc),
the gas supply pipe must be disconnected from the furnace
and capped before the pressure test. If the test pressure is
equal to or less than 0.5 psig (14 in. wc), close the manual
shut-off valve located on the gas valve before the test. It is
recommended that the ground joint union be loosened
before pressure testing. After all connections have been

A CAUTION

Use a backup wrench when connecting the gas pipe to
the furnace to avoid damaging gas controls.

VI. ELECTRICAL CONNECTIONS
A. 115-Volt Wiring

Refer to the unit rating plate or Table 5 for equipment elec
trical requirements. The control system requires an earth
ground for proper operation.

A CAUTION

Do not connect aluminum wire between disconnect
switch and furnace. Use only copper wire.