Carrier 58SX040 User Manual
58SX040
HEATING & COOLING
Deluxe'Gas-Fired Condensing Furnaces
Application Data
Installation Guidelines — Procedures
INTRODUCTIOIM
Portions of the following instructions have been
adopted in part from the National Fuel Gas Code
(NFPA 54-1984/ANSI Z223 1-1984) copyrighted by
the National Fire Protection Association and American
Gas Association. For further details, consult this
publication, or the current edition available from
National Fire Protection Association, Inc., Batterymarch
Park, Quincy, M A 02269, or American Gas Association,
1515 Wilson Boulevard, Arlington, VA 22209.
These instructions cover minimum requirements and
conform 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 pace with changing residential construction prac
tices. Carrier requires these standard procedures as a
minimum for a safe installation.
Refer also to regulations of the local gas supplier
as well as to local building, heating, plumbing, or other
codes in effect in area in which installation is made.
A WARNING
Never store items such as the following on, near, or
in contact with the furnace
1. Spray or aerosol cans, rags, brooms, dust mops,
vacuum cleaners, or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning
compounds; plastic items or containers; gasoline,
kerosene, cigarette lighter fluid, dry-cleaning
fluids, or other volatile fluids.
3 Paint thinners and other painting compounds.
4. Paper bags or other paper products.
LOCATION OF FURNACE AND
AIR FOR VENTILATION
Locate the furnace as near the center of the air distribu
tion system as possible.
Provide ample space for servicing and cleaning. Always
comply with the minimum fire protection clearances
shown on the unit rating plate This furnace must NOT
be installed directly on carpeting, tile, or any combustible
material other than wood flooring.
A CAUTION
Do not install furnace in unconditioned space that
could experience temperatures of 32 F or lower.
NOTE: For proper furnace operation, the furnace must
be installed within 1/2 in of level.
When furnace supply ducts deliver air to areas outside
the space containing the furnace, return air ducts must
also be sealed to furnace casing and must terminate
outside the space containing the furnace. Otherwise, a
negative pressure condition could develop within equip
ment room or space
Furnace Location Relative to Cooling Equip
ment — Install cooling coil in parallel with, or on
downstream side of, furnace to reduce potential for
condensation in heat exchanger. When a coil is installed
in parallel with a furnace, dampers or other means used
to control airflow must prevent chilled air from entering
furnace. For manual damper operation, equip dampers
with a means of preventing operation of either unit unless
damper is in the full-heat or full-cool position.
Special Locations — When installing furnace in a
CONTENTS
Page
INSPECTION
LOCATION OF FURNACE AND AIR FOR
VENTILATION
GAS PIPING
COMBUSTION-AIR, VENT, AND
CONDENSATE PIPING
ELECTRICAL CONNECTIONS ..................................... 5
START-UP, ADJUSTMENT, AND
SAFETY CHECK .......................................................... 6,7
Available power supply must meet specifications on
furnace rating plate and on all motors in the equipment
Check the available gas supply to see that it conforms
to the gas specification on the AGA rating plate.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 11 PC 101 Catalog No 515-806 Printed in U S.A Form 58SX-3XA Pg 1 2-85 Replaces: New
Tab 6a
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INSPECTION
I
1,2
2
2-5
lesidential garage, protect it from physical damage by
vehicles. Furnaces installed in public garages, airplane
hangars, or other buildings having hazardous atmos
pheres must comply with requirements of the National
Fire Protection Association, Inc.
Ventilation Air — Requirements depend upon
whether the furnace is located in an “unconfined” or
“confined” space:
Unconfined space — A space whose volume is not less
than 50 cu ft/1000 Btuh of the total input rating of all
appliances installed in the space Rooms are considered
a part of the unconfined space when they communicate
through openings not furnished with doors with the
space in which the appliances are installed.
No special ventilating means are required for furnaces
installed in unconfined spaces
Confined space — A space whose volume is less than
50 cu ft/1000 Btuh of the total input ratings of all
appliances installed in that space.
For casing ventilation purposes, provide the confined
space with 2 permanent openings, one within 12 in. of
top and one within 12 in. of bottom of enclosure. Each
opening shall have a minimum free area of one sq in /
1000 Btuh of total input rating of all equipment in
enclosure, but not less than 100 sq inches
Openings must freely communicate with interior areas
whose volume, when combined with tbe volume of the
confined space, meet the criteria for an unconfined space.
This can be accomplished through installation of either
permanent openings or louvered doors.
LOUVERS AND GRILLES — When calculating the
free area, consider the blocking effect of louvers, grilles,
or screens protecting openings Screen mesh size must
equal or exceed 1/4 inch Use the free area through the
design of the louver or grille, when known, to calculate
the opening size required to provide free area specified.
If free area is not known, assume that wood louvers will
have a 20 to 25% free area, while metal louvers and grilles
will have a 60 to 75% free area. Construct all louvers and
grilles providing combustion or dilution air so that they
cannot be closed
GAS PIPING
Gas piping must be installed in accordance with
national and local codes.
Run a separate gas supply line directly from the meter
to the furnace, if possible Table 1 shows recommended
gas pipe siziijg. Slope all pipe 1 /4 inch in 15 ft to prevent
traps. Slope all horizontal runs away from meter and
toward risers. Use risers to connect lines to furnace
and meter.
Apply joint compounds (pipe dope) sparingly and only
to male threads of joints Consult local gas supplier for
compound recommendations.
NOTE Use only compounds resistant to the action of
LP (propane) gas.
Install a sediment trap in the riser leading to the furnace
to trap dirt and condensate. Connect a tee to the riser
leading to the furnace, keeping straight-through section
of tee vertical. Connect a capped nipple into lower end
of tee, so that nipple extends below level of gas controls
(Fig. I).
Where a gum filter is required by local codes, install it
in accordance with their requirements.
An accessible manual shutoff valve must be installed
upstream of furnace gas controls and within 6 ft of
furnace. A 1/8-in. NPT plugged tapping, accessible for
test-gage connection,
must also be installed immediately
upstream of gas supply connection to furnace and down
stream of manual shutoff valve.
Install a ground joint union between gas control
manifold and manual gas sbutoff valve (Fig 1).
Table 1 — Maximum Capacity of Pipe*
NOMINAL
IRON PIPE
SIZE (In.)
'/2
Ÿ4
1
1V4
IV2
‘Cubic ft of gas per hour, for gas pressures of 0 5 psig (14 in wg)
or less, and a pressure drop of 0 5 in wg (based on a 0 60 specific
gravity gas)
INTERNAL
DIAMETER
(in.)
0.622 175 120
0.824 360 250 200
1.049
1.380 1400 950 770
1 610 2100 1460 1180
LENGTH OF PIPE (ft)
10 20 30
680 465 375
97
40
50
82 73
170 151
320
285
660 580
990 900
Fig. 1 — Ground Joint Union and Sediment Trap
Protect all segments of the piping system against
physical and thermal damage. Support all piping with
appropriate straps or hangers (one hanger every 6 ft
minimum). For pipe sizes larger than I/2 in., follow
recommendations of national codes.
A CAUTION
If a flexible connector is required or allowed by the
authority having jurisdiction, black iron pipe must
be installed at the gas valve and extend a minimum
of 2 in. outside the furnace casing
Pressure-test piping in accordance with local and
national plumbing and gas codes before attaching
furnace. Crack ground joint union before pressure
testing If pressure exceedsO.5 psig( 14 in. wg), disconnect
gas supply line from furnace before performing pressure
test If test pressure is equal to or less than 0.5 psig
(I4in. wg), close manual shutoff valve located on gas
valve before testing
After final connection to the furnace has been made,
purge lines and check for leakage with regulated gas
supply pressure
A WARNING
Never purge line into combustion chamber. Never
use matches, candles, flame, or other sources of
ignition to check for gas leakage. Use a soap-andwater solution to check for leaks.
COMBUSTION-AIR, VENT, AND
CONDENSATE PIPING
Construct all combustion-air and vent pipes for this
unit of schedule40 PVC, PVC-DWV, or ABS-DWV
pipe. The accessory vent terminal kit described below
must be used in constructing the vent terminal for this
unit. Pipes must terminate through either roof or sidewall; roof termination is preferable Locate sidewall
terminations to prevent damage to shrubs or siding
materials. Table 2 gives clearance requirements.
When a previously common-vented system (furnace
and water heater) is converted to water heater only, vent
system may be drastically oversized for water heater.
Consult National Fuel Gas Code for proper sizing and
revise vent system if necessary.
Combustion-Air and Vent Piping — The
schedule-40 PVC pipe and fittings must conform to
American National Standards Institute (ANSI) stand
ards and American Society for Testing and Materials
(ASTM) standards D1785, D2661, or D2665. PVC pipe
cement and primer must conform to ASTM D2235 or
D2564. See 'Table 3 for pipe sizing and Fig. 3, 4 and 5 for
exterior piping arrangements
A WARNING
Solvent cements are combustible. Keep away from
heat, sparks, and open flame. Use only in well venti
lated areas. Do NOT breathe vapors. Avoid contact
with the skin or eyes.
A WARNING
All combustion-air and vent pipes must be airtight
and watertight Pipes must terminate exactly as
shown in Fig. 3 through 5
A WARNING
Do NOT install
combustion
unit so that indoor air is used for
A CAUTION
Combustion air must not be taken from inside the
structure because that air frequently is contaminated
by halogens, which include fluoiides, chlorides,
bromides, and iodides. These elements are found
in aerosols, deteigents, bleaches, cleaning solvents,
salts, air fresheners and other household products.
Vapors from these products are highly corrosive to
gas-fired furnaces, even in extremely low concentra
tions (as low as 0 5 ppm).
Maintain a minimum ol .'16 in between com
bustion-air inlet and clothes-dryer vent
Locate combustion-air inlet as far as possible from
swimming pool and swimming pool pump house
A CAUTION
When the vent pipe is exposed to temperatures below
freezing — that is, when it passes through an un
heated space or when a chimney is used as a raceway
— the pipe must be insulated with 1/2-in thick
Armaflex insulation.
Furnace is shipped from factory assembled for righthand vent pipe connection. When left-hand vent connec
tion is desired, remove cap from left-hand side of inducer
outlet box and install over hole in right-hand side of box.
Remove plastic plug from left-hand casing side panel
and install plug in unused hole in the right-hand casing
side panel
Install the tuning valve in the vertical riser of the vent
pipe 18 in. above the elbow, as shown in Fig 2
To install piping.
1. Attach factory-supplied flexible coupling to furnace
combustion-air inlet connection and secure with
stainless steel hose clamp. Ensure that factorysupplied, perforated metal combustion-air disc is
installed in the flexible coupling
2 Working from furnace to outside, cut PVC pipe to
required length(s).
3. Deburr inside and outside of pipe
4. Chamfer outside edge of pipe for better distribution
of primer and cement
5. Clean and dry all surfaces to be joined.
6 Check dry fit of pipe and mark insertion depth on
pipe.
NOTE: All pipe should be cut, prepared, and pre
assembled before any joint is permanently cemented.
A CAUTION
When the combustion-air pipe is installed above a
suspended ceiling, the pipe must be insulated with
1/2-in Armaflex insulation
The combustion-air pipe should also be insulated
in warm, humid spaces such as basements.
Table 2 — Combustion-Air and
Vent Terminal Clearances
LOCATION
Dryer vent 3 ft
From plumbing vent stack 3 ft
From any opening where vent gases could
enter building
Above grade and anticipated snow depth 12 in.
Above grade when adjacent to public
walkway
CLEARANCE
12 in.
7 ft
Table 3 — Pipe Diameter (in.)
PIPE
LENGTH
(H)
5
10
15 2 2 2 2
20
25 2 2 2 2
30
35
NOTES
1. Assume two 45° elbows equal one 90° elbow.
2. Pipe lengths are “up to and Including” the tabulated values
3. Diameters listed are for schedule-40 PVC, PVC-DWV or
ABS-DWV pipe
4 Long radius elbows are desirable
5 Elbows and pipe sections supplied in vent terminal kit should
not be included in count
NUMBER OF 90° ELBOWS
(See Notes)
1 2 3 4
2 2 2 2
2 2 2
2 2 2 2
2
2
2
2
2
2
2 2
2 2
2 2
5
2
2
2
2
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