Carrier 59MN7, 59SC2, 59SC5, 59SP5, 59TN6 Owner's Manual

Condensing Gas Furnace

Owner’s Manual

NOTE TO INSTALLER:

THIS MANUAL MUST BE LEFT WITH THE

EQUIPMENT USER.

USER: PLEASE READ ALL INSTRUCTIONS

IN THE MANUAL AND RETAIN ALL

MANUALS FOR FUTURE REFERENCE.

! WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow warnings could result in personal injury, death, or property damage.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

-Do not try to light any appliance.

-Do not touch any electrical switch; do not use any phone in your building.

-Leave the building immediately.

-Immediately call your gas supplier from a nearby

phone. Follow the gas supplier’s instructions.

- If you cannot reach your gas supplier, call the fire

department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

A11263

!WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury and/or death.

Carbon Monoxide is invisible, odorless, and toxic! Install a carbon monoxide alarm in your home, even if you do not own a gas appliance. Locate the carbon monoxide alarm in the living area of your home and away from gas appliances and doorways to attached garages. Follow the alarm manufacturer’s instruction included with the alarm.

!WARNING

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Do not use this furnace if any part has been under water. A flooddamaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and to replace all gas controls, control system parts, and electrical parts that have been wet, or the entire furnace if deemed necessary.

TABLE OF CONTENTS

WELCOME TO A NEW GENERATION OF COMFORT . . . . 2 FURNACE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4 BEFORE STARTING YOUR FURNACE . . . . . . . . . . . . . . . . . 5 STARTING YOUR FURNACE . . . . . . . . . . . . . . . . . . . . . . . . . 5 SHUTTING DOWN YOUR FURNACE . . . . . . . . . . . . . . . . . . 7 PERFORMING ROUTINE MAINTENANCE . . . . . . . . . . . . . 8 FILTERING OUT TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . 9 COMBUSTION AREA AND VENT SYSTEM . . . . . . . . . . . 11 WINTERIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A CHECKUP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . 13 BEFORE YOU REQUEST A SERVICE CALL . . . . . . . . . . . 13 INSTALLATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

WELCOME TO TODAY’S GENERATION

OF COMFORT

Congratulations! In light of rising energy costs, a 90+% AFUE Condensing Gas Furnace from Carrier Corporation is among the soundest investments today’s homeowner can make.

Your new furnace is truly a triumph of technology in home heating. A revolutionary design employs two heat exchangers to “squeeze” out the maximum amount of heat from the fuel consumed. In fact, your new furnace is so efficient, over 90%* of the heat generated during combustion is captured and delivered inside your home.

This furnace is among the safest, most dependable, energyefficient furnaces you can buy today. We are proud of the technological advances incorporated into the design of this furnace. With only minimal care, your new furnace will deliver many years of moneysaving home comfort and enjoyment. Spend just a few minutes with this manual to learn the operation of your new furnace and the small amount of maintenance it takes to help keep it operating at peak efficiency year after year.

* The output capacity and any representations of efficiency for this furnace are based on standard U.S. Department of Energy test procedures.

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CERTIFIED

Use of the AHRI Certified TM Mark indicates a manufacturer’s participation in the program. For verification of certification for individual products, go to www.ahridirectory.org.

!WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death, or property damage.

Improper servicing could result in dangerous operation, serious injury, death or property damage.

SBefore servicing, disconnect all electrical power to furnace.

SWhen servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

S Verify proper operation after servicing.

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FURNACE COMPONENTS

Furnace shown in upflow position; may be used in downflow or horizontal orientation or applications.

HOT SURFACE

GAS BURNER

IGNITER

MANUAL RESET

ROLLOUT SWITCH

FLAME

SENSOR

MANUAL RESET

ROLLOUT SWITCH

GAS VALVE

OPERATING INSTRUCTIONS

NOT SHOWN (LOCATED ON

MAIN FURNACE DOOR, SEE

OPERATING INSTRUCTIONS

INSIDE DOOR FIGURE).

ELECTRICAL JUNCTION BOX (IF REQUIRED, LOCATION MAY VARY)

MAIN LIMIT SWITCH (BEHIND GAS VALVE)

INDUCER MOTOR ASSEMBLY

BLOWER DOOR

SAFETY SWITCH

FURNACE

CONTROL

BOARD

MEDIA CABINET

BLOWER AND

MOTOR

CAPACITOR/

POWER CHOKE

RATING PLATE NOT SHOWN (LOCATED ON BLOWER DOOR)

REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY IN APPEARANCE.

A11408

Fig. 1 - Furnace Components

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SAFETY CONSIDERATIONS

Installing and servicing of heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. Observe safety precautions in this manual, on tags, and on labels attached to the furnace and other safety precautions that may apply.

Recognize safety information. This is the safetyalert symbol . When you see this symbol on the furnace and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. DANGER, WARNING, and CAUTION are used with the safetyalert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

To minimize the possibility of serious personal injury, fire, damage to your furnace, or improper operation, carefully follow these safety rules which apply to both directvent and nondirect vent applications:

SYour new gas furnace may have been installed in one of two ways, as a directvent (2- pipeFig. 2) application or as a nondirect vent (1- pipeFig. 3) application.

SIn a directvent (2- pipe) application, your furnace uses air from outside the home for combustion and vents flue gas to the outdoors. This type of application will have two pipes running from the furnace to the outdoors. In some cases, the inlet air pipe may be located in an area that has access to outdoor air, such as an attic. In all cases, the outlet vent pipe must be routed to the outdoors. (See Fig. 2.) In this application, the vent and

airintake pipes must terminate outside the structure and must not be obstructed in any way. Do not block or obstruct air openings on furnace or spaces around furnace.

SIn a nondirect vent (1- pipe) application, your furnace uses air from adjacent to the furnace for combustion and vents flue gas to the outdoors. This type of application will have only one pipe running from the furnace to the outdoors. (See Fig. 3.) The other pipe will terminate in the same space as the furnace and is the source of combustion air for your furnace. Therefore, the furnace must not be enclosed in an airtight room or be sealed behind solid doors. It must have adequate airflow for efficient combustion and safe ventilation. Do not obstruct the combustionair pipe in any way. The vent pipe must terminate outside the structure and must not be obstructed in any way. Do not block or obstruct air openings or space around furnace.

!WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow warnings could result in personal injury, death, or property damage.

Keep insulation clear of furnace and maintain clearances shown on unit clearance label.

Do not keep combustible materials, gasoline, and other flammable liquids or vapors around your furnace.

A11254

Fig. 2 - Exterior Vent Pipes

A11255

Fig. 3 - Interior Combustion - Air Pipe

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!WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Do not keep combustible materials, gasoline, and other flammable liquids or vapors around your furnace.

SKeep the area around your furnace clear and free of combustible materials, gasoline, and other flammable liquids and vapors.

A92182

Fig. 4 - NO combustible materials near furnace

SDo not cover the furnace, store trash or debris near it, or in any way block the flow of fresh air to the unit.

!CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in intermittent unit operation.

For proper and safe operation the furnace needs air for combustion and ventilation. Do not block or obstruct air openings on the furnace, air opening to the area in which the furnace is installed, and the space around the furnace.

SIn addition to the safety rules above, make sure that the following combustionair requirements are met for nondirect vent applications:

SCombustion air must be clean and uncontaminated with chlorine or fluorine. These compounds are present in many products around the home, such as: water softener salts, laundry bleaches, detergents, adhesives, paints, varnishes, paint strippers, waxes,

and plastics.

SMake sure the combustion air for your furnace does not contain any of these compounds. During remodeling be sure the combustion air is fresh and uncontaminated. If these compounds are burned in your furnace, the heat exchangers may deteriorate.

SA furnace installed in an attic or other insulated space must be kept free and clear of insulating material. Examine the furnace

area when the furnace is installed or when insulation is added. Some insulation materials may be combustible.

SShould the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off electrical supply.

This furnace contains SAFETY DEVICES which must be MANUALLY RESET. If the furnace is left unattended for an

extended period of time, have it checked periodically for proper operation. This precaution will prevent problems associated with no heat, such as frozen water pipes, etc. See “Before You Request a Service Call” section in this manual.

BEFORE STARTING YOUR FURNACE

Examine the furnace installation to determine that:

1.All flue gas carrying areas external to the furnace (i.e. chimney, vent connector) are clear and free of obstructions.

2.The vent connector is in place, slopes upward and is physically sound without holes or gaps.

3.The returnair duct connection(s) is physically sound, is sealed to the furnace casing, and terminates outside the space containing the furnace.

4.The physical support of the furnace is sound without sagging cracks, gaps, etc. around the base.

5.There are no obvious signs of deterioration of the furnace.

6.The burner flames are in good adjustment, See Fig. 5 (by comparison with pictorial sketches or drawings of the main burner flame.)

Burner Flame

Burner

Manifold

A11461

Fig. 5 - Burner Flame Adjustment

!WARNING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death or property damage.

Should the gas supply fail to shut off or if overheating occurs, turn off the manual gas valve to the furnace BEFORE turning off the electrical supply and install lockout tag.

STARTING YOUR FURNACE

Instead of a continuously burning pilot flame which wastes valuable energy, your furnace uses an automatic, hot surface ignition system to light the burners each time the thermostat signals the furnace to start.

Follow these important safeguards:

SNever attempt to manually light the burners with a match or other source of flame.

A92319

Fig. 6 - Do Not Light Burner with Match

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