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Carrier 58ZAV manual

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Table of contents for the manual

  • Page 1

    WeatherMaker 8000™ 58ZAV Downflow/Horizontal Induced-Combustion Furnaces Installation, Start-Up, and Operating Instructions Sizes 050—135, Series 140 NOTE: Read the entire instruction manual before starting the installation. This symbol → indicates a change since the last issue. Index Page SAFETY CONSIDERATIONS ...............................[...]

  • Page 2

    ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will pre- vent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions w[...]

  • Page 3

    INTRODUCTION The model 58ZAV Series 140 Furnaces are available in sizes 46,000 through 135,000 Btuh input capacities. The design of the downflow/horizontal gas-fired furnace is A.G.A./C.G.A. certified for natural and propane gases and for installation on noncombustible flooring. The furnace is factory- shipped for use with natural gas. A factory ac[...]

  • Page 4

    Improper installation, adjustment, alteration, service, mainte- nance, or use can cause carbon monoxide poisoning, explo- sion, fire, electrical shock, or other conditions which may cause personal injury, loss of life, or property damage. Consult a qualified installer, service agency, local gas sup- plier, or your distributor or branch for informat[...]

  • Page 5

    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. All fuel-burning equipment must be supplied with air for combus- tion of the fuel. Sufficient air MUS[...]

  • Page 6

    Step 3—Supply Air Connections DOWNFLOW FURNACES Connect supply-air duct to supply-air opening on furnace. The supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used), when installed on non-combustible material. When installed on combus- tible material, supply-air duct attachment must [...]

  • Page 7

    to attach any portion of return-air duct. Bypass humidifier connec- tions should be made at ductwork or coil casing sides exterior to furnace. Step 5—Downflow Installation NOTE: This furnace is approved for use on combustible materials or wood flooring. A factory accessory floor base, as listed on the furnace rating plate, MUST be used. A factory[...]

  • Page 8

    Fig. 6—Furnace, Plenum, and Subbase Installed on a Combustible Floor A96285 DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR OPENING FURNACE (OR COIL CASING WHEN USED) COMBUSTIBLE FLOORING Fig. 7—Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor A96284 CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX [...]

  • Page 9

    INSTALL FURNACE 1. Position furnace in desired location. 2. Connect gas supply pipe. See Fig. 8 for typical piping entry. 3. Install field-supplied filter retainers as indicated in Fig. 11 and Table 4 before connecting return-air duct to furnace. 4. Connect supply- and return-air ducts. 5. Install 24- X 24-in. sheet metal shield on platform in fron[...]

  • Page 10

    Use the proper length of pipes to avoid stress on the gas control manifold. Failure to follow this warning could result in a gas leak, causing fire, explosion, personal injury, or death. Connect the gas pipe to the furnace using a backup wrench to avoid damaging gas controls. Never purge a line into a combustion chamber. Never use matches, candles,[...]

  • Page 11

    Canadian installations, all electrical connections must be made in accordance with Canadian Electrical Code CSA C22.1, or authori- ties having jurisdiction. NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control status code indicator light will flash rapidly and furnace will not operate. The cabinet MUST have a[...]

  • Page 12

    Fig. 15—Heating and Cooling Application Wiring Diagram A98521 115-V FIELD- SUPPLIED DISCONNECT AUXILIARY J-BOX 24-V TERMINAL BLOCK THREE-WIRE HEATING-ONLY FIVE WIRE NOTE 1 NOTE 2 FIELD-SUPPLIED DISCONNECT CONDENSING UNIT TWO WIRE FURNACE C O N T R O L R G C WC R GY GND GND FIELD 24-V WIRING FI[...]

  • Page 13

    Step 12—Start-up, Adjustment, and Safety Check GENERAL NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control status indicator light will flash rapidly and furnace will not operate. The furnace must have a 115-v power supply properly connected and grounded. Proper polarity must be maintained for correct opera[...]

  • Page 14

    Fig. 17—Furnace Wiring Diagram A98200e PCB BLOWER O FF DE LAY SELECTI O N CH ART 90 SEC 135 SEC 180 SEC 225 SEC GVR H I/L O RELAY SEC-1 SEC- 2 PL1 32 1 6 5 4 987 LED TEST/TW IN BLOWER OFF DELAY G R Y W C HUM HSIR IDR BLWR BLOWER SPEED SELECT FU1 COOL HEAT L2 PL3 PL2 VAC 120 L1 PR1 1 2 1 2 3 PR2 24 VAC-3A FUSE SPARE-2 SPARE-1 EAC-1 EAC-2 C 1. 5[...]

  • Page 15

    until the end of the ignition warm up and trial for ignition periods (a total of 24 sec). The blower then comes back on at heating speed. When the W input signal disappears, the control begins the normal inducer post-purge period and the blower changes to cooling speed after a 1-sec delay. If the W-Y-G signals disappear at the same time, the blower[...]

  • Page 16

    → Table 7—Model 58ZAV Orifice Size† and Manifold Pressure for Correct Input (Tabulated Data Based on 23,000 BTUH Per Burner, Derated 4 Percent per 1000 Ft Above Sea Level)* ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice No. Manifold [...]

  • Page 17

    → Table 7—Model 58ZAV Orifice Size† and Manifold Pressure for Correct Input (Continued) (Tabulated Data Based on 23,000 BTUH Per Burner, Derated 4 percent per 1000 Ft Above Sea Level)* ALTITUDE RANGE (FT) AVG GAS HEAT VALUE AT ALTITUDE (BTU/CU FT) SPECIFIC GRAVITY OF NATURAL GAS 0.58 0.60 0.62 0.64 0.66 Orifice No. Manifold Pressure Orifice N[...]

  • Page 18

    NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics. (3.) After correct manifold pressure is obtained, replace gas valve regulator adjustment[...]

  • Page 19

    EXAMPLE: (0—2000 ft altitude) Btu heating input = Btu/cu ft X cu ft/hr Heating value of gas = 1050 Btu/cu ft Time for 1 revolution of 2-cu ft dial = 82 sec Gas rate = 88 cu ft/hr (from Table 9) Btu heating input = 88 X 1050 = 92,400 Btuh In this example, the orifice size and manifold pressure adjustment is within ± 2 percent of the furnace input[...]

  • Page 20

    Recheck temperature rise. It must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise or above. 3. Set thermostat heat anticipator. The thermostat heat anticipation must be set to match the amp draw of the electrical components in the R-W circuit. Accurate amp draw readings can be obtained at thermostat sub[...]