Carrier 59MN7A Instruction Manual

159MN7AModulating 4---Way Multi po ise Gas Fur nac eSeries 200Installation, Start---up, Operating andSe rvice and Maint enance Inst ructionsNOTE: Read

10Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to OutdoorsFURNACEINPUT(BTUH)TWO HORIZONTAL DUC TS(1 SQ. IN./2,000 BTUH

11CONDENSATE TRAPFROZEN AND BURST WATER PIPE HAZARDFailure to protect against the risk of freezing may result inproperty damage.Special precautions MU

12Condensate TrapRelief PortCollector BoxPlugsPressure SwitchPortCondensate TrapOutletCondensate TrapRelief PortCollector BoxPlugVent ElbowVent Elbow

13Remove relief tube from relief port on condensate trap.Remove pressure switch tube frompressure switch port.Remove trap fromcollector box.Loosen cla

14Remove plug fromcollector box.DO NOT DISCARD.If alternate vent positionis required, loosen clampon inlet of vent elbow.Remove trap from collector bo

15If alternate vent positionis required, loosen clampon vent elbow inlet.Remove trap fromcollector box.Remove pressure switch tube from port on collec

16CONDENSATE DRAIN CONNECTIONFROZEN AND BURST WATER PIPE HAZARDFailure to protect against the risk of freezing may result inproperty damage.Special pr

1713. Secure the rubber elbow to the drain trap and the Z-pipewith spring clamps.14. Secure the grommet to the Z-pipe with the spring clamp.The remain

18INSTALL CLAMPS ON DRAIN TUBEATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAPPULL DRAIN STUB THROUGH CASINGOPEN SPRING CLAMPINSERT FACTORYïSUPPLIED 1/2ïIN.

19INSTALLATIONNOTE: This furnace is certified to leak 2% or less of nominal airconditioning CFM delivered when pressurized to 1--inch watercolumn with

2Required Notice for Massachusetts InstallationsIMPORTANTThe Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:5.08

20Bypass humidifier connections should be made at ductwork or coilcasing sides exterior to furnace. (See Fig. 24.)Bottom Return Air InletThese furnace

21For downflow applications, the Media Cabinet (or field suppliedaccessory air cleaner) must only be connected to the bottomopening on the furnace. Se

2214-3/16 and 17-1/2-in.Furnace16-in. Media Cabinet21-in. Furnace4-Ton or less, ACcapacity airflow20-in. Media Cabinet4-in.Block OffPlate1/2-in.Screws

23PLENUMOPENINGCABDFLOOROPENINGDOWNFLOWSUBBASESHEET METALPLENUMFLOOROPENINGFURNACE(OR COIL CASINGWHEN USED)COMBUSTIBLEFLOORINGAPPROVEDCOIL ASSEMBLYOR

24UPFLOW DOWNFLOW HORIZONTALYESNONOYESYESYESNO120°MINYES120°MINYES120°MIN90°90°PERFORATEDDISCHARGE DUCTFLANGEA10493Fig. 19 -- Duct Flanges1 3 / 4 ″1

25ANY COMBINATION OF 1, 2, OR 3 PERMITTED.A11036Fig. 23 -- Upflow Return Air Configurations and RestrictionsA11037Fig. 24 -- Downflow Return Air Confi

262-IN.(51 mm)ROLLOUT PROTECTION REQUIREDInstall 12” x 22” (305 x 559 mm) sheetmetal in front of burner compartmentarea.30 IN. (762 mm)MIN. WORK AREAC

27AIR DUCTSGeneral RequirementsThe duct system should be designed and sized according toaccepted national standards such as those published by: AirCon

28Table7–Cooling4and Heating Air Delivery -- CFM (Bottom Return5With Filter)(SW1-5 and SW4 -3 set to OFF, except a s indicated. See notes 1 and 2)Unit

29Table 7 -- Cooling4and Heating Air Delivery -- CFM (Bottom Return5With Filter) (Continued)Unit SizeClg/CF Switch Settings External Static Pressure (

3SAFETY CONSIDERATIONSFIRE, EXPLOSION, ELECTRICAL SHOCK, ANDCARBON MONOXIDE POISONING HAZARDFailure to follow this warning could result in dangerousop

30Table 7 -- Cooling4and Heating Air Delivery -- CFM (Bottom Return5With Filter) (Continued)Unit SizeClg/CF Switch Settings External Static Pressure (

31GAS PIPINGFIRE OR EXPLOSION HAZARDFailure to follow this warning could result in personalinjury, death, and/or property damage.Never purge a gas lin

32Table 8 – Maximum Capacity of PipeNOMINALIRON PIPESIZEIN. (MM)LENGTH OF PIPE --- FT (M)10(3.0)20(6.0)30(9.1)40(12.1)50(15.2)1/2 (13) 175 120 97 82 7

33J--Box InstallationFIRE OR ELECTRICAL SHOCK HAZARDFailure to follow this warning could result in personalinjury, death, or property damage.If field-

342. Humidifier (HUM)The HUM terminal is a 24 VAC output, energized when the bloweris operating during a call for heat.Connect an accessory 24 VAC, 0.

35J BOX LOCATIONSJ−B OXMOUNTINGSCREWSJ−B OXMOUNTINGBRACKETGROUNDSCREWJ−BOX COVERA11156Fig. 30 -- Installing J--Box (When Used)(Appearance May Vary)COP

3624 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip To HUM Terminal On Furnace Control Board To Humidifier Leads A11157Fig.

37 24-V THERMOSTAT TERMINALS PL2 – HOT SURFACE IGNITER & INDUCER MOTOR CONNECTOR 115-VAC (L2) NEUTRAL CONNECTIONS 115-VAC (L1) LINE VOLTAGE CONN

38Modulating and 2-Stage Furnace with Single-Speed Air ConditionerModulating and 2-Stage Furnace with Two-Speed Air ConditionerModulating and 2-Stage

39NOTES FOR THERMOSTAT WIRING DIAGRAMS1. Heat pump MUST have a high pressure switch for dual fuel applications.2. Refer to outdoor equipment Installat

4INTRODUCTIONThe 4--way multipoise Category IV condensing furnace is CSAdesign--certified for both direct--vent (2-pipe) and ventilatedcombustion air

40VENTINGFurnace is set in place in the required orientation.Special Venting Requirements for Installations inCanadaInstallation in Canada must confor

41A furnace shall not be connected to a chimney flue serving aseparate appliance designed to burn solid fuel.Other gas appliances with their own venti

42(1.2 M) of unobstructed distance to the property line of theadjacent lot, no type of vent termination is permitted for applianceswith inputs greater

43it is removed. Trim any excess metal from the knockout with tinsnips.The vent elbow can be rotated to the required location on thecasing if necessar

4414. Complete the vent and combustion air pipe as shown in“Install the Vent and Combustion Air Pipe”Installing the Vent TerminationRoof TerminationsA

45Table 11 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A. Installations)ASTM SPECIFICATION(MARKED ON MATERIAL)MATERIAL

46Table 12 – Maximum Allowable Exposed Vent Lengths Insulation Table -- Ft. / MMaximum Length of Uninsulated and Insulated Vent Pipe-Ft (M)ModulatingF

47NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows.Use Table 14 - Deductions

48ExampleA direct--vent 60,000 Btuh furnace installed at 2100 ft. (640 m) with 2--in.(51 mm) Vent piping. Venting system includes, FOR EACHPIPE, (3) 9

49Attach gaskets to vent pipe andcombustion air adapters.Vent Coupling and AdapterA11314Fig. 36 -- Vent Coupling and Adapter with GasketsMODULATING IN

57. An ESD service kit (available from commercial sources)mayalsobeusedtopreventESDdamage.ACCESSORIESSee Product Data Sheet for a list of accessories

5012346755Rotate vent elbow torequired position.Any other unusedknockout may be usedfor combustion airconnection.&A1130912345675Rotate vent elbow

51Attach vent pipe adapter with gasket to furnace casing.Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling.S

52HORIZONTAL LEFT - RIGHT VENT CONFIGURATION**Requires Accessory Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL LEFT -VERTICAL V

53HORIZONTAL RIGHT - VERTICAL VENT CONFIGURATIONHORIZONTAL RIGHT - LEFT VENT CONFIGURATION**Requires Internal Vent Kit See Product Data for Current Ki

54VENT PIPE FLUSH SHOWING COUPLINGVENT PIPE FLUSH WITH ADAPTERVENT PIPE ADAPTER WITH GASKETINSTALLED ON FURNACE VENTPIPE IS CUT FLUSH WITH TOP OFADAPT

55VVItemClearance Description Canadian Installation (1) U.S. Installation (2)AClearance above grade, veranda, porch, deck, bal-cony or anticipated sno

56Item Clearance Description Canadian Installation (1) U.S. Installation (2)AClearance above grade, veranda, porch, deck, bal-cony or anticipated snow

57At least 36 in. 18 in. maximu m V e r tical separation between comb ustion air and v ent 8 3/4 in. (222mm)f or 3 in. (76mm)ki t 6 3/4 in. (172mm)f

58NOTE: This illustration is forreference only. Your unit maydiffer in appearance or may notinclude all components shown.MAINTAIN 12 IN.CLEARANCEABOV

593” (76 mm)12” (305 mm) Pipe hangarVentilated Combustion Airintake termination in crawlspaceVentilated CombustionAir intake pipeCRAWL SPACEATTIChighe

6FIRE, INJURY OR DEATH HAZARDFailure to follow this warning could result in personalinjury, death and/or property damage.When the furnace is installed

60START--UP, ADJUSTMENT, AND SAFETYCHECKGeneral1. Furnace must have a 115-v power supply properly connec-ted and grounded.NOTE: Proper polarity must b

61Purge Gas LinesIf not previously done, purge the lines after all connections havebeen made and check for leaks.FIRE OR EXPLOSION HAZARDFailure to fo

621. Make sure the gas supply is turned off to the furnace and atthe electric switch on the gas valve.2. Remove the 1/8 inch NPT plug from the outlet

636. Re--check Minimum Heat Temperature RiseTo lock the furnace in Intermediate Heat:1. Turn SW1--2 OFF and SW4--2 ON at the furnace control.2. Connec

64(6.) Turn SW1--2 switch OFF.(7.) Install blower door.b. Electronic thermostat: Set cycle rate for 3 cycles per hr.Check Safety ControlsThe flame sen

65338307-201 Rev. FA11594Fig. 53 -- Service Label Information59MN7A

66A11623Fig. 54 -- Furnace Setup Switches and Description59MN7A

67ESU FO NOITPIRCSEDNOITISOP LAMRONEMAN HCTIWSHCTIWS PUTESSW1-1 Status Code Recovery OFFTurn ON to retrieve up to 7 stored status codes for troublesho

68Table 16 – Altitude Derate Multiplier for U.S.A.*ALTITUDEPERCENTOFDERATEDERATEMULTIPLIERFACTOR*FT. M0–2000 0 --- 6 1 0 0 1.002001–3000 610---914 4 -

69Table 19 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input RateTo Be Used with Modulating Furnaces Except 59MN7A060V21--20SAGLARUTANFOYT

7A11588Fig. 1 -- Dimensional Drawing59MN7A

70Table 19 -- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued)To Be Used with Modulating Furnaces Except 59MN7A060V21--20S

71Table 20 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input RateTo Be Used with Modulating Furnaces 59MN7A060V21--20 OnlySAGLARUTANFOYTIV

72Table 20 -- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued)To Be Used with Modulating Furnaces 59MN7A060V21--20 OnlySAG

73SERVICE AND MAINTENANCEPROCEDURESFIRE, INJURY OR DEATH HAZARDFailure to follow this warning could result in personalinjury, death and/or property da

742. Turn Setup Switch, SW1--1 “ON.”3. Manually close blower door switch.4. Control will flash up to 7 Status Codes.5. The last Status Code, or 8th Co

754. Inspect burner compartment before each heating season forrust, corrosion, soot or excessive dust. If necessary, havefurnace and burner serviced b

7615. Reconnect blower leads to furnace control. Refer to furnacewiring diagram, and connect thermostat leads if previouslydisconnected.NOTE: Be sure

77FIRE OR EXPLOSION HAZARDFailure to follow this warning could result in personalinjury, death, and/or property damage.Never purge a gas line into a c

7810. Turn power on at external disconnect, fuse or circuit break-er.11. Run the furnace through two complete heating cycles tocheck for proper operat

79UNIT COMPONENT DAMAGE HAZARDFailure to follow this caution may result in damage to thefurnace and other property damage.Do not use ethylene glycol (

8THE BLOWER IS LOCATEDTO THE RIGHT OF THEBURNER SECTION, ANDAIR CONDITIONED AIR ISDISCHARGED TO THE LEFT.THE BLOWER ISLOCATED BELOW THEBURNER SECTION,

80SET SCREWMOTOR WHEEL HUBMOTOR SHAFT FLATSCREWMOTOR ARMGROMMETSCREW LOCATIONBLO HSG ASSYBRACKETBRACKETENGAGEMENTSEE DETAIL ACAPACITOROR POWER CHOKE(W

81FLAME SENSOR(BELOW BURNER)FLAME ROLLOUTSWITCHBRACKET, IGNITERIGNITERBURNER SUPT. ASSYBURNER ASSYA11403Fig. 61 -- Burner Assembly59MN7A

82Is AMBER LED status light on?Is there 24V at SEC-1 and SEC-2?Is there 115V at L1 and L2?Replace furnace control.Is door switch closed?Replace transf

8311 NO PREVIOUS CODE – Status codes areerased after 72 hours or can be manuallyerased by putting setup switch SW1-1 inthe ON position and jumpering R

8425 INVALID MODEL SELECTION ORSETUP ERROR – If status code 25 onlyflashes 4 times on power-up the control ismissing its model plug PL4 and isdefaulti

85SEQUENCE OF OPERATIONUNIT OPERATION HAZARDFailure to follow this caution may result in intermittent unitoperation.Furnace control must be grounded f

86CPU will repeat the ignition sequence for up to three moreTrials-For-Ignition before going to Ignition-Lockout. Lock-out will be reset automatically

87inducer motor speed gets within 15% of the required inter-mediate-heat RPM the furnace control CPU will start a 5second blower airflow change delay.

88DHUM. When there is a dehumidify demand, the DHUM input isactivated, which means 24 vac signal is removed from the DHUMinput terminal. In other word

89338307-201 Rev. FA11595Fig. 63 -- Wiring Diagram59MN7A

9AIR FOR COMBUSTION ANDVENTILATIONIntroductionDirect Vent (2--pipe) ApplicationsWhen the furnace is installed as a direct vent (2-pipe) furnace, nospe

90PARTS REPLACEMENT INFORMATION GUIDECasing GroupBlower doorBottom plateControl doorDoor knob assemblyTop filler plateElectrical Group3--Amp fuseCircu