carrier furnace installation manual pdf

The Carrier Furnace is a high-efficiency heating system designed for residential and light commercial applications. This installation manual covers proper installation procedures, safety guidelines, technical specifications, and maintenance requirements for various Carrier furnace models. Below are key sections for safety precautions, installation steps, electrical connections, gas line connections, ventilation requirements, startup procedures, and troubleshooting guidelines.

Safety Precautions

Important safety warnings and precautions for furnace installation and operation.

Pre-Installation Requirements

Preparation steps before beginning furnace installation.

1. Inspect shipment: Check for damage and verify all components are present.
2. Location selection: Choose appropriate location meeting clearance requirements.
3. Permit requirements: Obtain necessary local building permits.
4. Tools and materials: Gather required tools and installation materials.
5. Existing system removal: Safely disconnect and remove old furnace if applicable.

WARNING! Failure to follow local codes and manufacturer instructions may result in hazardous conditions.

Installation Steps

Step-by-step furnace installation procedure.

1. Position furnace: Place in approved location with proper clearances.
2. Level unit: Ensure furnace is level for proper condensate drainage.
3. Install vent system: Connect vent pipes according to specifications.
4. Connect gas line: Use approved pipe and fittings; pressure test connections.
5. Electrical wiring: Connect power and control wiring per wiring diagram.
6. Ductwork connections: Attach supply and return ducts securely.
7. Condensate drain: Install drain line with proper slope and trap.
8. Combustion air: Provide adequate combustion air supply.

CAUTION! All installations must comply with local building codes and utility requirements.

Technical Specifications

• Model Series: Various Carrier furnace models (58 series, 59 series)
• Input Capacity: 40,000 to 120,000 BTU/hr
• Efficiency Rating: 80% AFUE to 98.5% AFUE
• Electrical Requirements: 115V/60Hz, 15 amp circuit
• Gas Type: Natural gas or propane (field convertible)
• Gas Pressure: Natural gas: 3.5" WC; Propane: 10" WC
• Vent Sizes: 2" to 6" PVC/CPVC depending on model
• Airflow Requirements: 400-2000 CFM based on furnace size
• Dimensions: Varies by model (typical: 21"W x 21"D x 56"H)
• Weight: 100-180 lbs depending on model

Electrical Connections

Proper electrical wiring and connections for furnace operation.

Power Supply: 115V/60Hz dedicated circuit with proper grounding.

Control Wiring: Thermostat connections (R, W, Y, G, C); follow wiring diagram.

Safety: Install disconnect switch within sight of furnace. Use wire nuts for secure connections. Verify proper polarity and grounding. Connect humidifier or electronic air cleaner if applicable.

Gas Line Connections

Gas supply line installation and testing procedures.

1. Shut off gas supply at main valve.
2. Install sediment trap/drip leg in gas line.
3. Use approved pipe dope on threaded connections.
4. Pressure test: 14" WC for 10 minutes with no pressure drop.
5. Check for leaks with soap solution.

Tip: Use two wrenches when making connections to avoid damaging gas valve.

Ventilation System

Vent and combustion air system requirements.

1. Vent pipe material: Use PVC, CPVC, or ABS as specified.
2. Vent sizing: Follow manufacturer tables for pipe diameter and length.
3. Slope: Horizontal runs should slope 1/4" per foot toward furnace.
4. Termination: Install vent terminations according to clearance requirements.
5. Combustion air: Provide adequate air supply for proper combustion.
6. Sealing: Use approved primer and cement for all joints.
7. Support: Secure vent pipes with proper hangers every 4 feet.
8. Clearances: Maintain required clearances from windows and doors.

WARNING! Improper venting can cause carbon monoxide poisoning.

Startup and Testing

Initial startup procedure and system verification.

1. Verify all connections are complete and secure.
2. Open gas supply valve slowly.
3. Turn on electrical power to furnace.
4. Set thermostat to call for heat.
5. Observe ignition sequence: inducer motor, pressure switch, hot surface igniter, gas valve.
6. Check flame: Should be steady blue with minimal yellow tips.
7. Measure temperature rise: Compare supply/return air temperatures.
8. Verify gas pressure: Adjust if necessary.
9. Check safety controls: Verify limit switches and pressure switches function properly.

CAUTION! Never bypass safety controls during testing.

Maintenance Guidelines

Regular maintenance requirements for optimal furnace performance.

Annual maintenance: Clean burners, heat exchanger, and flame sensor. Replace air filter monthly during heating season. Check vent system for obstructions. Verify condensate drain is clear. Lubricate inducer motor if required. Check electrical connections for tightness.

Warranty Information

Carrier furnace warranty coverage and registration requirements.

Limited warranty: Heat exchanger 20-year limited warranty; Parts 5-year limited warranty; Labor 1-year limited warranty. Warranty registration required within 90 days of installation. Keep original sales receipt and installation date. For warranty service, contact authorized Carrier dealer. Visit www.carrier.com or call 1-800-227-7437 for support.

Troubleshooting

Reset: Power cycle furnace to clear temporary fault codes.

Service: 1-800-227-7437; www.carrier.com