Carrier DIRECT VENT 4 58HDV manual

1 58HDV Dir ect V ent 4 - - - W ay Mult ipoise Co ndensing Gas Fur nace 95% Dow nflow / Ho riz ont al Orient atio ns 93.5% Upflow Orient atio n Installation Instructions Spec i al V e nti ng Requi re me nts f or I nst al l at ions i n Cana da Ins t al la t ion i n Ca nada mus t c onfor m to t he r equi re me nt s of CSA B149 code. V ent s yst e ms [...]

2 Require d Notice for M assachusetts Installations IMPOR T ANT The C ommonwe al t h of M as s ac hus et t s r e quir es c ompl ia nce wi th r e gula t ion 248 CMR as f oll ows : 5.08: Modi f ic a ti ons to NFP A - - 54, Chapt e r 10 2) Re vi se 10. 8.3 by a dding t he fol low ing a ddit i onal re quire me nts : a. For a l l s ide wal l hor i zont [...]

3 NOTE : Read the en tire in structio n m anu al before startin g the installatio n. NOTE : P lease retain th ese instru ctio ns w ith th e fu rnace after installatio n for fu tu re reference. SAF ETY CONSIDERA TIONS FURNACE RELIABI LITY HAZARD Imp rop er in stallation o r misap plicatio n of fu rnace may re qui re e xc es s ive s e rvi c ing or ca[...]

4 furn ace, the return air shall also be han dled b y a duct(s) sealed to the f ur nac e c as i ng and ter mi nat i ng outs ide t he spa ce cont a ini ng the fu rn ace. S A g as - - fired fu rn ace for in stallation in a resid ential g arage m ust be installed as specified in “ In stalla tion ” of the s e ins tr uc ti ons . S This fur na ce is [...]

5 INST ALLA TION CARBON MONOXIDE POI SONING HAZARD Fai l ure t o fol low thi s war ning coul d re sul t in pers onal inj ury or dea th. Th is furn ace can N OT b e comm on v en ted or con nected to any type B, BW or L vent or vent connec tor , nor to any port i on of a fa c tor y- - buil t or ma sonr y chi mney . If thi s fur na ce is r e pla c ing[...]

6 8. For hor i zont a l ins ta l la t ions , li ne c onta c t is pe rm is si bl e only betw een lines form ed by in tersectio n of back an d two sid es of fur na ce j a cke t, and buil ding joi s ts , s tuds or f ra ming. 9. Re side nti a l gar a ge ins ta l la ti ons r equi r e: S Bu rners and ig n ition so urces installed at least 18 ″ (457.2m [...]

7 2 5 -- 2 3 -- 3 6 b AIR INT AKE VENT H G E F TOP AIR INT AKE (KO) (AL TERNA TE) LEFT SIDE VENT 7 2 1 / 4 6 11 / 16 1 1 / 4 ELECTRICAL 4 13 / 16 1 1 / 16 1 11 / 16 17 5 / 16 24 1 / 16 19 13 / 16 28 3 / 4 29 7 / 8 TRAP (KO) UPFLOW/HORIZONTAL 1 7 / 8 21 5 / 8 24 13 1 / 4 4 7 / 8 TRAP (KO) (COU NTERFLOW) 13 11 / 16 31 11 / 16 1 3 / 8 THERMOST A T GAS[...]

8 If the fu rn ace is to b e susp en ded fro m th e flo or jo ists in a crawl space o r th e rafters in an attic, it i s necessary to use steel p ip e straps or a n a ngle iron f ra me t o ri gidl y att a ch t he fur na ce to pr eve nt move me nt. The se s tra ps s hould be at ta c hed to the fur nac e bottom side w ith sheet m etal screws and to t[...]

9 Conf ined Sp ace Installat ion NOTE : A co nfin ed space is defined as an area with less than 5 0 cub ic feet (1 .4 3 M)pe r 1, 000 BTUH ( 2.33 c m 2 / kW) input r a ti ng for all gas ap p liances in stalled in t he area. Requirements 1. Pr ovi de the s pa ce wi t h suf f ic i ent a ir f or prope r com bust ion and v en tilation o f flue gases us[...]

10 Ta b l e 1 Free Area BTUH (kW) Input Rating Minimum Free Area Required f or Eac h Ope ning or Duct t o Out doors T wo Horizontal Duc ts BTUH (kW) sq. in ./ 2,000(1 cm 2 /.09) Single Ope ning BTUH (kW) sq. i n. /3,000 (1 cm 2 /. 135) T wo Vertical D ucts or Ope nings BTUH (kW) sq. in ./ 4,000(1 cm 2 /.18) Round Duct BTUH (kW) sq. in ./4, 000(6.5c[...]

11 2. For fa n - - a ssisted app lia nces (su ch as this furn ace), calcu- la t e usi ng the fol l owing equa t ion: 1000 Btu / hr 15 ft 3 ( I fan ) Required V olume fan ² ACH wh ere: I other = all ap plian ces othe r than fan- - as si st ed input in Btu per hour I fan = fan - - a ssisted ap plia n ce i nput i n Btu pe r hour ACH =a ir c ha nge pe[...]

12 CARBON MONOXIDE POI SONING HAZARD Failur e to follow the steps o utlined below for each appliance con nected to the ventin g sys tem b eing placed into operation, coul d result in carbon monoxide poisoning or dea th: The follow ing s teps s hall be follo wed fo r each appliance con nected to the ventin g sys tem b eing placed into o peration , w[...]

13 Applicable ASTM Standards for V ent Materials Mate ri- als Sch. 40 Pipe SDR Pipe Cell Core Pipe Fittings Primer Sol v . Cem ent ABS D1527 __ F628 D2468 & D2661 -- -- D2235 PVC D1785 D 2241 F891 D2466 & D2665 F656 D2564 CPVC F441 F442 -- -- F438 -- -- F493 ABS to PVC -- -- -- -- -- -- -- -- -- -- D 3138 (2. ) Only use s olve nt ce ments t[...]

14 Ta b l e 3 Pip e Diamet er T ab le Single Piping ONL Y 40,000, 50, 000, 60,000 & 75,000 Btuh Furnaces 40 ′ (12.2m) & (5) 90 ° elbows w ith 2 ″ (50.8mm) P VC pipe 80,000 & 100, 000 Btuh Fur nace 40 ′ (12.2m) & (5) 90 ° elbows w ith 3 ″ (76.2mm) P VC pipe 125,000 Bt uh Furnace 40 ′ (12.2m) & (5) 90 ° elbows w ith 3[...]

15 12 inches (30 cm) for appliean ces >10,000 Btuh(3 kW) and < 100,000 Btuh(30kW), 36 inches (91cm) for appliances > 100,000 Btuh(30kW) V V A08600 Fig . 8 - - Direct V en t T erm ina tion C leara nce 58HDV[...]

16 A08601 Fig. 9 - - Othe r t han Dir ec t V ent T er mi nati on Cle aranc e 58HDV[...]

17 Condensate Drain T rap This f ur nac e r emove s both se ns ibl e a nd la t ent he a t fr om t he produc t s of com bust ion. Re mova l of the lat e nt he a t re s ult s in conde nsat i on of the wa t er vapor . The condens a te i s re moved fr om the f ur nac e t hrough t he dra ins i n the pla s ti c tr a ns ition an d th e ven t fitting . T h[...]

18 Drain T ube Corrugated 5 / 8 ″ ″ (15.9mm) ID & Clamps INLET EXHAUST IN ON OFF V E N T Drain T ube Black Rubbe r 1 / 2 ″ (12.7mm) ID & Clamps AIR FLOW Street Elbow 1 / 2 ″ (12.7mm) CPVC (Loose parts bag) Casing Grommet Black Rubbe r ″ (15.9mm) ID (Loose parts bag) Drain T ee Drain Conn ector Black PVC 3 / 4 ″ (18.1mm) PVC X 1 [...]

19 Plastic Cap Y ellow or black Ve n t D r a i n &C l a m p s INLET EXHAUST IN ON OFF V E N T Casing Grommet Black Rubbe r 5 / 8 ″ (15.9mm) ID (Loose parts bag) Drain Conn ector Black PVC 3 / 4 ″ (19.1mm) PVC X 1 / 2 ″ (12.7mm) CPVC (Loose parts bag) Drain T ube Corrug ated 5 / 8 ″ (15.9mm) ID & Clamps Coupling & Clamps (Optiona[...]

20 EXHAUST AIR FLOW INLET IN ON OFF V E N T Casing Grommet Black Rubber 5 / 8 ″ (15.9mm) CPVC (Loose parts bag) Drain Conn ector Black PVC 3 / 4 ″ (19.1mm) PVC X 1 / 2 ″ (12.7mm) CPVC (Loose parts bag) 2 5 -- 2 4 -- 6 8 Single Pressure Switch Details Dual Pressure Switch T ee Trap White PVC (loose parts ba g) 2 ″ (50.8mm) PVC Coupling Barbe[...]

21 Elbow T ube Black Rubber 1 / 2 ″ ″ ID (13 mm) & Clamps (Loose Parts Bag) AIR FLOW OFF ON AIR FLOW 25 - - 24- -69 Single Pressure Switch Detail Dual Pressure Switch T ee T rap White PVC (loose parts bag) Flexible T ubing C onnector , 3 / 16 ″ (5 mm) OD (loose parts bag) EXHAUS T Cut Here Drain T ube Black, 5 / 8 ″ (16 mm) ID Corrugate[...]

22 AIR FLOW OFF ON Drain Connector Black PVC 3 / 4 ″ CPVC (Loose parts bag) T rap Connection “Clamp ears” Pointed OUT Preassemble & insert into furnace Single Pressure Switch Detail Dual Pressure Switch T ee T rap White PVC (loose parts bag) Drain T ube Corrugated Black, 5 / 8 ″ (16 mm) WA R N I N G Move Caps to top of trap Drain Tube B[...]

23 AIR FLOW OFF ON Plastic Caps Y ellow or black Ve n t D ra i n &C l a m p s Trap Connec tion “Clamp ears” Pointed OUT Preassemble & insert into furnace 2 5 -- 2 4 -- 7 0 Single Pressure Switch Detail Dual Pressure Switch T ee T rap White PVC (loose parts bag) Cap and Clamp Open End Flexible tubing connector 3 / 16 ″ (4.8mm) OD (Loos[...]

24 AIR FLOW OFF ON 25 - - 24 - - 70a Single Pressure Switch Detail Dual Pressure Switch T ee Trap White PVC (loose parts bag) W ARNING Move Caps to top of trap Flexible T ube Connector 3 / 16 ″ (4.8mm) OD (Loose Parts Bag) Elbow T ube Blac k Rubber 1 / 2 ″ (12.7mm) ID & Clamps (Loose Parts Ba g) EXHAUS T Alternate Orientation Field Supplied[...]

25 OFF ON AIRFLOW 3 / 16 ″ (4.8mm) ID Rub- ber T ube Trap Connection “Clamp ears” Pointed OUT Preassemble & insert into furnace 2 5 -- 2 4 -- 7 0 b Single Pressure Switch Detail Dual Pressure Switch T ee Trap White PVC (loose parts bag) W ARNING A d dC a pa n dC l a m p Drain T ube Black Rubber 1 / 2 ″ (12.7mm) ID & Clamps EXHAUS T [...]

26 OFF ON AIR FLOW Coupling & Clamps (Optional) 2 5 -- 2 4 -- 7 0 c Single Pressure Switch Detail Dual Pressure Switch Te e Tr a p White PVC (loose parts bag) Flexible T ubing Connector 3 / 16 ″ (4.8mm) OD (Loose Parts Bag) Barbed Coupling 1 / 2 ″ (12.7mm) OD (Loose Parts Ba g) EXHAUS T Alternate Orientation Field Supplied T ee Cut Here Dra[...]

27 Open T ee Te e Tr a p Condensate Tr a p Evaporator Coil Drain Line (Optional) Main Drain Line INLET EXHAUST IN ON OFF V E N T Representative drawing onl y , s ome models may vary i n appearance. A07713 Fig. 20 - - Connect i ng T ee T rap to Conde ns ate T rap and Main Drai n Line The t e e t r ap m ust be c onnect e d to t he mai n c ondens a te[...]

28 Rubber Coupling &C l a m p s 90 ° Elbow Combustion Blower V ent Fitting &C l a m p s V ent Extension Pipe (Side Panel Exit) V ent Pipe (T op Panel Exit) V ent Pipe Rotate downward 5 ° to 10 ° NOTE: Built- - in channel will be angled 5 ° to 10 ° also. SIDE VIEW NOTE: The 90 ° elbow is approved for use inside the furnace ONL Y . Te e[...]

29 Using E xterior Ri sers 1. I ns ta l l e l bows a nd pipe t o for m r i se r as s hown in Fi g. 23 2. Se cure vent pipe to wa l l wi th ga lvani z ed s tr ap or othe r r us t resistant m aterial to restrain p ipe fro m m ov in g. 3. I ns ula t e pipe wi t h Arm af l ex or equi va le nt moist ur e re s is t ant cl os ed c e ll foa m insul a ti on[...]

30 Combustion Air Exhaust 12 ″ ″ (304.8mm) Min. Grade or Snow Level 36” Min 2” (50.8mm) Max 36”Min OR (914.4mm) (914. 4mm) A07718 Fig. 26 - - Conce ntr ic V ent and Combus ti on- - Air Roof T erm inat i on “A” Ve n t Dimension “A” is touching or 2 ″ (50.8mm) maximum separation. 2 5 -- 2 2 -- 0 2 d Ve n t Combustion Air 1 ″ (25[...]

31 CONCENTRIC VENT TERMINA TION V ent T erminati on Clearances CARBON MONOXIDE POI SONING, FI RE AND EXPLOSION HAZARD Fai l ure to f oll ow this wa rni ng could r e sul t in pe rsona l inj ur y , dea th, or prope rt y dama ge . Inl e t a nd out le t pi pe s may NO T be vent ed dir ec t ly a bove each othe r ( st a ndar d vent t er mi nal s ). ! W A[...]

32 B PVC Intake/Combustion Air B PVC V ent/Exhaust D A 1 1 / 2 ″ C Model A* B C D** KGAVT0801CVT 38 7 / 8 3 4 1 / 2 21 1 / 8 KGAVT0701CVT 33 3 / 8 2 3 1 / 2 16 5 / 8 * = Dimension will change accordingly as dimension D is lengthened or shortened. **= Dimension D may be lengthened to 60 ″ may also be shortened by cutting the pipes provided in th[...]

33 1 ″ (25.4mm) max. Maintain 12 ″ (304.8mm) clearance above highest anticipated snow level or grade whichever is greater . Combustion Air V ent 25- - 22- - 02 12 ″ (304.8mm) min. Roof Overhang A07736 Fig. 35 - - Conce ntr ic V ent and Combus ti on- - Air Side T er minat i on Combustion Air Ve n t Combustion Air Ve n t 45 ° Elbow (Field Supp[...]

34 10. Pr ope rl y s iz e gas pipe t o ha ndle c ombi ned a ppl ia nc e loa d or run gas pi pe di re c tl y fr om gas mete r or Propa ne gas re gul at or . NOTE : Ref er t o Fig. 37 or Fig. 38 for the gene r al la yout at the furn ace. T he rules listed ap p ly to n atu ral and P ro pan e gas pip e installatio ns. NOTE : On th e Du al Certified or [...]

35 Use elbows and 3 ″ (76 mm) pipe nipple to connect valve to piping when using left side gas pipe entry . * Union may be installed inside the cabinet when necessary because of clearances. Drip Leg and Union, Union* should be outside the cabinet. Manual shut - - off valve MUST be upstream of dripleg, union, and furnace. Propane low pressure switc[...]

36 Ta b l e 7 NA TURAL GAS MANI FO LD PRESSURE (in wc) 20,000 BTU per burner MEAN ELEV A TION ABOVE SEA LEVEL ft(m) HEA TING VA L U E a t AL TITUDE BTU/CU. FT . 0 to 2000 (0 to 609.6) 2001 to 3000 { (609.9 to 914.4) { 3001 to 4000 (914.7 to 1219.2) 4001 to 5000 (1219.5 to 1524) 5001 to 6000 (1524.3 to 1828.8) 6001 to 7000 (1829.1 to 2133.6) 7001 to[...]

37 Measure from face of ori- fice to the back side of the manifold. 1.1 1 ″ (28.2mm) 1.21 ″ (30.8mm) A07725 Fig. 39 - - Changing Ori fi c es 5. Rei ns ta ll ma nif old. Ensur e burner s do NOT bi nd on new orifices. Final Gas Piping Check 1. The f ur nac e a nd the e quipment shut of f va lve m ust be dis c onnec t ed f r om the ga s supply pip[...]

38 For two - - sta ge th ermo stat in stallation s, the R , W1 an d W2 wire s from th e th ermo stat con n ect to th e R , W1 an d W2 conne c ti ons on the f urna c e cont r ol boar d. Set TT SW1 DIP sw it ch #3 to ON posi t ion. Duri ng oper at ion, the f ur nac e wil l shi f t fr om Low Hea t t o High H ea t as r e ques t ed by t he the rmost a t[...]

39 Dip Switch See “ Wiring Diagram ” for switch settings FUSE 11 5 VA C HUM DEHUM Diagnostic Light 24 V AC HUM EAC A07780 Fig. 41 - - Contr ol Connec ti ons DUCTWORK AND FIL TER CARBON MONOXIDE POI SONING HAZARD Fai l ure t o fol low thi s war ning coul d re sul t in pers onal inj ury or dea th. Do N OT d raw return air from in side a clo set o[...]

40 2. I ns ula t e duc t work i n i ndoor unc ond ition ed areas w ith a minimum of 1 ″ (25.4m m) ins ul at i on wit h indoor type vapor barrier . Filter s A filter must be use d: Filters are s u pp lied with th ese furn aces, a n d add ition al filters may be purc ha se d fr om your dis tr i butor . Use eith er filter typ e: S W ash able, hig h [...]

41 Note : The thr ee ( 3) s c re ws i n the t op pa nel of the f urna c e ne xt t o the duct f l ange MUST be remo ved to p rov id e serviceab ility o f the prim ary heat exch an gers in the do wn flow in stallation 1. P ositio n p lenu m thr ough the f loor a nd set t he f urna c e over the openi ng in the fl oor . If nec e ss a ry , grout a round[...]

42 A = 4 1/4” (108mm) Minimum clearanc e from back of hol e to wall or other obstruction. A Hole in Floor M N 25- - 20 - - 46 L R H K 2 ″ (50.8mm) 2 ″ (50.8mm) 1 ″ (25.4mm) J P Plenum S T A07781 Fig. 47 - - Explode d Vie w of Subbase f or Furnac e Onl y 2 1 / 2 ″ (63.5mm) 1 1 / 2 ″ (38.1mm) A09182 Fig. 48 - - Explode d Vie w of Base f o[...]

43 1. W it h gas OFF , c onnec t manome t er to mani fol d pres sure t a p on the outle t o f ga s cont r ol val ve. See Fi g. 51Use a ma nome te r w it h a 0 to 12 i nc hes of wat e r c ol umn r ange . 2. T urn gas ON . Ope ra te t he fur na ce on Hi gh Hea t by usi ng a jum per w ire on th e R to W1 & W2 therm ostat co n nectio ns on the fur [...]

44 T o ch eck tem peratu re rise,u se the fo llow in g p roced u re: 1. Pl a ce ther mome t er s in s upply a nd r et urn a i r r e gis te rs as cl os e to fu rn ace as po ssible, av o idin g d irect rad iant h eat fro m h eat exch an gers. 2. Op erate furn ace on Hig h H eat for 10 min ut es w ith all th e re gi st e rs and duc t da mpe rs open by[...]

45 ON = 1 18 OFF = 0 A09197 Fig . 5 4 - - V aria ble S p eed T ap Select In terfa ce Bo ard DIP Switch See “ Wiring Diagra m ” for switch settings FUSE 11 5 VA C HUM DEHUM Diagnostic Light 24 V AC HUM EAC A09198 Fig. 55 - - Contr ol Board 58HDV[...]

46 SEQUENCE OF OPERA TI ON & DIAGNOSTI CS The f ol lowi ng is the nor ma l ope rat ing s e quenc e at fac t ory de fa ul t s e tt ings (SW1 OFF/ ON/ OFF , SW 2 al l OFF) NOTE : S W1 D IP switch es (G , Y/Y 2, W1 , W2 th ermo stat termin als) and D EH UM (1 /4” m ale q uick con nect termin al) are located o n th e FCB. SW 2 DIP switch es and Y[...]

47 NO TE 5) If a new Heatin g req u est arrives w hile th e con trol is w aiting fo r the H eat F an O f f Delay time to ex pire, th e F CB w ill wait fo r th e selected Heat Fan O f f Delay , and th en start a n ew heatin g cycle. Heating ( W1 & W2) Request (t wo - st age th ermost at op erati on, S W1 DIP sw itch #3 mu st be in ON position) ([...]

48 WIRING DI AGRAM 58HDV[...]

49 Ther mostat Wiring Guide 1. Thes e diagrams are for refer ence. See thermos tat wiring instructi ons for specific termina l assignments, connec tions or opera tion. 2. Humid ifier/hu midis tat is optional an d not included with the fu rnace. 3. Dehumidify feature requi res thermosta t with DEH UM feature or a s eparate d ehumidis tat to get the [...]

50 Y W G R W1 Y/Y2 G R C C OM TWO-STAGE or VS FURNAC E CONTROL SINGLE- STAGE AIR CONDITI ONER Y C SINGLE- STAG E THERM OSTAT W2 OPTIONAL HUMIDISTAT H-STAT 24V in COM OPTIONAL HUMIDIFIER OPTIONAL DEHUMIDISTAT Connect 1 to Y/Y2 for 1-stage AC/ HP applications 1 2 24V HUM DEHUM Y1 O TSIB NOTE 5 NO CONNECTION NO CONNECTION NOTE 3 NOTE 2 NOTE 2 NOTE 11 [...]

51 OPTIONAL DEHUMIDISTAT If no DE HUM fr om thermostat available Y1 W1 Y /Y2 G R 24V HUM C OM VS FURNAC E CONTROL SINGLE STAGE AIR CO NDIT IONER Y C TW O-STAG E THERMOSTAT W2 Y1 Y2 G R C W2 NOTE 3, 9, 10 O W1 TSIB NOTE 5 DEHUM HUM 24V in COM OPTIONAL HUMIDIFIER Connect 1 to Y1 for 2- stage AC-HP applications. OR Connect 1 to Y/Y2 for 1-stage AC- HP[...]

52 Copyright 2009 Carrier Corp. D 7310 W . Morris St . D Indianapolis , IN 46231 Printed in U. S.A. Edition Date: 04/09 Manufacturer reser ves the right to chang e, at any time, specifications and de signs without notice and without ob ligations. Catal og No : 58HDV - - - 01SI Replaces : NEW 58HDV[...]