Carrier | Arete den Be pflow Gas- INTRODUCTION S8GA.GC_Upflow GasFired Furnaces are AG.A, certified for installation on combustible flooring in alcoves, basements, closets or utility rooms. See 1 and Table 1 for furnace physical data, See Table 2 for Furnaces may be matched with certain 28 Series cooling coils to form combination heating/ cooling systems (sec Table 3) and employed with humidifiers and electronic air cleaners to form complete controtled-environment systems These units are tested and approved for use with natural gas. Approved kits are available for converting S8GA units so that they can be fired with liquified petroleum (LP) gases. Furnaces are shipped fully assembled. S8GA heating/cooling models are equipped with a printed circuit center which provides a central control connection point for furnace components and field-added accessories. All internal electric and gas controls are factory assembled and wired. When unpacking unit, should any in-transit damage be observed, file claim with transportation agency This publication covers fumace installation. It also shows terminal connections used for wiring accessories to furnace For accessory installation details, refer to applicable installation literature. INSTALLATION Location Selection When selecting a location for the furnace, observe the following’ L. Install furnace close to chimney and as cen- tralized as possible with respect to distribution system 2. Locate cooling coil (if used) downstream from. Furnace. 3. Ensure adequate door clearance for service 4, Ensure adequate ventilation, (See Combustion Air.) 5. Follow local and national utility codes. a. Allow AG.A. certified safety clearance of 1 in. from sides, top, and type B vent; 6 in from unlisted vent; 0 in. at rear b. Provide service clearance of 30 in. at front of unit, c. Insert vibration isolating material (cork or rubber) under furnace to make seal, To slip © O camer ired Furnaces O S SOA) CC ar, “7 material underneath furnace, tip it first on one side and then on the other, Make a positive seal on alll four sides d. Consult ANS Z21,30, Installation of Gas Appliances and Gas Piping Installation Procedures Install ductwork, filters and vents; complete external piping and wiring; and provide for come bustion end recirculating air DUCTWORK RECOMMENDATIONS 1. Install locking-type dampers in all branch or individual duets to balance out system, ol. spre ak Sree. Foun ENN, (Fed Foner If ovaw oven a —— + fie (ners, ae Fou xo eee. Sie Seance 3 anon notes: T Allow AGA safety elaarance of 1 in trom sides, top, ‘yf vont, Gin from aniisted vont, Oia at Fear 2 Corte etmension drawings mvatahie‘on ues. Fig. 1 — Dimensions Form S8GA,GC-1StIGA,GC FURNACE SERIES DIMENSIONS (i) 100 Cosing Only Height ‘Nish Plenum Supply Air Opening Return AirOpening Me ae 4 FILTER* Mounting Side Size 126% (in) 1e% AGA. RATINGS! Input (1000 Brh) Table 1 — Dimensions and Physical Data 80 1 | 200. 100 | 25 a0 | 200 | oo | 100 {200 G64. | m a Max ESP (in) BURNERS No 7 leo 566A ans 8906 vedo 59 = Era Ste esse Dera parmenent ori tte | Ratings shown for elevations wp to 2000 Hidect #8 of inp capacity fr BLOWER, '58G¢ Mortels Only BGA Models Only [Ar toma ran may be calculates sing the following fork 28° Tae aprciicwt of sn x GD eI i Foy levatons bows 2000 cay » BONNE eapocity 10 saves eve TO x chm Table 2 — Blower Data 586A, GC DIRECT DRIVE FURNACE - 080" zip 100 SERIES 100 [200 ys 20 00 Hp c as % 4 4% ESP (in. wal 73] wi | 50! 30 | 50 x0 | 0 3 2 | % piacere ea) v2a0 [175 80.950 | 1750 [1980 __tnon co) _ eae BLOWER - - 586A BELT DRIVE =a FURNAce 56 io 5 {se | _ SERIES ido {300 | i) 300" | 18D 300 MOTOR | Nom Size (in) | 12% x6, 609% fom : He ke EB w] LK % | % % Pep tes Jae Psp] ae] sa fae fs pose | cas aL i a7 » | 7 | ® a B B v BuPs: 1 4 oe eo) leas 9a) eileues 2 3 ESP (in. wa)* | 20| sa] 20 [ So af | 6] | % ®) 6] BH HW] 9 [w] s6 pene [pe P3000 725190 240i poesia oon] vars 00 l2000 "9550 [aio fren ‘i }986C Oweet Drive Models Only BL = Bolt Lenath BMPS — Bion Noto Putiey Soting fu es ternal Statie Pesaro PPD = Pulley igen Diameter (Fonge 2 1 SEEET 5G Dicct Drive Mudols Only Fite in pace [Win dice drive motor sot at “High” spond {Bo no cpa tower motor pulley yar! ein shown NOTE? Het a Application Bota itearure for fan performance saves rrnsopen trom cloud austin) =29in)Use tapered fittings or starter collars between ducts and plenum, 3. Use exible duct connection (asbestos cloth) between furnace and discharge plenum Install acoustical insulation in warm air plenum, install sound traps in short run ducts 5. Run return air connections under floor or run full size return from space outside enclosed area. Use one or both sides of furnace for conneetions. Jf outdoor air is used, combina- tion of outdoor and rerum air requires duct design and diverting dampers so installed that volune of circulating air entering furnace cannot be reduced or restricted helow that which would normally enter thru circulating air intake of furnace Table 3 — Furnace-Coil-Plenum Combinations com PLENUM FURNACE | Medel | Series Séca,ecoso | 100 | saccos | 200 | seoaoao | 200,300 38GA,6C100 | 100,200 S8Ga,cci00 | 300 58GA,GC125 | 100,200 Zen€.AFOO2 ane,arooe | 29Ae700021 S8GAi25 | 300 28AE,AFOOS, pak AFOO4 | 58GA150 | 100,300 | 28A€,AF005 | 28AE900031 S58GA175, 10,300 BAE,AFOOS | FILTERS Filters are shipped from factory in blower compartment of furnace (See Fig 2) To gain access, remove bottom front panel. Filters are factory mounted for either side or bottom return (ee Table 1), If the particular application calls for mounting the filter in a position other than that indicated, the filter can be cut according to the measurements specified in Table 4 Filter bracket can be relocated to secure filter when it is repositioned. 1 To install side-mounted filter, cut return air opening in furnace side as shown in Fig. | and ‘Table |. Position filter and secure in place with filter bracket provided. (See Fig. 2.) 2. To install botton-mounted filter, remove tray at bottom of blower compartment (see Fig. 2) Position filter and secure in place with filter bracket provided If an accessory return air duct is used, follow procedures outlined in the installation instruc- ions for that accessory VENTS -- Vent fumace to permanent chimney or thru roof with vent of approved design. (Type B vent is recommended.) Observe local ordinances. 6 BOTTOM TAB FOR Setar won 8 oA a Fig. 2 — Installing Filter Table 4 — Field-Cutting Factory-Supplied Filters For Other Than Factory-Specified Mounting Factory. | ‘ suppLied | MOUNTING FILTER (in.)) Side | Bottom FURNACE Model 38 | Series | 080 100 ~ | han 26% | “060 |00. 300 | te | oe Ihe lie on 3 | | fora 125 300 175,200 100,300 | 25%4.26% 050 | 200 | Gc | 100 100,200 LiStx26% } ro | 300” eee 1 ize flue pipe connections same as furnace vent connection. (See Fig. 1 and Table 1)2. Run pipe as directly as possible with minimum, number of turns. 3. Maintain minimum piteh of 1/4 in, per linear fon horizontal runs, Pitch should not exceed 75%h of vertical vent 4 Maintain minimum angle of 60 degrees from vertical for vent pipe crossovers in attic, Rigidly support pipe with hangers or straps 6. Do not connect into a chimney serving an open firepla If chimney is used, total equivalent straight Iength of flue piping between fumace and flue pipe connection at chimney must not be greater than 75% of vertical height of chimney above flue pipe connection 8 Install flue pipe to extend thru chimney wall but not beyond inside wall of Flue. 9 Minimum vertical stack height is $ ft Extend flue pipe at Ieast 3 ft above roof and 2 ft above any object within a 15-ft radius. Ensure that vent outlet terminates in an approved cap with, a venting capacity not less than that of the vent (See Table | for vent sizes.) 10 Insulate flue pipe where it passes near com bustible material. Undenwriter'’s Laboratories (UL) require that uninsulated flue pipe be installed with a minimum clearance of 6 in from combustible materials Vent piping which meets_with National Board of Fire Under writer's Specifications for type B vents, may be installed with a clearance of I in. from combustible materials If other gas appliances are vented into common flue, flue area must equal largest vent area plus one-half total areas of other vent connectors GAS PIPING ~ Install piping per national and local codes, and ANS 221.30. 1, Furnish gas line from main gas supply to furnace Size supply pipe per volumne of gas used and allowable pressure drop. (See Table 5 ) Supply pipe size must at least equal that of furnace gas connection. 3. Install drop pipe adjacent to, but not in front of furnace 4, Install manual shutoff valve on gas piping per local codes, 5. Install tee for drip leg in pipe at same elevation as gas inlet connection to unit, provide ground joint union between tee and furnace controls. 6. Extend drip leg and cap it 7 Test for pressure and leaks. CAUTION: Never use open lame for leak testing. Table 5 — Pipe Sizing”, Capacity For Natural Gas, Cu Ft/Hr pine size | PIPE LENGTH UD) (in) | 10 | 20,! 30 | 40 | 50 | 0 | 70] 80 % | 2/97] 73] 3 | 56) so] 46] 2 | 2m) 90 | se 2G) 8) 2/8 A 5B | 380 | 28 23 | 18 | 8 078 Ix |b] | 80 [to | 245 |e | |e, "Based on pressure drop of 0 in wg; 0 6 5p F 5 Without elaowe WIRING ~ Fig. 3 shows the printed circuit control center, which is factory-installed on S8GA hneating/cooling furnaces. Fig. 4 illustrates the field power and control wiring for 58GA.GC heating only furnaces; Fig, 5 illustrates the field power and control wiring for the S8GA_ heating/cooling models; Fig. 6 illustrates. the field power and control wirng for the S8GC heating/cooling models as BeceSSSaY wel Fig, 3 — 58GA Printed Circuit Control Center, Cover Removed When wiring units, make sure that all national and local codes are followed. Check against loo wiring connections, When msking aluminum conductor comnections to copper conductors or terminals, use only con- neetors which are UL approved (marked A1/Cu with the UL symbol) for the application. (UL approved connectors will be tin. plated, have separator bars for placement between conductors to prevent direct contact between aluminum and copper, and have large bearing surfaces to minimize pressures for minimum cold flowing of the alu- minum and subsequent loosening of the joint.) After insulation has been stripped from aluminum conductor, coat conductor end with corrosion inhibitor (Burdy “Penetrox A” or equivalent), and wire brush aluminum surface thru inhibitorCAUTION: Do not wire brush connectors and iugs. Tin plating will be broken. After cleaning, recoat aluminum conductor with inhibitor, and make up connection, (Coat entire connection.) If applicable, wrap connection for moisture and/or electrical protection cas, eee valve PILOT. Buk But amet ¥ SoMBINATION ‘0 THERMOSTAT | SOMBINATION FAN 2 switen BLK Bux. [__ispneron sox | eux \ guage : t | wet eK OIRECT ORIVE MOTOR = BELT DRIVE MOTOR LEGEND — Factory Power Wiring (118 Volt) Fiske Control Wiring (24 Voit) tory Conteot Wiring (24 Volt) @ wire notes 1 To change direct drive motor speed, move Mac ead to desire terminal on motor Factory spied selection is Tor sveran® conditions For optimum speed selection, refer to Blower Speed Adjustment 2. Whenever replacing origina wie supplied with faronor use AWN {80.0} wire or equivalent 3 Motor furnished with overload protection 44 Total electrical load sts tha 12 amps Fig, 4 — 58GA,GC Field Power and Control Wiring, Heating Only Diagram Field Power Wiring ~ (See Fig 4 thru Fig. 6.) 58GA,GC Heating Only and S8GC Heating/Cooling Models L. Connect separate 115-volt, single-phase, 60-Hz power supply thru hole in side of unit casing to 115-olt pigtails 2. If required by local codes, install fuse and manual switch between main box and fumace. S8GA Heating/Cooling Models and S8GA200100 Model 1, Connect separate 115-volt, single-phase, 60-Hz power supply to terminals Ly and L on the printed circuit control center. (See Fig. 3.) If required by local codes, install fuse and manual switch between main box and fumace. 3. When adding an clectronie air cleaner to the system, connect air cleaner fo terminals EAC] and EAC. These terminals supply. 115-volt power to the electronic unit 4, When adding a tine-voltage humidifier to the system, connect humidifier to terminals HU, and HU. Humidifier has its own contro! wiring, which is independent of the furnace except for the power connections provided at HU} and HU ige (24 volt) humidifier is installed, an accessory plug-in humidifier relay in the printed circuit control center 6. When replacing a single-speed motor with a dualspeed motor, be sure to remove jumper between HI and LO on the control center. Field Control Wiring — (See Fig, 4 thru Fig. 6.) 58GC Heating Only Models 1. Connect two 24-volt leads from accessory thermostat to low-voltage pigtails R and W. 58GC Heating/Cooling Models 1. Connect four 24-volt leads from accessory ther- mostat to low-voltage pigtails C,G, R,and W. 58GA Heating/Cooling Models and 58GA200100 Model 1. For heating with constant fan control, connect leads from room thermostat subbase to ter minals W, G, and R on the low-voltage terminal strip. (See Fig. 3.) This hook-up is used wher heating only with manual fan control at the thermostat is desired. Connect accessory thermostat to fumace and cooling unit. Connect terminals W,G, R, and ¥ on tie thermostat subbase to identically labeled terminals on the low-voltage terminal. strip. Connect yellow and black low-voltage leads from the remote condensing unit to the two C terminals on the low-voltage terminal strip. 3. When adding a low-voltage humidifier to the system, install a plug-in humidifier relay in receptacle HR on the control center. Connect humidifier directly to terminals Hand H on the low-voltage terminal strip. Connect leads from low-voltage humidistat in the conditioned space, to terminals HS and HS on the low- voltage terminal strip.foev reewostar onwecron wre a a ay lL Bitter suppl = a] hfe} sf “ SA aay ek | (Be mes WMOIER f™ on Ieee Ss fen : ae 0 one = (RECT RIVE HOTOR COMPONENT ARRANGEMENT umoieien Siuwostar | 1 1 pote | Sgregs | ehh SBF ba, pt SF bee fe fe pepe 5 “MOTOR : BLOWER peeetl ig, grime ob? a MOTOR Fan aE MED Loo com MeO HIS t ia! i TERMINAL JUMPER ELT ORIVE WIRING Bows RELAY LEGEND cna Ft Pom rng 175 — — Factory Power Wiring (115 Volt) 1 To change cirect drive motor speed, move black or red lead to de TH prin crt Cott Contr Weg 118 Yor aes eis ealraiel ce ay eon aaa Fins Coo! Wiring (24 Vom tondilars Por optimum Seo bon. eter 0 Blower Spor TIE aaory conor ing 24 or _ ee = TT trite Cac Conrt Carer Wing (24 Vo heer gore i ; @ serom Tonvel — Fett Connecion Pains (118 Vol and ese orev h ero potetion 2avony 4 Total electrical load is less than 12 amps Bin Quek Conroe Trial ~ Facto ive Cantons 5 Freleinsated acceory humiaifer rly (175 Volt one 24 Vor) Fig. 5 — 58GA Field Power and Control Wi jing, Heating/Cooling With Accessories Diagrams 6~ IMPORTANT: Set adjustable heat anticipator Gf provided) to agree with ampere value of combination gas valve. Failure to make adjust- ment will result in unsatisfactory temperature control. “HEAT VALVE ANTICIPATOR (Aigha Fetes) TF 555 rashew (Unite) 7000 LEGEND — Factory Power Wiring 1118 Vos = Field Controt Wiring (24 Vet) Foetory Controt Wicing (24 Von) @ wire 1 To changeairsctdrive mator speed, move black or red ead 0 de sired terminal on motor Factory specd selection f for average onions For optimum speed section, rele to Blower Spal 180.C) wire or equivtent 4A Total etc cal lad i less than 12 amps 51 turnace i usid witha cooling unit that or equipped witha love voltage transformer, connect black Iasd 10 bie Ieod on 6 Used only when cooling unit i eawioped with low voltage Fig. 6 — 58GC Field Power and Control Wiring, Heating/Cooling Diagram COMBUSTION AIR ~ See ANS 221.30. 1 If furnace is installed in a confined area, such as a closet or a utility room, provide air for combustion. a. Provide two air openings to interior space of equal area, one located near the fop of the enclosure and one at the bottom b. Make sure that openings have free area not fess than 100 sq in. in area, plus an additional 1 sq in. for each 1000 Btu in excess of 100,000 Btu input ¢. Air may come from under-the-floor space and from attic with openings in floor and ceiling 4. Air may come from attic, with one opening in ceiling and with a duct bringing air from attic to an opening within 12 in. of the floor ©. Air may come thru ducts or joist spaces freely communicating with the outdoors. f, Where openings to interior spaces are im- practical, follow the methods outlined in ANS 221.30. If furnace is installed in an unconfined area, such as in a full basement, it can normally be assumed that infiltration will provide sufficient air in building of conventional frame, brick or stone construction. In buildings of unusually tight construction, provide a permanent open- ing to the outdoors with a minimum free area of not less that 1 sq in, per 4000 Btuh total input ratings of all appliances in space. Consult local codes for special requirements CAUTION: Whenever gas appliance is installed in any area where corrosive atmosphere or chlorine or chlorinated compounds are present. bring combustion air into combustion area of furnace from outdoor source. Failure to do this can cause excessive corrosion in furnace heat exchanger. CIRCULATING AIR SUPPLY ordinancesand ANS 221.30. 1 Do not take circulating air from same space as combustion air. Supply may be any mixture of outdocr and return air with minimum tempera- ture of 50 F. Duets and diverting dampers should have been installed so that volume of circulating air entering furnace is unrestricted. Consult local START-UP AND SERVICE IMPORTANT: Remove shipping bracket (see Fig. 7) securing heat exchanger. On direct drive models, remove blower shipping bracket (see Fig. 7). On belt drive models. remove wood shipping Blocks (two) under motor support side rails.DIRECT ORIVE BLOWER On bet drive blowers, remove sioad shipping blocks under snator appar side rails 7 — Removing Shipping Brackets Initial Start-Up, When first lighting furnace pilot Open all warm air registers Set room thermostat to lowest setting, If humidifier is installed with system, open water supply valve. 4, If line voltage switch is provided in furnace circuit, tum it to “OFT” position ig. 8 and Fig, 9) to 5. Tum gas cock dial (see “OLY” position. 6. Wait approximately 5 minutes to allow gas which may have accumulated in burner com- partment to escape. 7. Turn gas cock dial to “Pilot” position 8. On Robertshaw 7000 valves depress and hold gas cock dial while lighting pilot bumer. If valve is equipped for 100% shutoft, allow pilot to burn approximately one-half minute before releasing dial (Robertshaw 7000 valve) or before depressing automatic pilot reset button (Essex TF 555 valve). If pilot does not remain lighted, repeat operation allowing longer period before releasing dial or depressing button, If necessary, adjust pilot. (S Burner Adjustment.) 9. Turn gas coek dial to “On” position 10, Set room thermostat at desired temperature position IMPORTANT: For the Robertshaw 7000 models equipped with a pressure regulator, do not adjust regulator if dial is positioned be- tween “Pilot™ and “On” positions on the gas cock dial. -¢ Pilot 3 ‘Steew ee 5 Tissetes NOTE Robertshaw (Unitrot! 7000 (Usad on 68GA Furnaces) as cove Dias eT Pile pram a Dr RREE EE SPRITE ofr 100% stot ‘sad on Boe Fig, 8 — Combination Gas Valves Pilot Burner Adjustment | Remove pilot adjustment cap. (See Fig. 8.) 2. Adjust pilot key to provide properly sized flame. (ignition flame should extend outward and upward approximately 1.5 in. from the stem of the pilot.) Turn screw clockwise for high flame or counterclockwise for low flame. Replace pilot adjustment cap. Combustion Air Adjustment Airgas mixture controls are provided on furnaces to enable adjustment of the primary airsupply to get proper flame characteristics. (See Fig 91) Adjust the controls as follows: 1 After furnace has been operating for 15 minutes, loosen air setting screw on each bumer Close air setting until yellow tips appear in flame. Then, open air setting until yellow tips disappear and flame has soft blue cone. Secure air settings in position by ti each air setting serew, htening, ainsoas MRTURE CONTROL ——— sca >= aR cas MIXTURE CONTROL sace Fig. 9 — 58GA,GC Gas Burners and Manifold Assemblies Blower Speed Adjustment Adjust on installation for nameplate tempera- lure rise. (See Table 1.) To ensure reliability of heat exchanger it is recommended that temperature rise be set below ‘maximum to ensure that femperature rise will not exceed maximun requirements should filter be- come excessively dirty a For direct drive speed change, make change at plug-in power terminal located in blower com partment. Move line lead to desired speed indicated Speeds on 3-position power terminal are High (1), medium (2), and low (3) Speeds on 4- position power terminal are* High (1), Medium- High (2), Medium-Low (3), and Low (4). For belt drive speed change (S8GA furnaces), perform the following. a. Loosen setserew on adjustable hub of motor sheave, b- Rotate hub clockwise to increase or counter- chekwise {0 decrease speed and. tighten setserew on flat hub section Belt Adjustment Adjustment is correct if one-finger pressure depresses center of belt 1 inch. Each blower speed change on a S8GA furnace requires a belt adjustment 1. Loosen motor support plate cap screws. 2. Slide motor for correct tension fir to loosen or out to tighten 3. Retighten cap screws. Fan and Limit Control | Constant air circulation provides even tempera- ture control. The fower the fan switch setting, the bager the fan will continue to run after bumers tum off. 2. After running fumace for 15 sninutes, restrict the return air supply by blocking the filters or by closing the return registers to test limit switch operation. 3. Allow furnace to shut down on high limit. Fan ‘must continue to run. 4. Remove restriction Burners should come on in afew minutes. 5. Adjust fan control “Off” setting per installation needs. “On” setting is 25 F above “Off” setting, differential is not adjustable. Input Adjustment 1, Turn off all other gas appliances on same meter, 2. Set thermostat high enough to ignite burners, Check cu ft of gas bumed per 5 minutes. Multiply value by 12 to determine input (in thousands of Btuh). Rating should be within 5% of nameplate input rating, 4. To adjust input, remove combination gas valve cap covering regulator adjusting screw. (See Fig. 8.) 5. With a small screwdriver, rotate adjustment serew clockwise to increase or counterclockwise to decrease pressure. Do not change pressure more than + 0.3 in. we, 6. Replace regulator adjustment serew cap, IMPORTANT: Refer to operating and main- tenance instruction literature to ensure better, longer, and more reliable service from your new Carrier furnace.TROUBLESHOOTING Burner Will Not Operate POWER FAILURE — Power switch off — set 10 on, blown fuse — replace; defective wiring — replace. NO POWER TO CONTROLS ~ Thermostat set too low, dirty or defective — reser, clean or replace as applicable, defective transformer — replace; faulty limit switch — replace; blown fusestat — replace. BURNER WILL NOT IGNITE — Low gas pressure or no gas to unit — check if manual shutoff valve is closed, check gas supply, check for clogged gas line and clean or repair, adjust gas pressure with all appliances operating, faulty thermocouple — cheek with millivoltmeter and replace if necessary; pilot light extinguished ~ locate cause and relight. pilot — clean Burner Operates, But Heating Inadequate UNIT UNDERSIZED ~ Size selected incorrectly never overfire, replace with properly sized unit. 10 FUEL INPUT TOO LOW — Wrong orifice size replace orifice; regulator set too low ~ readjust. THERMOSTAT OPENS TOO SOON — Wrong anticipator setting — readjust, thermostat out of calibration — recalibrate; thermostat set wrong check and reset as necessary, wrong thermostat location — relocate LIMIT SWITCH CYCLES BURNER — Dirty filters = clean or replace, faulty fan switch or motor — repair or replace, blower speed too low — readjust; fan switch set too high — readjust, duct system restricted — remove restriction. Poor Combustion and Flame Characteristics SMOKY FLAME — Insufficient air — adjust air inlet, flue restriction — remove restriction, down- draft — eliminate downdraft using flue caps on vents NOISY BURNER — Too much air — adjust air inlet, incorrect input — make correction as required.For replacoment items use Cartier specified parts [Manufacturer sores the right to change any produet specif cations without notice CARRIER AIR CONDITIONING COMPANY + SYRACUSE, NEW YORK Tab 10 Fou S8GA,60-151 New Printed in USA 870 Cordes ana Catalog No 595-805