Carrier 59SU5A User Manual

Installation, Start-up, Operating and Service Maintenance
Instructions
NOTE: Read the entire instruction manual before starting the
installation
Approved for installations up to 5,400 feet (1646 meters)
TABLE OF CONTENTS
REQUIRED NOTICE FOR MASSACHUSETTS INSTALLATIONS
IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 1 – Minimum Clearances to Combustible Materials for All Units
4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2 – Loose Parts Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CODES AND STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCE-
DURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . . . . . 8
Table 3 – Minimum Free Area Required for Each Combustion Air
Opening or Duct to Outdoors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 4 – Minimum Space Volumes for 100% Combustion, Ventila-
tion and Dilution Air from Outdoors . . . . . . . . . . . . . . . . . . . . . . 10
CONDENSATE TRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONDENSATE DRAIN CONNECTION . . . . . . . . . . . . . . . . . . . . 11
Table 5 – Condensate Trap Configurations . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 6 – Evaporator Coil Spacer or Shield Requirements. . . . . 16
Table 7 – Air Filter Selection and Duct Sizing - In. (mm) . . . . . 21
Table 8 – Opening Dimensions - In. (mm) . . . . . . . . . . . . . . . . . 21
Table 9 – Filter Media Pressure Drop (Clean) Versus Airflow - In.
W.C. (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 10 – Filter Media Pressure Drop (Clean) Versus Face Velocity-
In. W.C. (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 11 – Air Delivery - CFM (With Filter) . . . . . . . . . . . . . . . 22
GAS PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 12 – Maximum Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 24
ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 13 – Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 14 – Vent Termination Kit for Direct Vent (2-pipe) Systems29
Table 15 – Hanger Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 16 – Approved Combustion-Air and Vent Pipe, Fitting and Ce-
ment Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table 17 – Maximum Allowable Exposed Vent Length in Uncondi-
tioned Space - Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 18 – Maximum Equivalent Vent Length - Ft. . . . . . . . . . . 38
Table 19 – Deductions from Maximum Equivalent Vent Length - Ft.
(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
START-UP, ADJUSTMENT, AND SAFETY CHECK . . . . . . . . . 44
Table 20 – Altitude Derate Multiplier for USA. . . . . . . . . . . . . . 45
Table 21 – Gas Rate (CU ft./hr). . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 22 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude
- 40,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 23 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude
- 60,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 24 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude
- 80,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table 25 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude
- 100,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SERVICE AND MAINTENANCE PROCEDURES. . . . . . . . . . . . 50
WINTERIZATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . . . . . 59
MODEL NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
TRAINING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Most states in the USA and jurisdictions in Canada have laws that
require the use of Carbon Monoxide (CO) alarms with fuel burning
products. Examples of fuel burning products are furnaces, boilers, space
heaters, generators, water heaters, stoves/ranges, clothes dryers,
fireplaces, incinerators, automobiles, and other internal combustion
engines. Even if there are no laws in your jurisdiction requiring a CO
Alarm, it’s highly recommended that whenever any fuel burning product
is used in or around the home or business that the dwelling be equipped
with a CO Alarm(s). The Consumer Product Safety Commission
recommends the use of CO Alarm(s). The CO Alarm(s) must be
installed, operated, and maintained according to the CO Alarm
manufacturer’s instructions. For more information about Carbon
Monoxide, local laws, or to purchase a CO Alarm online, please visit the
following website. https://www.kidde.com.
A200352
Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1E, with permission of National Fire Protection Association, Quincy, MA
02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI
on the referenced subject, which is represented only by the standard in its entirety.
59SU5A
Up to 95% AFUE, Single-Stage, Upflow/Horizontal
Ultra Low NOx, 35-in. Tall, Condensing Gas Furnace
(Minor Series 2)
WARNING
!
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury and/or
death.
Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous
gas that can be fatal when inhaled. Follow all installation, maintenance,
and service instructions. See additional information below regarding
the installation of a CO Alarm.

Carrier 59SU5A Specifications

General

Brand	Carrier
Model	59SU5A
Category	Furnace
Language	English

Summary

Required Notice for Massachusetts Installations

Safety Considerations

Introduction

Air for Combustion and Ventilation

Introduction

Introduces the general principles of air supply for furnace operation.

2-pipe Applications

Specifies air requirements for direct-vent (2-pipe) furnace setups.

1-pipe Applications

Outlines air requirements for single-pipe furnace setups.

Ventilated Combustion Air Applications

Details air requirements for ventilated combustion air setups.

Outdoor Combustion Air Method

Specifies methods for providing sufficient outdoor air for combustion.

Condensate Trap

Condensate Drain Connection

Installation

Preparing the Furnace – Before Setting in Place

Steps for preparing the furnace unit before positioning it.

Filter Arrangement

Filter and Return Duct Sizing

Guidelines for sizing filters and associated ductwork for optimal airflow.

Air Ducts

General Requirements

General principles and standards for duct system design and installation.

Return Duct Sizing

Information on properly sizing return ductwork and filters.

Gas Piping

Gas Pipe Grommet

Details the use and installation of the gas pipe grommet.

Electrical Connections

115-V Wiring

Specific guidance for connecting the 115-volt power supply.

J-Box Installation

External Electrical Box on Furnace Casing

Steps for mounting an external electrical box to the furnace casing.

Power Cord Installation in Furnace J-Box

BX Cable Installation in Furnace J-Box

Instructions for installing BX cable into the furnace junction box.

24-V Wiring

Guidance for making 24-volt wiring connections.

Accessories

Information on connecting optional accessories to the furnace.

Alternate Power Supplies

Venting

General

General considerations for furnace venting system planning.

Materials

Approved materials for combustion air and vent piping.

Venting Systems

Direct Vent / 2-Pipe System

Specific requirements for direct-vent (2-pipe) venting configurations.

Ventilated Combustion Air Systems

Instructions for ventilated combustion air intake systems.

Non-Direct Vent (1-pipe) System

Requirements for non-direct vent (1-pipe) venting configurations.

Locating the Vent Termination

Guidance on selecting appropriate locations for vent terminations.

Size the Vent and Combustion Air Pipes

General

General guidelines for pipe sizing.

Recommended Combustion Air Inlet Moisture Trap

Additional Information for Polypropylene Venting Systems

Venting System Length Calculations

How to calculate total equivalent vent length and select pipe sizes.

Combustion Air and Vent Piping Insulation Guidelines

Guidelines for insulating combustion air and vent piping.

Install the Vent and Combustion Air Pipes

Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter

Procedures for installing vent and combustion air pipe adapters.

Optional Installation of the Vent Pipe

Installing the Vent Termination

Roof Terminations

Details for installing vent terminations on roofs.

Concentric Vent

Specific steps for installing concentric vent terminations.

Two-Pipe and Single-Pipe Terminations

Requirements for terminating 2-pipe and single-pipe vent systems.

Sidewall Terminations

Guidance for installing vent terminations on sidewalls.

Concentric Vent

Specific steps for installing concentric vent terminations on sidewalls.

2-Pipe and 1-Pipe Vent Termination

Requirements for terminating 2-pipe and 1-pipe vent systems on sidewalls.

Venting System Length Calculations

Inside Corner Terminations

Roof Termination (Preferred)

Concentric Vent and Combustion Air Roof Termination (preferred)

Specific steps for installing concentric vent terminations on roofs.

Concentric Vent and Combustion Air Side Termination

Steps for installing concentric vent terminations on sidewalls.

Start-Up, Adjustment, and Safety Check

General

General overview of the start-up and safety check process.

Prime Condensate Trap with Water

Instructions for priming the condensate trap with water.

Adjustments

Check Inlet Gas Pressure

Procedure for verifying and checking the furnace's inlet gas pressure.

Adjust gas valve outlet pressure determined in Step 2

Steps to adjust gas valve outlet pressure for correct input rate.

Verify natural gas input rate by clocking meter.

Method for verifying the furnace's natural gas input rate using a meter.

Set temperature rise.

How to set and verify the furnace's air temperature rise.

Set thermostat heat anticipator.

Procedure for setting the heat anticipator on a thermostat.

Check Safety Controls

Check Main Limit Switch(es)

How to test the function of the main limit switches.

Checklist

A list of essential checks before operating the furnace.

Service and Maintenance Procedures

General

Overview of maintenance tasks and personnel qualifications.

Electrical Controls and Wiring

Information on electrical controls, wiring, and troubleshooting.

LED Codes - Status

LED Activity

Description of different LED activity patterns and their meanings.

Code Description

Detailed list of error codes and their associated issues.

Component Test

Procedure for initiating the component self-test sequence.

Troubleshooting

Guidance for diagnosing and resolving furnace operational problems.

Care and Maintenance

Routine maintenance tasks to ensure furnace performance and longevity.

Cleaning and/or Replacing Air Filter

Blower Motor and Wheel Maintenance

Procedures for cleaning and maintaining the blower motor and wheel.

Blower Motor and Wheel Maintenance

Cleaning Flame Sensor

Instructions for cleaning the flame sensor to ensure proper operation.

Servicing Hot Surface Igniter

Flushing Collector Box and Drainage System

Procedures for flushing the collector box and drainage system.

Cleaning Heat Exchangers

Primary Heat Exchangers

Specific instructions for cleaning primary heat exchangers.

Winterization

Sequence of Operation

Explanation of the furnace's operating sequence in various modes.

Sequence of Operation - Heating

Detailed description of the furnace's heating cycle operation.

Sequence of Operation - Heating

Cooling Mode

Description of the furnace's cooling cycle operation.

Continuous Blower Mode

How the furnace operates with the blower running continuously.

Heat Pump:

Specific operating modes when used with a heat pump.

Connection Diagram

Schematic Diagram

Provides the electrical schematic for furnace operation.

Notes:

Important notes related to wiring and components.

Parts Replacement Information Guide

Model Nomenclature

Explanation of the furnace model number coding system.

Training

Information on training resources for HVAC professionals.