Carrier 59TN6A User Manual

Installation, Start-up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS ......................... 3
INTRODUCTION ................................... 4
CODES AND STANDARDS ........................... 4
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ... 4
ACCESSORIES ..................................... 5
LOCATION ........................................ 5
AIR FOR COMBUSTION AND VENTILATION .......... 9
CONDENSATE TRAP ............................... 12
Upflow ........................................ 12
Downflow ..................................... 12
Horizontal ...................................... 12
CONDENSATE DRAIN ............................. 16
INSTALLATION ................................... 19
Upflow ........................................ 19
Downflow ..................................... 19
Horizontal ...................................... 20
Filter Arrangement ............................... 20
AIR DUCTS ....................................... 27
Ductwork Acoustical Treatment ..................... 27
GAS PIPING ...................................... 31
ELECTRICAL CONNECTIONS ....................... 32
115-V Wiring ................................... 32
J-Box Installation ................................ 33
24-V Wiring .................................... 33
Accessories ..................................... 33
Alternate Power Supplies .......................... 34
VENTING ........................................ 40
Special Venting Requirements for Installations in Canada . 40
Materials ....................................... 41
Venting Systems ................................. 41
Locating Vent Termination ......................... 41
Size the Vent and Combustion Air Pipes ............... 42
Combustion Air and Vent Piping Insulation Guidelines ... 42
Configure the Furnace ............................ 43
Installing the Vent Termination ...................... 44
Venting System Length Calculations ................. 48
START-UP, ADJUSTMENT, AND SAFETY CHECK ...... 61
Select Setup Switch Positions ........................ 61
Prime Condensate Trap ............................. 61
Purge Gas Lines ................................... 61
Adjustments ...................................... 62
Check Safety Controls .............................. 64
Checklist ........................................ 64
SERVICE AND MAINTENANCE PROCEDURES ........ 72
Cleaning Heat Exchangers ........................... 77
SEQUENCE OF OPERATION ........................ 81
PARTS REPLACEMENT GUIDE ...................... 88
TABLE
Loose Parts Bag Contents .............................. 6
Minimum Clearances to Combustible Materials ............. 6
Minimum Free Area Required ......................... 11
Minimum Space Volumes ............................. 11
Filter Size Information ............................... 21
Opening Dimensions ................................ 23
Air Delivery CFM ................................... 28
Maximum Capacity of Pipe ........................... 32
Electrical Data ...................................... 35
Vent Termination Kit for Direct Vent (2-Pipe) Systems ...... 41
Combustion-Air Vent Pipe, Fitting 8: Cement Material ....... 45
Maximum Allowable Exposed Vent Lengths Insulation ...... 46
Maximum Equivalent Vent Length ...................... 47
Deductions from Maximum Equivalent Vent Length ........ 47
Altitude Derate Multiplier for U.S.A ..................... 69
Blower Off Delay Setup Switch ........................ 69
Gas Rate .......................................... 69
Orifice Size and Manifold Pressure ..................... 70
Always Ask For
Use of the AHRI Cellified rMMark indicates a
manufacturer's participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
ISO9001
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1-2009©, 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.

Carrier 59TN6A Specifications

General

Model	59TN6A
Type	Gas Furnace
Stages	Two-stage
Blower Type	Variable-speed
Fuel Type	Natural gas
Heating Capacity	40, 000 to 120, 000 BTU/h
Warranty	10-year parts limited warranty

Summary

Safety Considerations

Introduction

Codes and Standards

Electrostatic Discharge (ESD) Precautions Procedure

Location

Air for Combustion and Ventilation

Direct Vent (2-pipe) Applications

Explains requirements for 2-pipe furnace combustion air.

Non-Direct Vent (1-pipe) Applications

Details air for combustion for 1-pipe furnace installations.

Ventilated Combustion Air Applications

Covers furnace installation using ventilated combustion air.

Condensate Trap

Condensate Trap - Upflow Orientation

Instructions for upflow condensate trap setup and drainage.

Condensate Trap - Downflow Orientation

Relocation instructions for downflow condensate trap.

Condensate Trap - Horizontal Orientation

Repositioning trap for horizontal furnace installations.

Condensate Drain Connection

Upflow/Downflow Orientation

Routing condensate drain from trap through furnace casing.

Installation

Upflow Installation

Guidelines for installing furnace in upflow configuration.

Downflow Installation

Instructions for installing furnace in downflow configuration.

Horizontal Installation

Procedures for furnace installation in horizontal orientation.

Filter Arrangement

Details on filter placement and requirements for furnace.

Air Ducts

General Requirements

Standards for designing and sizing duct systems for furnaces.

Ductwork Acoustical Treatment

Guidance on applying acoustical lining to ductwork.

Gas Piping

Electrical Connections

115-V Wiring

Proper connection and grounding procedures for 115-V wiring.

J-Box Installation

Electrical Box on Furnace Casing Side

Installing external electrical box for field wiring.

Power Cord Installation in Furnace J-Box

Procedures for installing power cords into the furnace J-Box.

24-V Wiring

Connecting field 24-V wiring to the furnace control.

Thermostats

Information on compatible thermostats and wiring.

Alternate Power Supplies

Start-Up, Adjustment, and Safety Check

Select Setup Switch Positions

Configuring furnace setup switches for application requirements.

Prime Condensate Trap with Water

Priming the condensate trap to ensure proper drainage.

Purge Gas Lines

Procedure for purging gas lines and checking for leaks.

Adjustments

Adjust Temperature Rise

Procedures for adjusting temperature rise for proper furnace operation.

Adjust Cooling Airflow – High-Speed and Low-Speed Cooling

Adjusting blower speed for cooling airflow settings.

Check Safety Controls

Service

Troubleshooting

Guide for diagnosing and resolving furnace operational problems.

Retrieving Stored Fault Codes

Method to access and interpret stored fault codes.

Service and Maintenance Procedures

Electrical Controls and Wiring

Information on electrical connections and wiring diagrams.

Troubleshooting

Steps for diagnosing and resolving furnace issues using status codes.

Care and Maintenance

Cleaning and/or Replacing Air Filter

Instructions for cleaning or replacing the furnace air filter.

Blower Motor and Wheel Maintenance

Procedures for cleaning and maintaining the blower motor and wheel.

Cleaning Burners and Flame Sensor

Sequence of Operation

Two-Stage Heating (Adaptive Mode) with Single-Stage Thermostat

Explains heating operation with a single-stage thermostat.

Cooling mode

Details furnace operation during cooling cycles.

Continuous Blower Mode

Describes operation of the blower in continuous fan mode.

Parts Replacement Information Guide

Casing Group

Lists replacement parts for the furnace casing.

Electrical Group

Lists replacement parts for electrical components.

Blower Group

Lists replacement parts for the blower assembly.

Gas Control Group

Lists replacement parts for gas control components.

Heat Exchanger Group

Lists replacement parts for heat exchanger components.

Inducer Group

Lists replacement parts for the inducer assembly.

Filter Group

Lists replacement parts for furnace filters and cabinets.