Carrier 58GFA User Manual

Induced Combustion Furnaces

Service and Maintenance Instructions

For Sizes 065-150 Series 130

NOTE: Read the entire instruction manual before starting the

installation.
These procedures are for sizes 65,000 through 150,000 Btuh units.
Index Page

SAFETY CONSIDERATIONS.....................................................1

CARE AND MAINTENANCE..................................................1-4

Air Filter Arrangement.............................................................2

Blower Motor and Wheel......................................................2-3

Cleaning Heat Exchanger......................................................3-4

Electrical Controls and Wiring.................................................4

Pilot ...........................................................................................4

Troubleshooting ........................................................................4

Unit Wiring Diagram ............................................................5-6

Troubleshooting Chart..............................................................7

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified person­nel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.

Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code NFPA No. 54­1992/ANSI Z223.1-1992 (NFGC). In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1­and .2-M95 Natural Gas and Propane Gas Installation Codes
(NSCNGPIC). Wear safety glasses and work gloves. Have fire
extinguisher available during start-up and adjustment procedures
and service calls.

Recognize safety information. This is the safety-alert symbol
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.

Understand the signal word DANGER, WARNING, or CAU­TION. These words are used with the safety-alert symbol. DAN­GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard that could
result in personal injury or death. CAUTION is used to identify
unsafe practices which would result in minor personal injury or
product and property damage. NOTE is used to highlight sugges­tions that will result in enhanced installation, reliability, or
operation.

58GFA

®

ama

Fig. 1—Model 58GFA Upflow

The ability to properly perform maintenance on this equip-

.

ment requires certain expertise, mechanical skills, tools and
equipment. If you do not possess these, do not attempt to
perform any maintenance on this equipment other than those
procedures recommended in the User’s Manual. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS
PERSONAL INJURY, OR DEATH.

CARE AND MAINTENANCE

For continuing high performance and to minimize possible equip­ment failure, it is essential that periodic maintenance be performed
on this equipment. Consult your local dealer as to the proper
frequency of maintenance and the availability of a maintenance
contract.

CANADIAN GAS ASSOCIATION

APPROVED

R

A92057

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4
Tab 6a 8a

PC 101 Catalog No. 535-821 Printed in U.S.A. Form 58GFA-1SM Pg 1 10-95 Replaces: 58D, G-3SM

Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace. A failure to
follow this warning could result in personal injury.

Never store anything on, near, or in contact with the furnace,
such as:

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning com­pounds, plastic or plastic containers, gasoline, kerosene,
cigarette lighter fluid, dry cleaning fluids or other volatile
fluids.

3. Paint thinners and other painting compounds, paper bags or

other paper products.
A failure to follow this warning could result in corrosion of
the heat exchanger, fire, personal injury, or death.

The minimum maintenance that should be performed on this
equipment is as follows:

1. Check and clean air filter each month or more frequently if
required. Replace if torn.

2. Check blower motor and wheel for cleanliness and lubrication
each heating and cooling season. Clean and lubricate as
necessary.

3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.

As with any mechanical equipment, personal injury can result
from sharp metal edges, etc., therefore, be careful when
removing parts.

AIR FILTER ARRANGEMENT
The air filter arrangement may vary depending on the application.

Refer to Table 1 for filter size information.

Table 1—Filter Size Information (In.)

FURNACE

CASING WIDTH

14-3/16 (1) 16 X 25 X 1* (1) 14 X 25 X 1 Cleanable

17-1/2 (1) 16 X 25 X 1* (1) 16 X 25 X 1 Cleanable

21 (1) 16 X 25 X 1 (1) 20 X 25 X 1* Cleanable

24-1/2 (2) 16 X 25 X 1* (1) 24 X 25 X 1 Cleanable

* Factory-provided with the furnace. Filters may be field modified by cutting as
required.

Never operate unit without a filter or with filter access door
removed. A failure to follow this warning could result in fire,
personal injury or death.

1. Each furnace requires 1 or 2 filters which are installed in the
blower compartment. (See Fig. 2.)

To remove filters for cleaning or replacement, proceed as
follows:
a. Disconnect electrical power before removing access doors.

b. Remove blower and control access doors.
c. Release filter retainer from clip at front of furnace casing.

(See Fig. 2.) For side return, clips may be used on either or
both sides of the furnace.

FILTER QUANTITY AND SIZE

Side Return Bottom Return

FILTER

TYPE

MOUNTING

SCREWS

RELIEF

BOX

CONTROL

BOX

Fig. 2—Model 58GFA Upflow

d. Slide filter out.
e. Furnaces are equipped with permanent, washable filters.

Clean filters with tap water. Spray water through filter in
opposite direction of airflow.

f. Rinse and let dry. Oiling or coating of filter is not

recommended or required.
g. Reinstall filter.
h. Replace access doors.
i. Restore electrical power to furnace.

BLOWER MOTOR AND WHEEL
For long life, economy, and high efficiency, clean accumulated dirt

and grease from the blower wheel and motor annually.

The following steps should be performed by a qualified service
technician:

Some motors have prelubricated sealed bearings and require no
lubrication. These motors can be identified by the absence of oil
ports on each end of the motor. For those motors with oil ports,
lubricate motor every 5 years if motor is used on intermittent
operation (thermostat FAN switch in AUTO position), or every 2
years if motor is in continuous operation (thermostat FAN switch
in ON position).

Remember to disconnect the electrical supply before removing
access doors.

Clean and lubricate as follows:

2. Remove control assembly.

3. Remove blower leads from blower assembly. Note location of
wires for reassembly.

4. Remove screws holding blower assembly to blower deck and
slide blower assembly out of furnace.

5. Loosen screw in strap holding motor capacitor to blower
housing and slide capacitor out from under strap.

2

DRAFT
SAFEGUARD
SWITCH

FLUE
COLLECTOR
BOX

GAS
VALVE

PILOT

FILTER
RETAINER

WASHABLE
FILTER

A92178

6. Mark blower wheel, motor, and motor support in relation to
blower housing before disassembly to ensure proper reassem­bly.

7. Loosen setscrew holding blower wheel on motor shaft.

8. Remove bolts holding motor mount to blower housing and
slide motor and mount out of housing. Disconnect ground wire
attached to blower housing before removing motor.

9. Lubricate motor (when oil ports are provided).
a. Remove dust caps or plugs from oil ports located at each

end of motor.

b. Use a good grade of SAE 20 nondetergent motor oil and

put 1 teaspoon, 5 cc, 3/16 oz, or 16 to 25 drops in each oil
port. Do not over-oil.

c. Allow time for total quantity of oil to be absorbed by each

bearing.
d. Wipe excess oil from motor housing.
e. Replace dust caps or plugs on oil ports.

10. Remove blower wheel from housing.
a. Mark cutoff location to ensure proper reassembly.
b. Remove screws holding cutoff plate and remove cutoff

plate from housing.

c. Lift blower wheel from housing through opening.

11. Clean blower wheel and motor using a vacuum cleaner with
soft brush attachment. Do not remove or disturb balance
weights (clips) on blower wheel blades. The blower wheel
should not be dropped or bent as balance will be affected.

12. Reinstall blower wheel by reversing steps 9 a. through c. Be
sure wheel is positioned for proper rotation.

13. Reassemble motor and blower by reversing steps 2 through 7.
If motor has ground wire, be sure it is connected as before.

e. Gas valve
f. Edge connector leading to control box

4. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage sealant.

5. Remove complete inducer assembly from furnace, exposing
flue openings.

6. Clean cells using field-provided small wire brush, steel spring
cable, reversible electric drill, and vacuum cleaner.

a. Assemble wire brush and steel spring cable.

(1.) Use 48 in. of 1/4-in. diameter high-grade steel spring

cable (commonly known as drain clean-out or Roto­Rooter cable).

(2.) Use 1/4-in. diameter wire brush (commonly known as

25-caliber rifle cleaning brush).

NOTE: The items needed in steps (1.) and (2.) can usually be
purchased at local hardware stores.

(3.) Insert twisted wire end of brush into end of steel spring

cable, and crimp tight with crimping tool or strike with
ball-peen hammer. TIGHTNESS is very important.

(4.) Remove metal screw fitting from wire brush to allow

insertion into cable.

b. Clean each heat exchanger cell.

(1.) Attach variable-speed, reversible drill to end of steel

spring cable (end opposite brush).

(2.) Insert brush end of cable into upper opening of cell

and slowly rotate with drill. DO NOT force cable.
Gradually insert at least 36 in. of cable into 2 upper
passes of cell. (See Fig. 3.)

Be sure the motor is properly positioned in the blower
housing. The motor oil ports must be at a minimum of 45°
above the horizontal centerline of the motor after the blower
assembly has been reinstalled in the furnace.

14. Reinstall blower assembly in furnace. Connect blower leads to
blower speed selector.

15. Reinstall control assembly.

16. Turn on electrical power and check for proper rotation and
speed changes between heating and cooling.

17. Replace blower access door.

CLEANING HEAT EXCHANGER

The following steps should be performed by a qualified service
technician:

NOTE: Deposits of soot and carbon indicate the existence of a
problem which needs to be corrected. Take action to correct the
problem.

If it becomes necessary to clean the heat exchanger because of
carbon deposits, soot, etc., proceed as follows:

1. Turn off gas and electrical power to furnace.

2. Remove 2 screws that secure relief box. (See Fig. 3.)

3. Disconnect wires to the following components:
a. Draft safeguard switch
b. Inducer motor
c. Pressure switch
d. Limit overtemperature switch

A91252

Fig. 3—Cleaning Heat Exchanger Cell

(3.) Work cable in and out of cell 3 or 4 times to obtain

sufficient cleaning. DO NOT pull cable with great

force. Reverse drill and gradually work cable out.
(4.) Remove burner assembly and cell inlet plates.
(5.) Replace screws in center panel and cells before

cleaning.
(6.) Insert brush end of cable in lower opening of cell, and

proceed to clean 2 lower passes of cell in same manner

as 2 upper passes.
(7.) Repeat foregoing procedures until each cell in furnace

has been cleaned.
(8.) Remove residue from each cell using vacuum cleaner.
(9.) Clean burner assembly using vacuum cleaner with soft

brush attachment.

3