Carrier 58HDX User Manual

58HDX
4---WAY MULTIPOISE FIXED SPEED
CONDENSING GAS FURNACE

Service Guide

ama

NOTE: Read the entire instruction manual before starting the
installation. .

!

WARNING

ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD

Failure to follow warnings could result in personal injury,
death, or property damage.

Before servicing, disconnect all electrical power and gas
supply to furnace. Lockout and tag with appropriate label.

When servicing controls, label all wires prior to disconnecting.
Reconnect wires correctly.

Verify proper operation after servicing.

!

WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD

Failure to follow this warning could result in property damage,
personal injury, or death.

The ability to properly perform maintenance on this equipment
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.

CERTIFIED

TABLE OF CONTENTS

PAGE

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

GENERAL 2.........................................

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 2...

CARE AND MAINTENANCE 3.........................

Cleaning and/or Replacing Air Filter 3....................

Blower Motor and Wheel Maintenance 3..................

Cleaning Burners 4...................................

Cleaning Heat Exchangers 15...........................

Primary Heat Exchangers 15........................

Secondary Heat Exchangers 15......................

Flushing Collector Box and Drainage System 15............

Servicing Hot Surface Igniter 16.........................

Electrical Controls And Wiring 18.......................

Checking Heat Tape Operation (If Applicable) 18...........

Winterizing 18......................................

WIRING DIAGRAM 18................................

TROUBLESHOOTING 18..............................

SAFETY CONSIDERATIONS

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 words DANGER, WARNING, CAUTION,
and NOTE. 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 hazards
which 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 which will result in enhanced installation, reliability,
or operation.

!

1

!

WARNING

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

FIRE / EXPLOSION HAZARD

Failure to follow this warning could cause personal injury,
death, or property damage.

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.

Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified

service agency personnel should install, repair, or service

58HDX

heating equipment. Untrained personnel can perform basic
maintenance functions described in User’s Information
Manual such as cleaning and replacing air filters. All other

operations must be performed by trained and qualified service
agency 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 including the National Fuel Gas Code
(NFGC) NFPA 54--2006/ANSI Z223.1--2006 in the USA;
National Standard of Canada, Natural Gas and Propane Installation
Code CSA B149.1 (NSCNGPIC) in Canada; and the Installation
Standards, Warm Air Heating and Air Conditioning Systems
(NFPA 90B) ANSI/NFPA 90B. Wear safety glasses and work
gloves. Have a fire extinguisher available during start-up and
adjustment procedures and service calls.

!

CAUTION

!

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may damage furnace
components.

Electrostatic discharge can affect electronic components. Take
precautions during furnace installation and servicing to protect
the furnace electronic control. Precautions will prevent
electrostatic discharges from personnel and hand tools which
are held during the procedure. These precautions will help to
avoid exposing the control to electrostatic discharge by putting
the furnace, the control, and the person at the same
electrostatic potential.

AIRFLOW

UPFLOW

HORIZONTAL

LEFT

DOWNFLOW

AIRFLOW AIRFLOW

AIRFLOW

Fig. 1 -- Multipoise Orientations

HORIZONTAL

RIGHT

A93041

ELECTRICAL SHOCK AND UNIT DAMAGE
HAZARD

Failure to follow this caution may result in personal injury or
damage to furnace.

Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation.

GENERAL

This furnace van be installed as a direct vent (2-pipe) or

non-direct vent (1-pipe)

instructions are written as if the furnace is installed in an upflow
application. An upflow furnace application is where the blower is
located below the combustion and controls section of the furnace,
and conditioned air is discharged upward. Since this furnace can be
installed in any of the 4 positions shown in Fig. 1, you may need to
revise your orientation to component location accordingly.

condensing gas furnace. These

1. Disconnect all power to the furnace. DO NOT TOUCH
THE CONTROL OR ANY WIRE CONNECTED TO THE
CONTROL PRIOR TO DISCHARGING YOUR BODY’S
ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch a clean, unpainted, metal surface of the
furnace chassis which is close to the control. T ools held in a
person’s hand during grounding will be satisfactorily
discharged.

3. After touching the chassis you may proceed to service the
control or connecting wires as long as you do nothing that
recharges your body with static electricity (for example; DO
NOT move or shuffle your feet, DO NOT touch
ungrounded objects, etc.).

4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before
touching control or wires.

5. Use this procedure for installed and uninstalled
(ungrounded) furnaces.

6. Before removing a new control from its container, discharge
your body’s electrostatic charge to ground to protect the
control from damage. If the control is to be installed in a
furnace, follow items 1 through 5 before bringing the
control or yourself into contact with the furnace. Put all
used AND new controls into containers before touching
ungrounded objects.

2

7. An ESD service kit (available from commercial sources)
mayalsobeusedtopreventESDdamage.

CARE AND MAINTENANCE

For continuing high performance and to minimize possible
equipment failure, it is essential that maintenance be performed
annually on this equipment. Consult your local dealer about proper
maintenance and maintenance contract availability.

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury
or death.

Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Lockout and tag with
appropriate label. Follow the operating instructions on the
label attached to the furnace.

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

1. Check and clean or replace air filter each month as needed.

2. Check blower motor and wheel for cleanliness annually.

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

4. Check for proper condensate drainage. Clean as necessary.

5. Check for blockages in combustion-air and vent
pipes annually.

6. Check burners for cleanliness annually.

!

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Be careful of sharp metal edges, etc. Use care and wear
protective clothing, safety glasses, and gloves when
removing parts.

Procedure 1 — Cleaning and/or Replacing
Air Filter

The air filter arrangement may vary depending on the application
or orientation.

!

WARNING

FIRE, CARBON MONOXIDE AND POISONING
HAZARD

Failure to follow this warning could result in property damage,
personal injury, or death.

Never operate unit without a filter or with the blower access
panel removed. Operating a unit without a filter or with the
blower access door removed could cause damage to the
furnace blower motor. Dust and lint on internal parts of
furnace can cause a loss of efficiency.

NOTE: If filter has cross-mesh binding, binding must face blower.
If filter has an air direction arrow, arrow must point toward blower.
To clean or replace the filters, proceed as follows:

1. Turn off electrical supply to furnace.

2. Remove blower door.

3. Slide filter out of furnace (See Fig. 2 and 3).

4. Furnaces are equipped with permanent, washable filter(s).
Clean filter by spraying cold tap water through filter in
opposite direction of airflow.

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

6. Slide filter into furnace.

7. Replace blower door.

8. Turn on electrical supply to furnace.

Procedure 2 — Blower Motor and Wheel
Maintenance

To ensure long life, economy, and high efficiency, clean
accumulated dirt and grease from blower wheel and
motor annually.

The inducer and blower motors are pre-lubricated and require no
additional lubrication. These motors can be identified by the
absence of oil ports on each end of the motor.

The following items should be performed by a qualified service
technician.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove blower door.

3. Disconnect blower motor wires from furnace control board.
Field thermostat connections may need to be disconnected
depending on their length and routing.

4. Remove control box mounting screws, and position control
box, transformer, and door switch assembly to right side of
furnace casing.

5. If condensate trap is located in left-or right-hand side of
furnace casing, proceed to item 6, otherwise remove trap
and tubing as described below. (See top Fig. 6, 7, or 8.)

a. Disconnect field drain connection from condensate trap.

b. Disconnect drain and relief port tubes from

condensate trap.

c. Remove condensate trap from blower shelf.

6. Remove screws securing blower assembly to blower shelf
and slide blower assembly out of furnace.

7. Clean blower wheel and motor by using a vacuum with soft
brush attachment. Be careful not to disturb balance weights
(clips) on blower wheel vanes. Do not bend wheel or blades
as balance will be affected.

8. If greasy residue is present on blower wheel, remove wheel
from the blower housing and wash it with an appropriate
degreaser. To remove wheel:

a. Mark blower wheel location on shaft before disassembly

to ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

NOTE: Mark blower mounting arms and blower housing so each
arm is positioned at the same hole location during reassembly.

c. Mark blower wheel orientation and cutoff plate location

to ensure proper reassembly.

d. Remove screws securing cutoff plate and remove cutoff

plate from housing.

e. Remove bolts holding motor mounts to blower housing

and slide motor and mounts out of housing. Disconnect
capacitor and ground wire attached to blower housing
before removing motor. Motor mounts need not be
removed from motor.

58HDX

3

NOTE: Ensure tubes are not kinked or pinched, as this will

Center Clip
side-to-side

9”

(228.6 mm)

Fig. 2 -- Bottom Filter Arrangement

A07691

58HDX

affect operation.

c. Connect field drain to condensate trap.

13. Reconnect wires.

Refer to furnace wiring diagram, and connect thermostat leads if
previously disconnected. (See Fig.20.)

!

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component
damage.

Heating speed selection MUST be adjusted to provide proper
temperature rise as specified on the rating plate.

Table 1 – Speed Selector

COLOR SPEED

Black

Orange Medium High Heat

Blue Medium Low M1

Red Low M2

White Common Com

14. Turn on electrical supply. Manually close blower access
door switch. Use a piece of tape to hold switch closed.
Check for proper rotation by jumpering R to G.

High Cool

FACTORY

ATTACHED TO

Filter Rack

End Cap

A07690

Fig. 3 -- Filter Installed for Side Inlet

f. Remove blower wheel from housing.

!

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace component
failure.

The blower wheel should not be dropped or bent as balance
will be affected.

g. Clean wheel per instructions on degreaser cleaner. Do

not get degreaser cleaner in motor.

9. Reassemble motor and blower wheel by reversing items 8b
through 8f. Ensure wheel is positioned for proper rotation.
Be sure to reattach ground wire. Tighten setscrew to 140 to
160 in.--lb torque.

10. Reinstall blower assembly in furnace.

11. Reinstall control box, transformer, and door switch
assembly on blower shelf.

12. Reinstall condensate trap and tubing if previously removed.

a. Reinstall condensate trap in hole in blower shelf.

b. Connect condensate trap drain tubes. See Fig. 6, 7, or 8.

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury
or death.

Blower access door switch opens 115-v power to furnace
control. No component operation can occur. Caution must be
taken when manually closing this switch for service purposes.

15. If furnace is operating properly, remove tape to release
blower access door switch, remove jumper across R to G,
and replace blower access door.

Procedure 3 — Cleaning Burners

The following items should be performed by a qualified service
technician. If burners develop an accumulation of light dirt or dust,
they may be cleaned by using the following procedure:

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Using backup wrench, disconnect gas supply pipe from
furnace gas control valve.

!

CAUTION

ELECTRICAL SHOCK, UNIT DAMAGE HAZARD

Failure to follow this caution may result in personal injury or
furnace component damage.

Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation.

4

CELL PANEL

!

WARNING

BURNERS

BURNER BOX

MANIFOLD

GAS VALVE

A07826

Fig. 4 -- Burner Box Assembly

4. Remove wires from gas valve. Note location for reassembly.

5. Unplug igniter from harness.

6. Remove screws that secure manifold to burner box.
(See Fig. 4.)

NOTE: Do not remove burner box from cell panel.

7. Remove manifold, orifices, and gas valve as 1 assembly.

8. Remove screws attaching burner assembly in burner box.

NOTE: Use care when removing and reinstalling burners not to
strike the hot surface igniter.

9. Remove burner assembly from burner box.

NOTE: All burners are attached to burner bracket and can be
removed as 1 assembly.

10. Clean burners with soft brush and vacuum.

11. Reinstall manifold, orifice, and gas valve assembly in
burner box. Ensure burners fit over orifices.

FIRE, EXPLOSION, UNIT DAMAGE HAZARD

Failure to follow this warning could result in property damage,
personal injury, or death.

Gas valve switch MUST be facing forward or tilted upward.

14. Turn on gas and electrical supplies to furnace.

!

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings could result in personal
injury, death, or property damage.

Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the
detection of leaks to check all connections.

15. Check for gas leaks.

16. Replace main furnace door.

PRIMARYHX
INLET OPENINGS

58HDX

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury
or death.

Igniter wires must be securely placed in slot in manifold
grommet or else they could become pinched or severed and
electrically shorted.

12. Reconnect wires to gas valve and igniter. Refer to furnace
wiring diagram for proper wire location.

13. Reinstall gas supply pipe to furnace gas control valve using
backup wrench on gas valve to prevent rotation and
improper orientation.

NOTE: Use propane gas resistant pipe dope to prevent gas leaks.
DO NOT use Teflon tape.

A07827

Fig. 5 -- Cleaning Inlet Openings of Primary Heat Exchangers

5

″

″

″

″

″

″

″

″

″

58HDX

Casing Grommet
Black Rubber

5

(Loose parts bag)

Ven t Dr ain
&Clamps

Dual Pressure Switch Detail

FLOW

AIR

(15.9mm) ID

/

8

Plastic Caps (2)
Yellow or black

Coupling & Clamps
(Optional)

Drain Tube
Black Rubber

1

/

2

Clamps

Drain Connector Black PVC

3

/

(18.1mm) PVC X1/

4

(12.7mm) CPVC (Loose

2

parts bag)

Drain Tee

(12.7mm) ID &

Drain Tube
Corrugated

5

/8″″(15.9mm) ID &

Clamps

EXHAUST

ON

On Some Models
ONLY

Single Pressure Switch

Relief Tube
Black Rubber

3

(4.8mm) ID

Street Elbow

1

/

(12.7mm) CPVC

2

(Loose parts bag)

/

16

INLET

V

E

N

T

IN

OFF

3

Drain Line Vent Tee
(18.1mm) PVC or1/
CPVC (Field supplied)

Representative drawing only, some models may vary in appearance.

/

4

(12.7mm)

2

Drain Tube Black Rubber5/
Clamps, Cut length to fit (Loose parts bag)

(15.9mm) ID &

8

25--24 --67

A07706

Fig. 6 -- Upflow Installations Top Vent

6

Plastic Cap

″

″

″

″

°

°

″

″

″

″

″

Yellow or black

Coupling & Clamps
(Optional)

Ven t Dr ain
&Clamps

Either: The PVC
Drain Tee or a field
supplied 2
(50.8mm) PVC Tee

Dual Pressure Switch Detail

FLOW

FLOW

AIR

AIR

Drain Tube
Black Rubber

1

/

2

&Clamps

Drain Connector Black PVC

3

/

(19.1mm) PVC X1/

4

(12.7mm) CPVC
(Loose parts bag)

Tee Trap White PVC
(loose parts bag)

(12.7mm) ID

2

EXHAUST

Drain Tube
Corrugated

5

/

(15.9mm) ID

8

&Clamps

2″(50.8mm) PVC
Coupling

INLET

On Some Models
ONLY

V

E

N

T

IN

ON

OFF

Single Pressure Switch

Relief Tube
Black Rubber
(4.8mm) ID

3

/

16

58HDX

SIDE VIEW

Rotate downward

to 10

5

Casing Grommet
Black Rubber

5

/

(15.9mm) ID

8

(Loose parts bag)

NOTE: Built--in channel will

3

/

Drain Line Vent Tee
(12.7mm) CPVC (Field supplied)

(18.1mm) PVC or1/

4

2

be angled 5° to 10° also.

25--24 --67a

Representative drawing only, some models may vary in appearance.

A07707

Fig. 7 -- Upflow Installations Vent Through Left Side

7

″

″

″

″

″

°

°

Ven t Dr ain

″

″ 〈

″

″

″

″

&Clamps

Plastic Cap
Yellow or black

Dual Pressure Switch

On Some Models

INLET

ONLY

Either: The PVC Drain

Tee or a field supplied
Relief Tube
Black Rubber

3

/

4.8mm) ID

(50.8mm)

2

16

V

E

N

T

IN

ON

OFF

2

(50.8mm) PVC Tee

Single Pressure Switch Details

PVC
Coupling

58HDX

NOTE: Built--in channel will
be angled 5° to 10° also.

Drain Tube
Corrugated

5

/

(15.9mm) ID &

8

Clamps

SIDE VIEW

Rotate
downward

to 10

5

EXHAUST

AIRFLOW

Elbow Tubes (2) Black Rubber

1

/

2

(loose parts bag)

Barbed Coupling,1/
(loose parts bag)

Fig. 8 -- All Models Vent Through Right Side (Upflow)

2

Tee Trap White PVC
(loose parts bag)

(12.7mm) ID & Clamps

(12.7mm) OD

Casing Grommet
Black Rubber
(Loose parts bag)

Drain Line Vent Tee3/
(18.1mm) PVC or1/
(12.7mm) CPVC (Field sup-

4

2

plied)

Drain Connector Black PVC

3

/

(19.1mm) PVC X1/

4

(12.7mm) CPVC

2

(Loose parts bag)

5

/

(15.9mm) CPVC

8

25--24 --68

A07708

8

″

″

″

″

Plastic Cap

°

°

″

″

″

Yellow or black

Coupling & Clamps
(Optional)

Vent Dr ain
&Clamps

Either: The PVC
Drain Tee or a field
supplied 2
PVC Tee

Single Pressure Switch Detail

FLOW

AIR

Tee Trap White PVC
(loose parts bag)

Elbow Tube Black Rubber

1

/2″″ID (13 mm) & Clamps

(Loose Parts Bag)

Drain Tube Black,
Cut at straight section

(51 mm)

Drain Tube
Black Rubber

1

/

WARNING
Move Caps to
top of trap

5

/

(16 mm) ID Corrugated

8

EXHAUST

ID (13 mm) & Clamps

2

2″(51 mm) PVC Coupling

Dual Pressure Switch

FLOW

AIR

OFF

ON

SIDE VIEW

Rotate downward
5

to 10

NOTE: Built--in channel will

be angled 5° to 10° also.

Relief Tube
Black Rubber

3

/

16

(5 mm) ID

On Some Models
ONLY

INLET

Flexible Tubing Connector,

3

/

(5 mm) OD (loose parts bag)

16

Relief Tube,
Extension Black Rubber,

3

/

(5 mm) ID Cut to fit

16

(loose parts bag)

Trap Connection

“Clamp ears”
Pointed OUT

58HDX

Leave room for clamp

Cut Here

Barbed Coupling1/
(loose parts bag)

(13 mm) OD

2

Fig. 9 -- Downflow Left Side Vent and Trap

Preassemble &
insert into furnace

25--24 --69

A07767

9

″

″

″

″

″

″

°

°

Plastic Cap

″

″

″

Yellow or black

Trap Connection

“Clamp ears”
Pointed OUT

Vent Dr ain
&Clamps

NOTE: Built--in channel will

be angled 5° to 10° also.

58HDX

Single Pressure Switch Detail

SIDE VIEW

Rotate downward

to 10

5

AIR

FLOW

Elbow Tube Black Rubber

1

/

(13 mm) ID & Clamps

2

(Loose Parts Bag)

Dual Pressure Switch

Drain Tube Corrugated

5

/

Black,
ID&Clamps

(16 mm)

8

ON

Barbed Coupling

1

/

(13 mm) OD

2

(Loose Parts Bag)

Relief Tube
Black Rubber

3

/

(5 mm) ID

16

Drain Hose
Black Rubber

1

/

(13 mm) ID Cut to

2

Fit & Clamps

On Some
Models

Preassemble &
insert into furnace

Coupling & Clamps
(Optional)

2″(51 mm) PVC Coupling

ONLY

INLET

Either: The PVC
DrainTeeorafield

AIR FLOW

supplied 2

(51 mm) PVC Tee

Tee Trap White PVC
(loose parts bag)

Drain Connector Black

OFF

3

/

PVC

(19 mm)

4

1

PVC X

/2″

CPVC (Loose parts bag)

(13 mm)

WARNING
Move Caps to
top of trap

Drain Tube Black Rubber,

5

(loose parts bag)

/

ID (16 mm) Cut to fit & Clamps

8

A07768

Fig. 10 -- Downflow Right Side Vent and Trap

10

Vent Dr ain

″

″

″

″

″

&Clamps

Plastic Caps
Yellow or black

Single Pressure Switch Detail

Trap Connection

“Clamp ears”
Pointed OUT

EXHAUST

Field
Supplied Tee

Tee Trap White PVC
(loose parts bag)

Alternate O rientation

Coupling & Clamps
(Optional)

AIR FLOW

Relief Tube Black Rubber

3

/

(4.8mm) ID

16

Dual Pressure Switch

ON

OFF

Flexible tubing connector

3

/

(4.8mm) OD (Loose

16

Parts Bag)

Relief Tube Extension

AIR

FLOW

Black Rubber
Cut to Fit (Loose Parts Bag)

Drain Tube Corrugated

5

/

8

Remove KO before

3

/

16

(15.9mm) ID & Clamps

mounting Trap

Cut at straight section

Cap and Clamp
Open End

Drain Tube
Black Rubber

1

/

(12.7mm) ID

2

&Clamps

Leave room for clamp

Representative drawing only, some models may vary in appearance.

Fig. 11 -- Horizontal Left Through Top

Preassemble &
insert into furnace

(4.8mm) ID

Cut Here

58HDX

2 5 -- 2 4 -- 7 0

A07709

11

″

″

Alternate Orientation

″

″

″

″

″

Single Pressure Switch Detail

Yellow or black
Plastic Cap

Field
Supplied Tee

Tee Trap White PVC
(loose parts bag)

58HDX

On Some
Models ONLY

EXHAUST

INLET

Level or Sloped towards Tee

Dual Pressure Switch

Relief Tube Black Rub-

3

/

(4.8mm) ID

ber

16

ON

OFF

Flexible Tube Connector
(4.8mm) OD (Loose Parts Bag)

Relief Tubing Extension
Black Rubber
Cut to Fit (Loose Parts Bag)

3

/

16

3

/

16

(4.8mm) ID

FLOW

AIR

WARNING
Move Caps to
top of trap

Ven t Dr ain
&Clamps

Elbow Tube Black Rubber1/
ID & Clamps (Loose Parts Bag)

Barbed Coupling1/
(Loose Parts Bag)

Drain Tube Black Rubber

1

/

(12.7mm) ID & Clamps

2

Drain Tube Corrugated

5

/

(15.9mm) ID & Clamps

8

(12.7mm) OD

2

Cutatstraightsection

Leave room for clamp

(12.7mm)

2

Cut Here

Representative drawing only, some models may vary in appearance.

Fig. 12 -- Horizontal Left Side Vent

25--24 --70a

A07710

12

″

Trap Connection

″

″

″

″

″

″

″

Preassemble &
insert into furnace

“Clamp ears”
Pointed OUT

Single Pressure Switch Detail

AIRFLOW

Drain Tube Black
Rubber
ID & Clamps

3

/

(4.8mm) ID Rub-

16

ber Tube

Coupling & Clamps
(Optional)

1

/

(12.7mm)

2

Plastic Cap
Yellow or black

Ven t Dr ain
&Clamps

Alternate Orientation

EXHAUST

Field
Supplied Tee

Relief Tube Black Rub-

3

/

(4.8mm) ID

ber

16

Flexible Tubing Connector

3

/

(4.8mm) OD (Loose

16

Parts Bag)

Relief Tube Extension
Black Rubber
Cut to Fit (Loose Parts Bag)

3

/

16

(4.8mm) ID

Drain Tube Corrugated
Clamps Cut at straight section

Leave room for clamp

WARNING
AddCapandClamp

OFF

ON

Dual Pressure Switch

5

/

(15.9mm) ID &

8

Drain Tube Black Rubber

1

/

(12.7mm) ID & Clamps

2

Remove KO before

Cut Here

mounting Trap

Representative drawing only, some models may vary in appearance.

Fig. 13 -- Horizontal Right Through Top

Tee Trap White PVC
(loose parts bag)

INLET

On Some Models
ONLY

Barbed Coupling1/
OD (Loose Parts Bag)

2

2 5 -- 2 4 -- 7 0 b

58HDX

(12.7mm)

A07711

13

Single Pressure Switch Detail

″

″

″

″

″

″

″

FLOW

AIR

Plastic Cap
Yellow or black

Coupling & Clamps
(Optional)

Ven t Dr ain
&Clamps

EXHAUST

Field
Supplied Tee

Level or Sloped
towards Tee

Tee Tr ap
White PVC
(loose parts bag)

Relief Tube
Black Rubber
(4.8mm) ID

3

/

16

58HDX

Flexible Tubing Connector3/
(4.8mm) OD (Loose Parts Bag)

Relief Tube Extension
Black Rubber
Cut to Fit (Loose Parts Bag)

16

3

/

(4.8mm) ID

16

Dual Pressure Switch

5

/

Drain Tube Black,
Corrugated Cut at straight section

(15.9mm) ID & Clamps

8

Leave room for clamp

Cut Here

OFF

ON

Remove KO before
mounting Trap

Drain Tube
Black Rubber

1

/

(12.7mm) ID

2

& Clamps

Elbow Tube Black Rubber

1

/

(12.7mm) ID & Clamps

2

(Loose Parts Bag)

On Some Models
ONLY

INLET

Alternate Orientation

Barbed Coupling1/
OD (Loose Parts Bag)

(12.7mm)

2

2 5 -- 2 4 -- 7 0 c

Representative drawing only, some models may vary in appearance.

A07712

Fig. 14 -- Horizontal Right Side Vent

14

Procedure 4 — Cleaning Heat Exchangers

The following items should be performed by a qualified
service technician.

A. Primary Heat Exchangers

If heat exchangers get an accumulation of light dirt or dust on the
inside, they may be cleaned by the following procedure:

NOTE: If heat exchangers get a heavy accumulation of soot and
carbon, both the primary and secondary heat exchangers should be
replaced rather than trying to clean them thoroughly due to their
intricate design. A build-up of soot and carbon indicates that a
problem exists which needs to be corrected, such as improper
adjustment of manifold pressure, insufficient or poor quality
combustion air, improper vent termination, incorrect size or
damaged manifold orifice(s), improper gas, or a restricted heat
exchanger (primary or secondary). Action must be taken to correct
the problem.

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

!

CAUTION

ELECTRICAL SHOCK, UNIT DAMAGE HAZARD

Failure to follow this caution may result in personal injury or
furnace component damage.

Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation.

3. Disconnect wires or connectors to flame rollout switch, gas
valve, igniter, and flame sensor.

4. Using backup wrench, disconnect gas supply pipe from
gas valve.

5. Remove screws attaching burner box to cell panel.
(See Fig. 4.)

NOTE: Burner box, manifold, gas valve, and burner assembly
should be removed as 1 assembly.

6. Clean heat exchanger openings with a vacuum and a soft
brush. (See Fig. 5.)

NOTE: After cleaning, inspect heat exchangers to ensure they are
free of all foreign objects that may restrict flow of
combustion products.

7. Reverse items 4 and 5 for reassembly.

8. Refer to furnace wiring diagram and connect wires to flame
rollout switch, gas valve, igniter, and flame sensor.

9. Reconnect pressure switch tubes to gas valve and intake
housing. Refer to tube routing label on main furnace door
for proper tube location. Be sure tubes are not kinked.
(See Fig. 6 -- 14.)

10. Turn on gas and electrical supplies to furnace.

11. Check furnace operation through 2 complete heat operating
cycles. Burner flames should be clear blue, almost
transparent. (See Fig. 15.)

!

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings could result in personal
injury, death, or property damage.

Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the
detection of leaks to check all connections.

12. Check for gas leaks.

13. Replace main furnace door.

B. Secondary Heat Exchangers

NOTE: The condensing side (inside) of secondary heat

exchangers CANNOT be serviced or inspected . A small number of
bottom outlet openings can be inspected by removing inducer
assembly. See Flushing Collector Box and Drainage System
section for details on removing inducer assembly.

Procedure5—FlushingCollectorBoxand
Drainage System

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Disconnect inducer motor and pressure switch wires
or connectors.

Burner Face

58HDX

!

CAUTION

UNIT MAY NOT OPERATE

Failure to follow this caution may result in improper unit
operation.

The ground wire from the gas valve MUST be attached to the
burner box attachment screw or furnace lockout may occur.

A07734

Fig. 15 -- Burner Flame

15

GASKET

58HDX

A07828

Fig. 16 -- Gasket on Collector Box

4. Disconnect pressure switch tubes.

5. Disconnect vent pipe from inducer housing outlet by
loosening clamp.

6. Disconnect drain tube from inducer housing. (See Fig. 6 --

14.)

7. Remove inducer housing assembly by removing 4 bolts
attaching assembly to cell panel.

8. Flush inside of collector box with water until discharge
from condensate trap is clean and runs freely.

NOTE: Ensure that drain tube disconnected from inducer housing
is higher than collector box opening or water will flow out tube.

9. Inspect inside area of collector box for any pieces of foreign
materials and remove if present.

!

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace component
damage.

DO NOT use wire brush or other sharp object to inspect or
dislodge materials in secondary heat exchangers as failure of
the secondary heat exchanger may occur. Flush with
water only.

10. Reassemble inducer assembly by reversing items 5 through

7. Tighten the vent coupling screw(s) to 15 in.--lb.
of torque.

NOTE: If gasket between inducer housing and collector box is
damaged in any way, it must be replaced. (See Fig. 16.)

11. Refer to furnace wiring diagram and connect wires to
inducer motor and pressure switch or connectors.

12. Reconnect pressure tubes to pressure switch. See diagram
on main furnace door for proper location of tubes. Be sure
tubes are not kinked. (See Fig. 6 -- 14.)

13. Turn on gas and electrical supplies to furnace.

14. Check furnace operation through 2 complete heat operating
cycles. Check area below inducer housing, vent pipe, and
condensate trap to ensure no condensate leaks occur. If leaks
are found, correct problem.

!

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow the warnings could result in personal injury,
death, or property damage.

Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the
detection of leaks to check all connections.

15. Check for gas leaks.

16. Replace main furnace door.

Procedure 6 — Servicing Hot Surface Igniter

The igniter does NOT require annual inspection. Check igniter
resistance before removal.

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Disconnect igniter wire connection.

16

FIVE WIRE

THREE--WIRE

HEATING--ONLY

BLOWER DOOR SWITCH

BLK

WHT

115 --V FIE LD - -

SUPPLIED

DISCONNECT

Blower Off
Delay Jumper

24 VAC
HUM

GND

FUSE

BLK

WHT

AUXILIARY
J--BOX

GND

FURNACE

NOTE 2

C
O
N

T
R
O

L

24--V

TERMINAL

BLOCK

Diagnostic Light

WC RG Y

W

R

G

NOTES:

FIELD 24--V WIRING
FIELD 115--, 208/230--, 460--VWIRING
FACTORY 24--VWIRING
FACTORY 115-- V WIRING

NOTE 1

THERMOSTAT
TERMINALS

CONDENSING
UNIT

TWO
WIRE

FIELD--SUPPLIED
DISCONNECT

GND

208/230-- OR
460--V
THREE
PHASE

208/230--V
SINGLE
PHASE

1. Connect Y-terminal in furnace as shown for proper blower operation.

2. Some thermostats require a “C” terminal connection as shown.

3. If any of the original wire, as supplied, must be replaced, use same
type or equivalent wire.

Fig. 17 -- Field Wiring

a. Using a 1/4 in. nut driver, remove the single screw

securing the igniter bracket to the burner box and
carefully withdraw the igniter through the bottom of the
burner box without striking the igniter on surrounding
parts.

b. Inspect igniter for signs of damage or failure.

!

115 VAC
HUM

UNIT DAMAGE HAZARD

CAUTION

Failure to follow this caution may result in premature failure
of the igniter.

EAC

The igniter is fragile. DO NOT allow it to hit the side of the
burner box opening while removing or replacing it.

58HDX

A02174

A07727

Fig. 18 -- Control Center

4. Check igniter resistance. Igniter resistance is affected by
temperature. Only check resistance when the igniter is at
room temperature.

a. Using an ohm meter, check resistance across both

igniter leads in connector.

b. Cold reading should be between 40 ohms and 70 ohms.

5. Remove igniter.

!

CAUTION

BURN HAZARD

Failure to follow this caution may result in personal injury.

Allow igniter to cool before removal. Normal operating
temperatures exceed 2000°F (1093°C).

c. If replacement is required, replace igniter on igniter

bracket and then install assembly into burner box to
avoid damage to the igniter.

6. T o replace igniter and bracket assembly, reverse items 5a
and 5b.

7. Reconnect igniter wire connection.

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury
or death.

Igniter wires must be securely placed in slot in manifold
grommet or else they could become pinched or severed and
electrically shorted.

17

8. Turn on gas and electrical supplies to furnace.

9. Verify igniter operation by initiating furnace control self-test
feature or by cycling thermostat.

10. Replace main furnace door.

Procedure 7 — Electrical Controls and Wiring

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury
or death.

There may be more than 1 electrical supply to the furnace.
Check accessories and cooling unit for additional
electrical supplies.

1. Check for signs of physical damage to heat tape such as
nicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damage or
discolored insulation is evident, replace heat tape.

3. Check that heat tape power supply circuit is on.

Procedure 9 — Winterizing

!

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace component
damage.

Freezing condensate left in the furnace will damage
the furnace.

The electrical ground and polarity for 115-v wiring must be
maintained properly. Refer to Fig. 17 for field wiring information
and to Fig. 20 for furnace wiring information.

NOTE: If polarity is not correct, STATUS LED on furnace control

58HDX

board will flash rapidly and prevent furnace from operating. The
control system also requires an earth ground for proper operation
of furnace control and flame sensor.

The 24-v circuit contains an automotive-type, 5-amp fuse located
on the control. (See Fig. 18.) Any direct shorts of the 24-v wiring
during installation, service, or maintenance will cause this fuse to
blow. If fuse replacement is required, use ONLY a 5-amp fuse of
identical size. The control LED will flash status code 24 when fuse
needs to be replaced.

With power to unit disconnected, check all electrical connections
for tightness. Tighten all screws on electrical connections. If any
smoky or burned connections are found, disassemble connection,
clean all parts, strip wire, and reassemble properly and securely.

Reconnect electrical supply to unit and observe unit through 1
complete operating cycle for proper operation.

Procedure 8 — Checking Heat T ape Operation
(If Applicable)

In applications where the ambient temperature around the furnace
is 32°F(0°C) or lower, freeze protection measures are required. If
heat tape has been applied, check to ensure it will operate when
low temperatures are present.

!

CAUTION

UNIT AND PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in furnace component
damage or property damage.

If this furnace is to be operated in an unconditioned space
where the ambient temperatures may be 32°F(0°C) or lower,
freeze protection measures must be taken. (See Fig. 19.) See
CONDENSATE DRAIN PROTECTION section of
Installation, Start-Up and Operating Instructions.

NOTE: Heat tape, when used, should be wrapped around the
condensate drain trap and drain line. There is no need to use heat
tape within the furnace casing. Most heat tapes are temperature
activated, and it is not practical to verify the actual heating of the
tape. Check the following:

If the furnace will be off for an extended period of time in a
structure where the temperature will drop to 32°F(0°C) or below,
winterize as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door.

3. Disconnect the 1/2” I.D. rubber hose from the vent drain
fitting (or tee) that is located downstream of the combustion
blower. Insert a funnel into the hose and pour four (4)
ounces of sanitary type (RV) antifreeze into the condensate
trap. Reconnect the 1/2” I.D. rubber hose to the stub the
vent drain fitting. Secure with the hose clamp.

!

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component
damage.

Do not use ethylene glycol (Prestone II antifreeze/coolant or
equivalent automotive type). Failure of plastic components
may occur.

4. Disconnect the 5/8” I.D. rubber hose from the condensate
trap. Insert a funnel into the hose and pour four (4) ounces
of sanitary type (RV) antifreeze into the plastic transition
box. Squeeze the hose together near the and quickly
reconnect the 5/8” I.D. rubber hose to the stub on the
condensate trap. Secure with the hose clamp.

5. When you return home, your furnace will be ready to start,
as it is not necessary to drain the antifreeze from the furnace.

WIRING DIAGRAM

See Fig. 20 for Wiring Diagram.

TROUBLESHOOTING

Use the Troubleshooting Guide, the status code LED on the control
and the Component Test to isolate furnace operation p roblems.

A. Status Codes

For an explanation of status codes, refer to service label located on
front of blower door or Fig. 21.

NOTE: Removing the blower access door will open the blower
access door switch and terminate 115-v power to the control. This
will erase the stored status code.

NOTE: NO thermostat signals should be present at control and all
blower off delays must be completed to view previous codes.

18

!

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unit
components.

Make sure limit switch wire does not contact any metallic
component such as the gas valve. If wire is shorted, the 5-amp
fuse on furnace control board will open and the unit will
not operate.

58HDX

A07911

Fig. 19 -- Winterizing the Furnace

To retrieve last code, remove 1 of the red main limit wires for 1 to
4 sec until the LED light goes out, then reconnect it. (Do not leave
red wire disconnected for longer periods of time as the control will
assume an overtemperature condition exists and will respond with
blower operation.) This places the control in the status recall mode
and displays the first code stored in memory.

19

58HDX

Fig. 20 -- Wiring Diagram

20

A07824

58HDX

Fig. 21 -- Service Label

21

A07825

58HDX

Copyright 2009 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 05/09

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

22

Catalog No: 58HDX---01SM

Replaces: NEW