Carrier 58HDX User Manual

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

Service Guide

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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.

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

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.

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

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.

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

″

58HDX

Casing Grommet Black Rubber

(Loose parts bag)

Ven t Dr ain &Clamps

Dual Pressure Switch Detail

FLOW

AIR

(15.9mm) ID

Plastic Caps (2) Yellow or black

Coupling & Clamps (Optional)

Drain Tube Black Rubber

Clamps

Drain Connector Black PVC

(18.1mm) PVC X1/

(12.7mm) CPVC (Loose

parts bag)

Drain Tee

(12.7mm) ID &

Drain Tube Corrugated

/8″″(15.9mm) ID &

Clamps

EXHAUST

On Some Models ONLY

Single Pressure Switch

Relief Tube Black Rubber

(4.8mm) ID

Street Elbow

(12.7mm) CPVC

(Loose parts bag)

INLET

OFF

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

Representative drawing only, some models may vary in appearance.

(12.7mm)

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

(15.9mm) ID &

25--24 --67

A07706

Fig. 6 -- Upflow Installations Top Vent

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

AIR

Drain Tube Black Rubber

&Clamps

Drain Connector Black PVC

(19.1mm) PVC X1/

(12.7mm) CPVC (Loose parts bag)

Tee Trap White PVC (loose parts bag)

(12.7mm) ID

EXHAUST

Drain Tube Corrugated

(15.9mm) ID

&Clamps

2″(50.8mm) PVC Coupling

INLET

On Some Models ONLY

OFF

Single Pressure Switch

Relief Tube Black Rubber (4.8mm) ID

58HDX

SIDE VIEW

Rotate downward

to 10

Casing Grommet Black Rubber

(15.9mm) ID

(Loose parts bag)

NOTE: Built--in channel will

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

(18.1mm) PVC or1/

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

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