58HDX
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
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