Carrier 58MEC User Manual

58MEC D E L U X E 4 --- W AY M U LT I P O I S E 2 --- S T A G E CONDENSING GAS FURNACE SIZES 060 TO 120

Service and Maintenance Instructions

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

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 5...................................

Cleaning Heat Exchangers 7............................

Primary Heat Exchangers 7............................

Secondary Heat Exchangers 7..........................

Flushing Collector Box and Drainage System 8.............

Servicing Hot Surface Igniter 10.........................

Electrical Controls and Wiring 11........................

Checking Heat Tape Operation (If Applicable) 11...........

Winterizing 11......................................

WIRING DIAGRAM 13................................

TROUBLESHOOTING 13..............................

Status Codes 13.....................................

Component Tests 14..................................

TROUBLESHOOTING GUIDE 17.......................

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, and 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 which could result in personal injury or death. CAUTION is used to identify unsafe practices which may 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.

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 heating equipment.

WARNING

ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD

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

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.

WARNING

ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD

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

-- Before servicing, disconnect all electrical power to furnace and install lock out tag.

--When servicing controls, label all wires prior to

disconnecting. Reconnect wires correctly.

-- Verify proper operation after servicing.

FIRE OR EXPLOSION HAZARD

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

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 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 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 including the current edition of the National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 in the USA, CSA B149.1--05 National Standard of Canada, Natural Gas and Propane Installation Codes (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.

58MEC

CAUTION

UNIT DAMAGE HAZARD

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

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

R T L

Fig. 1 -- Multipoise Furnace in Upflow Orientation

AIRFLOW

A05079

GENERAL

This furnace can be installed as a direct vent (2--pipe) or non--direct vent (1--pipe) condensing gas furnace. These 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. 2, you may need to revise your orientation to component location accordingly.

ama

ISO 9001:2000

CERTIFIED

REGISTERED

UPFLOW

HORIZONTAL

LEFT

HORIZONTAL

RIGHT

DOWNFLOW

AIRFLOW

Fig. 2 -- Multipoise Orientation

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

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.

A05085

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. Tools 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 furnace failure, it is essential that maintenance be performed annually. Consult your local dealer for maintenance and maintenance contract availability.

WARNING

ELECTRICAL SHOCK EXPLOSION HAZARD

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

Turn off the gas and electrical supplies to the unit and install lock out tags before performing any maintenance or service. 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, gloves, and safety glasses when removing parts.

Step 1 — Cleaning and/or Replacing Air Filter

The air filter arrangement may vary depending on the application or orientation. See Tables 1 and 2 for filter size and type information.

WARNING

FIRE, CARBON MONOXIDE POISONING HAZARD

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

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 the filter has an airflow direction arrow, the arrow must point toward the blower.

To clean or replace filters, proceed as follows: If filter is installed in filter cabinet adjacent to furnace:

1. Turn off electrical supply to furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable filter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry. Oiling or coating of the filter is not recommended.

5. If equipped with factory specified disposable media filter, replace only with a factory specified media filter of the same size.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

If filter is installed in furnace blower compartment:

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

3. Release filter retainer wire. (See Fig. 3 or 4.)

NOTE: Filters shown in Fig. 3 and 4 can be in furnace blower compartment or in filter cabinet, but not in both.

4. Slide filter out of furnace.

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

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

7. Slide filter into furnace.

8. Recapture filter retaining wire.

9. Replace blower access panel and main furnace door.

10. Turn on electrical supply to furnace.

Step 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 main furnace door and blower access panel.

58MEC

Table 1 – Furnace Air Filter Table

FURNACE CASING WIDTH

IN (MM)

17--- 1/2 (445)

21 (533 )

24--- 1/2 (610)

SIDE RETURN{*

(1) 16 x 25 x 3/4 { (406 x 635 x 19) {

(1) 16 x 25 x 3/4 (406 x 635 x 19)

FILTER QUANTITY AND SIZE *

IN (MM)

BOTTOM RETURN*

IN (MM)

(1) 16 x 25 x 3/4 (406 x 635 x 19)

(1) 20 x 25 x 3/4 { (508 x 635 x 19) {

(1) 24 x 25 x 3/4 { (610 x 635 x 19) {

3/4 (19 mm) thick washable

Table 2 – Air Filter Located in Filter Cabinet

FILTER CABINET HEIGHT --- IN (MM) F I LT E R S I Z E --- I N ( M M ) FILTER TYPE

(1) 16 x 25 x 3/4*

16 (406)

58MEC

* Filters with a side return--air may have a different filter size. Measure the filter to obtain the correct size.

{ Factory -- provided with furnace.

20 (508)

24 (610)

(406 x 635 x 19) or

(1) 16 x 25 x 4--- 5/16

(406 x 635 x 110)

(1) 20 x 25 x 3/4*

(508 x 635 x 19) or

(1) 20 x 25 x 4--- 5/16

(508 x 635 x 110)

(1) 24 x 25 x 3/4*or

(610 x 635 x 19) or

(1) 24 x 25 x 4--- 5/16

(610 x 635 x 110)

NOTE: Blower wheel is fragile. Use care.

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

WASHABLE FILTER

FILTER SUPPORT

FILTER RETAINER

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

to ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

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.

WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET

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 do not need to

A00232

Fig. 3 -- Bottom Filter Arrangement

3. Disconnect blower motor wires from furnace control. Field thermostat connections may need to be disconnected de-

be removed from motor.

f. Remove blower wheel from housing.

WASHABLE

FILTER

IN FURNACE

pending 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 Fig. 5):

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

WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET

and slide blower assembly out of furnace. Detach ground wire and disconnect blower motor harness plugs from

Fig. 4 -- Filter Installed for Side Inlet

blower motor.

FILTER TYPE

IN (MM)*

Washable

FILTER RETAINER

A00233

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄2-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE TRAP

DRAIN TUBE

DRAIN OPTION)

Fig. 5 -- Factory--Shipped Upflow Tube Configuration

(Shown with Blower Access Panel Removed)

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in noise or 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 in motor.

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

NOTE: Be sure to attach ground wire to blower housing.

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. 5 or

tubing diagram on main furnace door for proper tube location.

A01030

(1.) Connect 1 tube (blue or blue and white striped)

from collector box.

(2.) Connect 1 tube (violet or unmarked) from inducer

housing.

(3.) Connect 1 tube (relief port, green or pink) from

collector box.

NOTE: Ensure tubes are not kinked or pinched, as this will 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. 16.)

NOTE: Refer to Table 3 for motor speed lead reconnection if leads were not identified before disconnection.

CAUTION

UNIT DAMAGE HAZARD

Failure follow this caution may result in unit component damage.

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

Table 3 – Speed Selection

COLOR SPEED

Gray 5 Cool

Yellow 4 Spare

Blue 3 High ---Heat

Orange 2 Spare

Red 1

WARNING

FACTORY

ATTACHED TO

Low Heat/Cont

Fan

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.

14. Turn on electrical supply. Manually close blower access door switch. Use a piece of tape to hold switch closed. Check for proper rotation and speed changes by performing a component self--test as shown at the bottom of Service label. (See Fig. 21.)

15. If furnace is operating properly, remove tape to release blower access door switch, replace blower access door, and replace main furnace door.

Step3—CleaningBurners

The following items should be performed by a qualified service technician. If the 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. Remove burner box cover.

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

58MEC

CAUTION

UNIT DAMAGE HAZARD

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

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

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

6. Remove burner box pressure tube from gas valve regulator fitting.

7. Unplug igniter from harness.

8. Remove igniter leads from slot in manifold grommet.

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

NOTE: Do not remove burner box from cell panel.

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

58MEC

11. Remove screws attaching burner assembly in burner box.

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

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

13. Clean burners with soft brush and vacuum.

14. Reinstall burner assembly, manifold, orifice, and gas valve assembly in burner box. Ensure manifold seal grommet is installed properly and burners fit over orifices.

15. Reinsert the igniter wires in the slot in the manifold grommet, dressing the wires to ensure there is no tension on the igniter itself. (See Fig. 7.)

CELL

PAN EL

IGNIT ER WIRES MUST BE PLACED IN THIS SLOT

A05074

Fig. 7 -- Igniter Wire Placement

UNIT COMPONENT ELECTRICAL SHORT HAZARD

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

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

CAUTION

MANIFOLD MOUNTING SCREW

GAS VALVE REGULATOR FITTING

GAS VALVE

Fig. 6 -- Burner Box Assembly

MANIFOLD

A96304

16. Reconnect wires to gas valve and igniter. Refer to furnace

wiring diagram for proper wire location.

17. Reinstall burner box pressure tube to gas valve regulator fit-

ting.

18. 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.

WARNING

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.

19. Replace burner box cover.

20. Turn on gas and electrical supplies to furnace.

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning 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.

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