Carrier 58MTB User Manual

58MTB
D e l u x e 4 --- W a y
Multipoise Fixed --- Capacity
Condensing Gas Furnace

Service and Maintenance Instructions

For Sizes 060-- 120, Series 100

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

!

WARNING

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS 2.........................

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 2...

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

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

Blower Motor and Wheel Maintenance 4..................

Cleaning Burners 6...................................

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

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

Secondary Heat Exchangers 8..........................

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..................................

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.

--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 possible
damage to this equipment, 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.

!

WARNING

ama

ISO 9001:2000

REGISTERED

CERTIFIED

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could 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.

1

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. Untrained personnel can perform basic
maintenance functions described in User’s Information

58MTB

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 National Fuel Gas Code
(NFGC) NFPA 54--2006/ANSI Z223.1--2006 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.

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Fig. 1 -- Multipoise Furnace in Upflow Orientation

AIRFLOW

UPFLOW

A05079

!

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.

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.

HORIZONTAL

LEFT

HORIZONTAL

RIGHT

DOWNFLOW

AIRFLOW

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.

AIRFLOW

A93041

2

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 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. 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.

Step 1 — Cleaning and/or Replacing Air Filter

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

!

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. Furnaces with a 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 with washable filter(s) should 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.

58MTB

!

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.

3

Table 1 – Furnace Air Filter Table

FURNACE CASING WIDTH

IN (MM)

17---1/2 (445)

21 (533 )

24---1/2 (610)

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

(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)

Table 2 – Air Filter Located in Filter Cabinet

FILTER CABINET HEIGHT --- IN (MM) F I L T E R SI Z E --- I N ( M M ) FILTER TYPE

(1) 16 x 25 x 3/4*

16 (406)

58MTB

20 (508)

24 (610)

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

(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)

FILTER TYPE*SIDE RETURN*

3/4” (19 mm) thick washable

3/4” (19 mm) thick washable

3/4” (19 mm) thick washable

Washable

Washable

Washable

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.

FILTER

FILTER
SUPPORT

FILTER
RETAINER

WASHABLE FILTER OR
DISPOSABLE MEDIA FILTER
IN FILTER CABINET

A08588

Fig. 3 -- Bottom Filter Arrangement

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

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

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 do not need to
be removed from motor.

f. Remove blower wheel from housing.

4

FILTER

IN FURNACE

!

CAUTION

WASHABLE FILTER OR
DISPOSABLE MEDIA
FILTER IN FILTER CABINET

Fig. 4 -- Filter Installed for Side Inlet

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

1

⁄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)

FILTER
RETAINER

A08589

A01030

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.

(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 to adjust the heating speed may shorten heat exchanger
life.

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

58MTB

5

Table 3 – Speed Selection

COLOR SPEED

White Common Com
Black High Cool

Yellow Medium High Spare

Orange{ Medium H i g h --- G a s H e a t

Blue Medium Low

*Continuous blower speed.
{Available on 5 ---speed blowers only.

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

58MTB

taken when manually closing this switch for service purposes.

Red Low* L o w --- G a s H e a t

!

WARNING

FACTORY

ATTACHED TO

S p a r e / H i g h --- G a s

Heat

13. Clean burners with soft brush and vacuum.

14. Reinstall 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

PANEL

MANIFOLD
MOUNTING
SCREWS

GASKET

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. 20.)

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.

!

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.

MANIFOLD

GAS VALVE
REGULATOR
FITTING

GAS
CONTROL
VALV E

Fig. 6 -- Burner Box Assembly

A02312

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.

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.

IGNIT ER WIRES MUST
BE PLACED IN THIS SLOT

Fig. 7 -- Igniter Wire Placement

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in electrical shock,
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.

6

A05074