Carrier 58VCA User Manual

HEATING & COOLING

© .

Variable-Speed Gas-Fired Condensing Furnaces

Service and Maintenance Instructions

For Sizes 060-100, Series 100

NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous
due to gas and electrical components. Only trained and qualified
personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions
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, tags, and
labels attached to or shipped with the unit and other safety
precautions that may apply.

Follow all safety codes, including NFPA 54/ANSI Z223.1-1988,
National Fuel Gas Code. Wear safety glasses and work gloves.
Have a fire extinguisher available during start-up and adjustment
procedures and service calls.

Recognize safety information. This is the safety-alert symbol ^ .
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.

Understand the signal word —DANGER, WARNING, or CAU
TION. These words are used with the safety-alert symbol. DAN
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards that 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.

Fig. 1—Model 58VUA Upflow Furnace

58VCA
58VUA

A91128

A WARNING

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 com
pounds, 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.
Failure to follow this warning can cause corrosion of the heat
exchanger, fire, personal injury, or death.

CARE AND MAINTENANCE

For continuing high performance and to minimize possible equip
ment failure, it is essential that maintenance be performed annually
on this equipment. Consult your local dealer for maintenance and
the availability of a maintenance contract.

Fig. 2—Model 58VCA Downflow Furnace

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations.

Book 1 4

Tab 6a 8a

PC 101 Catalog No. 565-997

Printed in U.S.A. Form 58V-1SM

Pg1

О

6-92

A92095

Replaces: 58SXB-1SM

A WARNING

The ability to properly perform maintenance on this equip
ment 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. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS
PERSONAL INJURY, OR DEATH.

A WARNING

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

INSTALLATION

-POSITION
OF FILTERS

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

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

2. Check blower motor and wheel for cleanliness and lubrication
each heating and cooling season. Clean and lubricate as
necessary. (See Step 2.)

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 of combustion-air and vent pipes.

A CAUTION

As with any mechanical equipment, personal injury could
result from sharp metal edges, etc. Be careful when removing
parts.

Step 1—Air Filter Cleaning and Replacement

The air filter arrangement may vary depending on the application.

A CAUTION

Never operate unit without a filter or with filter access door
removed. Failure to follow this warning could result in a fire
or personal injury.

DOWNFLOW FURNACES ONLY - Each furnace accommo
dates 2 filters which are installed in the return-air duct. (See Fig.

3.) To clean or replace the filters, proceed as follows:

1. Turn OFF electrical supply to unit.

2. Remove blower access door.

3. Reaching up behind top plate, tilt filters toward center of
return-air plenum, remove filters, and replace or clean as
needed.

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

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

6. Reinstall filters with cross-mesh binding facing blower.

7. Replace access door.

8. Turn ON electrical supply to furnace.

UPFLOW FURNACES ONLY — To clean or replace the air
filter, proceed as follows:

1. Turn OFF electrical supply to unit.

A92117

Fig. 3—Position of Filters in Downflow Furnace

CONTROL
BOX

Fig. 4—Filter Installed for Bottom Inlet

AUX J-BOX
& BLOWER

DOOR SWITCH

Fig. 5—Filter Installed for Side Inlet

2. Remove access doors.

3. Release filter retainer spring from behind flange of furnace
casing. (See Fig. 4 and 5.)

4. Slide filter out.

WA

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

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

7. Place filter in furnace with cross-mesh binding either up or
facing blower.

8. Replace access doors.

9. Turn ON electrical supply to furnace.

Step 2—Blower Motor and Wheel Maintenance

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

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

Some motors have prelubricated, sealed bearings and require no
lubrication. These motors can be identified by the absence of oil
ports on each end of the motor. For motors with oil ports, lubricate
as follows:

Lubricate motor every 5 years if motor is used for intermittent
operation (thermostat FAN switch in AUTO position), or every 2
years if motor is in continuous operation (thermostat FAN switch
in ON position).

Clean and lubricate as follows:

1. Turn OFF electrical supply to unit.

2. Remove access doors.

3. Upflow furnaces only —remove drain trap and control box:
a. Remove control box from bottom side of blower shelf and

position to 1 side.

b. Disconnect 9-circuit connector PL-13 from blower hous

ing.

c. Using backup wrench, disconnect drain pipe at coupling in

blower compartment.

d. Loosen hose clamp and remove 7/8-in. diameter drain hose

from drain trap.

e. Loosen hose clamp and disconnect 5/8-in. diameter drain

hose at bottom of inducer housing located under blower
shelf.

f. Remove screw securing drain trap assembly.

4. Downflow furnaces only — disconnect vent pipe, elbow, and
auxiliary limit switch. (See Fig. 6.)

a. Remove control box from top plate and position to 1 side.

AUXILIARY
UMIT

.SWITCH

c. Disconnect wires from auxiliary limit on blower housing.
d. Remove vent pipe enclosure from top side of blower shelf

and position to 1 side.
e. Loosen hose clamps on outlet elbow and remove elbow.
f. Loosen hose clamp on extension pipe outside of furnace

and remove pipe.

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

6. Squeeze side tabs of connector PL-13 and pull from blower
housing bracket.

7. Mark blower wheel location on shaft before disassembly to
insure proper reassembly.

8. 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. This

will insure that oilers point up. ■

9. Remove bolts holding motor mount to blower housing and
slide motor and mounts out of housing.

10. Lubricate motor (when oil ports are provided).
a. Remove dust caps or plugs from oil ports located at each

end of motor. If motor does not have these caps or plugs,
bearings are sealed and need no further lubrication.

b. Use a good grade of SAE 20 nondetergent motor oil and

add 1 teaspoon (5 cc, 3/16 oz, or 16 to 25 drops) in each oil
port. The use of other types or grades of oil will damage the
motor. Excessive oiling can cause premature bearing fail
ures.

c. Allow time for total quantity of oil to be absorbed by each

bearing.

d. After oiling motor, wipe excess oil from motor housing.

e. Replace dust caps or plugs on oil ports.

11. Remove blower wheel from housing:
a. Mark blower wheel orientation and cutoff plate location to

insure proper reassembly.

b. Remove screws securing cutoff plate and remove cutoff

plate from housing.

c. Remove blower wheel from housing.

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

13. Reassemble blower by reversing items ll.a. through ll.c.
Ensure wheel is positioned for proper rotation.

14. Reassemble motor and blower by reversing items 6 through 9.
If motor has ground wire, be sure it is reconnected.

Fig. 6—Downflow Furnace Blower Compartment

b. Disconnect 9-circuit connector PL-13 from blower hous

ing.

A92118

A CAUTION

Ensure the motor is properly positioned in the blower
housing. The motor oil ports must be at a minimum of 30°
above the horizontal centerline of the motor after the blower
assembly has been reinstalled in the furnace.

15. Reinstall blower assembly in furnace.

16. Upflow furnaces only — reinstall drain trap and control box:

a. Inspect drain trap and hoses to ensure they are not blocked

or restricted. Reinstall drain trap and hoses. Be sure to
tighten hose clamps.

b. Using backup wrench, attach drain pipe and tighten com

pression coupling.