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58YAV

Carrier 58YAV User Manual

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Service and Maintenance Instructions
For Sizes 070-155, Series 110 and 120
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS.....................................................1
INTRODUCTION..........................................................................1
CEDURE........................................................................................2
CARE AND MAINTENANCE.....................................................2
Cleaning and/or Replacing Air Filter.......................................2
Blower Motor and Wheel.........................................................3
Cleaning Heat Exchanger.........................................................4
Electrical Controls and Wiring.................................................5
Wiring Diagrams............................................................................9
Troubleshooting..............................................................................9
SAFETY CONSIDERATIONS
58YAV
Induced-Combustion Furnaces
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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. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No. 54-1999/ANSI Z223.1-1999. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1­and .2-M95 Natural Gas and Propane Gas Installation Codes (NSCNGPIC). Wear safety glasses and work gloves. Have 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 furnace and in instructions or manuals, be alert to the potential for personal injury.
A94085
Fig. 1—Model 58YAV Upflow Furnace
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. A FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS PERSONAL INJURY, OR DEATH.
Label all wires prior to disconnection when servicing con­trols. Wiring errors can cause improper and dangerous operation.
.
These procedures are written for size 66,000 through 154,000 Btuh input units of the 58YAV Gas-Fired Induced Combustion Furnace.
INTRODUCTION
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4 Tab 6a 8a
PC 101 Catalog No. 535-771 Printed in U.S.A. Form 58YAV–3SM Pg 1 10-00 Replaces: 58YAV–2SM
PROCEDURE
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.
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) may also be used to prevent ESD damage.
CARE AND MAINTENANCE
For continuing high performance and to minimize possible equip­ment failure, it is essential that periodic maintenance be performed on this equipment. Consult your local dealer as to proper frequency of maintenance and availability of a maintenance contract.
Never store anything on, near, or in contact with 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. A failure to follow this warning could result in corrosion of the heat exchanger, fire, personal injury, or death.
Turn off gas and electrical supplies to unit before performing any maintenance or service on it. Follow operating instruc­tions on label attached to furnace. A failure to follow this warning could result in personal injury.
The minimum maintenance that should be performed on this equipment is as follows:
1. Check and clean air filter each month or more frequently if required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.
3. Check electrical connections for tightness and controls for proper operation each heating season. Service as necessary.
As with any mechanical equipment, personal injury can result from sharp metal edges, etc.; therefore, be careful when removing parts.
Step 1—Cleaning and/or Replacing Air Filter
The air filter arrangement may vary depending on application. NOTE: If the filter has an airflow direction arrow, the arrow must
point toward the blower.
Never operate unit without a filter or with filter access door removed. A failure to follow this warning could result in fire, personal injury, or death.
To clean or replace filters, proceed as follows:
1. Filters installed in media cabinet adjacent to furnace (see Fig.
2)
FLUE COLLAR
MOUNTING
SCREWS
RELIEF
BOX
GAS
VALVE
CONTROL
HUM
C
24V
OM
GRYW
BLOCKED VENT SAFEGUARD
PRESSURE SWITCH
FLUE COLLECTOR BOX
FILTER RETAINER
WASHABLE FILTER
A99284
Fig. 2—Model 58YAV Upflow Furnace
a. Turn off electrical supply to furnace b. Remove filter cabinet door. c. Slide filter out of cabinet.
2
d. 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.
e. If equipped with factory-specified disposable media filter,
replace only with media filter having the same part number
and size. f. Slide filter into cabinet. g. Replace filter cabinet door. h. Turn on electrical supply to furnace.
2. Filters installed in side(s) and/or bottom of blower compart­ment (See Fig. 2)
a. Disconnect electrical power before removing access doors. b. Remove blower and control access doors. c. Release filter retainer from clip at front of furnace casing.
(See Fig. 2.) For side return, clips may be used on either or
both sides of the furnace. d. Slide filter(s) out. e. Furnaces are equipped with permanent, washable filters.
Clean filters with tap water. Spray water through filter in
opposite direction of airflow. f. Rinse and let dry. Oiling or coating of filter is NOT
recommended or required. g. Reinstall filter(s) h. Replace blower and control access doors i. Restore electrical power to furnace.
Step 2—Blower Motor and Wheel
The following items should be performed by a qualified service technician:
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 prelubricated and require no additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Remove control and blower access doors.
3. Disconnect blower leads from furnace control. Notice wire color and location for reassembly. All other factory wires can be left connected, but field thermostat connections may need to be disconnected depend­ing on their length and routing.
4. Remove 2 screws securing control and transformer support to furnace.
5. Hang control box and transformer support to front of furnace casing.
6. Remove screws holding blower assembly to blower deck and slide blower assembly out of furnace.
7. Clean blower wheel and motor using a vacuum with soft brush attachment. Do not remove or disturb balance weights (clips) on blower wheel blades. The blower wheel should not be dropped or bent as balance will be affected.
8. If a 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, motor, and blower housing so motor and each arm is positioned at the same 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 mount belly band need not be removed unless motor is to be replaced.
f. Remove blower wheel from housing.
The blower wheel should not be dropped or bend as balance will be affected.
9. Reassemble motor and blower by reversing items 9a through 9f. Be sure to reattach ground wire.
10. Reinstall blower assembly in furnace.
11. Reinstall control and transformer support assembly in furnace.
12. Reconnect blower leads to furnace control. Refer to furnace wiring diagram (See Fig. 6), and connect thermostat leads if previously disconnected.
NOTE: Refer to Table 1 for motor speed lead relocation if leads were not identified before disconnection
TABLE 1—SPEED SELECTOR
COLOR SPEED
Black High Cool
Yellow (When
Present)
Blue Medium Low Heat
Red Low Spare
White Common L2/COM
Medium High Spare
Heating speed selection MUST be adjusted to provide proper temperature rise as specified on the rating plate. Failure to adjust the heating speed may shorten heat exchanger life.
Blower access door switch opens 115-v power to control center. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. Failure to follow this warning could result in electrical shock, personal injury, or death.
NOTE: If thermostat terminals are jumpered before blower access door switch is closed, blower will run for 90 sec before beginning a heating or cooling cycle.
FACTORY-
ATTACHED
TO
3
14. If furnace is operating properly, REMOVE TAPE TO RE­LEASE BLOWER ACCESS DOOR SWITCH, replace blower access door.
Step 3—Cleaning Heat Exchanger
The following steps should be performed by a qualified service technician:
NOTE: If the heat exchangers get a heavy accumulation of soot and carbon, they should be replaced rather than trying to clean them thoroughly due to their intricate design. A build-up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, incorrect size, or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem. If it becomes necessary to clean heat exchanger because of light dust or corrosion proceed as follows:
1. Turn gas and electrical power to furnace to OFF.
2. Remove control access door.
3. Disconnect vent connector from furnace flue collar.
4. Remove 2 screws that secure relief box. (See Fig. 2.)
5. Disconnect wires to the following components. Mark wires to aid in reconnection of:
a. Blocked vent safeguard switch. b. Inducer motor. c. Pressure switch. d. Limit overtemperature switch(es). e. Gas valve. f. Hot surface ignitor. g. Flame-sensing electrode h. Flame rollout switch(es), if applicable.
6. Remove complete inducer assembly and relief box from furnace.
7. Remove 8 screws that secure flue collector box to center panel. Be careful not to damage collector box.
8. Remove burner assembly and cell inlet plates. IMPORTANT: Replace screws in center panel before cleaning.
NOTE: Be very careful when removing burner assembly to avoid breaking ignitor. See Fig. 3 for correct ignitor location.
9. Using field-provided small wire brush, steel spring cable, reversible electric drill, and vacuum cleaner, clean cells as follows:
a. Assemble wire brush and steel spring cable.
(1.) Use 48 in. of 1/4-in. diameter high-grade steel spring
cable (commonly known as drain clean-out or Roto­Rootert cable).
(2.) Use 1/4-in. diameter wire brush (commonly known as
25-caliber rifle cleaning brush).
(3.) Insert twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or strike with ball-peen hammer. TIGHTNESS IS VERY IMPOR­TANT.
(4.) Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Clean each heat exchanger cell.
(1.) Attach variable-speed, reversible drill to end of spring
cable (end opposite brush).
11
CELL PANEL
HOT SURFACE IGNITOR ASSEMBLY
C
IGNITOR
L
7
8
"
C
BURNER
L
IGNITOR ASSEMBLY
32
"
A93347
BURNER
13
32
"
Fig. 3—Position of Ignitor to Burner
(2.) Insert brush end of cable into upper opening of cell
and slowly rotate with drill. DO NOT force cable. Gradually insert at least 36 in. of cable into 2 upper passes of cell. (See Fig. 4.)
A91252
Fig. 4–Cleaning Heat Exchanger Cell
(3.) Work cable in and out of cell 3 or 4 times to obtain
sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work cable out.
(4.) Insert brush end of cable in lower opening of cell, and
proceed to clean 2 lower passes of cell in same manner as 2 upper passes.
(5.) Repeat foregoing procedures until each cell in furnace
has been cleaned. (6.) Using vacuum cleaner, remove residue from each cell. (7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly. (8.) Reinstall cell inlet plates and burner assembly. Care
must be exercised to center burners in cell openings.
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