Page 1
Induced Combustion Gas Furnace
Owner’s Manual
NOTE TO INSTALLER:
THIS MANUAL MUST BE LETT WITH
THE EQUIPMENT USER.
USER: Please read all instructions in the manual and retain
all manuals for future reference.
turn to the experjs^^^
A. WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings could result in injury, death,
or property damage.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance,
WHAT TO DO IF YOU SMELL GAS
-Do not try to light any appliance,
-Do not touch any electrical switch; do not use any
phone in your building.
-Leave the building immediately,
-Immediately call your gas supplier from a near by phone.
Follow the gas supplier’s instructions.
-If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
ISO 9001:2000
Use ofthe AHRI Certified TM Mark indicates a
manufacturer's participation in the program. For
verification of certification for individual products,
go to
www.ahridirectory.org.
Always Ask For
A. WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury and/or death.
Carbon Monoxide is invisible, odorless, and toxic! Carrier
Corp. recommends a carbon monoxide alarm in your home,
even if you do not own a gas appliance. Locate the carbon
monoxide alarm in the living area of your home and away
from gas appliances and doorways to attached garages.
Follow the alarm manufacturer’s instruction included with
the alarm.
A. WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Do not use this furnace if any part has been under water. A
flood-damaged furnace is extremely dangerous. Attempts to
use the furnace can result in fire or explosion. A qualified
service agency should be contacted to inspect the furnace and
to replace all gas controls, control system parts, electrical parts
that have been wet or the furnace if deemed necessary.
Page 2
WELCOME TO TODAY’S GENERATION
OF COMFORT
Congratulations! Your new, higher efficiency gas furnace is a
sound investment which will reward you and your family with
years of warm memories winter after winter.
Not only is your new furnace energy efficient, it is also extremely
reliable. Spend just a few minutes with this booklet to learn about
the operation of your new furnace—and the small amount of
maintenance it takes to keep it operating at peak efficiency. Years
went into the development of your new furnace. Take a little time
now to assure its most efficient operation for years to come,
FURNACE COMPONENTS
(Furnace shown in upflow position; may be used in downflow or
horizontal orientation or applications. Vent Elbow may be turned
to a different position, depending on type of installation)
TABLE OF CONTENTS
WELCOME TO A NEW GENERATION OF COMFORT
FURNACE COMPONENTS..............................................................2
GENERAL FURNACE SAFETY
IMPORTANT FACTS .......................................................................3
SAFETY CONSIDERATIONS .........................................................3
BEFORE STARTING YOUR FURNACE
STARTING YOUR FURNACE.........................................................4
SHUTTING DOWN YOUR FURNACE...........................................3
PERFORMING ROUTINE MAINTENANCE .................................6
FILTERING OUT TROUBLE
COMBUSTION AREA AND VENT SYSTEM
BEFORE YOU REOUEST A SERVICE CALL
MAINTENANCE CHECKLIST
INSTALLATION DATA
......................................................
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_______
fO
GENERAL FURNACE SAFETY
COMBUSTIBLE MATERIALS, GASOLINE WARNING, , , , f
FLOOD DAMAGE WARNING.........................................................f
FIRE OR EXPLOSION HAZARD WARNING
CARBON MONOXIDE WARNING
FURNACE MUST BE KEPT FREE AND CLEAR OF
INSULATING MATERIAL WARNING..........................................3
STARTING (LIGHTING) AND SHUTTING DOWN THE
FURNACE WARNING...................................................................4,3
PROPER FURNACE SHUTDOWN PROCEDURES.......................3
SERVICE AND MAINTENANCE ELECTRICAL HAZARD
WARNING......................................................................................... 6
IMPROPER VENT WARNING.........................................................6
SHARP EDGES CAUTION.............................................................. 6
NO FILTER CAUTION..................................................................... 6
FILTER ROD MODIFICATION CAUTION
DIRT, RUST, OR ACCUMULATION CAUTION
FURNACE NEEDS AIR FOR COMBUSTION AND
VENTILATION WARNING............................................................. 8
DRAFT SAFEGUARD SWITCH CAUTION
.................................................
................................
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...................................
GAS MANIFOLD
2
2
3
6
8
8
9
f
f
7
8
8
Fig. 1-80% AFUE Single Stage Furnace Components
Fig. 2-80% AFIJE Two-Stage Furnace Components
GAS BURNER
A10259
Page 3
IMPORTANT FACTS (DO’S AND DON’TS)
• DO: READ AND UNDERSTAND THIS MANUAL.
• DO: Have your furnace and vent system inspected annually by a
qualified service technician,
• DO: Inspect your filter monthly and clean or replace when
needed.
• DO: Provide adequate airflow to the furnace for efficient
combustion and safe ventilation.
• DO: Keep your furnace free and clear of insulating material.
Some materials may be combustible. Examine the furnace area
when the furnace is installed or when insulation is added,
• DO NOT: Enclose your furnace in an airtight room or seal it
behind solid doors,
• DO NOT: Keep combustible materials, gasoline, and other
flammable liquids or vapors around your furnace,
• DO NOT: Cover your furnace in any manner.
• DO NOT: Store anything (including trash or debris) near your
furnace,
• DO NOT: In any way block or restrict airflow around your
furnace,
• DO NOT: In any way block or restrict airflow to your supply air
and return air grills,
• DO NOT: Use your furnace room as a broom closet or a place to
store any kind of chemical or cleaner.
• DO NOT: Contaminate the air used for combustion of your
furnace with any kind of chemical or fumes. This could also
cause heat exchangers, metal vent systems or components to
deteriorate.
NOTE: These chemicals or fumes are present in many products
around the home, such as: water softener salts, any type of
household cleaning product, any type of laundry product,
adhesives, paints, varnishes, paint strippers, waxes and plastics, etc.
During remodeling be sure the combustion air is fresh and
uncontaminated. If these compounds are burned in your furnace,
the heat exchangers and metal vent system may deteriorate,
NOTE: The qualified installer or agency must use only
factory-authorized replacement parts, kits, and accessories when
modifying this product.
This furnace contains safety devices which must be manually reset.
If the furnace is left unattended for an extended period of time,
have it checked periodically for proper operation. This precaution
will prevent problems associated with no heat, such as frozen water
pipes, etc. See “Before You Request a Service Call” section in this
manual.
A. WARNING
EIRE OR EXPLOSION HAZARD
Failure to follow this safety warning could result in injury,
death, or property damage.
Do not keep combustible materials, gasoline, and other
flammable liquids or vapors around your furnace.
A. WARNING
EIRE OR EXPLOSION HAZARD
Failure to follow safety warnings could result in personal
injury, death, or property damage.
Keep insulation clear of furnace and maintain clearances
shown on unit clearance label.
BEFORE STARTING YOUR FURNACE
Examine the furnace installation to determine that:
1, All flue gas carrying areas external to the furnace (i.e, chim
ney, vent connector) are clear and free of obstructions,
2, The vent connector is in place, slopes upward and is physic
ally sound without holes or excessive corrosion,
3, The return-air duct connection(s) is physically sound, is
sealed to the furnace casing, and terminates outside the
space containing the furnace,
4, The physical support of the furnace is sound without sag
ging cracks, gaps, etc, around the base,
3, There are no obvious signs of deterioration of the furnace.
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 or replacing air filters. All other operations must be
performed by trained service personnel. Observe safety precautions
in this manual, on tags, and on labels attached to the furnace, and
other safety precautions that may apply.
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 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.
Page 4
STARTING YOUR FURNACE
Your furnace uses an automatic, hot surface ignition system to light
the burners each time the thermostat signals the furnace to start.
Follow these important safeguards:
• Never attempt to manually light the burners with a match
or other source of flame.
Fig. 3 - Do Not Light Burner with Match
Read and follow the operating instructions on inside of
main furnace door, especially the item that reads as fol
lows:
“Wait 5 minutes to clear out any gas. Then smell for gas,
including near the floor. If you smell gas, STOP! Fol
low “B” in the safety information above on this furnace
label. If you don’t smell gas, go to the next step,”
If a suspected malfunction occurs with your gas control
system, such as the burners do not light when they
should, refer to the shutdown procedures on inside of
main furnace door, or in the “Shutting Down Your Fur
nace” section and call your dealer as soon as possible.
2, Close the external manual gas valve.
Fig. 5 - Close Valve
3, Turn OFF electrical supply to the furnace.
Fig. 6 - Turn Off Electrical Supply
4, Remove the outer door.
^ WARNING
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death or property damage.
Should the gas supply fail to shut off or if overheating
occurs, turn off the manual gas valve to the furnace
BEFORE turning off the electrical supply and install
lockout tag.
• CHECK AIR FILTER: Before attempting to start your
furnace, be sure the furnace filter is clean and in place.
See “Performing Routine Maintenance” section in this
manual. Do not run the furnace without a filter in place.
Then proceed as follows:
STEPS FOR STARTING YOUR FURNACE
f. Set your room thermostat to the lowest temperature setting.
A10263
Fig. 7 - Remove Furnace Door
3, Turn the control switch on the gas control to the OFF position
and wait 3 minutes. Then smell for gas, including near the
floor. If you smell gas, STOP! Follow “B” on furnace label.
If you don’t smell gas, go to next step.
Fig. 8 - Control Switch to OFF
6, After waiting 3 minutes, if you still smell gas, STOP! Follow
the safety information on the cover of this manual. If you do
not smell gas, go to the next step,
7, Turn the control switch to ON,
Page 5
Fig. 9 - Control Switch to ON
8, Replace the outer door.
Fig. 10 - Furnace Door Replaced
9, Turn ON the electrical supply to the furnace.
12, Afterabout 17 seconds, the gas valve permits gas to flow to the
main burners where it is ignited. Hot flames begin to warm
the furnace’s heat exchanger. After a time delay of approxim
ately 23-43 seconds the furnace blower is switched on,
NOTE: If the main burners fail to ignite, the furnace control
system will go through three more ignition cycles. Then if burners
fail to ignite, the system will lockout. If lockout occurs or the
blower does not come on, shut down your furnace and call your
dealer for service.
13, Set your thermostat to the temperature that satisfies your
comfort requirements, SUGGESTION: Setting the thermo
stat back a few degrees—and compensating for the differ
ence with warmer clothing—can make a big difference in
your fuel consumption on extremely cold days. The few de
grees at the top of your thermostat “comfort level” are the
most costly degrees to obtain.
When the room temperature drops below the temperature selected
on the thermostat, the furnace will switch on automatically. When
the room temperature reaches the setting selected on the thermostat,
the furnace will be automatically switched off.
Continuous Fan Operation -Some thermostats have a “FAN”
switch with 2 selections: AUTO and ON, When thermostat is set
on AUTO, the furnace blower cycles on and off, controlled by the
thermostat. In ON position, the furnace blower runs continuously
except for a 42-62 sec delay at the “call for heat,” Continuous fan
keeps the temperature level in your home more evenly balanced. It
also continuously filters the indoor air.
Comfort Fan™ -On all but the 38STA or 38STX, the continuous
fan blower speed can be increased or decreased if desired due to
change of seasons, large gatherings in your home, etc. Simply
change your “FAN” switch from “on” to “off” (or “auto”
depending on your thermostat), and then return to “on”, within f to
3 seconds. The blower will switch to the next highest speed. There
are at least 3 speeds to choose from. If the blower is running on its
highest speed, a request to change will direct the blower to return
to its lowest speed.
Fig. 11 - Turn On Electrical Supply
10, Open the external manual gas valve.
Fig. 12 - Open Valve
11, Set the room thermostat to a temperature slightly above the
room temperature. This will automatically signal the furnace
to start. The inducer motor will start and the hot surface igniter
will energize. When hot, the igniter will have an orange glow.
SHUTTING DOWN YOUR FURNACE
Should you ever suspect a malfunction in your furnace, you will
need to turn the furnace off. The following procedures must be
followed:
1, Set your room thermostat to the lowest temperature setting.
(See Fig. 3.)
2, Close the external manual gas valve (See Fig. 4).
3, Turn off electrical supply to the furnace, (See Fig. 3.)
4, Remove outer furnace door. (See Fig. 6.)
3, Turn the switch on the gas control to the OFF position, (See
Fig.7,)
6, Replace the outer furnace door. (See Fig. 9.)
7, If the furnace is being shut down because of a malfunction, call
your dealer as soon as possible.
Page 6
PERFORMING ROUTINE MAINTENANCE
With proper maintenance and care, your furnace will operate
economically and dependably. Instructions for basic maintenance
are found on this and the following pages. However, before
beginning maintenance, follow these safety precautions:
^ WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Turn off electrical power supply to your furnace before
removing the access doors to service or perform
maintenance.
^ CAUTION
CUT HAZARD
Failure to follow this caution may result in personal injury.
Although special care has been taken to minimize sharp
edges, be extremely careful when handling parts or reaching
into the furnace. Wear safety glasses, gloves, and
appropriate protective clothing.
Eig. 13 - Turn Off Electrical Supply
2, Remove filter cabinet door (See Fig, 14 and 15,)
NOTE: It may be necessary to remove 1 thumbscrew.
FILTERING OUT TROUBLE
^ CAUTION
UNIT PERFORMANCE HAZARD
Failure to follow this caution may result in product damage.
Never operate your furnace without a filter in place. Doing
so may damage the furnace blower motor. An
accumulation of dust and lint on internal parts of your
furnace can cause a loss of efficiency.
A dirty filter will cause excessive stress on the furnace, heat
exchanger, and blower motor and can cause it to overheat and
automatically shut down. The furnace filter should be checked
every 4 weeks and cleaned or replaced if necessary.
If installed with factory specified disposable media filter, check or
replace filter before each heating and cooling season. Replace
disposable media filter at least twice a year.
If your furnace filter needs replacing, be sure to use the same size
and type of filter that was originally specified. The air filter for the
furnace may be located in a filter cabinet attached to the side or
bottom of the furnace. If air filter has been installed in another
location, contact your dealer for instructions. To inspect, clean
and/or replace the air filter(s), follow these steps:
1, Turn off the electrical supply to the furnace.
Fig. 15 - Removing Bottom Filter Cabinet Door
3, Slide air filter out of filter cabinet. Keep dirty side up (if
dirty) to avoid spilling dirt, (See Fig, 16 and 17,)
Page 7
Fig. 17 - Slide Bottom Filter Out of Furnace
4, Inspect the filter. If torn, replace it.
NOTE: If a washable filter has been replaced with:
a. Factory specified disposable media filter — Do not
clean. If dirty, replace only with media filter having the
same part number and size. Install with airflow direction
arrow pointing towards blower.
b. Electronic Air Cleaner (EAC) — Refer to EAC
Owner’s Manual for maintenance information.
3. Wash filter (if dirty) in sink, bathtub, or outside with a
garden hose. Always use cold tap water. A mild liquid de
tergent may be used if necessary. Spray water through filter
in the opposite direction of airflow. Allow filter to dry.
6. Reinstall clean air filter.
7. Replace filter cabinet door. (See Fig. f8 and f9.)
8. Turn on electrical supply to furnace (See Fig. f f).
Fig. 19 - Replace Bottom Filter Cabinet Door
NOTE: If side return ducts are used, 2 filters may be required in
some models. The procedure listed above may be used to remove
side filters.
A CAUTION
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
Use care when cutting support rods in filters to protect against
flying pieces and sharp rod ends. Wear safety glasses, gloves,
and appropriate protective clothing.
Filters may be field modified by cutting filter material and support
rods (3) in filters. Alternate sizes and additional filters may be
ordered from your dealer.
FURNACE CASING WIDTH
IN (MM)
14-1/2 (368)
17-1/2 (445)
21 (533)
24 (610)
*Some furnaces may have 2 filters
FILTER QUANTITY AND SIZE '
SIDE RETURN
IN (MM)
(1) 16x25
(406 X 635)
(1) 16x25 (1) 16x25
(406 X 635) (406 X 635)
(1) 16x25
(406 X 635)
(1) 16x25
(406 X 635)
BOTTOM RETURN
IN (MM)
(1) 14x25
(356 X 635)
(1) 20x25
(508 X 635)
(1) 24x25
(610 X 635)
FILTER TYPE”
4-5/16” (110 mm) thick
media-type
3/4” (19 mm) thick washable or
4-5/16” (110 mm) thick
media-type
3/4” (19 mm) thick washabie
or 4-5/16” (100 mm) thick
media-type
3/4” (19 mm) thick washable or
4-5/16” (100 mm) thick
media-type
Page 8
COMBUSTION AREA AND VENT SYSTEM
A WARNING
UNIT OPERATION HAZARD
Failure to follow this warning could result in personal injury
or death.
For proper and safe operation the furnace needs air for
combustion and ventilation. Do not block or obstruct air
openings on the furnace, air opening to the area in which the
furnace is installed, and the space around the furnace.
A. WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
or death.
If holes are found or if the vent pipe is obstructed or is not
connected, toxic fumes can escape into your home. DO NOT
OPERATE YOUR FURNACE, Call your dealer for service.
Inspect the combustion area and vent system before each heating
season. An accumulation of dirt, soot, or rust can mean a loss of
efficiency and improper performance. Buildups on the main
burners can cause faulty firing. This “delayed ignition” is
characterized by an alarmingly loud sound.
NOTE: If your furnace makes a loud noise when the main burners
are ignited, shut down the furnace and call your servicing dealer.
Use your flashlight and follow these steps for inspecting the
combustion area and vent system of your furnace:
1, Turn off electrical supply to the furnace and remove the ac
cess door. (See Fig. 6 and 7.)
2, Carefully inspect the gas burner for dirt, rust, or scale. In
spect the elbow, flue connection area, and the vent pipe for
rust.
If rusty joints or seams, or signs of water leakages are
found, call your dealer for service.
4, Restore electrical power to the furnace, (See Fig. If.)
3, Start the furnace and observe its operation. If possible,
watch the burner flames. Are they burning bright blue? If
not or if you suspect some other malfunction, call your ser
vicing dealer.
6, Replace the access door. (See Fig. 10.)
BEFORE YOU REQUEST A
“SERVICE CALL”
Before you call for service, check for several easily solved
problems:
• Check for sufficient airflow. Check the air filter for dirt. Check
for blocked return-air or supply-air grilles. Be sure they are
open and unobstructed. If this isn’t the cause of the problem, call
your servicing dealer. If your furnace isn’t operating at all, check
the following list for easily solved problems:
• Is your thermostat set above room temperature? Is the HEAT
mode selected?
• Is the electrical power supply switch on? Is the blower access
door firmly in place? Are any fuses blown? (There is a fuse on
the furnace control.) Has a circuit breaker tripped?
• Is the manual shut-off valve in the gas supply pipe leading to
the furnace open? Does the lever point in the same direction that
the pipe runs (open)? Or is it at a right angle to the pipe (closed)?
NOTE:
Before proceeding with the next checks, turn off the
electrical power supply to the furnace. Remove access door.
• Is the switch on the gas valve turned to the ON position? If this
or the preceding check shows an interruption in the gas supply,
make sure the gas has not been shut off for safety reasons. If
nothing else seems to be wrong, follow the start-up procedures
found on pages 4 and 3 of this booklet.
A CAUTION
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
If for some reason the vent is blocked, the draft safeguard
switch will shut off the furnace. (See Page 2 for switch
location.) The switch will automatically reset after the furnace
cools off. If the furnace fails to operate, contact a qualified
service agency.
Eig. 20 - Burner Elanie
^ WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury or death.
If dirt, rust, soot, or scale accumulations are found, call
your dealer. Do not operate your furnace.
3, Inspect the vent pipe for a sag, holes, or a disconnection. A
horizontal vent pipe must slope upward away from furnace.
Check the manual reset limit switches located on the ends of the
burner enclosure (see Fig. 1 and 2). If the furnace has
experienced a high-temperature condition due to inadequate
combustion air, these switches will shut off the furnace. Reset
the switches by pushing the button on the switch. If the switch
trips a second time, turn off the furnace and call for service.
If your furnace still fails to operate, call your servicing dealer for
troubleshooting and repairs. Tell your dealer the model and
serial numbers for your furnace, (You should have them
recorded on page 10 of this booklet.) By knowing exactly which
furnace you have, the dealer may be able to offer suggestions
over the phone or save valuable time through knowledgeable
preparation for the service call.
Page 9
In addition to the type of routine maintenance you might be willing to perform, your furnace should be inspected regularly by a properly
trained service technician. You should work with your dealer or service technician to assure your inspection includes the following at a
minimum,
MAINTENANCE CHECKLIST
DESCRIPTION
Furnace specific, external Items:
Clean or replace air filters. X
Inspect cabinet for signs of damage. X
Inspect and clean door louvers if needed. X
Inspect electrical disconnect for proper function. Repair or replace as
necessary.
Inspect external wiring for damage. X
Inspect gas supply line and manual shut-off for leaks. X
Furnace specific, Internal Items:
Inspect and clean blower assembly (includes blower housing, blower
wheel and motor).
Inspect gas valve and check for proper manifold gas pressure Adjust as
needed.
Inspect ignition system and safety controls. Clean and adjust as
needed.
Inspect control box, associated controls, wiring and connections. X
Check combustion blower housing for lint and debris and clean as ne
cessary.
Inspect burner assembly - clean as needed. X
Inspect heat exchanger - clean as needed. X
Inspect flue system—check for proper attachment to the furnace, any
dislocated sections, and for signs of corrosion. Replace if necessary.
System:
Inspect airflow system (ductwork)—check for leaks and repair as
needed.
Inspect evaporator coil, drain pan and condensate drain lines as applic
able, Clean as needed.
INSPECTION INTERVAL
Monthly Bi-annually Annually
X
X
X
X
X
X
X
X
This list may not include all maintenance items, and inspection interval times may vary depending on operational conditions of the furnace.
Ask your servicing dealer for further details about an economical service contract that covers seasonal inspections.
Page 10
NOTE TO EQUIPMENT OWNER:
For your convenience, please record the model and serial numbers of your new equipment in the spaces
provided. This information, along with the installation data and dealer contact information will be helpful
should your system require maintenance or service.
FURNACE
Model #_
Serial #
AIR CONDITIONER OR HEAT PUMP
Model #___________________________________
Serial #
Serial #
___________________________________
INDOOR COIL (Furnace Coll or Fan Coll)
Model #___________________________________
This manual must be left with the equipment owner.
INSTALLATION INFORMATION:
Date Installed
DEALERSHIP CONTACT INFORMATION:
Company Name
Address_
Phone Number
Technician Name
NOTE TO INSTALLER:
___________________________
Turn to the Experts“
TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under the
“Heating Equipment” or “Air Conditioning Contractors & Systems” heading 'ior dealer listing by brand name.
Have available the Model No.. Series Letter, & Serial No. of your equipment to ensure correct replacement part.
Copyright 2010 Carrier Corporation Printed in the U.S.A, Edition Date: 08/10
Manufacturer reserves the right to change, at any time, specifications and design without notice and without obligation. Replaces: OM58-126
10
Catalog No: OM58-131
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