Carrier Gas 58MSA User Manual
Visit www.carrier.com
Service and Maintenance Instructions
For Sizes 040—120, Series 110
A93040
NOTE: Read the entire instruction manual before performing any
service or maintenance.
This symbol → indicates a change since the last issue.
Index Page
SAFETY CONSIDERATIONS..................................................1-2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........2
GENERAL......................................................................................2
CARE AND MAINTENANCE................................................2-10
Cleaning and/or Replacing Air Filter.......................................3
Blower Motor and Wheel Maintenance................................3-4
Cleaning Burners...................................................................4-5
Cleaning Heat Exchangers ....................................................5-6
Primary Heat Exchangers ................................................5-6
Secondary Heat Exchangers................................................6
Flushing Collector Box and Drainage System .....................6-7
Servicing Hot Surface Ignitor ...............................................7-8
Electrical Controls and Wiring.................................................8
Troubleshooting...................................................................8-10
Checking Heat Tape Operation (If Applicable) .................9-10
Winterizing..............................................................................10
WIRING DIAGRAM...................................................................12
SERVICE LABEL .......................................................................13
TROUBLESHOOTING GUIDE ............................................14-15
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, on tags,
and on 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
54-1996/ANSI Z223.1-1996 and the Installation Standards, Warm
58MSA
4-Way Multipoise Fixed-Capacity
Condensing Gas Furnace
®
ama
CANADIAN GAS ASSOCIATION
APPROVED
R
As an ENERGY STAR®
Partner, Carrier Corporation
has determined that this product meets the ENERGY
STAR® guidelines for energy
efficiency.
REGISTERED QUALITY SYSTEM
→ Fig. 1—Multipoise Furnace in Upflow Orienta-
Air Heating and Air Conditioning Systems (NFPA 90B)
ANSI/NFPA 90B. In Canada, refer to the CAN/CGA-B149.1- and
.2-M95 National Standard of Canada, Natural Gas and Propane
Installation Codes (NSCNGPIC). 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 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.
A98306
tion
.
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. 535-744 Printed in U.S.A. Form 58MSA-3SM Pg 1 5-99 Replaces: 58MSA-2SM
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. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS
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.
Failure to follow this warning can cause corrosion of the heat
exchanger, fire, personal injury, or death.
GENERAL
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. Therefore,
since this furnace can be installed in any of the 4 positions shown
in Fig. 2, you must revise your orientation to component location
accordingly.
AIRFLOW
UPFLOW
AIRFLOW
HORIZONTAL
LEFT
DOWNFLOW
HORIZONTAL
RIGHT
AIRFLOW
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
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.
AIRFLOW
A93041
Fig. 2—Multipoise Orientations
CARE AND MAINTENANCE
For continuing high performance and to minimize possible equipment failure, it is essential that maintenance be performed annually
on this equipment. Consult your local dealer for maintenance and
maintenance contract availability.
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 or death.
The minimum maintenance that should be performed on this
equipment is as follows:
1. Check and clean or replace air filter each month as required.
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.
Personal injury could result from sharp metal edges, etc. Use
care when removing parts.
2
WASHABLE
FILTER
WASHABLE
FILTER
FILTER
RETAINER
FILTER
SUPPORT
FILTER
RETAINER
A93046
Fig. 3—Bottom Filter Arrangement
Step 1—Cleaning and/or Replacing Air Filter
The air filter arrangement may vary depending on the application
or orientation.
Never operate unit without a filter or with the blower access
panel removed. Failure to follow this warning could result in
a fire or personal injury.
To clean or replace the filters, proceed as follows:
1. Turn off electrical supply to furnace.
2. Remove main furnace door and blower access panel.
3. Release filter retainer wire. (See Fig. 3 and 4.)
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 of filter is not
recommended.
7. Place filter in furnace.
8. Replace blower access panel and main furnace door.
9. Turn on electrical supply to furnace.
NOTE: If the filter has cross-mesh binding, the binding must face
the blower. If the filter has an air direction arrow, the arrow must
point toward the blower.
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.
3. Disconnect wires.
A93045
Fig. 4—Filter Installed for Side Inlet
All factory wires can be left connected, but field thermostat
connections may need to be disconnected depending on their
length and routing.
4. 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.
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.
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.
f. Remove blower wheel from housing.
g. Clean wheel per instructions on degreaser cleaner.
9. Reassemble motor and blower wheel by reversing items 8b
through 8f. Ensure wheel is positioned for proper rotation. Be
sure to reattach ground wire.
10. Reinstall blower assembly in furnace.
3
11. 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. 8 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.
c. Connect field drain to condensate trap.
NOTE: Ensure tubes are not kinked or pinched, as this will affect
operation.
12. Reinstall control box, transformer, and door switch assembly
on blower shelf.
13. Reconnect wires.
Refer to furnace wiring diagram, and connect thermostat leads
if previously disconnected. (See Fig. 15.)
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) Medium High Spare
Blue Medium Low Heat
Red Low Spare
White Common Com
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.
14. Turn on electrical supply. Manually close blower access panel
door switch. Use a piece of tape to hold switch closed. Check
for proper rotation and speed changes between heating and
cooling by jumpering R to G and R to Y on control center
thermostat terminals. (See Fig. 11.)
Blower access panel 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.
15. If furnace is operating properly, release blower access panel
door switch, replace blower access panel, and replace main
furnace door.
Step 3—Cleaning Burners
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 gas
valve.
FACTORY
ATTACHED TO
5. Remove wires from gas valve. Note location for reassembly.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation.
6. Remove burner box pressure tube from gas valve regulator
fitting.
7. Remove screws that secure manifold to burner box. (See Fig.
5.)
MANIFOLD
MOUNTING
SCREW
MANIFOLD
GAS VALVE
REGULATOR
FITTING
GAS VALVE
A93295
Fig. 5—Burner Box Assembly
8. Remove manifold, orifices, and gas valve as 1 assembly.
9. Remove screws attaching burner assembly in burner box.
10. Remove burner assembly from burner box.
NOTE: All burners are attached to burner bracket and can be
removed as 1 assembly.
11. Clean burners with soft brush and vacuum.
12. Reinstall manifold, orifice, and gas valve assembly in burner
box. Ensure manifold seal grommet is installed properly and
burners fit over orifices.
13. Reconnect wires to gas valve. Refer to furnace wiring diagram
for proper wire location.
14. Reinstall burner box pressure tube to gas valve regulator
fitting.
15. Reinstall gas supply pipe to gas 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.
Gas valve switch or knob MUST be facing forward or tilted
upward. Failure to follow this warning could result in
property damage, personal injury, or death.
16. Replace burner box cover.
17. Turn on gas and electrical supplies to furnace.
18. Check for gas leaks.
4
Never use matches, candles, flame, or other sources of
ignition to check for gas leakage. Use a soap-and-water
solution. Failure to follow this warning could result in a fire,
personal injury, or death.
19. Replace main furnace door.
Step 4—Cleaning Heat Exchangers
The following items should be performed by a qualified service
technician.
PRIMARY HEAT EXCHANGERS
If the heat exchangers get an accumulation of light dirt or dust on
the inside, they may be cleaned by the following procedure:
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, both the primary and secondary heat exchangers
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, improper vent termination, incorrect size
or damaged manifold orifice(s), improper gas, or a restricted heat
exchanger (primary or secondary). Action must be taken to correct
the problem.
1. Turn off gas and electrical supplies to furnace.
2. Remove main furnace door.
3. Disconnect wires or connectors to rollout switch, gas valve,
ignitor, and flame sensor.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation.
PRIMARY HX
INLET OPENINGS
Fig. 6—Cleaning Inlet Openings of Primary Heat
Exchangers
→
NOTE: Inspect combustion-air intake housing. If foamed gasket
was removed, check for any damage. If gasket is damaged in any
way, it must be repaired. To repair, remove damaged gasket
section, apply sealant releasing agent such as PAM cooking spray
or equivalent (must not contain corn or canola oil, aromatic or
halogenated hydrocarbons or inadequate seal may occur) to burner
box and apply a small bead of G.E. RTV 162, G.E. RTV 6702, or
Dow-Corning RTV 738 sealant to edge of combustion-air intake
housing. (See Fig. 7.)
A93080
4. Disconnect combustion-air intake pipe from intake housing.
5. Remove the pressure switch tube from intake housing.
6. Remove screws attaching intake housing to burner box, and
rotate intake housing away from burner box for removal.
7. Using backup wrench, disconnect gas supply pipe from gas
valve.
8. Disconnect pressure tubing from gas valve.
9. Remove 2 screws attaching top filler panel and rotate upwards
to gain access to screws attaching burner box to cell panel.
10. Remove screws attaching burner box to cell panel. (See Fig.
5.)
NOTE: Burner box cover, manifold, gas valve, and burner
assembly should be removed as 1 assembly.
11. Clean heat exchanger openings with a vacuum and a soft
brush. (See Fig. 6.)
NOTE: After cleaning, inspect the heat exchangers to ensure they
are free of all foreign objects that may restrict flow of combustion
products.
12. Reverse items 4 through 10 for reassembly.
The ground wire from the gas valve MUST be attached to the
burner box attachment screw. Failure to attach this ground
wire to an adequate casing ground will cause the furnace
control to lock out.
NOTE: Be sure burner box gasket is installed between burner box
and cell panel. If gasket is damaged, replace it.
RTV
PAM
A93087
Fig. 7—Combustion-Air Intake Housing Gasket
Repair
13. Refer to furnace wiring diagram and connect wires to rollout
switch, gas valve, ignitor, and flame sensor.
14. Reconnect pressure switch tubes to gas valve and intake
housing. Refer to tube routing label on main furnace door for
proper tube location. Be sure tubes are not kinked. (See Fig.
8.)
15. Turn on gas and electrical supplies to furnace.
16. Check furnace operation through 2 complete heat operating
cycles. Look through sight glass in burner enclosure to check
burners. Burner flames should be clear blue, almost transparent. (See Fig. 9.)
17. Check for gas leaks.
5
Loading...