Carrier 58EFA Installation and user guide

58EFA

Gas-Fired

Horizontal

Induced-Combustion

Furnaces

HEATING

COOLING

Service

and

Maintenance

Instructions

For

Sizes

050-125,

Series

110

NOTE:

Read

the

entire

instruction

manual

before

starting

the

installation.

SAFETY

CONSIDERATIONS

Installing

and

servicing

heating

equipment

can

hazardous

due

gas

and

electrical

components.

Only

trained

and

qualified

person¬

nel

should

install,

repair,

service

heating

equipment.

Untrained

personnel

can

perform

basic

maintenance

functions

such

cleaning

and

replacing

air

filters.

All

other

operations

must

performed

trained

service

personnel.

When

working

heating

equipment,

observe

precautions

the

literature,

tags,

and

labels

attached

shipped

with

the

unit

and

other

safety

precautions

that

may

apply.

all

safety

codes,

including

NFPA

54/ANSI

Z223.1-1988,

National

Fuel

Gas

Code.

Wear

safety

glasses

and

work

gloves.

Have

fire

extinguisher

available

during

start-up

and

adjustment

procedures

and

service

call.

Recognize

safety

information.

This

the

safety-alert

When

you

see

this

symbol

the

unit

and

instructions

manuals,

alert

the

potential

for

personal

injury.

Understand

the

signal

word

—DANGER,

WARNING,

CAU¬

TION.

These

words

are

used

with

the

safety-alert

symbol.

DAN-

GfeRldentifies

the

most

serious

hazards

which

will

result

severe

personal

injury

death.

WARNING

signifies

hazards

that

could

result

personal

injury

death.

CAUTION

used

identify

unsafe

practices,

which

would

result

minor

personal

injury

product

and

property

damage.

CARE

AND

MAINTENANCE

For

continuing

high

performance

and

minimize

possible

equip¬

ment

failure,

essential

that

maintenance

performed

annually

this

equipment.

Consult

your

local

dealer

for

maintenance

and

the

availability

maintenance

contract.

Fig.

1—Model

58EFA

Horizontal

Furnace

Manufacturer

reserves

the

right

discontinue,

change

any

time,

specifications

designs

without

notice

and

without

incurring

obligations.

101

Catalog

No.

565-839

Printed

U.S.A.

Form

58EFA-2SM

8-92

Replaces:

58EFA-1SM

Book

Tab

Turn

OFF

the

gas

and

electrical

supplies

the

unit

before

performing

any

maintenance

service.

the

operating

instructions

the

label

attached

the

furnace.

Failure

this

warning

could

result

personal

injury.

The

minimum

maintenance

that

should

performed

this

equipment

follows:

Check

and

clean

replace

air

filter

each

month,

required.

(See

Step

1.)

Check

blower

motor

and.wheel

for

cleanliness

and

lubrication

each

heating

and

cooling

season.

Clean

and

lubricate

necessary.

(See

Step

2.)

Check

electrical

connections

for

tightness

and

controls

for

proper

operation

each

heating

season.

Service

necessary.

Check

for

blockages

vent

pipe.

with

any

mechanical

equipment,

personal

injury

could

result

from

sharp

metal

edges,

etc.

careful

when

removing

parts,

panels,

components.

Step

1—Air

Filter

Cleaning

and

Replacement

The

air

filter

arrangement

may

vary

depending

the

application.

Each

furnace

may

supplied

with

permanent,

washable

filter

and

wire

filter

retainer

option.

so,

the

filter

normally

located

the

return-air

plenum

opening

before

the

blower.

(See

Fig.

2.)

SPEED

SELECTOR

SCREWS

(2)

BLOWER

SUPPORT

BRACKET

Fig.

2—Blower

Compartment

Table

1—Horizontal

Furnace

Filters

FURNACE

SIZE

(INPUT

BTUH)

FILTER

SIZE

(IN.)

FILTER

TYPE

50,000

(1)

13x23x1

Cleanable

75,000

(1)

13x23x1

Cleanable

100,000

(1)

16x23x1

Cleanable

125,000

(1)

20x23x1

Cleanable

Never

operate

unit

without

filter

with

filter

access

door

removed.

Failure

this

warning

could

result

fire

personal

injury.

clean

replace

the

filters,

proceed

follows:

Turn

OFF

electrical

supply

unit.

Remove

blower

access

door

located

inlet

(return

air)

end

furnace;

screws

must

removed.

Bend

wire

filter

retainer

until

clears

furnace

flange

and

swing

toward

the

blower.

Remove

filter

from

furnace.

filter

tom,

replace

it.

Furnaces

may

equipped

with

permanent,

washable

filters.

Clean

these

filters

spraying

cold

tap

water

through

filter

opposite

direction

airflow.

mild

liquid

detergent

may

used

necessary.

Rinse

filters

and

let

dry.

Oiling

coating

filters

not

recommended

required

for

factory-supplied

filters.

Reinstall

filters

with

cross-mesh

binding

facing

blower.

Replace

blower

access

door

and

reinstall

screws.

Turn

electrical

supply

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

performed

qualified

service

technician:

Some

motors

have

prelubricated,

sealed

bearings

and

require

lubrication.

These

motors

can

identified

the

absence

oil

ports

each

end

the

motor.

For

motors

with

oil

ports,

lubricate

follows:

Lubricate

motor

every

years

motor

used

for

intermittent

operation

(thermostat

FAN

switch

AUTO

position),

every

years

motor

continuous

operation

(thermostat

FAN

switch

position).

Clean

and

lubricate

follows:

Turn

OFF

electrical

supply

unit.

Remove

blower

access

door;

screws

must

removed.

Remove

blower

assembly

follows:

Remove

screws

securing

front

blower

support

bracket

and

remove

bracket.

(See

Fig.

2.)

Using

3/8-in.

ratchet

with

3-in.

extension,

reach

through

4-in.

diameter

holes

rear

blower

support

bracket

and

remove

screws

securing

bracket

blower

shelf.

(See

Fig.

Disconnect

motor

leads

from

motor

speed

selector.

(See

Fig.

2.)

Remove

blower

assembly

from

unit.

Mark

blower

wheel

location

shaft

before

disassembly

insure

proper

reassembly.

Loosen

setscrew

holding

blower

wheel

motor

shaft.

Disconnect

ground

wire

from

blower

housing.

Remove

bolts

holding

motor

mount

blower

housing

and

slide

motor

and

mount

out

housing.

Lubricate

motor

(when

oil

ports

are

provided).

Remove

dust

caps

plugs

from

oil

ports

located

each

end

motor.

motor

does

not

have

these

caps

plugs,

bearings

are

sealed

and

need

further

lubrication.

Use

good

grade

SAE

nondetergent

motor

oil

and

add

teaspoon

cc,

3/16

oz,

drops)

each

oil

port.

The

use

other

types

grades

oil

will

damage

the

motor.

Excessive

oiling

can

cause

premature

bearing

fail¬

ures.

Allow

time

for

total

quantity

oil

absorbed

each

bearing.

After

oiling

motor,

wipe

excess

oil

from

motor

housing.

Replace

dust

caps

plugs

oil

ports.

emove

blower

wheel

from

housing.

Mark

blower

wheel

orientation

and

cutoff

plate

location

insure

proper

reassembly.

Remove

screws

securing

cutoff

plate

and

remove

cutoff

plate

from

housing.

Remove

blower

wheel

from

housing.

10.

Clean

blower

wheel

and

motor

using

vacuum

with

soft

brush

attachment.

careful

not

disturb

balance

weights

(clips)

blower

wheel

vanes.

not

drop

bend

wheel

balance

will

affected.

11.

Reassemble

blower

reversing

items

9.a.

through

9.c.

Ensure

wheel

positioned

for

proper

rotation.

12.

Reassemble

motor

and

blower

reversing

items

through

Reconnect

motor

ground

wire.

CAUTION

Ensure

the

motor

properly

positioned

the

blower

housing.

The

motor

oil

ports

must

minimum

30°

above

the

horizontal

centerline

the

motor

after

the

blower

assembly

has

been

reinstalled

the

furnace.

13.

Reinstall

blower

assembly

furnace.

14.

Connect

electrical

leads

motor

speed

selector;

not

force

leads.

15.

Turn

electrical

supply

and

check

for

proper

rotation

and

speed

changes

between

heating

and

cooling.

Step

3—Cleaning

Heat

Exchangers

and

Burners

The

following

items

should

performed

qualified

service

technician:

becomes

necessary

clean

the

heat

exchanger

because

carbon

deposits,

soot,

etc.,

proceed

follows:

NOTE:

Deposits

soot

and

carbon

indicate

problem

exists

that

needs

corrected.

Action

must

taken

correct

the

problem.

Turn

OFF

gas

and

electrical

supplies

furnace.

Using

backup

wrench,

disconnect

gas

supply

ground

joint

union.

Remove

gas

pipe

from

gas

valve.

Disconnect

electrical

wiring

from

gas

valve.

Remove

burner/manifold

assembly

follows:

Remove

air

inlet

plate/burner

removal

cover.

Remove

manifold

retention

plate

from

front

unit.

Loosen

screws

manifold

retention

plate

rear

unit.

Disconnect

wiring

ignition

electrode/flame

sensor.

Remove

bumer/manifold

assembly

from

unit.

Place

burner/manifold

assembly

flat

work

surface

and

clean

burner

ports.

Use

soft

brush

loosen

dirt,

then

vacuum.

Using

small

rubber

mallet,

gently

tap

each

burner

opening

loosen

any

debris

heat

exchanger

cells.

Brush

each

heat

exchanger

cell

using

nylon

heat

exchanger

brush

with

long,

flexible

handle.

Vacuum

each

heat

exchanger

cell

and

burner

box

with

crevice

tool

attachment.

Check

position

and

alignment

pilot

assembly

burners

and

ignition

electrode

ignition

hood.

(See

Fig.

3.)

10.

einstall

burner/manifold

assembly

and

front

manifold

reten¬

tion

plate.

11.

Tighten

screws

securing

rear

manifold

retention

plate.

12.

Reconnect

wiring

ignition

electrode/flame

sensor.

13.

Reinstall

air

inlet

plate/bumer

removal

cover.

14.

Using

wiring

diagram

(Fig.

7.)

reconnect

wiring

gas

valve.

15.

Apply

joint

compound

(pipe

dope)

sparingly

male

ends

gas

pipe

and

reinstall

gas

pipe

gas

valve.

NOTE:

Joint

compound

must

resistant

the

action

propane

gas.

16.

Reconnect

ground

joint

union.

17.

Turn

gas

and

electrical

supplies

furnace.

18.

Check

gas

supply

line

for

leaks.

WARNING

Never

use

matches,

candles,

flame,

other

sources

ignition

check

for

gas

leakage.

Use

soap-and-water

solution.

Failure

this

warning

could

result

fire,

personal

injury,

death.

19.

heck

furnace

operation

through

complete

operating

cycles.

Look

through

vent

openings

burner

enclosure

check

burners.

Main

burner

flames

should

clear

blue,

almost

transparent.

Pilot

flame

should

soft

blue

color,

well

defined,

and

must

provide

good

impingement

the

ignition

electrode/flame

sensor.

Pilot

flame

should

extend

above

burner

carryover

port

provide

proper

burner

ignition.

(See

Fig.

and

5.)

Fig.

4—Position

Pilot

Ignition

Electrode/Flame

Sensor

PILOT

FLAME

BURNER

FLAME

Step

4—Pilot

Assembly

Check

the

pilot

assembly

and

clean

necessary

the

beginning

each

heating

season.

The

pilot

flame

should

high

enough

for

proper

impingement

the

ignition

electrode/flame

sensor

and

light

the

burners.

Remove

any

accumulation

soot

and

carbon

from

the

flame

sensor.

Check

spark

ignition

electrode

gap.

(See

Fig.

and

5.)

Step

5—Electrical

Controls

and

Wiring

NOTE:

There

may

than

electrical

supply

the

unit.

Refer

Fig.

for

field

application

wiring

and

Fig.

for

unit

wiring.

With

power

disconnected

the

unit,

check

all

electrical

connections

for

tightness.

Tighten

all

screws

electrical

connec¬

tions.

any

smokey

burned

connections

are

found,

disassemble

the

connection,

clean

all

parts,

strip

wire,

and

reassemble

properly

and

securely.

Reconnect

electrical

power

the

unit

and

observe

unit

through

complete

operating

cycle.

Electrical

controls

are

difficult

check

without

proper

instrumentation.

good

voltmeter

needed

check

for

correct

operation

controls

and

wiring.

the

furnace

fails

operate,

check

the

following

items

before

calling

for

service:

the

thermostat

set

correctly

"call

for

heat?"

Are

the

electrical

and

gas

supplies

ON?

Are

the

filters

clean?

Refer

the

Trouble

Analysis

chart

this

manual

for

further

information.

FIELD

24-VOLT

WIRING

___FIELD

115-,

208/230-,

460-VOLT

WIRING

TERMINAL

BLOCK

NOTES:

CONNECT

Y-TERMINAL

SHOWN

FOR

PROPER

COOLING

OPERATION.

ANY

THE

ORIGINAL

WIRE,

SUPPLIED,

MUST

REPLACED,

USE

SAME

TYPE

EQUIVALENT

WIRE.

PROPER

POLARITY

MUST

MAINTAINED

FOR

115-VOLT

WIRING.

Fig.

6-rHeating

and

Cooling

Application

Wiring

Diagram

A91338

Trouble

Analysis

Chart

SYMPTOM

PROBABLE

CAUSE

REMEDY

Pilot

will

not

light.

spark

electrode.

Check

115-v

electrical

supply

furnace.

Check

spark

gap.

Check

draft

inducer

motor,

repair

necessary.

Check

pressure

switch;

contacts

must

closed

(vent

piping

must

free

from

obstructions).

Also,

check

for

kinks

obstructions

pressure

tubing.

Check

for

accumulation

moisture

dirt

electrode

ceramic;

clean

necessary.

Check

for

cracked

ceramic;

replace

electrode

necessary.

Check

for

loose

broken

wiring

and

between

control

box

and

electrode.

Check

for

24-v

electrical

supply

ignition

control

box.

24v

are

supplied

box,

and

above

steps

have

been

completed;

replace

ignition

control

box.

Spark

shorting

out

main

burner.

Align

electrode

tip

away

from

burner—maintain

proper

spark

gap.

gas

pilot

assembly.

Check

pilot

gas

valve

opening.

Check

for

broken

loose

wiring

connections.

deficiency

found,

replace

gas

valve.

Burners

will

not

ignite.

115-v

electrical

supply

furnace.

Check

fuse,

circuit

breaker,

and

wiring.

24-v

electrical

supply

control

circuit.

Check

transformer;

replace

necessary.

Miswired

loose

connections.

Check

all

wiring

and

connections;

repair

nec¬

essary.

gas

main

burners.

Check

main

gas

valve

opening.

Check

for

broken

loose

wiring

connections.

deficiency

found,

replace

gas

valve.

Flame

rollout

shutoff

switch

activated.

Check

venting

system

for

blockage;

correct

im¬

proper

venting

condition.

Flame

probe

connecting

lead

shorted

open.

Correct

electrical

shorting

open

circuit

re¬

quired.

Dirty

pilot

(yellow

flame).

Clean

pilot

orifice.

Inadequate

heating.

Gas

input

furnace

too

low.

Check

gas

pressure

manifold.

Clock

gas

meter

for

input.

too

low,

increase

manifold

pressure

and/or

replace

orifices

with

correct

size.

Limit

switch

cycles

main

burners.

Dirty

air

filters;

clean

replace.

Blower

speed

too

low;

adjust

higher

speed.

Restricted

supply-

return-air

ductwork

regis¬

ters;

repair

necessary.

Incorrect

heat

anticipator

setting;

determine

proper

setting

and

adjust

necessary.

Furnace

undersized

for

application.

Replace

with

properly

sized

furnace.

Aldehyde

odors

(CO),

sooting

floating

flame.

Incomplete

combustion

(poor

flame

characteristics).

Lack

combustion

air—see

installation

instruc¬

tions.

Overfired

furnace;

reduce

input

replace

ori¬

fices.

Check

vent

piping

for

restriction;

clean

neces¬

sary.

Cracked

heat

exchanger;

replace.

1992

CARRIER

Corp.

•

7310

Morris

•

Indianapolis,

46231

15071

Manufacturer

reserves

the

right

discontinue,

change

any

time,

specifications

designs

without

notice

and

without

incurring

obligations.

101

Catalog

No.

565-839

Printed

U.S.A.

Form

58EFA-2SM

8-92

Replaces:

58EFA-1SM

Book

Tab

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