Carrier 58WAV Guide

INDUCED-COMBUSTION 58WAV & 58ZAV

GAS FURNACE

USER’S INFORMATION MANUAL FOR

THE OPERATION AND MAINTENANCE

OFYOUR NEW GAS-FIRED FURNACE

— Do not store or use gasoline or other ﬂammable

vapors and liquids in the vicinity of this or any

other appliance.

— WHAT TO DO IFYOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a

neighbor’s 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.

WARNING: If the information in this manual

is not followed exactly, a ﬁre or explosion may

result causing property damage, personal injury or

loss of life.

NOTETO INSTALLER:

THIS MANUAL MUST BE LEFTWITHTHE

EQUIPMENT USER.

Do not use this furnace if any part has been under

water. Immediately call a qualiﬁed service techni-

ciantoinspectthefurnaceand to replaceanypart

of the control system and gas control which has

been under water.

WELCOME TO TODAY’S

GENERATION OF

COMFORT

Congratulations!Your new, higher

efﬁciencygas furnaceis asound invest-

ment 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 opera-

tion for years to come.

MODEL 58WAV

UPFLOW FURNACE

MODEL 58ZAV

DOWNFLOW/

HORIZONTAL FURNACE

UPFLOW FURNACE COMPONENTS

Relief Box

Rating Plate

Gas Valve Control Knob or Electric Switch (On/Off)

Gas Valve

Gas Burner

Flame Sensor

Air Filter Retainer

Air Filter

Blower and Blower Motor

Draft Safeguard Tube and Switch

Gas Manifold

Manual Reset Limit Switch

Hot Surface Ignitor

Blower Door Safety Switch

DOWNFLOW/HORIZONTALFURNACE

COMPONENTS

Manual-Reset Auxiliary Limit Switch (when used)

Blower and Blower Motor

Relief Box

Gas Valve Control Knob or Electric Switch (On/Off)

Gas Valve

Gas Burner

Rating Plate

Blower Door Safety Switch

Draft Safeguard Tube and Switch

Gas Manifold

Manual Reset Limit Switch (2)

Hot Surface Ignitor

Flame Sensor

IMPORTANT FACTS

Your furnace must have adequate airﬂow for efﬁcient com-

bustion and safe ventilation. Do not enclose it in an airtight

room or “seal’’ it behind solid doors.

To minimize the possibility of serious personal injury, ﬁre,

furnace damage, or improper operation;

carefully follow

these safety rules:

•Keep the area around your furnace free of combustible

materials, gasoline, and other ﬂammable liquids and vapors.

•Do not cover the furnace, store trash or debris near it, or

in any way block the ﬂow of fresh air to the unit.

•Combustion air must be clean and uncontaminated with

chlorine or ﬂuorine. These compounds are present in

many products around the home, such as: water softener

salts, laundry bleaches, detergents, adhesives, paints, var-

nishes, paint strippers, waxes, and plastics.

Make sure the combustion air for your furnace does not con-

tain any of these compounds. During remodeling be sure the

combustion air is fresh and uncontaminated. If these com-

pounds are burned in your furnace, the heat exchangers and

metal vent system may deteriorate.

•A furnace installed in an attic or other insulated space

must be kept free and clear of insulating material. Examine

the furnace area when installing the furnace or adding more

insulation. Some materials may be combustible.

NOTE:

Do not use this furnace if any part has been under

water. Immediately call a qualiﬁed service technician to

inspect the furnace and to replace any part of the control

system and any gas control which has been under water.

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 manu-

ally reset. If the furnace is left unattended for an extended

period of time, have it checked periodically for proper oper-

ation. 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.

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazard-

ous due to gas and electrical components. Only trained and

qualiﬁed personnel should install, repair, or service heating

equipment.

Untrained personnel can perform basic maintenance func-

tions such as cleaning and replacing air ﬁlters. All other

operations must be performed by trained service person-

nel. Observe safety precautions in this manual, on tags, and

onlabelsattachedtothefurnace,andothersafetyprecautions

that may apply.

Recognize safety information. This is the safety-alert sym-

bol . 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 sym-

bol. 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 prop-

erty damage. NOTE is used to highlight suggestions which

will

result in enhanced installation, reliability, or operation.

STARTING YOUR FURNACE

Instead of a continuously burning pilot ﬂame, 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.

•Read and follow the operating instructions on the furnace,

especially the item that reads as follows:

Wait 5 minutes to clear out any gas. Then smell for gas,

includingnear the ﬂoor.Ifyou smellgas,

STOP!

Follow“B’’

in the safety information above on this 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 the furnace, or in the

next section, to turn off your system, then call your dealer as

soon as possible.

•

CheckAir Filter:

Before attempting to start your furnace,

be sure the furnace ﬁlter is clean and in place. (See the main-

tenance section of this manual.) Then proceed as follows:

STEPS FOR STARTING YOUR

FURNACE

1. Set your room thermostat to the lowest temperature set-

ting. (See Fig. 7.)

2. Close the external manual gas valve. (See Fig. 8.)

3. Turn OFF electrical supply to the furnace. (See Fig. 9.)

4. Remove the furnace access door(s).

a. Downﬂow/Horizontal—Remove blower door after

removing 2 screws ﬁrst, then remove the control

door. (See Fig. 10.)

b. Upﬂow—Remove control door. (See Fig. 11

10 11

5. The gas valve will have EITHER a control knob or con-

trol switch to turn off and on. Turn the control knob or

switch on the gas valve to the OFF position and wait

5 minutes. (See Fig. 12 or 13.)

6. After waiting 5 minutes, turn the control knob or switch

on the gas valve to the ON position. (See Fig. 14 or 15.)

7. Replace the access door(s). See Fig. 16 for upﬂow and

Fig. 17 for downﬂow. Replace control door ﬁrst on

downﬂow furnaces. Then replace blower door (secure

with 2 screws).

WARNING

Should overheating occur or the gas valves fail to

shut off the gas supply, turn off the manual gas

valve (See Fig. 8.) to the furnace BEFORE turning

off the electrical supply. A failure to follow this

warning could result in a fire or explosion, and

personal injury or death.

18 19

8. Turn ON the electrical supply to the furnace. (See

Fig. 18.)

9. Open the external manual gas valve. (See Fig. 19.)

10. 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 ignitor will energize. When hot, the

ignitor will have an orange glow.

11. After 15 to 70 sec, 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 approximately 45 sec, the furnace blower is

switched on.

NOTE:

If the main burners fail to ignite, the furnace control

system will go through 3 more ignition cycles. Then, if burn-

ers fail to ignite, the system will lockout. If lockout occurs,

ortheblowerdoesnotcomeon—shutdownyourfurnaceand

call your dealer for service.

12. Set your thermostat to the temperature that satisﬁes

your comfort requirements. SUGGESTION: Setting

the thermostat back a few degrees—and compensating

for the difference with warmer clothing—can make a big

difference in your fuel consumption on extremely cold

days. The few degrees at the top of your thermostat “com-

fort 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 auto-

matically. When the room temperature reaches the setting

selected on the thermostat, the furnace will be automatically

switched off.

Some thermostats have a “FAN’’ switch with 2 selections:

AUTOandON.WhenthermostatissetonAUTO,thefurnace

blower cyclesonand off,controlledby thethermostat. InON

position, the furnace blower runs continuously except for a

45-secdelayatthe“call forheat.’’Thiskeepsthetemperature

level in your home more evenly balanced. It also continuous-

ly ﬁlters the indoor air.

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. 20.)

2. Close the external manual gas valve (See Fig. 8 on

page 4.)

3. Turn OFF electrical power to your furnace. (See Fig. 21.)

OFF

16 17

4. Remove the control access door on your furnace. (See

Fig. 10 or 11.) On upﬂow furnaces, removing the blower

access door is not required.

5. Turn the control knob or switch on the gas valve to the

OFF position. (See Fig. 22 or 23.)

6. Replace the control access door. (See Fig. 16 or 17.)

7. If the furnace is being shut down because of a malfunc-

tion, call your dealer as soon as possible.

PERFORMING ROUTINE

MAINTENANCE

With proper maintenance and care, your furnace will operate

economically and dependably. Basic maintenance, which can

easilybeaccomplished by someonewho followsthe directions,

isfoundonthisand thefollowingpages.However, beforebegin-

ning maintenance, follow these safety precautions:

FILTERING OUT TROUBLE

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 3 or 4 weeks and cleaned if necessary.

If installed with factory speciﬁed disposable media ﬁlter,

check or replace ﬁlter before each heating and cooling sea-

son. Replace disposable media ﬁlter at least once a year.

If your furnace ﬁlter needs replacing, be sure to use the

same size and type of ﬁlter that was originally supplied. Use

the Furnace Filter Table and match your furnace size with

the proper ﬁlter size.

The air ﬁlter for upﬂow furnaces is normally located in the

blower compartment. (See Fig. 3) or in the factory-supplier

ﬁlter cabinet attached to the side or bottom of the blower cab-

inet. Filters for the downﬂow furnaces are normally located

inthereturn-airplenumabovetheblower.Ifairﬁlterhasbeen

installed in another location, contact your dealer for instruc-

tions. To inspect, clean and/or replace the air ﬁlter(s), follow

these steps:

•

Upﬂow Furnaces Only—

1. Turn off the electrical supply to the furnace. (See

Fig. 21.)

2. Remove door/access panel

•AIR FILTER(S) LOCATED IN BLOWER COM-

PARTMENT

Remove control and blower access doors. (See Fig. 10

and 11)

•AIR FILTER LOCATED IN FILTER CABINET

Remove ﬁlter cabinet door (See Fig. 30 and 31)

NOTE: It will be necessary to remove 1 thumbscrew.

OFF

WARNING

Turn off electrical power supply to your furnace

before removing the access doors to service or

perform maintenance. A failure to follow this

warning could result in personal injury or death.

CAUTION

Although special care has been taken to minimize

sharp edges, be extremely careful when handling

parts or reaching into the furnace.

CAUTION

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.

24 25

3. Remove air ﬁlter from furnace.

•AIR FILTER LOCATED IN BLOWER COMPART-

MENT:

a. Slide ﬁlter retainer sideways until it is free of latch.

(See Fig. 24)

b. Gently remove air ﬁlter and carefully turn the dirty

side up (if dirty) to avoid spilling dirt from the ﬁlter

(see Fig. 25)

•AIR FILTER LOCATED IN FILTER CABINET:

a. Re-install door.

b. Slide air ﬁlter out of furnace. Keep dirty side up (if

dirty) to avoid spilling dirt. (See Fig. 32 and 33)

4. Inspect the ﬁlter. If torn, replace it.

NOTE:

If washable ﬁlter that was shipped with the furnace

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.

5. Wash ﬁlter (if dirty) in sink, bathtub, or outside with a gar-

den hose. Always use cold tap water. A mild liquid deter-

gent 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. Reinstallﬁlterretainer(forblowercompartmentlocations

only)

8. Replace control and blower doors (See Fig. 16 and 17) or

ﬁlter cabinet door (Fig. 34 and 35)

9. Turn on electrical supply to furnace (see Fig 18).

NOTE:

For upﬂow models only—ifside returnducts are used,

2 ﬁlters may be required in some models.The procedure listed

above may be used to remove side ﬁlters.

•

Downﬂow/Horizontal Furnaces Only:

Two ﬁlters are located in the return-air plenum above the

blower (above line-of-sight) resting in theV-shaped channel

on top of the furnace. (See Fig. 27.)

1. Turn off electrical supply to the furnace. (See Fig. 21.)

2. Remove 2 screws from blower access door and remove

the door.

3. Remove the left-side ﬁlter by tipping the ﬁlter toward

the center and raising it from theV-shaped channel in

which it rests. (See Fig. 27 and 28.)

4. Lower ﬁlter down along side of the blower and remove

from the furnace.

5. To remove the right-side ﬁlter, lift from V-shaped channel

and remove through left side the same way as left-side ﬁlter.

6. Inspect the ﬁlter. If torn, replace the ﬁlter.

7. Wash the ﬁlter (if dirty) in a sink, bathtub, or outside

with a garden hose.Always use cold tap water.A mild

liquid detergent may be used if necessary. Spray water

through the ﬁlter in opposite direction of airﬂow. Allow

ﬁlter to dry.

8. Reinstall the clean ﬁlters.

27 28

9. Replace blower door and secure with 2 screws. Turn

ON electrical supply to your furnace. (See Fig. 18.)

UPFLOW FURNACE AIR FILTERTABLE

AIR FILTER LOCATED IN BLOWER COMPARTMENT

FURNACE

CASING

WIDTH (IN.)

FILTER SIZE (IN) FILTER

TYPESide Return Bottom Return

14-3/16 (1) 16 x 25 x 1* (1) 14 x 25 x 1 Cleanable

17-1/2 (1) 16 x 25 x 1* (1) 16 x 25 x 1* Cleanable

21 (1) 16 x 25 x 1 (1) 20 x 25 x 1* Cleanable

24-1/2 (1 or 2) 16 x 25 x 1 (1) 24 x 25 x 1* Cleanable

AIR FILTER LOCATED IN FILTER CABINET

FILTER

CABINET

HEIGHT (IN) FILTER

SIZE (IN) FILTER

TYPE

16 (1) 16 x 25 x 1*

or (1) 16 x 25 x 4-5/16 Cleanable

Disposable

20 (1) 20 x 25 x 1*

or (1) 20 x 25 x 4-5/16 Cleanable

Disposable

24 (1) 24 x 25 x 1*

or (1) 24 x 25 x 4-5/16 Cleanable

Disposable

* Factory provided with the furnace. 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.

COMBUSTION AREA AND

VENT SYSTEM

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. Build-

upsonthemainburnerscancausefaultyﬁring.This“delayed

ignition’’ is characterized by an alarmingly loud sound. 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 access doors. (See Fig. 9, and 10 or 11.)

2. Carefully inspect the gas burner for dirt, rust, or scale

(see Fig. 29). Inspect the relief box, ﬂue connection

area, and the vent pipe for rust.

NOTE:

If dirt,rust,soot, orscaleaccumulations arefound,call

your servicing dealer. DO NOT OPERATE THE FURNACE.

DOWNFLOW/HORIZONTAL FURNACE FILTERTABLE

FURNACE CAS-

ING WIDTH (IN.) FILTER SIZE (IN) FILTER

TYPE

14-3/16 (2) 16 x 20 x 1* Cleanable

17-1/2 (2) 16 x 20 x 1* Cleanable

21 (2) 16 x 20 x 1* Cleanable

24-1/2 (2) 16 x 20 x 1* Cleanable

CAUTION

Use care when cutting support rods in filters to

protect against flying pieces and sharp rod ends.

Wear safety glasses, gloves, and appropriate pro-

tective clothing. Failure to follow this caution

could result in personal injury.

3. Inspect the vent pipe for a sag, holes, or a disconnection.

A horizontal vent pipe must slope upward. If rusty joints

or seams, or signs of water leakages are found,

call your dealer for service.

4. Replace the access doors and restore electrical power

to the furnace. Be sure bottom door ﬂange is inside of

the furnace casing. (See Fig. 16 and 17, and 26.)

5. 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 servicing dealer.

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 doors.

•Is the control knob or switch on the gas valve turned to the

ON position? If this or the preceding check shows an interrup-

tion in the gas supply, make sure the gas has not been shut off

forsafetyreasons.If nothingelseseemsto bewrong,followthe

startup procedures found on pages 4 and 5 of this booklet.

•If for some reason the vent is blocked, the draft safeguard

switch will shut off the furnace. Reset the switch by pushing

the button located on top of the switch. (See page 2 or 3 for

switch location.)

If the switch trips a second time, turn off the furnace and call

for service.

•Downﬂow/Horizontal Only—Check the manual reset aux-

iliary limit switch (when used) located on the blower housing.

If the blower motor fails, this switch will shut off the furnace.

Reset it by pushing the button on the switch. If it trips again,

turn off the furnace and call for service.

•Check the manual reset limit switch(es) located near the

burners. If the furnace has experienced a high-temperature con-

dition due to inadequate combustion air, these switches will

shut off the furnace. Reset the switch(es) 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 deal-

er for troubleshooting and repairs. Tell your dealer the model

and serial numbers for your furnace. (You should have them

recorded on page 8 of this booklet.) By knowing exactly which

furnace you have, the dealer may be able to offer suggestions

WARNING

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. A failure to follow this

warning could result in personal injury or death.

over the phone or save valuable time through knowledgeable

preparation for the service call.

Regular dealer maintenance

In addition to the type of routine maintenance you might be

willing to do, your furnace should be inspected regularly by a

properly trained service technician.A semiannual inspection

(or annual inspection, at least) should include the following:

1. Inspection of all ﬂue product passages including the burn-

ers, heat exchanger, relief box, and vent pipe.

2. Inspection of all combustion and ventilation air

passages and openings.

3. Close check of all gas pipes leading to and inside of your

furnace.

4. Inspection, cleaning, and lubrication (when required) of

the blower motor and wheel.

NOTE: Refer to the unit Service Procedures for blower motor

oiling information.When required, the motor must be oiled by

a qualiﬁed service technician.

5. Routine inspection and cleaning/replacement of the air ﬁlter.

6. Inspection of all supply- and return-air ducts for obstruc-

tions, air leaks, and insulation.Any problems found should

be resolved at this time.

7. Inspectionof furnaceinstallationfor propersupport andany

obvious deterioration of the furnace. The support must be

sound and without sags, gaps, cracks, etc., around the fur-

nace base so as to provide an air seal between the support

and furnace.

8. A check for loose connections attaching individual compo-

nents.Inspectionofallelectrical wiringandtheir connections.

9. Operationalcheckofthefurnaceitselftodetermineworking

condition. Repair or adjustment should be made at this time.

Ask your servicing dealer for further details about an econom-

ical service contract that covers seasonal inspections.

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