Carrier 58ZAV Series Guide

USER'S INFORMATION MANUAL FOR

THE OPERATION AND MAINTENANCE

OFYOUR NEW GAS-FIRED FURNACE

]

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. ]

-- 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.

• 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.

Do not use this furnace if any part has been under

water. Immediately call a qualified service techni-

cian to inspect the furnace and to replace any part

of the control system and gas control which has

been under water.

NOTE TO INSTALLER:

THIS MANUAL MUST BE LEFT WITH THE

EQUIPMENT USER.

WELCOME TO TODAY'S

GENERATION OF

COMFORT

Congratulations! Your new, higher

efficiency gas furnace is a sound 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 developlnent 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/Oft)

[_ Gas Valve

_] Gas Burner

[] Flame Sensor

_] Air Filter Retainer

_8] Air Filter

[_ Blower and Blower Motor

[] Draft Safeguard Tube and Switch

F_ Gas Manifold

[_ Manual Reset Limit Switch

[_ Hot Surthce Imlitor

F_ Blower Door Safety Switch

DOWNFLOW/HORIZONTAL FURNACE

COMPONENTS

Manual-Reset Auxiliary Limit Switch (when used)

_] Blower and Blower Motor

Relief Box

[] Gas VaNe Control Knob or Electric Switch (On/Oft)

_] Gas VaNe

_] Gas Burner

Rating Plate

_8] 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 el_cient coin-

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 tree of combustible

materials, gasoline, and other flammable liquids and vapors.

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

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

• Colnbustion 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 Colnbustion air for your furnace does not con-

tain any of these compounds. During remodeling be sure the

colnbnstion air is fresh and uncontaminated. If these coin-

pounds are burned in ymir fltrnace, the heat exchangers and

metal vent system may deteriorate.

• A flmmce installed in an attic or other insulated space

must be kept tree 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. Ilnmediately 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 lnaimal.

SAFETY CONSIDERATIONS

Installing and servicing heating equiplnem can be hazard-

ous due to gas and electrical COlnponents. Only trained and

qualified personnel should install, repair, or service heating

equipment.

Untrained personnel can perforln basic maintenance func-

tions such as cleaning and replacing air filters. All other

operationslnUStbeperformedbytrainedserviceperson-

nel.Observesafetyprecautionsinthislnanual,ontags,and

onlabelsattachedtothefllrnace,andothersafetyprecautions

thatmayapply.

Recognizesafetyinformation.Thisisthesafety-alertsym-

bolz_x.Whenyouseethissymbolonthefurnaceandin

instructionsorlnanuals,bealerttothepotentialforpersonal

injury.

UnderstandthesignalwordsDANGER,WARNING,and

CAUTION.Thesewordsareusedwiththesafety-alertsym-

bol.DANGERidentifiesthelnOStserioushazardswhich

willresultinseverepersonalinjuryordeath.WARNING

signifieshazardswhichcouldresultinpersonalinjuryor

death.CAUTIONisusedtoidentifyunsafepracticeswhich

wouldresultinminorpersonalinjuryorproductandprop-

ertydamage.NOTEisusedtohighlightsuggestionswhich

willresultinenhancedinstallation,reliability,oroperation.

STARTING YOUR FURNACE

Instead of a continuously burning pilot flame, your furnace

uses an amomatic hot surface ignition system to light the

burners each time the thermostat signals the furnace to start.

Follow these important safeguards:

• Never attempt to lnanually light the burners with a match

or other source of flame.

• Read and follow the operating instructions on the fllrnace,

especially the item that reads as follows:

Wait 5 minutes to clear out any gas. Then smell f\_r gas,

including near the floor. If you smell gas, STOP! Follow "B"

in the safety inforlnation 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 shmdown procedures on the furnace, or in the

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

soon as possible.

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.

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 lnanual.) Then proceed as follows:

STEPS FOR STARTING YOUR

FURNACE

1. Setyourroom thermostat to the lowest temperature set-

ring. (See Fig. 7.)

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

ilu

-->

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

4. Remove the flmmce access door(s).

a. Downflow/Horizonta_Remove blower door after

removing 2 screws first, then relnove 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 offand on. Turn the control knob or

switch on the gas valve to the OFF position and wait

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

6. After waiting 5 lninutes, 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 fllrnaces. Then replace blower door (secure

with 2 screws).

_.....

18 19

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

Fig. 18.)

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

10. Set the room therlnostat to a telnperature slightly

above the rooln telnperature. This will autolnatically

signal the furnace to start. The inducer lnotor will start,

and the hot surfhce 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 lnain burners where it is ignited. Hot flames begin

m warm the flmmce'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 fhil to ignite, the system will lockout. If lockout occurs,

or the blower does not come on shut down your t'urnace and

call your dealer for service.

12. Set your therlnostat to the telnperature that satisfies

your colnfort requirelnents. SUGGESTION: Setting

the therlnostat back a few degrees and compensating

for the difference with warmer clothing can lnake a big

difference in your fuel consumption on extremely cold

days. The few degrees at the top of your therlnostat "coin-

fort level" are the most costly degrees to obtain.

When the room telnperature drops below the telnperature

selected on the therlnostat, the furnace will switch on auto-

matically. When the room telnperature reaches the setting

selected on the therlnostat, the filrnace will be automatically

switched off.

Some therlnostats have a "FAN" switch with 2 selections:

AUTO and ON. When therlnostat is set onAUTO, the fitrnace

blower cycles on and oft; controlled by the therlnostat. In ON

position, the furnace blower runs continuously except for a

45- sec delay at the "call for heat." This keeps the telnperature

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

ly filters the indoor air.

SHUTTING DOWN YOUR FURNACE

Should you ever suspect a lnalflmction in your furnace, you

will need to turn the furnace off'. The following procedures

must be followed:

1. Set your room therlnostat to the lowest telnperature

setting. (See Fig. 20.)

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

page 4.)

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

F!'W

i i J\

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 m the

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

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

7. If the filrnace is being shut down because of a lnalfunc-

tion, call your dealer as soon as possible.

PERFORMING ROUTINE

MAINTENANCE

With proper lnaimenance and care, your fimmce will operate

economically and dependably. Basic lnaintenance, which can

easily be accolnplished by solneone who follows the directions,

is found on this and the following pages. However, before begin-

ning lnaintenance, follow these safety precautions:

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.

Although special care has been taken to minimize

sharp edges, be extremely careful when handling

parts or reaching into the furnace.

FILTERING OUT TROUBLE

A dirty filter will cause excessive stress on the flmmce, heat

exchanger, and blower motor and can cause it to overheat

and amomatically shut down. The flmmce filter should be

checked every 3 or 4 weeks and cleaned if necessary.

If installed with t:actory 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.

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.

The air filter for upflow furnaces is normally located in the

blower colnpartlnent. (See Fig. 3) or in the t:actory-supplier

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

inet. Filters for the downflow furnaces are normally located

in the return-air plenum above the blower. If air filter has been

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 1t)

• AIR FILTER LOCATED IN FILTER CABINET

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

NOTE: It will be necessary to remove 1 tlmmbscrew.

24 25

3. Remove air filter froln flmmce.

• AIR FILTER LOCATED IN BLOWER COMPART-

MENT:

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

(See Fig. 24)

b. Gently relnove air filter and carefidly turn the dirty

side up (if dirty) m avoid spilling dirt froln 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 filrnace

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 inforlnation.

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

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

gent may be used if necessary. Spray water tln_ough filter

in the opposite direction of airflow. Allow filter to dry.

6. Reinstall clean air filter

7. Reinstall filter retainer (for blower COlnpartlnent locations

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 if side return ducts are used,

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

above may be used to relnove side filters.

•Downflow/Horizontal Furnaces Only:

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

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

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

1. Turn offelectrical supply to the filrnace. (See Fig. 21 .)

2. Remove 2 screws froln blower access door and relnove

the door.

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

the center and raising it from the V-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 relnove the right-side filter, lift froln V-shaped chmmel

and relnove flmmgh left side the same way as left-side filter.

6. Inspect the filter. If tom, 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.

Reinstall the clean filters.

27 I28

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

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

FU1LNACE

CASING

WIDTH (IN.)

14-316

17-12

24-1/2

UPFLOW FURNACE AIR FILTERTABLE

AIR FILTER LOCATED IN BLOWER COMPARTMENT

FILTER SIZE (IN)

Side Return

(1) 16x25xl*

(1) 16x25xl

(lor2) 16x25x

Bottom Return

(1) 14x25xl

(1) 16x25xl*

(1)20x25xl*

(1)24x25xl*

FILTER

TYPE

Cleanable

AIR FILTER LOCATED IN FILTER CABINET

FILTER

CABINET FILTER FILTER

HEIGHT (IN') SIZE (IN) TYPE

16 (1) 16 x 25 x 1" Cleanable

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

20 (1) 20 x 25 x 1" Cleanable

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

24 (1) 24 x 25 x 1" Cleanable

or (1) 24 x25 x 4-5/16 Disposable

DOWNFLOW/HORIZONTAL FURNACE FILTERTABLE

FURNACE CAS- FILTER

ING WIDTH (IN.) FILTER SIZE (IN) 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

* Factor}" 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.

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.

COMBUSTION AREA AND

VENT SYSTEM

Inspect the colnbnstion area and veto system before each

heating season. An accumulation of dirt, soot, or rust can

mean a loss of efficiency and improper performance. Build-

ups on the main bnrners can cause t:aulty firing. 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 selwicing dealer.

Use your flashlight and follow these steps for inspecting the

colnbnstion area and vent system of your furnace:

1. Tnrn off electrical supply to the furnace and remove

the access doors. (See Fig. 9, and 10 or 11.)

2. Carefully inspect the gas bnrner 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, or scale accumulations are found, call

your selwicing dealer. DO NOT OPERATE THE FURNACE.

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.

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

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

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

5. Start the filrnace and observe its operation. If possible,

watch the burner flames. Are they burning bright blue?

If not or if you suspect SOlneother lnalfimction, call

your selwicing 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 therlnostat set above room telnperature? Is the

HEAT mode selected?

• Is the electrical power supply switch on? Is the blower

access door firmly in place? Are any fllses blown? (There is a

fuse on the fimmce control.) Has a circuit breaker tripped?

• Is the lnanual shut-offvalve 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 fimmce. Relnove access doors.

• Is the comrol 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, lnake sure the gas has not been shut off

for safety reasons. If nothing else seems to be wrong, follow the

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

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

switch will slam offthe fimmce. 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 offthe filrnace and call

for service.

• Downflow/Itorizontal Only Check the lnanual reset aux-

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

If the blower motor tails, 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 lnantml reset limit switch(es) located near the

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

dition due to inadequate colnbustion air, these switches will

shut offthe furnace. Reset the switch(es) by pushing the button

on the switch. If the switch trips a second time, turn offthe

furnace and call for service.

• If your fimmce still fails to operate, call your servicing deal-

er *br troubleshooting and repairs. Tell your dealer the lnodel

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

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

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

overthephoneorsavevaluabletimethroughknowledgeable

preparationfortheselwicecall.

Regular dealer maintenance

In addition to the type of routine lnaintenance you lnight be

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

properly trained selwice teclmician. A selniammal 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 Colnbustion and ventilation air

passages and openings.

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

filrnace.

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

the blower lnotor and wheel.

NOTE: Refer to the unit Service Procedures for blower motor

oiling inforlnation. When required, the lnomr lnUStbe oiled by

a qualified selwice technician.

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

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

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

be resolved at this time.

7. Inspection of filrnace installation for proper support and any

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 fimmce.

8. A check for loose comaections attaching indivi&ml compo-

nents. Iaaspectionof all electrical wiring and their comaections.

9. Operational check of the fimmce itself to deterlnine worldng

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

Ask your servicing dealer for further details about an econoln-

ical sela,ice contract that covers seasonal inspections.

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