Carrier Furnace 58GFA User Manual

58GFA  
Induced Combustion Furnaces  
Service and Maintenance Instructions  
For Sizes 065-150 Series 130  
NOTE: Read the entire instruction manual before starting the  
installation.  
These procedures are for sizes 65,000 through 150,000 Btuh units.  
CANADIAN GAS ASSOCIATION  
Index  
Page  
ama  
®
A PPROVED  
R
SAFETY CONSIDERATIONS.....................................................1  
CARE AND MAINTENANCE..................................................1-4  
Air Filter Arrangement.............................................................2  
Blower Motor and Wheel......................................................2-3  
Cleaning Heat Exchanger......................................................3-4  
Electrical Controls and Wiring.................................................4  
Pilot ...........................................................................................4  
Troubleshooting ........................................................................4  
Unit Wiring Diagram ............................................................5-6  
Troubleshooting Chart ..............................................................7  
SAFETY CONSIDERATIONS  
Installing and servicing heating equipment can be hazardous due to  
gas and electrical components. Only trained and qualified person-  
nel 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 NFPA No. 54-  
1992/ANSI Z223.1-1992 (NFGC). In Canada, refer to the current  
edition of the National Standard of Canada CAN/CGA-B149.1-  
and .2-M95 Natural Gas and Propane Gas Installation Codes  
(NSCNGPIC). Wear safety glasses and work gloves. Have fire  
extinguisher available during start-up and adjustment procedures  
and service calls.  
A92057  
Fig. 1—Model 58GFA Upflow  
The ability to properly perform maintenance on this equip-  
ment 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.  
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 word DANGER, WARNING, or CAU-  
TION. These words are used with the safety-alert symbol. DAN-  
GER identifies the most serious hazards which will result in severe  
personal injury or death. WARNING signifies a hazard that 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 sugges-  
tions that will result in enhanced installation, reliability, or  
operation.  
CARE AND MAINTENANCE  
For continuing high performance and to minimize possible equip-  
ment failure, it is essential that periodic maintenance be performed  
on this equipment. Consult your local dealer as to the proper  
frequency of maintenance and the availability of a maintenance  
contract.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 6a 8a  
1
4
PC 101  
Catalog No. 535-821  
Printed in U.S.A.  
Form 58GFA-1SM  
Pg 1  
10-95  
Replaces: 58D, G-3SM  
 
6. Mark blower wheel, motor, and motor support in relation to  
blower housing before disassembly to ensure proper reassem-  
bly.  
e. Gas valve  
f. Edge connector leading to control box  
4. Remove 8 screws that secure flue collector box to center  
panel. Be careful not to damage sealant.  
7. Loosen setscrew holding blower wheel on motor shaft.  
8. Remove bolts holding motor mount to blower housing and  
slide motor and mount out of housing. Disconnect ground wire  
attached to blower housing before removing motor.  
5. Remove complete inducer assembly from furnace, exposing  
flue openings.  
6. Clean cells using field-provided small wire brush, steel spring  
cable, reversible electric drill, and vacuum cleaner.  
9. Lubricate motor (when oil ports are provided).  
a. Remove dust caps or plugs from oil ports located at each  
end of motor.  
a. Assemble wire brush and steel spring cable.  
(1.) Use 48 in. of 1/4-in. diameter high-grade steel spring  
cable (commonly known as drain clean-out or Roto-  
Rooter cable).  
b. Use a good grade of SAE 20 nondetergent motor oil and  
put 1 teaspoon, 5 cc, 3/16 oz, or 16 to 25 drops in each oil  
port. Do not over-oil.  
(2.) Use 1/4-in. diameter wire brush (commonly known as  
25-caliber rifle cleaning brush).  
c. Allow time for total quantity of oil to be absorbed by each  
bearing.  
NOTE: The items needed in steps (1.) and (2.) can usually be  
purchased at local hardware stores.  
d. Wipe excess oil from motor housing.  
e. Replace dust caps or plugs on oil ports.  
10. Remove blower wheel from housing.  
a. Mark cutoff location to ensure proper reassembly.  
(3.) Insert twisted wire end of brush into end of steel spring  
cable, and crimp tight with crimping tool or strike with  
ball-peen hammer. TIGHTNESS is very important.  
b. Remove screws holding cutoff plate and remove cutoff  
plate from housing.  
(4.) Remove metal screw fitting from wire brush to allow  
insertion into cable.  
c. Lift blower wheel from housing through opening.  
b. Clean each heat exchanger cell.  
11. Clean blower wheel and motor using a vacuum cleaner with  
soft brush attachment. Do not remove or disturb balance  
weights (clips) on blower wheel blades. The blower wheel  
should not be dropped or bent as balance will be affected.  
(1.) Attach variable-speed, reversible drill to end of steel  
spring cable (end opposite brush).  
(2.) Insert brush end of cable into upper opening of cell  
and slowly rotate with drill. DO NOT force cable.  
Gradually insert at least 36 in. of cable into 2 upper  
passes of cell. (See Fig. 3.)  
12. Reinstall blower wheel by reversing steps 9 a. through c. Be  
sure wheel is positioned for proper rotation.  
13. Reassemble motor and blower by reversing steps 2 through 7.  
If motor has ground wire, be sure it is connected as before.  
Be sure the motor is properly positioned in the blower  
housing. The motor oil ports must be at a minimum of 45°  
above the horizontal centerline of the motor after the blower  
assembly has been reinstalled in the furnace.  
14. Reinstall blower assembly in furnace. Connect blower leads to  
blower speed selector.  
15. Reinstall control assembly.  
16. Turn on electrical power and check for proper rotation and  
speed changes between heating and cooling.  
A91252  
17. Replace blower access door.  
CLEANING HEAT EXCHANGER  
Fig. 3—Cleaning Heat Exchanger Cell  
The following steps should be performed by a qualified service  
technician:  
(3.) Work cable in and out of cell 3 or 4 times to obtain  
sufficient cleaning. DO NOT pull cable with great  
force. Reverse drill and gradually work cable out.  
NOTE: Deposits of soot and carbon indicate the existence of a  
problem which needs to be corrected. Take action to correct the  
problem.  
(4.) Remove burner assembly and cell inlet plates.  
(5.) Replace screws in center panel and cells before  
cleaning.  
If it becomes necessary to clean the heat exchanger because of  
carbon deposits, soot, etc., proceed as follows:  
(6.) Insert brush end of cable in lower opening of cell, and  
proceed to clean 2 lower passes of cell in same manner  
as 2 upper passes.  
1. Turn off gas and electrical power to furnace.  
2. Remove 2 screws that secure relief box. (See Fig. 3.)  
3. Disconnect wires to the following components:  
a. Draft safeguard switch  
(7.) Repeat foregoing procedures until each cell in furnace  
has been cleaned.  
b. Inducer motor  
(8.) Remove residue from each cell using vacuum cleaner.  
c. Pressure switch  
(9.) Clean burner assembly using vacuum cleaner with soft  
brush attachment.  
d. Limit overtemperature switch  
3
 
(10.) Reinstall cell inlet plates and burner assembly. Care  
must be exercised to center the burners in the cell  
openings.  
PILOT HEAD V–NOTCH FALLS  
DIRECTLY BELOW FRONT EDGE  
OF BURNER CARRYOVER.  
7. After cleaning flue openings, check sealant on flue collector to  
ensure that it has not been damaged. If new sealant is needed,  
contact your dealer or distributor.  
8. Clean and replace flue collector assembly, making sure all 8  
screws are secure.  
1
/  
8
9. Reinstall 2 screws in relief box.  
10. Reconnect wires to the following components:  
a. Draft safeguard switch  
b. Inducer motor  
c. Pressure switch  
A91249  
d. Limit overtemperature switch  
e. Gas valve  
Fig. 4—Position of Pilot to Burner  
securely. Electrical controls are difficult to check without proper  
instrumentation; therefore, reconnect electrical power to unit and  
observe unit through 1 complete operating cycle.  
f. Edge connector leading to control box  
11. Replace blower access doors.  
12. Turn on electrical power and gas.  
13. Set thermostat and check furnace for proper operation.  
The 24-v circuit contains an automotive-type, 3-amp fuse located  
on the main control board. Any direct shorts during installation,  
service, or maintenance could cause this fuse to blow. If fuse  
replacement is required, use ONLY a 3-amp fuse of identical size.  
PILOT  
Never use a match or other open flame to check for gas leaks.  
Use a soap-and-water solution. A failure to follow this  
warning could result in fire, personal injury or death.  
Check the pilot and clean if necessary at the beginning of each  
heating season. The pilot flame should be high enough for proper  
impingement of the flame sensing element (or thermocouple) and  
to light the burners. Remove the accumulation of soot and carbon  
from the flame sensing element (or thermocouple). Refer to Fig. 4  
for proper location of pilot on burner assembly.  
14. Check for gas leaks.  
15. Replace control access door.  
ELECTRICAL CONTROLS AND WIRING  
TROUBLESHOOTING  
NOTE: There may be more than 1 electrical supply to unit.  
Page 7 contains a troubleshooting chart. This chart can be a useful  
tool in isolating furnace operation problems. Beginning with the  
word "Start," answer each question and follow the appropriate  
arrow to the next item.  
The electrical ground for 115-v wiring must be maintained  
properly. Refer to Fig. 5 for field wiring information and to Fig. 6  
for unit wiring information.  
With power disconnected to unit, check all electrical connections  
for tightness. Tighten all screws on electrical connections. If any  
smoky or burned connections are noticed, disassemble the connec-  
tion, clean all parts and stripped wire, and reassemble properly and  
The chart will help identify the problem or failed component. After  
replacing any component, verify correct operating sequence as  
indicated by bold arrows.  
4
 
FIELD 24-VOLT WIRING  
FIELD 115-, 208/230-, 460-VOLT WIRING  
FACTORY 24-VOLT WIRING  
FACTORY 115-VOLT WIRING  
NOTE 2  
THERMOSTAT  
TERMINALS  
W
C
R
G
Y
FIVE  
WIRE  
FIELD-SUPPLIED  
FUSED DISCONNECT  
THREE-WIRE  
HEATING-  
ONLY  
208/230- OR  
460-VOLT  
THREE  
PHASE  
W
R
BLK  
BLK  
WHT  
WHT  
208/230-  
VOLT  
SINGLE  
PHASE  
GND  
GND  
G
AUXILIARY  
J-BOX  
115-VOLT FIELD-  
SUPPLIED  
FUSED  
DISCONNECT  
C
Y
GND  
NOTE 1  
CONTROL  
CONDENSING  
UNIT  
BOX  
TWO  
WIRE  
24-VOLT  
TERMINAL  
BLOCK  
NOTES: 1. Connect Y-terminal as shown for proper operation.  
2. Some thermostats require a "C" terminal connection as shown.  
3. If any of the original wire, as supplied, must be replaced, use  
same type or equivalent wire.  
FURNACE  
A95241  
Fig. 5—Heating and Cooling Application Wiring Diagram  
5
 
GV  
DSS  
L2  
TO 115V AC FIELD DISCONNECTIONS  
NOTE #4  
PRS  
L1  
SCHEMATIC  
DIAGRAM  
MGV  
CONNECTION DIAGRAM  
NO  
NC  
TH  
BRN  
ILK  
TR  
C
EQUIPMENT GROUND  
PILOT  
L1  
LO  
SPARE-2  
L1  
MED LO  
MED HI  
HI  
CFR  
HFR  
HEAT  
FL  
LS  
ALS  
START  
SPARE-1  
COOL  
NOTE #9  
OL  
(WHEN USED)  
NOTE #6  
CAP  
COM  
IDM  
COM  
BLWM  
WHT  
BLK  
EAC-1  
EAC-2  
IDR  
PL1-3  
PL1-1  
IDM  
BLU  
TRAN  
115V AC  
NOTE #4  
ILK  
FUSED DISCONNECT  
SWITCH (WHEN REQ’D)  
LS  
FL  
PR-1  
ALS  
PR-2  
FU1  
PL1-4  
TRAN  
BLK  
PL1-7  
BLK  
FU2  
24V AC  
3A  
SEC-1  
SEC-2  
FUSE  
WHT  
NOTE #7  
(WHEN USED)  
NOTE #6  
WHT  
GRN  
COM  
PR2  
HFR  
PL1  
1
2
4
5
6
7
8
9
GRN  
PR1  
L2  
CFR  
L1  
JB  
R
LOGIC  
PL1-9  
HFR  
3
EAC-2  
EAC-1  
TIME  
DELAY  
LO  
HI  
BLWM  
GRN  
BRN  
WHT (COM)  
BLK (HI)  
GV  
TR  
MGV  
DSS  
C
PL1-8  
OL  
SPARE-1  
SPARE-2  
Y
TH  
PRS  
IDR  
RED  
NOTE #9  
YEL (MED HI)  
NO  
NC  
START  
PILOT  
SEC-2  
SEC-1  
BLU  
BLU (MED LO)  
RED (LO)  
BRN  
PL1-2  
PL1-6  
IDR  
FU1  
W
W
Y
R
C
G
GROUND  
3AMP  
FUSE  
SCREW  
REQUIRED  
IDR  
NOTE #7  
PCB  
CFR  
NOTE #8  
NOTE #1  
G
C
NOTE #9  
LEGEND  
JUNCTION  
ALS  
AUXILIARY LIMIT SWITCH, OVERTEMP.  
-MANUAL RESET, SPST-(N.C.)  
UNMARKED TERMINAL  
PCB TERMINAL  
BLWM BLOWER MOTOR  
NOTES:  
CAP  
CFR  
DSS  
CAPACITOR  
COOLING FAN RELAY, SPDT  
DRAFT SAFEGUARD SWITCH, SPST-(N.C.),  
MANUAL RESET  
1. Internally connected to equipment ground through mounting screw.  
FACTORY POWER WIRING (120 AC)  
FACTORY CONTROL WIRING (120 AC)  
FIELD POWER WIRING (120 AC)  
CONDUCTOR ON PCB  
2. If any of the original equipment wire is replaced, use wire rated for 105°C.  
3. Blower motor (BLWM) & Inducer motor (IDM) contain auto-reset  
thermal overload switch.  
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC)  
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)  
FL  
FUSIBLE LINK  
4. Use only copper wire between the disconnect switch and the furnace  
junction box (JB).  
FU1  
FU2  
GV  
HFR  
IDM  
IDR  
ILK  
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE  
FUSE FIELD INSTALLED  
GAS VALVE-REDUNDANT OPERATORS  
HEATING FAN RELAY, SPST (N.O.)  
INDUCED DRAFT MOTOR  
INDUCED DRAFT RELAY, SPST-(N.O.)  
BLOWER ACCESS PANEL INTERLOCK SWITCH,  
SPST-(N.O.)  
FIELD WIRING SCREW TERMINAL  
FIELD GROUND  
5. Symbols are electrical representations only6.  
6. Auxiliary limit switch (ALS) used on downflow models only.  
7. The transformer 24VAC winding is protected by a 3 AMP automotive  
blade type fuse on the control board. A 24VAC short to ground during  
installation, checkout, operation, service or maintenance could cause  
this fuse to open. Do not replace the 3 AMP fuse with any other size fuse.  
8. Blower motor (BLWM) adjustable OFF-DELAY. Factory set: 120 seconds  
cut resistor: 180 seconds.  
EQUIPMENT GROUND  
FIELD SPLICE  
PLUG RECEPTACLE  
JB  
JUNCTION BOX  
LS  
LIMIT SWITCH, AUTO RESET, SPST(N.C.)  
OL  
AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.  
PRINTED CIRCUIT BOARD (FURNACE CONTROL)  
9-CIRCUIT CONNECTOR (PCB1)  
PCB  
PL1  
PR5  
PRESSURE SWITCH, SPDT  
TRAN TRANSFORMER (115V AC/24V AC)  
9. When CFR relay is energized, HFR relay is also energized.  
322876-101 REV. A  
A95464  
Fig. 6—Unit Wiring Diagram  
6
 
START  
Turn on 115-VAC  
power to unit.  
Disconnect all thermostat  
wires from board.  
Turn off 115-VAC  
power to unit.  
NO  
Are  
Is 24VAC  
across screws  
W & C or  
all thermostat  
wires to board  
disconnected?  
Is 24VAC  
across screws  
R & C?  
YES  
YES  
YES  
Is blower  
running?  
G & C?  
NO  
NO  
NO  
YES  
Check/Replace:  
1. Limit switch  
Jumper across  
screws R & G.  
Replace  
board.  
2. Limit shield (if used)  
3. Fuse link  
4. Auxillary limit switch (if used)  
5. Wire harness  
YES  
Is  
Is  
Is  
Is  
YES  
NO  
NO  
24VAC  
115VAC  
across HI &  
COM?  
115VAC  
across L1 &  
L2?  
blower running  
on cooling  
speed?  
across screws  
R & C?  
YES  
YES  
NO  
NO  
Replace  
blower motor  
and/or start  
capacitor.  
Check/Replace:  
1. Unit power  
2. Door switch  
3. Power harness  
Check/Replace:  
1. 3-amp board  
fuse  
Is  
NO  
115VAC  
Replace  
board.  
across EAC-1  
& COM?  
2. Transformer  
Check pressure  
tube for leak or  
YES  
Is  
24VAC  
NO  
crimp; otherwise,  
Replace  
board.  
Remove  
R & G jumper.  
across PL1-2  
& screw C on  
board?  
replace pressure switch  
NO  
YES  
YES  
Is heat  
exchanger  
pressure drop greater  
than 0.35-in.  
wc?  
Is 24VAC  
across pressure  
switch N/O contact  
& screw C on  
board?  
Repair wire  
harness.  
Does  
blower turn  
off?  
YES  
NO  
NO  
NO  
YES  
Check/Replace:  
1. Vent systems  
2. Induce wheel  
Is 24VAC  
across pressure  
switch N/O contact  
& screw C on  
board?  
YES  
Check/Replace:  
1. Draft safeguard switch  
2. Wire harness  
Jumper across  
screws R & W.  
3. Flue choke  
4. Inducer voltage  
5. Inducer motor bearings  
NO  
Check/Replace:  
1. Pilot  
Is  
inducer motor  
on?  
YES  
Is  
YES  
YES  
NO  
Is  
24VAC across gas  
valve?  
unit lit?  
2. Thermocouple  
3. Gas valve  
NO  
YES  
Is  
Is  
Is  
Replace  
blower motor  
and/or start  
capacitor.  
blower running  
on heat speed 45  
sec after unit  
lights?  
YES  
NO  
115VAC across  
inducer motor  
connector?  
115VAC across  
inducer motor  
connector?  
Replace  
inducer motor.  
NO  
NO  
YES  
Is  
Is  
Is  
24VAC  
YES  
NO  
24VAC across  
PL-2 & screw  
C on board?  
115VAC  
across EAC-1  
& COM?  
NO  
across  
PL-1 & screw  
C on board?  
Replace  
board.  
Check/Repair  
wire harness;  
otherwise,  
replace  
NO  
YES  
YES  
Check/Replace  
thermostat  
Replace  
board.  
Remove  
R & M jumper.  
Repair wire  
harness.  
and/or  
pressure  
thermostat wiring.  
switch.  
NO  
After  
NO  
YES  
off-delay  
does blower  
turn off?  
Reconnect all  
thermostat wires.  
Does unit  
operate?  
NOTE: After replacing any component, verify correct operating  
YES  
sequence as indicated by bold arrows.  
END OF TEST.  
A91253  
7
 
SERVICE TRAINING  
Packaged Service Training programs are an excellent way to increase your  
knowledge of the equipment discussed in this manual, including:  
• Unit Familiarization  
• Installation Overview  
• Maintenance  
• Operating Sequence  
A large selection of product, theory, and skills programs is available, using popular  
video-based formats and materials. All include video and/or slides, plus companion  
book.  
Classroom Service Training plus "hands-on" the products in our labs can mean  
increased confidence that really pays dividends in faster troubleshooting, fewer  
callbacks. Course descriptions and schedules are in our catalog.  
CALL FOR FREE CATALOG 1-800-962-9212  
[ ] Packaged Service Training  
[ ] Classroom Service Training  
A94328  
Copyright 1995 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231  
58gfa1sm  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 6a 8a  
1
4
PC 101  
Catalog No. 535-821  
Printed in U.S.A.  
Form 58GFA-1SM  
Pg 8  
10-95  
Replaces: 58D, G-3SM  
 

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