Carrier 58MVB Series User manual

®
to the Expertg
Owner's Manual
NOTE TO INSTALLER:
THIS MANUAL MUST BE LEFT WITH THE
EQUIPMENT USER.
USER: PLEASE READ ALL INSTRUCTIONS
IN THE MANUAL AND RETAIN ALL
MANUALS FOR FUTURE REFERENCE.
FIRE OR EXPLOSION HAZARD
Failure to follow warnings could result in injury, death,
or property damage.
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.
-Leave the building immediately.
-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.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
and/or death.
Carbon Monoxide is invisible, odorless, and toxic! Install a
carbon monoxide alarm in your home, even if you do not
own a gas appliance. Locate the carbon monoxide alarm in
the living area of your home and away from gas appliances
and doorways to attached garages. Follow the alarm
manufacturer's instruction included with the alarm.
A05069
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Do not use this furnace if any part has been under water. A
flood-damaged furnace is extremely dangerous. Attempts to
use the furnace can result in fire or explosion. A qualified
service agency should be contacted to inspect the furnace and
to replace all gas controls, control system parts, electrical parts
that have been wet or the furnace if deemed necessary.

TABLE OF CONTENTS
WELCOME TO A NEW GENERATION OF COMFORT .... 2
FURNACE COMPONENTS ........................... 3
SAFETY CONSIDERATIONS ......................... 4
BEFORE STARTING YOUR FURNACE ................. 5
STARTING YOUR FURNACE ......................... 5
SHUTTING DOWN YOUR FURNACE .................. 7
PERFORMING ROUTINE MAINTENANCE ............. 8
FILTERING OUT TROUBLE .......................... 9
COMBUSTION AREA AND VENT SYSTEM ............ 9
HEADING SOUTH FOR THE WINTER ................ 13
A CHECK-UP CHECKLIST .......................... 14
BEFORE YOU REQUEST A SERVICE CALL ........... 14
INSTALLATION DATA ............................. 15
WELCOME TO TODAY'S GENERATION
OF COMFORT
Congratulations! In light of rising energy costs, a 90+% AFUE
Condensing Gas Furnace from Carrier Corporation is among the
soundest investments today's homeowner can make.
Your new furnace is truly a triumph of technology in home
heating. A revolutionary design employs two (2) heat exchangers
to "squeeze" out the maximum amount of heat from the fuel
consumed. In fact, your new furnace is so efficient, over 90%* of
the heat generated during combustion is captured and delivered
inside your home. That is more than a 30%* increase in heating
efficiency over conventional furnaces.
This furnace is among the safest, most dependable,
energy-efficient furnaces you can buy today. We are proud of the
technological advances incorporated into the design of this furnace.
With only minimal care, your new furnace will deliver many years
of money-saving home comfort and enioyment. Spend just a few
minutes with this manual to learn the operation of your new
furnace and the small amount of maintenance it takes to help keep
it operating at peak efficiency year after year.
*The output capacity and any representations of efficiency for this furnace
are based on standard U.S. Department of Energy test procedures.
As an ENERGY STAR
Partner, Carrier Corp.
has determined that this
product meets the
ENERGYSTAR®
guidelines for energy
efficiency.
EFFICIENCY
CERTIFIED a
A05069

FURNACE COMPONENTS
(Furnace shown in upflow position; may be used in downflow or
horizontal orientation or applications.
17
3
15
13
7
19
Single Stage Furnace
A08315
418
6
5
15
14
13
7
19
10
Two-Stage Furnace
A08316
1. Combustion-air intake connection (right or left side).
2. Burner sight glass for viewing burner flame.
3. Burner assembly (inside), operates with energy-saving, in-
shot burners and hot surface igniter for safe, dependable
heating.
4. Redundant gas valve. Safe and efficient. Features 1 gas con-
trol with 2 internal shutoff valves.
5. Vent outlet, uses PVC pipe to carry flue gas from the fur-
nace's combustion system (right or left side).
6. Inducer motor. Pulls hot flue gases through the heat ex-
changers, maintaining negative pressure for added safety.
7. Blower access panel safety interlock switch.
8. Air filter (sold separately on some models) and retainer
(location in furnace may vary).
9. Condensate drain connection, collects moisture condensed
from burned gases for disposal into home drain system.
(location in furnace varies)
10. Heavy-duty blower, circulates air across the heat ex-
changers to transfer heat into the home.
11. Secondary condensing heat exchanger (inside). Wrings out
more heat through condensation. Constructed with polypro-
pylene-laminated steel to ensure durability.
12. Primary serpentine heat exchanger (inside), stretches fuel
dollars with the S-shaped heat-flow design. Solid construc-
tion of corrosion-resistant aluminized steel means reliabil-
ity.
13. Furnace control board.
14. 3-amp fuse provides electrical and component protection.
15. Light emitting diode (LED) on furnace control board.
Status code light is for diagnosing furnace operation and
service requirements.
16. Pressure switch(es) ensure adequate flow of flue gas
through furnace and out vent system.
17. Rollout switch (manual reset) to prevent over temperature.
18. Junction box for 115-v electrical power supply. (May be
located on right or left side).
19. Transformer (24v) behind furnace control board provides
low-voltage power to furnace control board and thermostat.

SAFETY CONSIDERATIONS
Installing and servicing of 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 flmctions such
as cleaning and replacing air filters. All other operations must be
performed by trained service personnel. Observe safety precautions
in this manual, on tags, and on labels attached to the furnace and
other safety precautions that may apply.
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 words DANGER, WARNING, CAUTION,
and NOTE. DANGER, WARNING, and CAUTION 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
may result in nfinor personal injury or product and property
damage. NOTE is used to highlight suggestions which will result
in enhanced installation, reliability, or operation.
To nfininfize the possibility of serious personal injury, fire, damage
to your furnace, or improper operation, carefully follow these
safety rules which apply to both direct-vent and non-direct vent
applications:
• Your new gas furnace may have been installed in 1 of 2 ways, as
a direct-vent (2-pipe-Fig. 1) application or as a non-direct vent
(l-pipe-Fig. 2) application.
• In a direct-vent (2-pipe) application, your furnace uses air from
outside the home for combustion and vents flue gas to the
outdoors. This type of application will have 2 pipes running
from the furnace to the outdoors. (See Fig. 1.) In this
application, the vent and air-intake pipes nmst ternfinate outside
the structure and nmst not be obstructed in any way. Do not
block or obstruct air openings on furnace or spaces around
furnace.
• In a non-direct vent (1-pipe) application, your furnace uses air
from adjacent to the furnace for combustion and vents flue gas
to the outdoors. This type of application will have only 1 pipe
running from the furnace to the outdoors. (See Fig. 2.) The other
pipe will ternfinate in the same space as the furnace and is the
source of combustion air for your furnace. Therefore, the furnace
must not be enclosed in an airtight room or be sealed behind
solid doors. It must have adequate airflow for efficient
combustion and safe ventilation. Do not obstruct the
combustion-air pipe in any way. The vent pipe nmst ternfinate
outside the structure and must not be obstructed in any way. Do
not block or obstruct air openings or space around furnace.
Fig. 1 -Exterior Vent Pipes
A05098
Fig. 2 - Interior Combustion -Air Pipe
A05101
• Keep the area around your furnace clear and free of combustible
materials, gasoline, and other flammable liquids and vapors.
See Fig. 3.
FIRE OR EXPLOSION HAZARD
Failure to follow warnings could result in personal injury,
death, or property damage.
Keep insulation clear of furnace and maintain clearances
shown on unit clearance label.
A92182
Fig. 3 - NO combustible materials near furnace

• Donotcoverthefurnace,storetrash or debris near it, or in any
way block the flow of fresh air to the unit.
• In addition to the safety rules above, make sure that the
following combustion-air requirements are met for non-direct
vent applications:
• Combustion air nmst be clean and uncontanfinated with chlorine
or fluorine. These compounds are present in many products
around the home, such as: water softener salts, laundry bleaches,
detergents, adhesives, paints, varnishes, paint strippers, waxes,
and plastics.
• Make sure the combustion air for your furnace does not contain
any of these compounds. During remodeling be sure the
combustion air is fresh and uncontanfinated. If these compounds
are burned in your furnace, the heat exchangers may deteriorate.
• A furnace installed in an attic or other insulated space must be
kept free and clear of insulating material. Exanfine the furnace
area when the furnace is installed or when insulation is added.
Some insulation materials may be combustible.
• Should the gas supply fail to shut off or if overheating occurs,
shut off the gas valve to the furnace before shutting off electrical
supply.
This furnace contains SAFETY DEVICES which must be
MANUALLY RESET. If the furnace is left unattended for an
extended period of time, have it checked periodically for proper
operation. 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.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Do not keep combustible materials, gasoline, and other
flammable liquids or vapors around your furnace.
UNIT OPERATION HAZARD
Failure to follow this caution may result in internfittent unit
operation.
For proper and safe operation the furnace needs air for
combustion and ventilation. Do not block or obstruct air
openings on the furnace, air opening to the area in which the
furnace is installed, and the space around the furnace.
BEFORE STARTING YOUR FURNACE
Exanfine the furnace installation to deternfine that:
1. All flue gas carrying areas external to the furnace (i.e. china-
ney, vent connector) are clear and free of obstructions.
2. The vent connector is in place, slopes upward and is physic-
ally sound without holes or excessive corrosion.
3. The return-air duct connection(s) is physically sound, is
sealed to the furnace casing, and ternfinates outside the
space containing the furnace.
4. The physical support of the furnace is sound without sag-
ging cracks, gaps, etc. around the base.
5. There are no obvious signs of deterioration of the furnace.
6. The burner flames are in good adjustment, See Fig. 4 (by
comparison with pictorial sketches or drawings of the main
burner flame.)
Fig. 4-Burner Flame Adjustment
A92330
STARTING YOUR FURNACE
Instead of a continuously burning pilot flame which wastes
valuable energy, 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. See Fig. 5.
Fig. 5 - Do Not Light Burner with Match
A92319
• Read and follow the operating instructions on inside of
main furnace door, especially the item that reads as fol-
lows:
"Wait 5nfinutes to clear out any gas. Then smell for gas,
including near the floor. If you smell gas, STOP! Fol-
low "B" in the safety information on furnace 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 inside of
main furnace door, or in the "Shutting Down Your Fur-
nace" section and call your dealer as soon as possible.
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal iniury,
death or property damage.
Should the gas supply fail to shut off or if overheating occurs,
turn off the manual gas valve to the furnace BEFORE turning
off the electrical supply and install lockout tag.

• CHECKAIRFILTER:Beforeattempting to start your
furnace, be sure the furnace filter is clean and in place.
See "Perfornfing Routine Maintenance" section in this
manual. Do not run the furnace without a filter in place.
Then proceed as follows:
STEPS FOR STARTING YOUR FURNACE
1. Set your room thermostat to the lowest temperature setting.
See Fig. 6.
Fig. 6 - Lowest Temperature Setting
2. Close the external manual gas valve. See Fig. 7.
Fig. 7 - Close Valve
3. Turn OFF electrical supply to the furnace. See Fig. 8.
A09564
A06188
Fig. 9-Remove Furnace Door
A05099
5. Turn thecontrol switch on the gas control to the OFF position
and wait 5nfinutes. See Fig. 10. Then smell for gas, including
near the floor. If you smell gas, STOP! Follow "B" on furnace
label. If you don't smell gas, go to next step.
OR
j"GAS CONTROL SWITCH
SHOWN IN "OFF" POSITION
Fig. 10 - Control Switch to OFF
A09600
6. After waiting 5nfinutes, turn control switch on the gas control
to the ON position. Turn the control switch to ON. See Fig.
11.
TWO STAGE GAS CONTROL
OR
Fig. 8 - Turn Off Electrical Supply
4. Remove the main furnace door. See Fig. 9.
A92185
Fig. 11 - Control Switch to ON
7. Replace main furnace door. See Fig. 12.
A09599

Fig. 12 - Furnace Door Replaced
A05100
8. Turn ON theelectrical supply tothefurnace and wait I minute.
See Fig. 13.
Fig. 13 -Turn on Electrical Supply
A92359
9. Open the external manual gas valve. See Fig. 14.
J
Fig. 14 - Open Valve
A06189
10. Set the room thermostat to a temperature slightly above the
room temperature. This will automatically signal the furnace
to start.
11. When the furnace receives the start signal, the inducer is star-
ted. When the pressure switch senses that there is sufficient
combustion air, the hot surface igniter is energized.
After the hot surface igniter is heated for 17 seconds, the gas
valve permits gas to flow to the main burners. After ignition
and a time delay of about 60 sec, the furnace blower will start.
Variable-capacity furnaces start at low speed until the control
makes the necessary adjustments to operate the blower at
either the low- or high-heat speed.
NOTE: If the main burners fail to ignite after four attempts, the
furnace control system will lock out. If lockout occurs, main
burners fail to light, or blower does not come on, shut down the
furnace and call your dealer for service.
12. Set your thermostat to the temperature that satisfies your
comfort requirements. SUGGESTION: Setting the thermo-
stat back a few degrees--and compensating for the differ-
ence with warmer clothing--can make a big difference in
your fuel consumption on extremely cold days. The few de-
grees at the top of your thermostat "comfort 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 automatically. When
the room temperature reaches the setting selected on the thermostat,
the furnace will be automatically switched off.
Continuous Fan Operation -Some thermostats have a "FAN"
switch with 2 selections: AUTO and ON. When them]ostat is set
on AUTO, the furnace blower cycles on and off, controlled by the
thermostat. In ON position, the furnace blower runs continuously.
Continuous fan keeps the temperature level in your home more
evenly balanced. It also continuously filters the indoor air.
Comfort Fan TM - On all but the base series furnace, the blower
speed can be increased or decreased if desired due to change of
seasons, large gatherings in your home, etc. Simply change your
FAN from ON to OFF for 1 to 3 seconds (or AUTO depending on
your thermostat), and then return to ON. The blower will switch to
the next higher speed. There are at least three speeds to choose
from. If the blower is running on its highest speed, a request to
change will direct the blower to return to its lowest speed.
SHUTTING DOWN YOUR FURNACE
Should you need to shut down your furnace for service or
maintenance, 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. 15.
Fig. 15 - Lowest Temperature Setting
2. Close the external manual gas valve. See Fig. 16.
F,
.===_ i
l
Fig. 16 - Close the External Manual Valve
3. Turn off electrical supply to the furnace. See Fig. 17.
A09564
A06188

[]NIT AND PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in unit component or
property damage.
Furnace is not to be installed, operated, and then turned off
and left turned off in an unoccupied structure during winter.
(See "Winterization" procedures in this manual.
A92185
Fig. 17 - 1hrn Off Electrical Supply
4. Remove main furnace door.
5. Turn control switch on the gas control to OFF position. See
Fig. 18.
SENGLE-STAGE GAS CONTROL
Z2_
TWO STAGE GAS CONTROL
A09600
Fig. 18 - Control Switch to OFF
6. Replace main furnace door. See Fig. 19.
\
A05100
Fig. 19 -Furnace Door Replaced
7. If the furnace is being shut down because of a malfunction, call
your dealer as soon as possible.
PERFORMING ROUTINE MAINTENANCE
NOTE: The qualified installer or agency must use only
factory-authorized replacement parts, kits, and accessories when
modifying this product.
Installing and servicing of 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. Observe safety precautions in this manual, on tags, and
on labels attached to the furnace and other safety precautions that
may apply.
With proper maintenance and care, your furnace will operate
economically and dependably. Instructions for basic maintenance
are found on this and the following pages. However, before
beginning maintenance, follow these safety precautions:
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
Turn off electrical power supply to your furnace and
install lockout tag before removing the access doors to
service or perform maintenance.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Although special care has been taken to minimize sharp
edges, be extremely careful when handling parts or reaching
into the furnace. Wear safety glasses, gloves, and
appropriate protective clothing.

FILTERING OUT TROUBLE
UNIT PERFORMANCE HAZARD
Failure to follow this caution may result in unit component
damage.
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.
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 4 weeks and cleaned or replaced if necessary.
If installed with factory-specified disposable media filter, check or
replace filter before each heating and cooling season. 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 specified.
The air filter for the furnace may be located in the blower
compartment or in the factory-supplied filter cabinet attached to
the side or bottom of the furnace casing. If air filter has been
installed in another location, contact your dealer for instructions.
To inspect, clean and/or replace the air filter(s), follow these steps:
1. Turn off electrical supply to the furnace. See Fig. 20.
2. Remove air filter from furnace.
• AIR FILTER(S) LOCATED IN BLOWER COMPARTMENT:
a. Remove main furnace door. See Fig. 21.
b. Remove blower access panel. See Fig. 22.
NOTE: It will be necessary to remove two screws.
• AIR FILTER(S) LOCATED IN BLOWER COMPARTMENT
BOTTOM:
c. Slide filter retainer sideways until it is free of latch (See
Fig. 25).
d. Slide air filter out of furnace. See Fig. 26.
• AIR FILTER(S) LOCATED IN BLOWER COMPARTMENT
SIDE:
a. Remove filter retainer from latch. See Fig. 27.
b. Gently remove air filter and carefully turn the dirty side
up (if dirty) to avoid spilling dirt from the filter (See
Fig. 28).
• AIR FILTER(S) LOCATED IN FILTER CABINET:
a. Remove filter cabinet door. (See Fig. 23 and 24.)
NOTE: It will be necessary to remove one thumbscrew.
b. Slide air filter out of furnace. Keep dirty side up (if
dirty) to avoid spilling dirt. See Fig. 29 and 30.
3. Inspect the filter. If torn replace it.
NOTE: If a washable filter was shipped with the furnace and has
been replaced by:
• 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 ar-
row pointing towards blower.
• Electronic Air Cleaner (EAC), refer to the EAC Owner's
Manual for maintenance information.
4. If washable filter, wash 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 filter in the opposite direction of airflow. Allow fil-
ter to dry.
5. Reinstall clean air filter.
6. Reinstall filter retainer (for blower compartment locations
only.)
7. Replace blower access panel and main furnace door (See
Fig. 33 and 34) or filter cabinet door (Fig. 29 and 30).
8. Turn on electrical supply to the furnace.
If your furnace air filter needs to be replaced, be sure to use a
factory-authorized filter of the same size that was originally
specified. Use the filter tables and compare your furnace size with
the proper filter size.
Fig. 20 -3'urn Off Electrical Supply
A92185
Fig. 21 -Main Furnace Door
A05099
Fig. 22 - Blower Access Panel
A93204

A00225
Fig. 23 -Removal of Filter Cabinet Door from Side Blower
Cabinet
A93012
Fig. 27 -Release Filter Retaining Rod (Side Inlet)
A00226
Fig. 24 - Removal of Filter Cabinet Door from Bottom
Blower Cabinet
A93010
Fig. 25 - Release Filter Retaining Rod (Bottom Inlet)
A93013
Fig. 28 -Slide Filter Out of Furnace (Side Inlet)
_)/,// //b _ :
A00227
Fig. 29 - Removal of Filter from Side Blower Cabinet
Fig. 26 - Slide Filter Out (Bottom Inlet)
A93011
"_'_-_...._ - _ _i__ /
A00228
Fig. 30 - Removal of Filter from Bottom Blower Cabinet
10