Carrier 58TM Instruction Manual

INDUCED-COMBUSTION 58TUA & 58TMA
HEATING & COOLING
GAS FURNACE
USER’S INFORMATION MANUAL FOR
THE OPERATION AND MAINTENANCE
OF YOUR NEW GAS-FIRED FURNACE
NOTE TO INSTALLER:
THIS MANUAL MUST BE LEFT WITH THE
EQUIPMENT USER.
—Do not store or use gasoline or other flamma-
ble 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.
WARNING: If the information in this manual is
not followed exactly, a fire or explosion may
result causing property damage, personal in-
jury or loss of life.
This document was created with FrameMaker 4.0.2

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Welcome to today’s
generation of comfort
Congratulations! Your new, high-
efficiency gas furnace is a sound
investment which will reward you
andyour family with years of warm
memories winter after winter.
Not only is your new furnace energy
efficient, it is also extremely reliable
and supplies superior home comfort.
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.
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MODEL 58TUA
UPFLOW FURNACE
2
MODEL 58TMA
DOWNFLOW/
HORIZONTAL FURNACE
Upflow furnace components
Relief Box
Gas Valve Control Knob (On/Off)
2-Stage Gas Valve
Gas Burner
Hot Surface Ignitor
Blower Door Safety Switch
Blower and Blower Motor
Draft Safeguard Tube and Switch
Rating Plate
Gas Manifold
Filter Retainer
Air Filter
Flame Sensor
Manual Reset Flame Rollout Switch
Status LED Light
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4
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8
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Downflow/horizontal furnace components
Manual Reset Auxiliary Limit Switch
Blower and Blower Motor
Relief Box
Rating Plate
Gas Valve Control Knob (On/Off)
2-Stage Gas Valve
Gas Burner
Blower Door Safety Switch
Draft Safeguard Tube and Switch
Gas Manifold
Hot Surface Ignitor
Flame Sensor
Manual Reset Flame Rollout Switch (2)
Status LED Light
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2
3
4
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Important facts
Your furnace must have adequate airflow for efficient com-
bustionand safe ventilation. Do not encloseitin 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.
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•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 surethecombustion airfor yourfurnacedoes notcon-
tainanyofthesecompounds.Duringremodelingbesurethe
combustion air is fresh and uncontaminated. If air with
vapors of these compounds is 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 areawhen installing thefurnace oraddingmore
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
inspectthefurnace andto replaceanypartofthecontrol sys-
tem, electrical components and any gas control which has
been under water.
NOTE: The qualified installer or agency must use only fac-
tory-authorized replacement parts, kits, and accessories
when servicing this product.
This furnace contains safety devices which must be manu-
ally reset. If the furnace is left unattended for an extended
periodoftime, 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-
ousduetogasandelectrical components.Only trainedand

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qualifiedpersonnelshouldinstall,repair,orserviceheating
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. Observesafetyprecautionsin this manual,ontags and
labelsattachedtothe furnace, andothersafety precautions
that may apply.
Recognize safety information. This is the safety-alert sym-
bol . When you see this symbol on the furnace and in
instructions ormanuals,be alertto the potentialforperson-
al injury.
Understand the signal words DANGER, WARNING, and
CAUTION.Thesewordsareusedwiththesafety-alertsym-
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.CAUTIONisusedtoidentifyunsafepracticeswhich
would result in minor personal injury or product and prop-
erty damage.
Starting your furnace
Insteadof a continuously burningpilot flame, your furnace
uses an automatic hot surface ignition system to light the
burners each time the thermostat turns your furnace on.
Follow these important safeguards:
•Neverattempttomanuallylighttheburnerswithamatch
or other source of flame.
•Readandfollowtheoperatinginstructionsonthefurnace,
especially the item that reads as follows:
Wait 5 minutes to clear out any gas. Then smell for gas,
includingnearthefloor.Ifyousmellgas,
STOP! Follow“B’’
in the above safety information 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 see
“Shutting Down your Furnace” section in this manual, then
call your dealer as soon as possible.
WARNING
Should overheating occur or the gas valves fail to
shut off the gas supply, turn off the manual gas
valve to the furnace BEFORE turning off the elec-
trical supply. (See Fig. 8.) A failure to follow this
warning could result in a fire or explosion, and
personal injury or death.
!
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!
•Check Air Filter: Before attempting to start your
furnace, be sure the furnace filter is clean and in place.
(See the maintenance section of this manual.) Then pro-
ceed as follows:
Steps for starting your furnace
1. Set your room thermostat to the lowest temperature
setting. (See Fig. 7.)
2. Close the external manual gas valve. (See Fig. 8.)
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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. Turnthe control knobon thegasvalvetotheOFFposi-
tion and wait 5 minutes. (See Fig. 12.)
6. After waiting 5 minutes, turn the control knob on the
gas valve to the ON position. (See Fig. 13.)
7. Replace the access door(s). See Fig. 14 for upflow and
Fig. 15 for downflow. Replace control door first on
downflow furnaces. Replace blower door and secure
with 2 screws.
8. Turn ON the electrical supply to the furnace. (See
Fig. 16.)

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9. Open the external manual gas valve. (See Fig. 17.)
10. Set the room thermostat to a temperature slightly
above the room temperature. This will automatically
signalthefurnacetostart.Theinducermotorwillstart,
andthehotsurfaceignitorwillenergize.Whenhot,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,thefurnace control
system will go through 3 more ignition cycles. If burners
still fail to ignite, the system will lockout. (Under some cir-
cumstancesthefurnacemayresetfromlockoutandattempt
toigniteifa call for heat still exists.) If lockout occurs or the
blowerdoesnotcomeon,refertotheshutdownprocedures
onthefurnaceorsee“ShuttingDownYourFurnace”section
in this manual, and 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
forthedifferencewithwarmerclothingcanmakeabig
difference in your fuel consumption. The few degrees
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 auto-
matically. When the room temperature reaches the setting
selected on the thermostat, the furnace will automatically
switch off.
Some thermostats have a “FAN’’ switch with 2 selections,
AUTO and ON. When thermostat is set on AUTO, the fur-
naceblowercyclesonandoff,controlledbythethermostat.
In ON position, the furnace blower runs continuously
except for a 77-sec delay at the “call for heat.’’ This keeps
the temperature level in your home more evenly balanced.
It also continuously filters the indoor air. When the FAN
switchismovedfromONtoAUTO, thefurnaceblowerwill
continue running for 90 sec before stopping.
Shutting down your furnace
Shouldyoueversuspectamalfunctionin yourfurnace,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. 18.)
2. Close the external manual gas valve. (See Fig. 8.)
3. Turn offelectricalpower toyourfurnace.(See Fig.19.)
18 19
4. Remove the control access door on your furnace. (See
Fig. 10 or 11.) On upflow furnaces, removing the blow-
er access door is not required.
5. Turnthe control knobon thegasvalvetotheOFFposi-
tion. (See Fig. 20.)
6. Replace the control access door. (See Fig. 14 or 15.)
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 oper-
ate economically and dependably. Basic maintenance,
which can easily be accomplished by someone who fol-
lows the directions, is found on this and the following
pages. However, before beginning maintenance, follow
these safety precautions:
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.
!

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Filtering out trouble
Adirtyfilterwillcauseexcessivestressonthefurnace,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 your furnace filter needs replacing, be sure to use the
samesizeandtypeoffilterthatwasoriginallysupplied.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
blowercompartment.Filtersforthedownflowfurnacesare
normallylocatedinthereturn-airplenumabovetheblower.
Ifthefiltershavebeeninstalledin anotherlocation, contact
your dealer for instructions. 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. 19.)
2. Removecontrolandbloweraccessdoors.(SeeFig.11.)
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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 inter-
nal parts of your furnace can cause a loss of
efficiency.
!
!
3. Push filter retainer toward the bracket opening to
release the filter. (See Fig. 21.)
4. Gently remove the filter and carefully turn the dirty
side up (if dirty) to avoid spilling dirt from the filter.
(See Fig. 22.)
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5. Inspect the filter. If torn, replace the filter.
6. Wash the filter (if dirty) in a sink, bathtub, or outside
with a garden hose. Always use cold tap water. A mild
liquid detergentmaybeusedifnecessary.Spraywater
through the filter in the opposite direction of airflow
through the cross-mesh binding (when present) side.
Allow filter to dry.
7. Reinstall the clean filter with the cross-mesh binding
(when present) side facing the furnace blower.
8. Put filter retainerbackin the bracketopeningandlock
it in place.
9. Replace blower and control access doors and turn on
electrical supply to the furnace. (See Fig. 23, 14, and
16.)
NOTE: Two filtersmaybe requiredinsome upflow models
if side return ducts are used. 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(aboveline-of-sight)restingintheV-shapedchannel
on top of the furnace. (See Fig. 24.)
1. Turn off electrical supply to the furnace. (See Fig. 19.)
2. Remove2screwsfrombloweraccessdoorandremove
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. 24 and 25.)
4. Lower filterdownalongsideoftheblowerandremove
from the furnace.
5. To remove the right-side filter, lift from V-shaped chan-
nel 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 detergentmaybeusedifnecessary.Spraywater
through the filter in opposite direction of airflow
through the cross-mesh binding (when present) side.
Allow filter to dry.
8. Reinstall the clean filters with the cross-mesh binding
(when present) side facing the furnace blower.

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9. Replace blower door and secure with 2 screws. Turn
on electrical supply to your furnace. (See Fig. 16.)
*Factory provided with the furnace. Filters may be field modified by cut-
ting and folding the frame as indicated on the filter. 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
meana loss of efficiencyandimproper performance. Build-
ups on the main burners can cause faulty 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
servicing dealer.
Useyourflashlightandfollowthesestepsforinspectingthe
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. 26). Inspect the relief box, flue connection
area, and the vent pipe for rust.
UPFLOW FURNACE FILTER TABLE (IN.)
FURNACE
CASING
WIDTH
FILTER SIZE FILTER
TYPESide ReturnBottom 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 (2) 16 x 25 x 1* (2) 12 x 25 x 1 Cleanable
DOWNFLOW/HORIZONTAL
FURNACE FILTER TABLE (IN.)
FURNACE
CASING
WIDTH FILTER SIZE FILTER TYPE
14-3/16 (2) 14 x 20 x 1* Cleanable
17-1/2 (2) 14 x 20 x 1* Cleanable
21 (2) 16 x 20 x 1* Cleanable
24-1/2 (2) 16 x 20 x 1* Cleanable
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NOTE: If dirt, rust, soot, or scale accumulations are found,
call your servicing dealer. DO NOT OPERATE THE FUR-
NACE.
3. Inspect the vent pipe for a sag, holes, or a disconnec-
tion.A horizontalventpipe mustslopeupward. Ifrusty
joints or seams, or signs of water leakages are found,
call your dealer for service.
4. Replace the access doors and restore electrical supply
to the furnace. Be sure bottom door flange is inside of
the furnace casing. (See Fig. 14 and 15.)
5. Startthefurnace andobserve itsoperation. Ifpossible,
watchtheburnerflames.Aretheyburningbrightblue?
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.
Ifyourfurnace isn’toperating atall, checkthefollowinglist
for easily solved problems:
•Is your thermostat set above room temperature? Is the
switch in the HEAT position?
•Is the electrical power supply switch on? Is the blower
accessdoorfirmlyinplace?Areanyfusesblown?(Thereisa
fuse on the furnace control.) Has a circuit breaker tripped?
•Isthe manual shut-off valve in thegassupply pipe leading
to the furnace open? Does the lever point in the same direc-
tion that the pipe runs (open)? Or is it at a right angle to the
pipe (closed)?
NOTE:Beforeproceedingwiththenextchecks,turnoffthe
electrical power supply to the furnace. Remove access
doors.
•Is the control knob 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 for safety reasons. If nothing else seems to be wrong,
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.
!

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under the
“Heating Equipment’’or “Air Conditioning Contractors & Systems’’ headings for dealer listing by brand name.
Have available the Model No., Series Letter & Serial No. of your equipment to insure correct replacement part.
Carrier Corporation Syracuse, New York 13221
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations .
Copyright 1994 Carrier Corporation Form: OM58-68 Replaces: OM58-63 Printed in the U.S.A. 6-94 PC 101 Catalog No. 565-894
follow the startup procedures found on pages 4 and 5 of
this booklet.
•Iffor somereason theventis blocked,thedraft safeguard
switchwillshutoff 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
auxiliary limit switch located on the blower housing. If the
blowermotorfails,thisswitchwillshutoffthefurnace.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 flame rollout switch(es) located
near the burners. If the furnace has experienced a high-
temperature condition due to inadequate combustion air,
theseswitcheswillshutoffthefurnace.Resettheswitch(es)
bypushing the button on the switch. Ifthe switchtrips a sec-
ond time, turn off the furnace and call for service.
•If your furnace still fails to operate, call your servicing
dealer 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 over the phone or save valuable time
through knowledgeable preparation for the service call.
• Your furnace control board has an LED fault code
light that indicates the furnace status. The LED will
flash short and long flashes. Look through the sight glass
on the furnace door and determine the code (number of
short and long flashes). Give the code and furnace model
number to your dealer when you call. By knowing exactly
whichfurnaceyouhaveandtheLEDcodebeingdisplayed,
yourdealer cansave valuabletimethrough knowledgeable
preparation for the service call.
Regular dealer maintenance
Inadditiontothetypeofroutinemaintenanceyoumightbe
willingtodo,yourfurnaceshouldbeinspectedregularlyby
a properly trained service technician. A semiannual inspec-
tion (or annual inspection, at least) should include the fol-
lowing:
1. Inspection of all flue product passages including the
burners, heat exchanger, relief box, and vent pipe.
2. Inspection of all combustion and ventilation air pas-
sages 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. Routineinspectionandcleaning/replacementoftheair
filter.
6. Inspection of all supply- and return-air ducts for
obstructions, air leaks, and insulation. Any problems
found should be resolved at this time.
7. Inspectthereturn-airductconnection(s)atthefurnace
to ensure it is physically sound, sealed to the furnace
casing, and terminates outside the space containing
the furnace.
8. Inspection of furnace installation for proper support
and any obvious deterioration of the furnace. The sup-
port must be sound and without sags, gaps, cracks,
etc.,aroundthefurnacebasesoastoprovideanairseal
between the support and furnace.
9. A check for loose connections attaching individual
components. Inspection of all electrical wiring and
their connections.
10. Operational check of the furnace itself to determine
working condition. Repair or adjustment should be
made at this time.
Ask your servicing dealer for further details about an eco-
nomical service contract that covers seasonal inspections.
INSTALLATION DATA
Date Installed
Dealer Name
Address
City
State Zip
Telephone
FURNACE
Product No.
Model No.
Serial No.
SPLIT-SYSTEM
Product No.
Model No.
Serial No.
INDOOR COIL:
Product No.
Model No.
Serial No.