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.
0
MODEL 58WAV
UPFLOW FURNACE
2
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
1
2
3
4
5
7
8
9

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
4
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.
5
• 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.
6
• 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.)
ff
ilu
-->
8
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).
4

12
2
13
14
/
15
16
OR
OR
/
17
_.....
I
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
F!'W
ON
i i J\
21
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.
22
©
OR
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.
23
_J
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.
26
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
8.
I
filter to dry.
Reinstall the clean filters.
0
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
21
24-1/2
UPFLOW FURNACE AIR FILTERTABLE
AIR FILTER LOCATED IN BLOWER COMPARTMENT
FILTER SIZE (IN)
Side Return
(1) 16x25xl*
(1) 16x25xl*
(1) 16x25xl
(lor2) 16x25x
Bottom Return
(1) 14x25xl
(1) 16x25xl*
(1)20x25xl*
(1)24x25xl*
FILTER
TYPE
Cleanable
Cleanable
Cleanable
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.
29
NOTE: If dirt, rust, soot, or scale accumulations are found, call
your selwicing dealer. DO NOT OPERATE THE FURNACE.
30
31
32

33
34
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.
35
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.
10

11

INSTALLATION DATA
Date Installed
Dealer Name
Address
City
State Zip
Telephone FURNACE
Product No.
Model No.
Serial No.
Product No.
Model No.
Serial No.
INDOOR COIL:
Product No.
Model No.
Serial No.
SPLIT-SYSTEM
Carrier
A United Technologies Company
TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the
"Heating Equipment" or "Air Conditioning Contractors & Systems" heading for dealer listing by brand name.
Have available the Model No., Series Letter, & Serial No. of your equipment to ensure correct replacement part.
Carrier Corporation 7310 West Morris St. Indianapolis, IN 46231
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Copyright 2000 Carrier Corporation Form: ©M58-g3 Replaces: OM58-74 Printed in the US.A. 10-00 PC 101 Catalog No. 535-778