Carrier INDUCED COMBUSTION 58YAV Instruction Manual

WARNING:If the information in this manual
is not followed exactly, a fire or explosion may
result causing property damge, personal in-
jury 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 eletrical 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 perform-
ed by a qualified installer, service
agency or the gas supplier.
®
HEATING & COOLING

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Welcome to today’s generation
of comfort
Congratulations!Your new, higher efficiency gas furnace
is a sound investment 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
booklettolearnabouttheoperationofyournew furnace—
and the small amount of maintenance it takes to keep it
operating at peak efficiency.Years went into the develop-
ment of your new furnace. Take a little time now to assure
its most efficient operation for years to come.
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MODEL 58YAV
UPFLOW FURNACE
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Upflow furnace components
Inducer
Rating Plate (Model and Serial No.)
Gas Valve Control Knob or Electric Switch (On/Off)
Gas Valve
Gas Burner
Flame Sensor
Air Filter Retainer
Air Filter
Blower and Blower Motor
Draft Safeguard Tube and Switch
Gas Manifold
Replaceable Fuse Link
Hot Surface Ignitor
Blower Door Safety Switch
Masonry Chimney Adapter (When Used)
(Blocked Vent Shutoff Switch Inside)
Vent Pipe
Furnace Control
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IMPORTANT FACTS
Your furnace must have adequate surrounding airflow for
efficient combustion 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 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 sure the combustion air for your furnace does not con-
tain any of these compounds. The combustion air during
remodeling must be fresh and uncontaminated. If these com-
pounds are 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 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. Immediately 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 or replaced. 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
“BeforeYou Request a Service Call’’ section in this manual.
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazard-
ous due to gas and electrical components. Only trained and
qualified personnel should install, repair, or service heating
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. Observe safety precautions in this manual, on tags, and
onlabelsattachedtothefurnace,andothersafetyprecautions
that may apply.
Recognize safety information. This is the safety-alert sym-
bol . 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, and
CAUTION. These words are used with the safety-alert sym-
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. CAUTION is used to identify unsafe practices which
would result in minor personal injury or product and prop-
erty damage.
STARTING YOUR FURNACE
Instead of a continuously burning pilot flame, 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.
•Read and follow the operating instructions on the furnace,
especially the item that reads as follows:
Wait 5 minutes to clear out any gas. Then smell for gas,
includingnear thefloor. Ifyou smell gas,
STOP! Follow“B’’
in the safety information 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 shutdown procedures on the furnace, or in the
next section, to turn off your system, then call your dealer as
soon as possible.
•
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 manual.) Then proceed as follows:
WARNING
Should overheating occur, or the gas valves fail to
shut off the gas supply, turn off the manual gas
valve (See Fig. 6.) 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.
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STEPS FOR STARTING YOUR
FURNACE
1. Set your room thermostat to the lowest temperature set-
ting. (See Fig. 5.)
2. Close the external manual gas valve. (See Fig. 6.)
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3. Turn OFF electrical supply to the furnace. (See Fig. 7.)
4. Remove control access door. (See Fig. 8.)
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5. The gas valve will have EITHER a control knob or con-
trol switch to turn off and on. Turn the control knob or
switch on the gas valve to the OFF position and wait
5 minutes. (See Fig. 9 or 10.)
6. After waiting 5 minutes, turn the control knob or switch
on the gas valve to the ON position. (See Fig. 11 or 12.)
7. Replace control access door. (See Fig. 13.)
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OFF
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8. Turn ON the electrical supply to the furnace. (See
Fig. 14.)
9. Open the external manual gas valve. (See Fig. 15.)
10. Set the room thermostat to a temperature slightly
above the room temperature. This will automatically
signal the furnace to start. The inducer motor will start,
and the hot surface ignitor will energize. When hot, the
ignitor will have an orange glow.
11. After 32 to 70 sec, the gas valve permits gas toflow to
the main burners where it is ignited. Hotflames 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, the furnace control
system will go through 3 more ignition cycles.Then, if burn-
ers fail to ignite, the system will lockout. If lockout occurs,
ortheblowerdoes notcomeon—shutdownyourfurnaceand
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
for the difference with warmer clothing—can make a big
difference in your fuel consumption on extremely cold
days. The few degrees at the top of your thermostat“com-
fort 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 degree
selected on the thermostat, the furnace will be switched off
automatically.
Some thermostats have a “FAN’’ switch with 2 selections:
AUTO and ON. When set onAUTO, the furnace blower
cycles on and off, controlled by the thermostat. In the ON
position, the furnace blower runs continuously except for a
45-secdelayat the “call forheat.’’Thiskeepsthetemperature
level in your home more evenly balanced. It also continuous-
ly filters the indoor air.
SHUTTING DOWN YOUR FURNACE
Should you ever suspect a malfunction in your furnace, 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.)
2. Close the external manual gas valve (See Fig. 6 on
page 4.)
3. Turn OFF electrical power to your furnace. (See Fig. 7.)
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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 to the
OFF position. (See Fig. 22 or 23.)
6. Replace the control access door. (See Fig. 16 or 17.)
7. If the furnace is being shut down because of a malfunc-
tion, call your dealer as soon as possible.
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PERFORMING ROUTINE
MAINTENANCE
With proper maintenance and care, your furnace will operate
economically and dependably. Basic maintenance, which can
easilybe accomplished by someone who followsthe directions,
isfoundon this andthefollowingpages.However,beforebegin-
ning 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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ON
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ON
OFF
OR
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FILTERING OUT TROUBLE
A dirty filter will cause excessive stress on the furnace 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 installed with factory 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.
The air filter is normally located in the blower compartment.
(See Fig. 2) or in the factory-supplier filter cabinet attached
to the side or bottom of the blower cabinet. 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 the electrical supply to the furnace. (See
Fig. 17.)
2. Remove door/access panel
•AIR FILTER(S) LOCATED IN BLOWER COM-
PARTMENT
Remove control and blower access doors. (See Fig. 8)
•AIR FILTER LOCATED IN FILTER CABINET
Remove filter cabinet door (See Fig. 24 and 25)
NOTE: It will be necessary to remove 1 thumbscrew.
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3. Remove air filter from furnace.
•AIR FILTER LOCATED IN BLOWER COMPART-
MENT:
a. Slide filter retainer sideways until it is free of latch.
(See Fig. 20)
b. Gently remove air filter and carefully turn the dirty
side up (if dirty) to avoid spilling dirt from thefilter
(see Fig. 21)
•AIR FILTER LOCATED IN FILTER CABINET:
a. Slide air filter out of furnace. Keep dirty side up (if
dirty) to avoid spilling dirt. (See Fig. 26 and 27)
4. Inspect the filter. If torn, replace it.
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NOTE: If washable filter that was shipped with the furnace
has been replaced by:
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 information.
5. Washfilter (if dirty) in sink, bathtub, or outside with a gar-
den hose. Always use cold tap water. A mild liquid deter-
gent may be used if necessary. Spray water throughfilter
in the opposite direction of airflow. Allow filter to dry.
6. Reinstall clean air filter
7. Reinstallfilterretainer(forblowercompartmentlocations
only)
8. Replace control and blower doors (See Fig. 13 and 22) or
filter cabinet door (Fig. 28 and 29)
9. Turn on electrical supply to furnace (see Fig 18).
NOTE:
For upflowmodelsonly—ifside return ducts are used,
2 filters may be required in some models.The procedure listed
above may be used to remove sidefilters.
* Factory 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.
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 internal parts
of your furnace can cause a loss of efficiency.
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UPFLOW FURNACE AIR FILTERTABLE
AIR FILTER LOCATED IN BLOWER COMPARTMENT
FURNACE
CASING
WIDTH (IN.)
FILTER SIZE (IN) FILTER
TYPESide Return Bottom 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 (1 or 2) 16 x 25 x 1 (1) 24 x 25 x 1* Cleanable
AIR FILTER LOCATED IN FILTER CABINET
FILTER
CABINET
HEIGHT (IN) FILTER SIZE (IN) FILTER TYPE
16 (1) 16 x 25 x 1* or (1)
16 x 25 x 4-5/16 Cleanable Disposable
20 (1) 20 x 25 x 1*
or (1) 20 x 25 x 4-5/16 Cleanable Disposable
24 (1) 24 x 25 x 1*
or (1) 24 x 25 x 4-5/16 Cleanable Disposable

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COMBUSTION AREA AND
VENT SYSTEM
Inspect the combustion area and vent system before each
heating season. An accumulation of dirt, soot, or rust can
mean a loss of efficiency and improper performance. Build-
upsonthemainburnerscancausefaultyfiring.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.
Use your flashlight and follow these steps for inspecting the
combustion area and vent system of your furnace:
1. Turn off the gas and electrical supplies to the furnace and
remove the access doors. (See Fig. 7 and 8.)
2. Carefullyinspect the gas burner(see Fig. 23) for dirt, rust,
or scale. Then inspect the inducer, vent connection area,
and the vent pipe for rust.
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NOTE:
Ifdirt, rust,soot,or scaleaccumulationsare found,call
your servicing dealer. DO NOT OPERATE THE FURNACE.
3. Inspect the vent pipe for a sag, holes, or a disconnection.
A horizontal vent pipe must slope upward away from the
furnace. If rusty joints or seams, or signs of water leakag-
es are found, call your dealer for service.
4. Replace the access doors and restore gas and electrical
supplies to the furnace. Be sure bottom doorflange is
inside of the furnace casing. (See Fig. 13, 14, 15 and 22.)
5. Start the furnace and observe its operation. If possible,
watch the burner flames.Are they burning bright blue?
If not (or if you suspect some other malfunction), call
your servicing dealer.
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CAUTION
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.
WARNING
If holes caused by deterioration are found—or
holes in the vent pipe—or if the vent pipe is ob-
structed or is not connected—toxic fumes can es-
cape 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.
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BEFORE YOU REQUEST A
“SERVICE CALL’’
Before you call for service,check for several
easily solved problems:
•Check for sufficient airflow surrounding the furnace.
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, call your servicing dealer.
If your furnace isn’t operating at all, check the following list
for easily solved problems:
•Is your thermostat set above room temperature? Is the
HEAT mode selected?
•Is the electrical power supply switch on? Is the blower
access door firmly in place? Are any fuses blown? (There is a
3-amp automotive type fuse on the furnace control board.) Has
a circuit breaker tripped?
•Is the manual shut-off valve 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 furnace. Remove access doors.
•Is the control 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, make sure the gas has not been shut off
for safety reasons. If nothing else seems to be wrong, follow
the startup procedures found on pages 3, 4, and 5 of this user’s
manual.
•If for some reason the vent is blocked, the draft safeguard
switch or blocked vent shutoff switch (when used) will shut off
the furnace. Reset the switch by pushing the button located on
top of the switch. (See page 2 for switch location.)
If the switch trips a second time, turn off the furnace and call
for service.
Regular dealer maintenance
In addition to the type of routine maintenance you might be
willing to do, your furnace should be inspected regularly by a
properly trained service technician.An annual inspection (or
biennial inspection, at least) should include the following:
1. Inspectionof all combustionproduct passages—including
the burners, heat exchanger, inducer, and vent pipe.
2. Inspection of all combustion air and ventilation air
passages and openings.
3. Close check of all gas pipes leading to (and inside of) your
furnace for leaks.
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 should be oiled
by a qualified service technician. (Wrong oil type or excessive
oil is detrimental to the motor.)
5. Routine inspection and cleaning/replacement of the airfilter.
6. Inspection of all supply- and return-air ducts for obstruc-
tions, air leaks, and insulation.Any problems found should
be resolved at this time.
7. Inspectionoffurnace installationfor propersupportand 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 furnace.
8. A check for loose connections attaching individual compo-
nents.Inspectionof all electricalwiringand theirconnections.
9. Operationalcheckofthefurnaceitselftodetermineworking
condition. Repair or adjustment should be made at this time.
Ask your servicing dealer for further details about an econom-
ical service contract that covers seasonal inspections.

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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: OM58-92 Replaces: OM58-80 Printed in the U.S.A. a11-00 PC 101 Catalog No. 535-780
INSTALLATION DATA
Date Installed
Dealer Name
Address
City
State Zip
Telephone
FURNACE
Product No.
Model No.
Serial No.
SPLIT-SYSTEM
INDOOR COIL:
Product No.
Model No.
Serial No.
INDOOR COIL:
Product No.
Model No.
Serial No.
ACCESSORIES:
Product No.
Model No.
Serial No.
Product No.
Model No.
Serial No.
Product No.
Model No.
Serial No.
Product No.
Model No.
Serial No.