Carrier INDUCED COMBUSTION FURNACES 58GFA Installation and user guide

58GFA
Induced Combustion Furnaces
Service and Maintenance Instructions
For Sizes 065-150 Series 130
NOTE: Read the entire instruction manual before starting the
installation.
These procedures are for sizes 65,000 through 150,000 Btuh units.
Index Page
SAFETY CONSIDERATIONS.....................................................1
CARE AND MAINTENANCE..................................................1-4
Air Filter Arrangement.............................................................2
Blower Motor and Wheel......................................................2-3
Cleaning Heat Exchanger......................................................3-4
Electrical Controls and Wiring.................................................4
Pilot ...........................................................................................4
Troubleshooting ........................................................................4
Unit Wiring Diagram ............................................................5-6
Troubleshooting Chart..............................................................7
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified person-
nel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code NFPA No. 54-
1992/ANSI Z223.1-1992 (NFGC). In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1-
and .2-M95 Natural Gas and Propane Gas Installation Codes
(NSCNGPIC). Wear safety glasses and work gloves. Have fire
extinguisher available during start-up and adjustment procedures
and service calls.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal word DANGER, WARNING, or CAU-
TION. These words are used with the safety-alert symbol. DAN-
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard that could
result in personal injury or death. CAUTION is used to identify
unsafe practices which would result in minor personal injury or
product and property damage. NOTE is used to highlight sugges-
tions that will result in enhanced installation, reliability, or
operation.
The ability to properly perform maintenance on this equip-
ment requires certain expertise, mechanical skills, tools and
equipment. If you do not possess these, do not attempt to
perform any maintenance on this equipment other than those
procedures recommended in the User’s Manual. FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS
PERSONAL INJURY, OR DEATH.
CARE AND MAINTENANCE
For continuing high performance and to minimize possible equip-
ment failure, it is essential that periodic maintenance be performed
on this equipment. Consult your local dealer as to the proper
frequency of maintenance and the availability of a maintenance
contract.
®ama
CANADIAN GAS ASSOCIATION
APPROVED
R
Fig. 1—Model 58GFA Upflow A92057
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 6a 8a PC 101 Catalog No. 535-821 Printed in U.S.A. Form 58GFA-1SM Pg 1 10-95 Replaces: 58D, G-3SM

Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace. A failure to
follow this warning could result in personal injury.
Never store anything on, near, or in contact with the furnace,
such as:
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
cleaners or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning com-
pounds, plastic or plastic containers, gasoline, kerosene,
cigarette lighter fluid, dry cleaning fluids or other volatile
fluids.
3. Paint thinners and other painting compounds, paper bags or
other paper products.
A failure to follow this warning could result in corrosion of
the heat exchanger, fire, personal injury, or death.
The minimum maintenance that should be performed on this
equipment is as follows:
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness and lubrication
each heating and cooling season. Clean and lubricate as
necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
As with any mechanical equipment, personal injury can result
from sharp metal edges, etc., therefore, be careful when
removing parts.
AIR FILTER ARRANGEMENT
The air filter arrangement may vary depending on the application.
Refer to Table 1 for filter size information.
Table 1—Filter Size Information (In.)
FURNACE
CASING WIDTH FILTER QUANTITY AND SIZE FILTER TYPE
Side 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 (2) 16 X 25 X 1* (1) 24 X 25 X 1 Cleanable
* Factory-provided with the furnace. Filters may be field modified by cutting as
required.
Never operate unit without a filter or with filter access door
removed. A failure to follow this warning could result in fire,
personal injury or death.
1. Each furnace requires 1 or 2 filters which are installed in the
blower compartment. (See Fig. 2.)
To remove filters for cleaning or replacement, proceed as
follows:
a. Disconnect electrical power before removing access doors.
b. Remove blower and control access doors.
c. Release filter retainer from clip at front of furnace casing.
(See Fig. 2.) For side return, clips may be used on either or
both sides of the furnace.
d. Slide filter out.
e. Furnaces are equipped with permanent, washable filters.
Clean filters with tap water. Spray water through filter in
opposite direction of airflow.
f. Rinse and let dry. Oiling or coating of filter is not
recommended or required.
g. Reinstall filter.
h. Replace access doors.
i. Restore electrical power to furnace.
BLOWER MOTOR AND WHEEL
For long life, economy, and high efficiency, clean accumulated dirt
and grease from the blower wheel and motor annually.
The following steps should be performed by a qualified service
technician:
Some motors have prelubricated sealed bearings and require no
lubrication. These motors can be identified by the absence of oil
ports on each end of the motor. For those motors with oil ports,
lubricate motor every 5 years if motor is used on intermittent
operation (thermostat FAN switch in AUTO position), or every 2
years if motor is in continuous operation (thermostat FAN switch
in ON position).
Remember to disconnect the electrical supply before removing
access doors.
Clean and lubricate as follows:
2. Remove control assembly.
3. Remove blower leads from blower assembly. Note location of
wires for reassembly.
4. Remove screws holding blower assembly to blower deck and
slide blower assembly out of furnace.
5. Loosen screw in strap holding motor capacitor to blower
housing and slide capacitor out from under strap.
Fig. 2—Model 58GFA Upflow A92178
DRAFT
SAFEGUARD
SWITCH
RELIEF
BOX
MOUNTING
SCREWS
FLUE
COLLECTOR
BOX
GAS
VALVE
PILOT
FILTER
RETAINER
WASHABLE
FILTER
CONTROL
BOX
2

6. Mark blower wheel, motor, and motor support in relation to
blower housing before disassembly to ensure proper reassem-
bly.
7. Loosen setscrew holding blower wheel on motor shaft.
8. Remove bolts holding motor mount to blower housing and
slide motor and mount out of housing. Disconnect ground wire
attached to blower housing before removing motor.
9. Lubricate motor (when oil ports are provided).
a. Remove dust caps or plugs from oil ports located at each
end of motor.
b. Use a good grade of SAE 20 nondetergent motor oil and
put 1 teaspoon, 5 cc, 3/16 oz, or 16 to 25 drops in each oil
port. Do not over-oil.
c. Allow time for total quantity of oil to be absorbed by each
bearing.
d. Wipe excess oil from motor housing.
e. Replace dust caps or plugs on oil ports.
10. Remove blower wheel from housing.
a. Mark cutoff location to ensure proper reassembly.
b. Remove screws holding cutoff plate and remove cutoff
plate from housing.
c. Lift blower wheel from housing through opening.
11. Clean blower wheel and motor using a vacuum cleaner with
soft brush attachment. Do not remove or disturb balance
weights (clips) on blower wheel blades. The blower wheel
should not be dropped or bent as balance will be affected.
12. Reinstall blower wheel by reversing steps 9 a. through c. Be
sure wheel is positioned for proper rotation.
13. Reassemble motor and blower by reversing steps 2 through 7.
If motor has ground wire, be sure it is connected as before.
Be sure the motor is properly positioned in the blower
housing. The motor oil ports must be at a minimum of 45°
above the horizontal centerline of the motor after the blower
assembly has been reinstalled in the furnace.
14. Reinstall blower assembly in furnace. Connect blower leads to
blower speed selector.
15. Reinstall control assembly.
16. Turn on electrical power and check for proper rotation and
speed changes between heating and cooling.
17. Replace blower access door.
CLEANING HEAT EXCHANGER
The following steps should be performed by a qualified service
technician:
NOTE: Deposits of soot and carbon indicate the existence of a
problem which needs to be corrected. Take action to correct the
problem.
If it becomes necessary to clean the heat exchanger because of
carbon deposits, soot, etc., proceed as follows:
1. Turn off gas and electrical power to furnace.
2. Remove 2 screws that secure relief box. (See Fig. 3.)
3. Disconnect wires to the following components:
a. Draft safeguard switch
b. Inducer motor
c. Pressure switch
d. Limit overtemperature switch
e. Gas valve
f. Edge connector leading to control box
4. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage sealant.
5. Remove complete inducer assembly from furnace, exposing
flue openings.
6. Clean cells using field-provided small wire brush, steel spring
cable, reversible electric drill, and vacuum cleaner.
a. Assemble wire brush and steel spring cable.
(1.) Use 48 in. of 1/4-in. diameter high-grade steel spring
cable (commonly known as drain clean-out or Roto-
Rooter cable).
(2.) Use 1/4-in. diameter wire brush (commonly known as
25-caliber rifle cleaning brush).
NOTE: The items needed in steps (1.) and (2.) can usually be
purchased at local hardware stores.
(3.) Insert twisted wire end of brush into end of steel spring
cable, and crimp tight with crimping tool or strike with
ball-peen hammer. TIGHTNESS is very important.
(4.) Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Clean each heat exchanger cell.
(1.) Attach variable-speed, reversible drill to end of steel
spring cable (end opposite brush).
(2.) Insert brush end of cable into upper opening of cell
and slowly rotate with drill. DO NOT force cable.
Gradually insert at least 36 in. of cable into 2 upper
passes of cell. (See Fig. 3.)
(3.) Work cable in and out of cell 3 or 4 times to obtain
sufficient cleaning. DO NOT pull cable with great
force. Reverse drill and gradually work cable out.
(4.) Remove burner assembly and cell inlet plates.
(5.) Replace screws in center panel and cells before
cleaning.
(6.) Insert brush end of cable in lower opening of cell, and
proceed to clean 2 lower passes of cell in same manner
as 2 upper passes.
(7.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
(8.) Remove residue from each cell using vacuum cleaner.
(9.) Clean burner assembly using vacuum cleaner with soft
brush attachment.
Fig. 3—Cleaning Heat Exchanger Cell A91252
3

(10.) Reinstall cell inlet plates and burner assembly. Care
must be exercised to center the burners in the cell
openings.
7. After cleaning flue openings, check sealant on flue collector to
ensure that it has not been damaged. If new sealant is needed,
contact your dealer or distributor.
8. Clean and replace flue collector assembly, making sure all 8
screws are secure.
9. Reinstall 2 screws in relief box.
10. Reconnect wires to the following components:
a. Draft safeguard switch
b. Inducer motor
c. Pressure switch
d. Limit overtemperature switch
e. Gas valve
f. Edge connector leading to control box
11. Replace blower access doors.
12. Turn on electrical power and gas.
13. Set thermostat and check furnace for proper operation.
Never use a match or other open flame to check for gas leaks.
Use a soap-and-water solution. A failure to follow this
warning could result in fire, personal injury or death.
14. Check for gas leaks.
15. Replace control access door.
ELECTRICAL CONTROLS AND WIRING
NOTE: There may be more than 1 electrical supply to unit.
The electrical ground for 115-v wiring must be maintained
properly. Refer to Fig. 5 for field wiring information and to Fig. 6
for unit wiring information.
With power disconnected to unit, check all electrical connections
for tightness. Tighten all screws on electrical connections. If any
smoky or burned connections are noticed, disassemble the connec-
tion, clean all parts and stripped wire, and reassemble properly and
securely. Electrical controls are difficult to check without proper
instrumentation; therefore, reconnect electrical power to unit and
observe unit through 1 complete operating cycle.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the main control board. Any direct shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3-amp fuse of identical size.
PILOT
Check the pilot and clean if necessary at the beginning of each
heating season. The pilot flame should be high enough for proper
impingement of the flame sensing element (or thermocouple) and
to light the burners. Remove the accumulation of soot and carbon
from the flame sensing element (or thermocouple). Refer to Fig. 4
for proper location of pilot on burner assembly.
TROUBLESHOOTING
Page 7 contains a troubleshooting chart. This chart can be a useful
tool in isolating furnace operation problems. Beginning with the
word "Start," answer each question and follow the appropriate
arrow to the next item.
The chart will help identify the problem or failed component. After
replacing any component, verify correct operating sequence as
indicated by bold arrows.
Fig. 4—Position of Pilot to Burner A91249
1/8″
PILOT HEAD V–NOTCH FALLS
DIRECTLY BELOW FRONT EDGE
OF BURNER CARRYOVER.
4

Fig. 5—Heating and Cooling Application Wiring Diagram A95241
115-VOLT FIELD-
SUPPLIED
FUSED
DISCONNECT
AUXILIARY
J-BOX
CONTROL
BOX
24-VOLT
TERMINAL
BLOCK
THREE-WIRE
HEATING-
ONLY
FIVE
WIRE
NOTE 1
NOTE 2 FIELD-SUPPLIED
FUSED DISCONNECT
CONDENSING
UNIT
TWO
WIRE
FURNACE
R
G
C
WCR GY
GND
GND
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
208/230- OR
460-VOLT
THREE
PHASE
208/230-
VOLT
SINGLE
PHASE
WHT
BLK
WHT
BLK
NOTES: Connect Y-terminal as shown for proper operation.
Some thermostats require a "C" terminal connection as shown.
If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
W
Y
GND
THERMOSTAT
TERMINALS
1.
2.
3.
5

Fig. 6—Unit Wiring Diagram A95464
LEGEND
ALS AUXILIARY LIMIT SWITCH, OVERTEMP.
-MANUAL RESET, SPST-(N.C.)
BLWM BLOWER MOTOR
CAP CAPACITOR
CFR COOLING FAN RELAY, SPDT
DSS DRAFT SAFEGUARD SWITCH, SPST-(N.C.),
MANUAL RESET
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC)
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FL FUSIBLE LINK
FU1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE
FU2 FUSE FIELD INSTALLED
GV GAS VALVE-REDUNDANT OPERATORS
HFR HEATING FAN RELAY, SPST (N.O.)
IDM INDUCED DRAFT MOTOR
IDR INDUCED DRAFT RELAY, SPST-(N.O.)
ILK BLOWER ACCESS PANEL INTERLOCK SWITCH,
SPST-(N.O.)
JB JUNCTION BOX
LS LIMIT SWITCH, AUTO RESET, SPST(N.C.)
OL AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.
PCB PRINTED CIRCUIT BOARD (FURNACE CONTROL)
PL1 9-CIRCUIT CONNECTOR (PCB1)
PR5 PRESSURE SWITCH, SPDT
TRAN TRANSFORMER (115V AC/24V AC)
JUNCTION
UNMARKED TERMINAL
PCB TERMINAL
FACTORY POWER WIRING (120 AC)
FACTORY CONTROL WIRING (120 AC)
FIELD POWER WIRING (120 AC)
CONDUCTOR ON PCB
FIELD WIRING SCREW TERMINAL
FIELD GROUND
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE
NOTES:
322876-101 REV. A
1. Internally connected to equipment ground through mounting screw.
2. If any of the original equipment wire is replaced, use wire rated for 105°C.
3. Blower motor (BLWM) & Inducer motor (IDM) contain auto-reset
thermal overload switch.
4. Use only copper wire between the disconnect switch and the furnace
junction box (JB).
5. Symbols are electrical representations only6.
6. Auxiliary limit switch (ALS) used on downflow models only.
7. The transformer 24VAC winding is protected by a 3 AMP automotive
blade type fuse on the control board. A 24VAC short to ground during
installation, checkout, operation, service or maintenance could cause
this fuse to open. Do not replace the 3 AMP fuse with any other size fuse.
8. Blower motor (BLWM) adjustable OFF-DELAY. Factory set: 120 seconds
cut resistor: 180 seconds.
9. When CFR relay is energized, HFR relay is also energized.
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
FU2
WHT
GRN GRN
JB
IDM
ILK
TH
GV PRS
FL
TR
PILOT
MGV BRN
DSS NO C
NC
YEL
LS
ALS
(WHEN USED)
NOTE #6
WHT
RED
RED
BLU BRN
ORN
BLK
RED
BLU
BLK
BLK
BLU
L1 PR1 PL1
WHT
BLK
TRAN
WHT RED
WHT
NOTE #4
BLK
WHT
BLK
PR2 L2 HFR
CFR
LO
HI
COM
NOTE #9
EAC-2
EAC-1
SPARE-1
SPARE-2 IDR
147
258
369
SEC-2
SEC-1
PCB
FU1
3AMP
FUSE GROUND
SCREW
REQUIRED
NOTE #1
NOTE #7
GWYRC
NOTE #8
OL
START
BRN
BRN
CAP
BLK (HI)
RED (LO)
WHT ( C OM)
YEL (MED HI)
BLU (MED LO)
GRN
RED
BLU
MGV
ILK L1 L2 TO 115V AC FIELD DISCONNECTIONS
NOTE #4
EQUIPMENT GROUND
L1
IDR PL1-3
PL1-1
L1
EAC-2
SPARE-1
HEAT
SPARE-2
COOL
COM
EAC-1
START
OL
COM
HI
MED HI
MED LO
LO
BLWM
CAP
CFR
HFR
NOTE #9
IDM
PR-2
SEC-2
FL ALS PL1-4 FU1 PR-1
(WHEN USED)
NOTE #6
3A SEC-1
FUSE
NOTE #7
LS
115V AC
TRAN
24V AC
HFR
LOGIC
TIME
DELAY
GV
TR
PL1-8
TH
DSS
PILOT
IDR
PL1-2
NOTE #9
C
PRS
NO
NC
PL1-6 IDR
Y
W
G
PL1-9
PL1-7
R
CFR
C
SCHEMATIC
DIAGRAM
BLWM
CONNECTION DIAGRAM
6

A91253
Is 24VAC
across pressure
switch N/O contact
& screw C on
board?
YES
NO
Is 24VAC
across pressure
switch N/O contact
& screw C on
board?
Is heat
exchanger
pressure drop greater
than 0.35-in.
wc?
Is
24VAC across gas
valve?
Is
unit lit?
Check/Replace:
1. Vent systems
2. Induce wheel
3. Flue choke
4. Inducer voltage
5. Inducer motor bearings
Check/Replace:
1. Limit switch
2. Limit shield (if used)
3. Fuse link
4. Auxillary limit switch (if used)
5. Wire harness
START
Disconnect all thermostat
wires from board.
Turn on 115-VAC
power to unit.
Is blower
running? Is 24VAC
across screws
R & C?
Is 24VAC
across screws
W & C or
G & C?
Are
all thermostat
wires to board
disconnected?
Turn off 115-VAC
power to unit.
Replace
board.
Is
115VAC
across L1 &
L2?
Is
24VAC
across screws
R & C?
Is
115VAC
across HI &
COM?
Is
blower running
on cooling
speed?
Jumper across
screws R & G.

Is
115VAC
across EAC-1
& COM?
Replace
board.
Remove
R & G jumper.
Replace
blower motor
and/or start
capacitor.
Check/Replace:
1. Unit power
2. Door switch
3. Power harness
Check/Replace:
1. 3-amp board
fuse
2. Transformer
Check pressure
tube for leak or
crimp; otherwise,
replace pressure switch
Does
blower turn
off?
Jumper across
screws R & W.
Is
24VAC
across PL1-2
& screw C on
board?
Replace
board.
Repair wire
harness.
Check/Replace:
1. Draft safeguard switch
2. Wire harness
Check/Replace:
1. Pilot
2. Thermocouple
3. Gas valve
Is
inducer motor
on?
Replace
inducer motor.
Is
115VAC across
inducer motor
connector?
Is
blower running
on heat speed 45
sec after unit
lights?
Is
115VAC across
inducer motor
connector?
Is
115VAC
across EAC-1
& COM?
Is
24VAC across
PL-2 & screw
C on board?
Check/Repair
wire harness;
otherwise,
replace
pressure
switch.
Replace
board. Remove R & M jumper. Repair wire harness.
Is
24VAC
across
PL-1 & screw
C on board?
Replace
blower motor
and/or start
capacitor.
Replace
board.
Check/Replace
thermostat
and/or
thermostat wiring.
After
off-delay
does blower
turn off? Reconnect all
thermostat wires. Does unit
operate?
END OF TEST.
YES YES
NO NO YES
NO
NO NO
YES NO NO
YES
YES
NO
NO
YES
YES
YES
NO
NO
NO
NO
YES
YES
YES
YES
YESNO
NO
NO
NO
NO
NO
YES
NO
NO
NO
YES
YES
YES
YES
YES
NO
YES
YES
YES
YES
NO
NOTE: After replacing any component, verify correct operating
sequence as indicated by bold arrows.
7

A94328
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
 • Unit Familiarization • Maintenance
 • Installation Overview • Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training [ ] Classroom Service Training
Copyright 1995 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 58gfa1sm
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 6a 8a PC 101 Catalog No. 535-821 Printed in U.S.A. Form 58GFA-1SM Pg 8 10-95 Replaces: 58D, G-3SM