Carrier UPFLOW INDUCED-COMBUSTION FURNACES 58PAV User manual

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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
booklettolearnabouttheoperationofyournewfurnace—
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.
1
MODEL 58PAV
UPFLOW FURNACE
2
MODEL 58RAV
DOWNFLOW/HORIZONTAL FURNACE

3
Upflow furnace components
Relief Box
Rating Plate
Gas Valve Control Knob (On/Off)
Gas Valve
Gas Burner
Flame Sensor
Air Filter Retainer
Air Filter
Blower and Blower Motor
Draft Safeguard Tube and Switch
Gas Manifold
Manual Reset Limit Switch
Hot Surface Ignitor
Blower Door Safety Switch
4
1
2
3
4
5
6
7
8
9
10
11
122
13
14
11
10
8
9
12
13
7
6
5
4
3
2
1
3
Downflow/horizontal furnace components
Manual-Reset Auxiliary Limit Switch
Blower and Blower Motor
Relief Box
Gas Valve Control Knob (On/Off)
Gas Valve
Gas Burner
Rating Plate
Blower Door Safety Switch
Draft Safeguard Tube and Switch
Gas Manifold
Manual Reset Limit Switch (2)
Hot Surface Ignitor
Flame Sensor
11
1
10
12
3
4
8
7
5
13
9
6
2
14
1
2
3
4
5
6
7
8
9
10
11
12
13

4
Important facts
Your furnace must have adequate airflow for efficient
combustion and safe ventilation. Do not enclose it in an
airtight room or “seal” it behind solid doors.
Tominimizethepossibilityofseriouspersonalinjury,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.
5
•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
chlorineorfluorine.Thesecompoundsarepresentinmany
products around the home, such as: water softener salts,
laundrybleaches, 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 uncontaminated. If
these compounds are burned in your furnace, the heat
exchangers and metal vent system may deteriorate.
• A furnace installed in an attic or other insulated space
mustbekeptfreeandclearofinsulatingmaterial.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 qualifiedinstaller or agency must use only fac-
tory-authorized replacement parts, kits, and accessories
when modifying this product.
This furnace contains safety devices which must be man-
uallyreset.Ifthefurnaceisleftunattendedforanextended
period of time, have it checked periodically for proper
operation. This precaution will prevent problems associ-
ated 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-
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 on labels attached to the furnace and other safety pre-
cautions 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 per-
sonal injury.
Understand the signal word—DANGER, WARNING, or
CAUTION. These words 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 that could result in personal
injury or death. CAUTION is used to identify unsafe prac-
tices which would result in minor personal injury or prod-
uct and property damage.
Starting your furnace
Insteadofacontinuouslyburningpilotflame,yourfurnace
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.
6
• Read and follow the operating instructions on the fur-
nace, especially the item that reads as follows:
Wait 5 minutes to clear out any gas. Then smell for gas,
including near the floor. If you 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.
WARNING
Should overheating occur, or the gas valve 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.
!
!

5
• Check Air Filter: Before attempting to start your fur-
nace, be sure the furnace filter is clean and in place. (See
the maintenance section of this manual.) Then proceed 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.)
7
8 9
3.TurnOFFtheelectricalsupplytothefurnace.(SeeFig.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. Turn the control knob on the gas valve to the OFF
position 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. Then replace blower door (secure
with 2 screws).
8.TurnONtheelectrical supplytothefurnace. (SeeFig.16.)
9. Open the external manual gas valve. (See Fig. 17.)
SYSTEM
COOL OFF HEAT FAN AUTO ON
50
70
90
50
70
90
C
L
O
S
E
12 13
14 15
16 17
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 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, the furnace con-
trol system will go through 3 more ignition cycles. Then,
if burners fail to ignite, the system will lockout. If lockout
occurs, or the blower doesn’t come on—shut down your
furnace 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 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 “comfort level”
are the most costly degrees to obtain.
When the room temperature drops below the temperature
selected on the thermostat, the furnace will be
FF
O
ON
O
P
E
N

6
switched on automatically. When the room temperature
reaches the degree selected on the thermostat, the furnace
will be automatically switched off.
Some thermostats have a “fan” switch with 2 selections:
AUTO or ON. When set on AUTO, the furnace blower
cycles on and off, controlled by the thermostat. In the ON
position, the furnace blower runs continuously except for
a 45-sec delay at the “call for heat.” This keeps the tem-
perature level in your home more evenly balanced. It also
continuously 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 pro-
cedures 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 on
page 5.)
3. Turn OFF the electrical power to your furnace. (See
Fig. 19.)
18 19
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 on the gas valve to the OFF
position. (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 mal-
function, call your dealer as soon as possible.
Performing routine maintenance
With the proper maintenance and care, your furnace will
operate economically and dependably. Basic mainte-
nance,whichcaneasilybeaccomplishedbysomeonewho
follows the directions, is found on this and the following
pages. However, before beginning maintenance, follow
these safety precautions:
20
SYSTEM
COOL OFF HEAT FAN AUTO ON
50
70
90
50
70
90
FF
O
Filtering out trouble
A dirty filter will cause excessive stress on the furnace
blower motor and can cause it to overheat and automati-
cally 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
same size and type of filter that was originally supplied.
Use the Furnace Filter Table and compare your furnace
size with the proper filter size.
Theairfilterforupflow furnaces is normally located in the
blower compartment. Filters for the downflow furnaces
are normally located in the return air plenum above the
blower. If the filters have been installed in another loca-
tion,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. Remove control and blower access doors.
21 22
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
sideup(if dirty) toavoid“spilling”dirtfrom the filter.
(See Fig. 22.)
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.
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 effi-
ciency.
!
!
!

7
23
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.Amild
liquiddetergentmaybeusedifnecessary.Spraywater
through the filter in the opposite direction of airflow
(through the cross-mesh binding side).Allow filter to
dry.
7. Reinstall the clean filter with the cross-mesh binding
side facing the furnace blower.
8.Put filter retainer back inthe bracket opening and lock
it in place.
9. Replace blower and control access doors and turn ON
electrical power to your furnace. (See Fig. 14, 16, and
23.)
NOTE:
For upflow models only—if side return ducts are
used, 2 filters may be required in some models. The pro-
cedure 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 (above line-of-sight) resting in the V-shaped chan-
nel on top of the furnace. (See Fig. 24.)
1. Turn OFF electrical supply to the furnace. (See Fig.
19.)
2.Removebloweraccessdoorsafterremoving2screws.
3. Remove the left side filter by tipping the filter toward
the center—raise it from the V-shaped channel in
which it rests. (See Fig. 24 and 25.)
24 25
4. Lower filter down along side of the blower and
remove from the furnace.
5. To remove the second filter, lift from V-shaped chan-
nel and remove 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
witha garden hose.Alwaysuse cold tap water.Amild
liquiddetergentmaybeusedifnecessary.Spraywater
through the filter in the opposite direction of airflow
through the cross-mesh binding side. Allow filter to
dry.
8. Reinstall the clean filters with the cross-mesh binding
side facing the furnace blower.
9. Replace blower door (secure with 2 screws) and turn
ON electrical power to your furnace.
UPFLOW FURNACE FILTER TABLE
DOWNFLOW/HORIZONTAL
FURNACE FILTER TABLE
*Factoryprovidedwiththe furnace.Filters maybe fieldmodifiedbycutting
to size. 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
mean a loss of efficiency and improper performance.
Buildups 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—call your ser-
vicing dealer.
Use your flashlight and follow these steps for inspecting
the combustion area and vent system of your furnace:
1. Turn off the electrical supply to the furnace and
remove the access doors. (See Fig. 9 and 10, or 11.)
2. Carefully inspect the gas burner (see Fig. 26) for dirt,
rust, or scale. Then, inspect the relief box, flue con-
nection area, and the vent pipe for rust.
NOTE:Ifdirt, rust, soot, or scale accumulationsare found,
call your servicing dealer. DO NOT OPERATE THE
FURNACE.
3. Inspect the vent pipe for a sag, holes, or a disconnec-
tion. A horizontal vent pipe must slope upward. If
rusty joints or seams, or signs of water leakages are
found call your dealer for service.
FURNACE
CASING
WIDTH
FILTER SIZE 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 (2) 16 x 25 x 1* (1) 24 x 25 x 1*Cleanable
FURNACE
CASING WIDTH FILTER SIZE FILTER 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

8
26
4. Replace the access doors and restore electrical power
to the furnace. Be sure bottom door flange is inside of
the furnace casing. (See Fig. 14, 15, and 23.)
5.Startthefurnaceandobserveitsoperation.Ifpossible,
watch the burner flames. Are they burning bright
blue? If not (or if you suspect some other malfunc-
tion), 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, 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
switch in the HEAT position?
•Is the electrical power supply switch ON? Is the blower
access door firmly in place?Are any fuses blown? (There
is a fuse on the furnace control board.) Has a circuit break-
er tripped?
•Is the manual shut-off valve in the gas supply pipe lead-
ing to the furnace open? Does the lever point in the same
direction that the pipe runs (open)? Or is it at right angles
(closed)?
NOTE:
Before proceeding with the next checks, turn OFF
the electrical power supply to the furnace. Remove the
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,
follow the startup procedures found on pages 4 and 5 of
this booklet.
• If for some reason the vent is blocked, the draft safe-
guard switch will shut off the furnace. Reset the switch by
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.
!
pushing the button located on top of the switch (see page
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
auxiliarylimitswitchlocatedontheblowerhousing.Ifthe
blower motor fails, 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.
•Checkthemanual-resetlimitswitch(es)locatednearthe
burners.Ifthefurnacehasexperiencedahigh-temperature
condition, due to inadequate combustion air, these switch-
es will shut off the furnace. Reset the switch(es) by push-
ing the button on the switch. If the switch trips a second
time, turn off the furnace and call for service.
• If your furnace still fails to operate, call your servicing
dealerfortroubleshootingandrepairs.Tellyourdealerthe
model and serial numbers for your furnace. (You should
have them recorded on page 9 of this booklet.) By know-
ingexactlywhichfurnaceyouhave,thedealermaybeable
to offer suggestions over the phone, or save valuable time
through knowledgeable preparation for the service call.
Regular dealer maintenance
In addition to the type of routine maintenance you might
be willing to do, your furnace should be inspected regu-
larly by a properly trained service technician. An annual
inspection (or semiannual inspection, at least) should
include the following:
1.Inspectionofallflue 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. Routine inspection and cleaning/replacement of the
air 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. Inspection of furnace installation for proper support
andany obvious deterioration ofthe furnace.Thesup-
port must be sound and without sags, gaps, cracks,
etc., around the furnace base so as to provide an air
seal between the support and furnace.
8. A check for loose connections attaching individual
components. Inspection of all electrical wiring and
their connections.
9. 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.

9
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.

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 1992 Carrier Corporation Form: OM58-60 Replaces: OM58-52 Printed in the U.S.A. 494 8-92 PC 101 Catalog No. 535-892