Carrier INDUCED COMBUSTION FURNACES 58GFA Instruction manual

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 personnel 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. 541992/ANSI Z223.1-1992 (NFGC). In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1and .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 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 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 suggestions that will result in enhanced installation, reliability, or
operation.
®
ama
CANADIAN GAS ASSOCIATION
A PP R O VED
R
A92057
Fig. 1—Model 58GFA Upflow
The ability to properly perform maintenance on this equipment 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 equipment 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.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-821
Printed in U.S.A.
Form 58GFA-1SM
Pg 1
10-95
Replaces: 58D, G-3SM
Tab 6a 8a
MOUNTING
SCREWS
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.
DRAFT
SAFEGUARD
SWITCH
RELIEF
BOX
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 compounds, 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.
GAS
VALVE
PILOT
CONTROL
BOX
FILTER
RETAINER
The minimum maintenance that should be performed on this
equipment is as follows:
WASHABLE
FILTER
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.
A92178
Fig. 2—Model 58GFA Upflow
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
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.
As with any mechanical equipment, personal injury can result
from sharp metal edges, etc., therefore, be careful when
removing parts.
f. Rinse and let dry. Oiling or coating of filter is not
recommended or required.
AIR FILTER ARRANGEMENT
g. Reinstall filter.
The air filter arrangement may vary depending on the application.
Refer to Table 1 for filter size information.
h. Replace access doors.
i. Restore electrical power to furnace.
Table 1—Filter Size Information (In.)
FURNACE
CASING WIDTH
14-3/16
17-1/2
21
24-1/2
FILTER QUANTITY AND SIZE
Side Return
Bottom Return
(1) 16 X 25 X 1* (1) 14 X 25 X 1
(1) 16 X 25 X 1* (1) 16 X 25 X 1
(1) 16 X 25 X 1 (1) 20 X 25 X 1*
(2) 16 X 25 X 1* (1) 24 X 25 X 1
FLUE
COLLECTOR
BOX
BLOWER MOTOR AND WHEEL
FILTER
TYPE
For long life, economy, and high efficiency, clean accumulated dirt
and grease from the blower wheel and motor annually.
Cleanable
Cleanable
Cleanable
Cleanable
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).
* 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.
Remember to disconnect the electrical supply before removing
access doors.
1. Each furnace requires 1 or 2 filters which are installed in the
blower compartment. (See Fig. 2.)
Clean and lubricate as follows:
To remove filters for cleaning or replacement, proceed as
follows:
a. Disconnect electrical power before removing access doors.
2. Remove control assembly.
b. Remove blower and control access doors.
4. Remove screws holding blower assembly to blower deck and
slide blower assembly out of furnace.
3. Remove blower leads from blower assembly. Note location of
wires for reassembly.
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.
5. Loosen screw in strap holding motor capacitor to blower
housing and slide capacitor out from under strap.
2
6. Mark blower wheel, motor, and motor support in relation to
blower housing before disassembly to ensure proper reassembly.
e. Gas valve
f. Edge connector leading to control box
7. Loosen setscrew holding blower wheel on motor shaft.
4. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage sealant.
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.
5. Remove complete inducer assembly from furnace, exposing
flue openings.
9. Lubricate motor (when oil ports are provided).
6. Clean cells using field-provided small wire brush, steel spring
cable, reversible electric drill, and vacuum cleaner.
a. Remove dust caps or plugs from oil ports located at each
end of motor.
a. Assemble wire brush and steel spring cable.
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.
(1.) Use 48 in. of 1/4-in. diameter high-grade steel spring
cable (commonly known as drain clean-out or RotoRooter cable).
c. Allow time for total quantity of oil to be absorbed by each
bearing.
(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.
d. Wipe excess oil from motor housing.
e. Replace dust caps or plugs on oil ports.
(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.
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.
(4.) Remove metal screw fitting from wire brush to allow
insertion into cable.
c. Lift blower wheel from housing through opening.
b. Clean each heat exchanger cell.
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.
(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.)
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.
A91252
17. Replace blower access door.
Fig. 3—Cleaning Heat Exchanger Cell
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.
(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.
If it becomes necessary to clean the heat exchanger because of
carbon deposits, soot, etc., proceed as follows:
(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.
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
(7.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
b. Inducer motor
(8.) Remove residue from each cell using vacuum cleaner.
c. Pressure switch
(9.) Clean burner assembly using vacuum cleaner with soft
brush attachment.
d. Limit overtemperature switch
3
(10.) Reinstall cell inlet plates and burner assembly. Care
must be exercised to center the burners in the cell
openings.
PILOT HEAD V–NOTCH FALLS
DIRECTLY BELOW FRONT EDGE
OF BURNER CARRYOVER.
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.
1/8″
9. Reinstall 2 screws in relief box.
10. Reconnect wires to the following components:
a. Draft safeguard switch
b. Inducer motor
c. Pressure switch
A91249
d. Limit overtemperature switch
Fig. 4—Position of Pilot to Burner
e. Gas valve
securely. Electrical controls are difficult to check without proper
instrumentation; therefore, reconnect electrical power to unit and
observe unit through 1 complete operating cycle.
f. Edge connector leading to control box
11. Replace blower access doors.
12. Turn on electrical power and gas.
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.
13. Set thermostat and check furnace for proper operation.
PILOT
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.
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.
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.
TROUBLESHOOTING
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.
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.
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 connection, clean all parts and stripped wire, and reassemble properly and
The chart will help identify the problem or failed component. After
replacing any component, verify correct operating sequence as
indicated by bold arrows.
4
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
NOTE 2
W
FIVE
WIRE
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATINGONLY
BLK
BLK
W
WHT
WHT
R
GND
GND
115-VOLT FIELD- AUXILIARY
J-BOX
SUPPLIED
CONTROL
FUSED
BOX
DISCONNECT
208/230- OR
460-VOLT
THREE
PHASE
G
C
GND
NOTE 1
CONDENSING
UNIT
Y
24-VOLT
TERMINAL
BLOCK
FURNACE
208/230VOLT
SINGLE
PHASE
TWO
WIRE
NOTES: 1. Connect Y-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced, use
same type or equivalent wire.
A95241
Fig. 5—Heating and Cooling Application Wiring Diagram
5
GV
CONNECTION DIAGRAM
DSS
MGV
TH
TR
PRS
L1
NO
BRN
L2
TO 115V AC FIELD DISCONNECTIONS
ILK
C
SCHEMATIC
DIAGRAM
NOTE #4
NC
EQUIPMENT GROUND
PILOT
L1
LS
FL
ALS
SPARE-1
NOTE #9
IDM
(WHEN USED)
NOTE #6
PL1-3
RED
BLU
WHT
115V AC
LS
FL
ALS
GRN
CAP
BRN
PR2 L2
START
YEL
WHT
RED
RED
BLU
BRN
ORN
BLK
BLU
RED
BLK
PL1 1 4 7
2 5 8
3 6 9
L1 PR1
CFR
HFR
EAC-1
SEC-2
HFR
R
LOGIC
PL1-9
TIME
DELAY
MGV
DSS
BLK (HI)
GV
SPARE-1
YEL (MED HI)
SPARE-2
Y
IDR
NOTE #9
RED
BLU
NO
NC
SEC-2
SEC-1
RED (LO)
W
Y
R
C
G
PCB
3AMP
FUSE
NOTE #7
NOTE #8
PILOT
PL1-2
PL1-6
IDR
GROUND
SCREW
REQUIRED
W
IDR
CFR
NOTE #1
G
LEGEND
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)
C
PL1-8
TR
TH
PRS
FU1
ALS
PR-2
HI
BLU (MED LO)
BRN
(WHEN USED)
NOTE #6
TRAN
24V AC
3A
FUSE SEC-1
NOTE #7
LO
WHT (COM)
OL
PL1-7
COM
JB
EAC-2
BLWM
BLK
WHT
WHT
FU1 PR-1
PL1-4
BLK
GRN
IDM
PL1-1
TRAN
NOTE #4
ILK
GRN
BLWM
EAC-1
EAC-2
IDR
BLK
WHT
CAP
COM
COM
BLK
FU2
START
OL
COOL
WHT
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
L1
LO
MED LO
MED HI
HI
SPARE-2
HEAT
CFR
HFR
NOTE #9
C
JUNCTION
UNMARKED TERMINAL
NOTES:
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
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.
322876-101 REV. A
A95464
Fig. 6—Unit Wiring Diagram
6
START
Turn on 115-VAC
power to unit.
Disconnect all thermostat
wires from board.
Turn off 115-VAC
power to unit.
NO
Is blower
running?
Is 24VAC
across screws
R & C?
YES
NO
NO
Is
115VAC
across HI &
COM?
NO
YES
Replace
board.
NO
YES
NO
YES
Replace
board.
YES
NO
YES
Is
115VAC
across L1 &
L2?
NO
YES
Is heat
exchanger
pressure drop greater
than 0.35-in.
wc?
Does
blower turn
off?
YES
NO
YES
Check/Replace:
1. 3-amp board
fuse
2. Transformer
Is
24VAC
across PL1-2
& screw C on
board?
NO
Replace
board.
YES
Is 24VAC
across pressure
switch N/O contact
& screw C on
board?
Repair wire
harness.
NO
Check/Replace:
1. Vent systems
2. Induce wheel
3. Flue choke
4. Inducer voltage
5. Inducer motor bearings
Jumper across
screws R & W.
NO
Check/Replace:
1. Unit power
2. Door switch
3. Power harness
Check pressure
tube for leak or
crimp; otherwise,
replace pressure switch
Remove
R & G jumper.
Is
24VAC
across screws
R & C?
YES
NO
Replace
blower motor
and/or start
capacitor.
Is
115VAC
across EAC-1
& COM?
YES
NO
Is 24VAC
across screws
W & C or
G & C?
Check/Replace:
1. Limit switch
2. Limit shield (if used)
3. Fuse link
4. Auxillary limit switch (if used)
5. Wire harness
Jumper across
screws R & G.
Is
blower running
on cooling
speed?
YES
Are
all thermostat
wires to board
disconnected?
Is 24VAC
across pressure
switch N/O contact
& screw C on
board?
YES
Check/Replace:
1. Draft safeguard switch
2. Wire harness
NO
Is
inducer motor
on?
YES
Is
unit lit?
NO
Replace
inducer motor.
YES
Is
blower running
on heat speed 45
sec after unit
lights?
Is
115VAC across
inducer motor
connector?
Check/Repair
wire harness;
otherwise,
replace
pressure
switch.
Is
24VAC across
PL-2 & screw
C on board?
Is
24VAC across gas
valve?
YES
Check/Replace:
1. Pilot
2. Thermocouple
3. Gas valve
YES
NO
NO
NO
NO
Is
24VAC
across
PL-1 & screw
C on board?
Is
115VAC
across EAC-1
& COM?
Replace
board.
Replace
blower motor
and/or start
capacitor.
YES
Replace
board.
NO
YES
YES
YES
NO
YES
NO
Is
115VAC across
inducer motor
connector?
Remove
R & M jumper.
Repair wire
harness.
Check/Replace
thermostat
and/or
thermostat wiring.
NO
NO
After
off-delay
does blower
turn off?
NOTE: After replacing any component, verify correct operating
sequence as indicated by bold arrows.
YES
Reconnect all
thermostat wires.
Does unit
operate?
YES
END OF TEST.
A91253
7
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
A94328
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
PC 101
Catalog No. 535-821
Printed in U.S.A.
Form 58GFA-1SM
Pg 8
10-95
Replaces: 58D, G-3SM
Tab 6a 8a