Carrier 58HDX Furnace User Manual
Contents
1. e 2 bal Field ent Drain amp Clamps Supplied Level Sloped towards Tee Trap 17 White PVC loose parts bag Elbow Tube Black Rubber Relief Tube o I 12 7mm ID amp Clamps Plack Rubber M Loose Parts Bag 4 8mm ID bo cy pL p clum On Some Models Y i IN NE E Flexible Tubing Connector 3 16 Sa INLET 4 8mm OD Loose Parts Bag Gi S e Extensi iif CPP e oN 2 Alternate Orientation Black Rubber 3 16 4 8mm ID bor Cut to Fit Loose Parts Bag befo Dual Pressure Switch A mounting Trap A Drain Tube Black 5 15 9mm ID amp Clamps Corrugated Cut at straight section Drain Tube Barbed Coupling 1 3 12 7mm Black Rubber OD Loose Parts Bag 1 5 12 7mm ID amp Clamps Leave room for clamp a 25 24 70c Representative drawing only some models may vary in appearance 07712 Fig 14 Horizontal Right Side Vent 14 Procedure 4 Cleaning Heat Exchangers The following items should be performed by a qualified service technician A Primary Heat Exchangers If heat exchangers get an accumulation o2. THERMOSTAT FIVE WIRE wy O 9 TERMINALS FIELD SUPPLIED THREE WIRE DISCONNECT HEATING ONLY D T 208 230 OR BLOWER DOOR SWITCH e o oj E l 0v x ee EM E e THREE PHASE Bile De PALA leva ON 4 L C BHE 2 Daloa Log N e e e 208 230 V T Y e e e SINGLE RIS I PHASE 115 V FIELD AUXILIARY 2 SUPPLIED _ J BOX L GND DISCONNECT e porcus MEX eng CONDENSING UNIT 24 V TWO TERMINAL WIRE BLOCK NOTES 1 Connect Y terminal in furnace as shown for proper blower operation FURNACE 2 Some thermostats require a terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A02174 Fig 17 Field Wiring Blower Off Delay Jumper 24 VAC HUM 115 VAC HUM EAC A07727 Fig 18 Control Center 4 Check igniter resistance Igniter resistance is affected by temperature Only check resistance when the igniter is at room temperature a Using an ohm meter check resistance across both igniter leads in connector b Cold reading should be between 40 ohms and 70 ohms 5 Remove igniter 4 CAUTION BURN HAZARD Failure to follow this caution may result in personal
3. Clamp ears 3 n Pointed OUT M ID Rub gt gt Plastic fh Yellow or black L Coupling amp Clamps Preassemble amp Optional 5 insert into furnace 5 Drain Tube Black 5 Rubber 1 3 12 7mm Vent Drain x ID amp Clamps amp Clamps xu upplied Tee WARNING B Relief Tube Black Rub Add Cap and Clamp CH E ber 3 46 4 8mm ID MEL DELE Flexible Tubi C t exible Tubing Connector 4 c 4 8mm OD Loose e c s Ts i ot Mie Tee Trap White PVC Relief Tube Extension 3 A loose parts bag Black Rubber 3 46 4 8mm ID 44 E Cut to Fit Loose Parts Bag gt lt INLET 11 A XS On Some Models p S ONLY Dual Pressure Switch M arbed Coupling 1 2 12 7mm qu Drain Tube Corrugated 5 8 15 9mm ID amp d Clamps Cut at straight section D Loose Parts Bag Drain Tube Black Rubber 1 5 12 7mm ID amp Clamps Remove KO before Leave room for clamp Cut Here mounting Trap Representative drawing only some models may vary in appearance Fig 13 Horizontal Right Through Top 13 25 24 70b A07711 58HDX Plastic Cap 4 Yellow or black Coupling amp Clamps Single Pressure Switch Detail Optional M ST mS COOOL
4. JOVIIOA INN 971313 PRINTED CIRCUIT BOARD NOTE 5 3noooj UON UB 0 Aejap yo samog 695 AINO S13QOW 41 HDLIMS 55388 41 3002 40102 3802 03385 VEGOW NO 5NION3d3G 531935 NI COL L HOLMS 3955394 4 NO 531035 NI OLLHOLIMS 1 YIWYOISNVYL 20 iring Diagram CAPACITOR Cc wy R HUM 24VAC Fig 20 HEAT OFF DELAY CAPACITOR 7HOOW NO ONIGN3d3G 531035 NI Z OL t HOLIMS 35155334 s1aGOW 3WOS MET s1330W 3WOS gt INVYSVIG NOILOANNOOD 1N3WdIno3 NO SNION34d3G 531935 NI SYOLINGNOD Si3dd05 OLLHOLIMS 100 TIOH SNIOIAH3S 30438 193NNOOSIG QuVZVH MOOHS TVOIH LO3 3 ONINSVM 123NNOOSIG Q13l4 DVASLL OL s3aavi XGH8S If status code recall is needed briefly 2 3 seconds remove then reconnect one limit switch wire main or rollout to display last stored status code Do not remove power or blower door before initiating status code recall or code will be lost Code is automatically cleared after 72 hours or upon power reset Proper flame sense microamps 0 7 microamps D C minimum 2 0 4 0 microamps nominal LED CODE DIAGNOSTIC FLASH CODES
5. 4 Cleaning Heat Exchangers 15 Primary Heat Exchangers 15 Secondary Heat Exchangers 15 Flushing Collector Box and Drainage System 15 Servicing Hot Surface 16 Electrical Controls And Wiring 18 Checking Heat Tape Operation If Applicable 18 eae 18 WIRING DIAGRAM 18 TROUBLESHOOTING eese eee 18 SAFETY CONSIDERATIONS Recognize safety information This is the safety alert symbol ZN 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 CAUTION and NOTE 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 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 property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation 58HDX 4 WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could cause personal injury death or property damage Never store anything on near or in contact with the fu
6. Trap Connection Clamp ears Pointed OUT Black Rubber Pessenbei She 5 mm ID insert into furnace 1B Coupling amp Clamps aw Optional Drain Hose Black Rubber 1f 13 mm ID Cut to Fit amp Clamps yo uumme 2 51 mm PVC Coupling Models ONLY a e Either PVC Drain Tee or a field En supplied 2 51 mm PVC Tee BI B M a 7 1 Tee Trap White PVC 1 1 Drain Tube Corrugated loose parts bag Black 5lg 16 mm Drain Connector Blac Da Clamps e PVC 3 4 19 mm WARNING PVC X 1 2 13 Move Caps to CPVC Loose parts bag top of trap oh 5 a Drain Tube Black Rubber E 5 6 ID 16 mm Cut to fit amp Clamps loose parts bag 07768 Fig 10 Downflow Right Side Vent and Trap 10 Vent Drain Single Pressure Switch Detail
7. amp Clamps Plastic Caps MEM Trap Connection Yellow or black ep 7 2 Clamp ears d Pointed OUT 1 4 Preassemble amp Alternate Orientation BE z _S insert into furnace lt Relief Tube Black Rubber 3 46 4 8mm ID Dual Pressure Switch 47 ccce 5 E Ow dle ii D S Flexible tubing connector A as 00 4 8mm OD Loose Parts Bag Relief Tube Extension SE Black Rubber Ihe 4 8mm NM ES Cut Fit Loose Parts Bag om gt Q s Drain Tube Corrugated BB 5 8 15 9mm ID amp Clamps R n Remove KO before 1 mounting Trap co 3 Drain Tube ID Cut at straight section Field Coupling amp Clamps Black Rubber Supplied Tee Optional 1 5 12 7mm ID amp Clamps Tee Trap White PVC Cap and Clamp loose parts bag n En Leave room for clamp Cut Here Open End 25 24 70 Representative drawing only some models may vary in appearance A07709 Fig 11 Horizontal Left Through Top 11 58HDX Alternate Orientation Al 4 2 EXHAUST Field Supplied Tee t 2 Single Pressure Switch Detail OIC ipe Level or Sloped towards Tee Yellow or black Plastic Cap y Tee Trap White PVC loose parts bag IN Lr X
8. NOTE Removing the blower access door will open the blower access door switch and terminate 115 power to the control This will erase the stored status code NOTE NO thermostat signals should be present at control and all blower off delays must be completed to view previous codes 18 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in damage to unit components Make sure limit switch wire does not contact any metallic component such as the gas valve If wire is shorted the 5 amp fuse on furnace control board will open and the unit will not operate 32 F 0 C MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED TX A07911 Fig 19 Winterizing the Furnace To retrieve last code remove 1 of the red main limit wires for 1 to 4 sec until the LED light goes out then reconnect it Do not leave red wire disconnected for longer periods of time as the control will assume an overtemperature condition exists and will respond with blower operation This places the control in the status recall mode and displays the first code stored in memory 19 9 A38 01 608 FURNACE CONTROL J1 COOL ON DELAY 5 SEC 23S 081 Ovi 09 ost 001 OFF DELAY 23S 0 1 Obi 09 08 00 HEAT OFF DELAY 3s 001 Ort 09 y gt 001 DELAY OFF DELAY COOL OFF DELAY 90 SEC HEAT ON DELAY 30 SEC EAC
9. HUM 1 0AMAX COMBINED A07824 JOJOBUUD YOINb OM Jo JO Q UUOD e ui eq speo pue Jeonpul pd Jepou uo Buipuedeg EL O vrl 2 0 105095 eure ZI seuojws urejuoo Jeonpul pue 8 L sunou Jaye joseJ ojne 20 8 njsseoonsun eAnnoesuoo JNO Jaye Indo spuooes 06 Jo fi pue Ort 00L 09 Buneeu seb jou 11 fuosseooy sejdepy Kauullu2 SSAg pue uoiws einssejd d7 ueuM uonoejes peeds uo 20 suononuisur uonel eisur suonipuoo 104 paads jewo g esn dwe G e uj vejd y uwous se pejoidep jou pue pejuud pJeoq episui uonejueseudei euiej saod 20 199Us pejoeuuoo JSNW SIUL uonounf au pue uos y jeddoo juo esi O 901 Peres si jueuidinbo jo Aue jJ TWNIWYSL Q3xuvuWNn Jeunuou vrl NO YOLDNGNOD 91313 JOVIIOA INNT
10. OFF ON SOLID HEARTBEAT bright dim 2 FLASHES 3 FLASHES 4 FLASHES 5 FLASHES 6 FLASHES 6 1FLASHES 7 FLASHES 8 FLASHES 9 FLASHES 10 FLASHES 24 VAC or 115VAC is off fuse is open Soft lockout Furnace Control error 1 hr delay If code repeats immediately following power reset then replace control Normal operation or no previous Diagnostic Code Pressure switch es closed when should be open Pressure switch open when should be closed on single stage models Low pressure switch open when should be closed on 2 stage VS models Limit or roll out switch open Flame sensed out of sequence Failure to ignite or flame sense lost while running Soft lockout Max of four trials for ignition reached 3 hr delay Soft lockout Limit or roll out switch open longer than 2 minutes 1 hr delay roll out switch requires manual reset Permanent lockout Gas valve relay contact stuck closed or mis wired gas valve power reset only High pressure switch open when should be closed on 2 stage VS models only Line voltage polarity reversed If twinned refer to kit instructions 330713 101 REV D 07825 Fig 21 Service Label 21 58HDX Copyright 2009 Carrier Corp 7310 W Morris St Indianapolis IN 46231 Printed in U S A Edition Date 05 09 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations 22 Catalog No
11. AIRFLOW AIRFLOW A93041 V AIRFLOW Fig 1 Multipoise Orientations 1 Disconnect all power to the furnace DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch a clean unpainted metal surface of the furnace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily discharged 3 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity for example DO NOT move or shuffle your feet DO NOT touch ungrounded objects etc 4 If you touch ungrounded objects recharge your body with static electricity firmly touch furnace again before touching control or wires 5 Use this procedure for installed uninstalled ungrounded furnaces 6 Before removing a new control from its container discharge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 5 before bringing the control or yourself into contact with the furnace Put all used AND new controls into containers before touching ungrounded objects 7 An ESD service kit available commercial sources 2 Remove blower door may also be used to prevent ESD damage 3 Slide filter out of furnace See Fig 2 and 3 CARE AN
12. winterize as follows 1 Turn off electrical supply to furnace 2 Remove main furnace door 3 Disconnect the 1 2 LD rubber hose from the vent drain fitting or tee that is located downstream of the combustion blower Insert a funnel into the hose and pour four 4 ounces of sanitary type RV antifreeze into the condensate trap Reconnect the 1 2 I D rubber hose to the stub the vent drain fitting Secure with the hose clamp 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in unit component damage Do not use ethylene glycol Prestone antifreeze coolant equivalent automotive type Failure of plastic components may occur 4 Disconnect the 5 8 I D rubber hose from the condensate trap Insert a funnel into the hose and pour four 4 ounces of sanitary type RV antifreeze into the plastic transition box Squeeze the hose together near the and quickly reconnect the 5 8 I D rubber hose to the stub on the condensate trap Secure with the hose clamp 5 When you return home your furnace will be ready to start as it is not necessary to drain the antifreeze from the furnace WIRING DIAGRAM See Fig 20 for Wiring Diagram TROUBLESHOOTING Use the Troubleshooting Guide the status code LED on the control and the Component Test to isolate furnace operation problems A Status Codes For an explanation of status codes refer to service label located on front of blower door or Fig 21
13. wj D J P d 1 Models ONLY Vent Drain Dual Pressure Switch eA amp Clamps Relief Tube Black Rub 3 ber 4 8mm ID Elbow Tube Black Rubber 1 3 12 7mm RON ES 21 ID Clamps Loose Parts Bag lt Barbed Coupling 1 2 12 7mm OD Loose Parts Bag Drain Tube Black Rubber 113 12 7mm ID amp Clamps Drain Tube Corrugated Flexible Tube Connector 3 46 4 8mm OD Loose Parts Bag A 5 6 15 9mm ID amp Clamps Relief Tubing Extension Black Rubber 3 46 4 8mm ID Cut to Fit Loose Parts Bag Cut at straight section Representative drawing only some models may vary in appearance Fig 12 Horizontal Left Side Vent 12 WARNING p Move Caps to top of trap Leave room for clamp Cut Here 25 24 70a A07710 Trap Connection Single Pressure Switch Detail Alternate Orientation
14. Vent Drain amp Clamps o D ie i e Single Pressure Switch Dual Pressure Switch Detail Relief Tube a Black Rubber 3 6 J A 4 8mm ID 2 Drain Tube 7 Black Rubber 1 5 12 7mm ID amp Clamps L Drain Tube Street Elbow Corrugated 15 12 7mm CPVC lg 15 9mm ID amp Loose parts bag Clamps 3 E Drain Connector Black PVC I 3 4 18 1mm PVC X 1 3 12 7mm CPVC Loose Casing Grommet Black Rubber 5 8 15 9mm ID Loose parts bag Drain Line Vent 3 18 1mm PVC or 1 2 12 7mm CPVC Field supplied Representative drawing only some models may vary in appearance Drain Tube Black Rubber 5 5 15 9mm ID amp Clamps Cut length to fit Loose parts bag 25 24 67 07706 Fig 6 Upflow Installations Top Vent Plastic Yellow or black d Coupling amp Clamps E 2 50 8mm PVC 4 Coupling d On Some Models ONLY 19 Optional Vent Drain amp Clamps Either The PVC Drain Tee or a field supplied 2 50 8mm PVC Tee Dual Pressure Switch Detail 5 Tee Trap Drain Tube Black Rubber 1 5 12 7mm ID
15. amp Clamps 5 Drain Connector Black PVC 3 4 19 1mm PVC X 1 2 12 7mm CPVC Loose parts bag Casing Grommet Black Rubber 5 8 15 9mm ID Loose parts bag Representative drawing only some models may vary in appearance loose parts bag EXHAUST White PVC Drain Tube Corrugated 5 8 15 9mm ID AR amp Clamps 5 27 Drain Line Vent 3 18 1mm PVC 1 12 7mm CPVC Field supplied Fig 7 Upflow Installations Vent Through Left Side Single Pressure Switch Relief Tube Black Rubber 3 16 4 8mm ID SIDE VIEW NOTE Built in channel will be angled 5 to 10 also 25 24 67a 07707 58HDX Plastic Cap Yellow or black L On Some Models x ONLY r 5 Dual Pressure Switch VentD
16. igniter Refer to furnace wiring diagram for proper wire location 13 Reinstall gas supply pipe to furnace gas control valve using backup wrench on gas valve to prevent rotation and improper orientation NOTE Use propane gas resistant pipe dope to prevent gas leaks DO NOT use Teflon tape A WARNING FIRE EXPLOSION UNIT DAMAGE HAZARD Failure to follow this warning could result in property damage personal injury or death Gas valve switch MUST be facing forward or tilted upward 14 Turn on gas and electrical supplies to furnace A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings could result in personal injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections 15 Check for gas leaks 16 Replace main furnace door PRIMARY HX INLET OPENINGS A07827 Fig 5 Cleaning Inlet Openings of Primary Heat Exchangers 58HDX On Some Models E ONLY m Plastic Caps 2 ii Yellow or black t amp Clamps E 5 m asso gt
17. injury Allow igniter to cool before removal Normal operating temperatures exceed 2000 F 1093 C 17 a Using a 1 4 in nut driver remove the single screw securing the igniter bracket to the burner box and carefully withdraw the igniter through the bottom of the burner box without striking the igniter on surrounding parts b Inspect igniter for signs of damage or failure 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in premature failure of the igniter The igniter is fragile DO NOT allow it to hit the side of the burner box opening while removing or replacing it c If replacement is required replace igniter on igniter bracket and then install assembly into burner box to avoid damage to the igniter To replace igniter and bracket assembly reverse items 5a and 56 Reconnect igniter wire connection A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Igniter wires must be securely placed in slot in manifold grommet or else they could become pinched or severed and electrically shorted 58HDX 8 Turn on gas and electrical supplies to furnace 9 Verify igniter operation by initiating furnace control self test feature or by cycling thermostat 10 Replace main furnace door Procedure 7 Electrical Controls and Wiring 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could r
18. 58HDX 4 WAY MULTIPOISE FIXED SPEED CONDENSING GAS FURNACE Turn to the Experts Service Guide EFFICIENCY RATING CERTIFIED ama NOTE Read the entire instruction manual before starting the installation A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow warnings could result in personal injury death or property damage Before servicing disconnect all electrical power and gas supply to furnace Lockout and tag with appropriate label When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in property damage personal injury or death 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 TABLE OF CONTENTS PAGE SAFETY CONSIDERATIONS 1 GENERAD 3I ERE Was edie e ERR eR repre 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 2 CARE AND MAINTENANCE 3 Cleaning and or Replacing Air Filter 3 Blower Motor and Wheel Maintenance 3 Cleaning Burners
19. 58HDX 01SM Replaces NEW
20. D MAINTENANCE 4 Furnaces are equipped with permanent washable filter s Clean filter by spraying cold tap water through filter in For continuing high performance and to minimize possible opposite direction of airflow equipment failure it is essential that maintenance be performed annually on this equipment Consult your local dealer about proper 5 Rinse filter and let dry Oiling or coating of filter is not maintenance and maintenance contract availability recommended 6 Slide filter into furnace y WARNING 7 Replace blower door 8 Turn on electrical supply to furnace HAZARD ELECTRICAL SHOCK Procedure 2 Blower Motor and Wheel Failure to follow this warning could result in personal injury Maintenance or death To ensure long life economy and high efficiency clean accumulated dirt and grease from blower wheel and motor annually Turn off the gas and electrical supplies to the unit before performing any maintenance or service Lockout and tag with appropriate label Follow the operating instructions on the label attached to the furnace The inducer and blower motors are pre lubricated and require no additional lubrication These motors can be identified by the absence of oil ports on each end of the motor The minimum maintenance that should be performed on this The following items should be performed by a qualified service equipment is as follows technician 1 Check and clean or replace air filter each
21. Replacing 7 Clean blower wheel and motor by using a vacuum with soft Air Filter brush attachment Be careful not to disturb balance weights clips on blower wheel vanes Do not bend wheel or blades The air filter arrangement may vary depending on the application as balance will be affected or orientation 8 If greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate A V V ARNING degreaser To remove wheel a Mark blower wheel location on shaft before disassembly FIRE CARBON MONOXIDE AND POISONING to ensure proper reassembly HAZARD Failure to follow this warning could result in property damage b Loosen setscrew holding blower wheel on motor shaft NOTE Mark blower mounting arms and blower housing so each arm is positioned at the same hole location during reassembly personal injury or death Never operate unit without a filter or with the blower access panel removed Operating a unit without a filter or with the blower access door removed could cause damage to the furnace blower motor Dust and lint on internal parts of j furnace can cause a loss of efficiency plate from housing e Remove bolts holding motor mounts to blower housing and slide motor and mounts out of housing Disconnect capacitor and ground wire attached to blower housing before removing motor Motor mounts need not be removed from motor c Mark blower wheel orientation and cutoff plate l
22. TION ELECTRICAL SHOCK AND UNIT DAMAGE HAZARD Failure to follow this caution may result in personal injury or damage to furnace Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation GENERAL This furnace van be installed as a direct vent 2 pipe or non direct vent 1 pipe condensing gas furnace These instructions are written as if the furnace is installed in an upflow application An upflow furnace application is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can be installed in any of the 4 positions shown in Fig 1 you may need to revise your Orientation to component location accordingly ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may damage furnace components Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electrostatic potential AIRFLOW C UPFLOW HORIZONTAL RIGHT HORIZONTAL LEFT DOWNFLOW
23. Using backup wrench disconnect gas supply pipe from furnace gas control valve 4 CAUTION ELECTRICAL SHOCK UNIT DAMAGE HAZARD Failure to follow this caution may result in personal injury or furnace component damage Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation CELL PANEL BURNERS BURNER BOX MANIFOLD GAS VALVE A07826 Fig 4 Burner Box Assembly 4 Remove wires from gas valve Note location for reassembly 5 Unplug igniter from harness 6 Remove screws that secure manifold to burner box See Fig 4 NOTE Do not remove burner box from cell panel 7 Remove manifold orifices and gas valve as 1 assembly 8 Remove screws attaching burner assembly in burner box NOTE Use care when removing and reinstalling burners not to strike the hot surface igniter 9 Remove burner assembly from burner box NOTE burners are attached to burner bracket and can be removed as 1 assembly 10 Clean burners with soft brush and vacuum 11 Reinstall manifold orifice and gas valve assembly in burner box Ensure burners fit over orifices A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Igniter wires must be securely placed in slot in manifold grommet or else they could become pinched or severed and electrically shorted 12 Reconnect wires to gas valve and
24. ee Flushing Collector Box and Drainage System section for details on removing inducer assembly Procedure 5 Flushing Collector Box and Drainage System 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Disconnect inducer motor and pressure switch wires or connectors Burner Face A07734 Fig 15 Burner Flame 15 58HDX GASKET A07828 Fig 16 Gasket on Collector Box 4 Disconnect pressure switch tubes 5 Disconnect vent pipe from inducer housing outlet by loosening clamp 6 Disconnect drain tube from inducer housing See Fig 6 14 7 Remove inducer housing assembly by removing 4 bolts attaching assembly to cell panel 8 Flush inside of collector box with water until discharge from condensate trap is clean and runs freely NOTE Ensure that drain tube disconnected from inducer housing is higher than collector box opening or water will flow out tube 9 Inspect inside area of collector box for any pieces of foreign materials and remove if present 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace component damage DO NOT use wire brush or other sharp object to inspect or dislodge materials in secondary heat exchangers as failure of the secondary heat exchanger may occur Flush with water only 10 Reassemble inducer assembly by reversing items 5 through 7 Tighten the vent coupling screw
25. esult in personal injury or death There may be more than 1 electrical supply to the furnace Check accessories and cooling unit for additional electrical supplies The electrical ground and polarity for 115 v wiring must be maintained properly Refer to Fig 17 for field wiring information and to Fig 20 for furnace wiring information NOTE If polarity is not correct STATUS LED on furnace control board will flash rapidly and prevent furnace from operating The control system also requires an earth ground for proper operation of furnace control and flame sensor The 24 v circuit contains an automotive type 5 amp fuse located on the control See Fig 18 Any direct shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 5 amp fuse of identical size The control LED will flash status code 24 when fuse needs to be replaced With power to unit disconnected check all electrical connections for tightness Tighten all screws on electrical connections If any smoky or burned connections are found disassemble connection clean all parts strip wire and reassemble properly and securely Reconnect electrical supply to unit and observe unit through 1 complete operating cycle for proper operation Procedure 8 Checking Heat Tape Operation If Applicable In applications where the ambient temperature around the furnace is 32 F 0 C or lower
26. f light dirt or dust on the inside they may be cleaned by the following procedure NOTE If heat exchangers get a heavy accumulation of soot and carbon both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate design A build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger primary or secondary Action must be taken to correct the problem 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 4 CAUTION ELECTRICAL SHOCK UNIT DAMAGE HAZARD Failure to follow this caution may result in personal injury or furnace component damage Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation 3 Disconnect wires or connectors to flame rollout switch gas valve igniter and flame sensor 4 Using backup wrench disconnect gas supply pipe from gas valve 5 Remove screws attaching burner box to cell panel See Fig 4 NOTE Burner box manifold gas valve and burner assembly should be removed as 1 assembly 6 Clean heat exchanger openings with a vacuum and a soft brush See Fig 5 NOTE After cleaning inspect hea
27. freeze protection measures are required If heat tape has been applied check to ensure it will operate when low temperatures are present 4 CAUTION UNIT AND PROPERTY DAMAGE HAZARD Failure to follow this caution may result in furnace component damage or property damage If this furnace is to be operated in an unconditioned space where the ambient temperatures may 32 F 0 or lower freeze protection measures must be taken See Fig 19 See CONDENSATE DRAIN PROTECTION Installation Start Up and Operating Instructions section of NOTE Heat tape when used should be wrapped around the condensate drain trap and drain line There is no need to use heat tape within the furnace casing Most heat tapes are temperature activated and it is not practical to verify the actual heating of the tape Check the following 1 Check for signs of physical damage to heat tape such as nicks cuts abrasions gnawing by animals etc 2 Check for discolored heat tape insulation If any damage or discolored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on Procedure 9 Winterizing 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace component damage Freezing condensate left in the furnace will damage the furnace If the furnace will be off for an extended period of time in a structure where the temperature will drop to 32 F 0 C or below
28. l x T 5 2 51 mm PVC Coupling Vent Drain NOTE Built in channel will amp Clamps Either The PVC be angled 5 to 10 also Drain Tee or a field supplied 2 51 mm PVC Tee Relief Tube Single Pressure Switch Detail Dual Pressure Switch Black Rubber 3 16 5 mm ID On Some Models m d ONLY INLET Drain Tube i i Tee Trap White PVC Black Rubber Fake Tubing Connector loose parts bag 1 5 ID 13 mm amp Clamps 5 mm OD loose parts bag Elbow Tube Black Rubber fl ID 13 amp Clamps bd Loose Parts Bag E HON DUET 3 16 5 mm ID Cut to fit loose parts bag WARNING Move Caps to top of trap Trap Connection Clamp ears Pointed OUT CQ Drain Tube Black 5 5 16 mm ID Corrugated Cut at straight section 8 5 SO Barbed Coupling 1 2 13 mm OD loose parts bag Leave room for clamp Cut Here Fig 9 Downflow Left Side Vent and Trap Preassemble amp insert into furnace 25 24 69 A07767 58HDX Plastic Cap Yellow or black Vent Drain amp Clamps SIDE VIEW Rotate downward 5 to 10 NOTE Built in channel will be angled 5 to 10 also Single Pressure Switch Detail Elbow Tube Black Rubber 1 5 13 mm ID amp Clamps Loose Parts Bag Barbed Coupling 1 13 mm OD Loose Parts Bag Dual Pressure Switch
29. month as needed Clean blower motor and wheel as follows 2 Check blower motor and wheel for cleanliness annually 3 Check electrical connections for tightness and controls for 1 Turn off electrical supply to furnace proper operation each heating season Service as necessary 2 Remove blower door 4 Check for proper condensate drainage Clean as necessary 3 Disconnect blower motor wires from furnace control board 5 Check for blockages in combustion air and vent Field thermostat connections may need to be disconnected pipes annually depending on their length and routing 6 Check burners for cleanliness annually 4 Remove control box mounting screws and position control box transformer and door switch assembly to right side of A C AUTION furnace casing 5 If condensate trap is located in left or right hand side of furnace casing proceed to item 6 otherwise remove trap CUT HAZARD and tubing as described below See top Fig 6 7 or 8 Failure to follow this caution may result in personal injury a Disconnect field drain connection from condensate trap Be careful of sharp metal edges etc Use care and wear b Disconnect drain and relief port tubes from protective clothing safety glasses and gloves when condensate trap removing parts Remove condensate trap from blower shelf 6 Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace Procedure 1 Cleaning and or
30. ocation to ensure proper reassembly d Remove screws securing cutoff plate and remove cutoff NOTE If filter has cross mesh binding binding must face blower If filter has an air direction arrow arrow must point toward blower To clean or replace the filters proceed as follows 1 Turn off electrical supply to furnace 58HDX Center Clip side to side 228 6 mm di Fig 2 Bottom Filter Arrangement Filter Rack End Cap A07690 Fig 3 Filter Installed for Side Inlet f Remove blower wheel from housing 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace component failure The blower wheel should not be dropped or bent as balance will be affected g Clean wheel per instructions on degreaser cleaner Do not get degreaser cleaner in motor 9 Reassemble motor and blower wheel by reversing items 8b through 8f Ensure wheel is positioned for proper rotation Be sure to reattach ground wire Tighten setscrew to 140 to 160 in Ib torque 10 Reinstall blower assembly in furnace 11 Reinstall control box transformer and door switch assembly on blower shelf 12 Reinstall condensate trap and tubing if previously removed a Reinstall condensate trap in hole in blower shelf b Connect condensate trap drain tubes See Fig 6 7 or 8 NOTE Ensure tubes are not kinked or pinched as this will affect operation c Connect field drain to condensa
31. raln l Either The PVC Drain 3 Tee or a field supplied fom Relief Tube 2 50 8mm PVC o gt Black Rubber 3 46 4 8mm ID Single Pressure Switch Details 1 2 50 8mm Pvc nf Coupling 5 e uU 5 T Drain 2 Corrugated 3 5 8 15 9 ID Eas mm Tee Trap White PVC loose parts bag E M Tubes 2 Black Rubber m __ 15 12 7mm ID amp Clamps loose parts bag Barbed Coupling 1 2 12 7mm OD Drain Line Vent Tee 3 4 Ae loose parts bag 18 1mm PVC 1 3 SIDE VIEW CPVC Field sup Rotate m plied lt downward je dp Drain Connector Black PVC 5 to 10 010 3 4 19 1mm PVC X 1 12 7 Loose parts bag Casing Grommet Black Rubber 5 8 15 9mm CPVC NOTE Built in channel will be angled 5 to 10 also Loose parts bag 25 24 68 A07708 Fig 8 All Models Vent Through Right Side Upflow Plastic 4 SIDE VIEW Yellow or black Rotate downward r 5 to 10 2 an Low Coupling amp Clamps zx i Optiona
32. rnace 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 Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified service agency personnel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions described in User s Information Manual such as cleaning and replacing air filters All other operations must be performed by trained and qualified service agency 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 including the National Fuel Gas Code NFGC 54 2006 ANSI Z223 1 2006 in the USA National Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 NSCNGPIC in Canada and the Installation Standards Warm Air Heating and Air Conditioning Systems NFPA 90B ANSI NFPA 90B Wear safety glasses and work gloves Have a fire extinguisher available during start up and adjustment procedures and service calls 4 CAU
33. s to 15 in lb of torque NOTE If gasket between inducer housing and collector box is damaged in any way it must be replaced See Fig 16 11 Refer to furnace wiring diagram and connect wires to inducer motor and pressure switch or connectors 12 Reconnect pressure tubes to pressure switch See diagram on main furnace door for proper location of tubes Be sure tubes are not kinked See Fig 6 14 13 Turn on gas and electrical supplies to furnace 14 Check furnace operation through 2 complete heat operating cycles Check area below inducer housing vent pipe and condensate trap to ensure no condensate leaks occur If leaks are found correct problem A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the warnings could result in personal injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections 15 Check for gas leaks 16 Replace main furnace door Procedure 6 Servicing Hot Surface Igniter The igniter does NOT require annual inspection Check igniter resistance before removal 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Disconnect igniter wire connection 16 FIELD 24 V WIRING FIELD 115 208 230 460 VWIRING FACTORY 24 VWIRING FACTORY 115 V WIRING 2
34. t exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products 7 Reverse items 4 and 5 for reassembly 4 CAUTION UNIT MAY NOT OPERATE Failure to follow this caution may result in improper unit operation The ground wire from the gas valve MUST be attached to the burner box attachment screw or furnace lockout may occur 8 Refer to furnace wiring diagram and connect wires to flame rollout switch gas valve igniter and flame sensor 9 Reconnect pressure switch tubes to gas valve and intake housing Refer to tube routing label on main furnace door for proper tube location Be sure tubes are not kinked See Fig 6 14 10 Turn on gas and electrical supplies to furnace 11 Check furnace operation through 2 complete heat operating cycles Burner flames should be clear blue almost transparent See Fig 15 A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings could result in personal injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections 12 Check for gas leaks 13 Replace main furnace door B Secondary Heat Exchangers NOTE The condensing side inside of secondary heat exchangers CANNOT be serviced or inspected A small number of bottom outlet openings can be inspected by removing inducer assembly S
35. te trap 13 Reconnect wires Refer to furnace wiring diagram and connect thermostat leads if previously disconnected See Fig 20 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in unit component damage Heating speed selection MUST be adjusted to provide proper temperature rise as specified on the rating plate Table 1 Speed Selector FACTORY COLOR SPEED ATTACHED TO Black High Cool Orange Medium High Heat Blue Medium Low M1 Red Low M2 White Common Com 14 Turn on electrical supply Manually close blower access door switch Use a piece of tape to hold switch closed Check for proper rotation by jumpering R to G 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to furnace control No component operation can occur Caution must be taken when manually closing this switch for service purposes 15 If furnace is operating properly remove tape to release blower access door switch remove jumper across R to G and replace blower access door Procedure 3 Cleaning Burners The following items should be performed by a qualified service technician If burners develop an accumulation of light dirt or dust they may be cleaned by using the following procedure 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3
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