Carrier 58mca080

GAS FURNACE

MULTIPOISE, CONDENSING 58MCA, 58MTA, 58MVP, 58MXA

USER’S INFORMATION MANUAL FOR OPERATION AND MAINTENANCE OF YOUR GAS-FIRED FURNACE

USER: Please read all instructions in the manual and retain all manuals for future reference.

NOTE TO INSTALLER: THIS MANUAL MUST BE LEFT WITH THE EQUIPMENT USER.

||WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage.

!| |---|

— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.


— Installation and service must be performed by a qualified installer, service agency or the gas supplier.| |---|

|WARNING: Carbon Monoxide is invisible, odorless, and toxic! Carrier Corporation recommends a carbon monoxide alarm in your home, even if you do not own a gas appliance. Locate the carbon monoxide alarm in the living area of your home and away from gas appliances and doorways to attached garages. Follow the alarm manufacturer’s instruction included with the alarm.

!| |---|

|Do not use this furnace if any part has been under water. A flood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and to replace all gas controls, control system parts, electrical parts that have been wet or the furnace if deemed necessary.| |---|

TABLE OF CONTENTS

WELCOME TO A NEW GENERATION OF COMFORT . . . . . . .2 GENERAL FURNACE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 FURNACE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 BEFORE STARTING YOUR FURNACE. . . . . . . . . . . . . . . . . . . . . . .4 STARTING AND SHUTTING DOWN YOUR FURNACE . . . . . . .4

Steps for Starting Your Furnace. . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Shutting Down Your Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

########## PERFORMING ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . .6

Filtering Out Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 COMBUSTION AREA AND VENT SYSTEM. . . . . . . . . . . . . . . . . . .8

Heading South for the Winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A CHECK-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,10 BEFORE YOU REQUEST A SERVICE CALL . . . . . . . . . . . . . . . . .10 INSTALLATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

##### WELCOME TO A NEW GENERATION OF COMFORT

Congratulations! In light of rising energy costs, the 58MXA, 58MCA, 58MTA, and WeatherMaker Infinity, Multipoise, GasFired Condensing Furnaces are among the soundest investments today’s homeowner can make.

Your new furnace is truly a triumph of technology in home heating. A revolutionary design employs 2 heat exchangers to “squeeze” out the maximum amount of heat from the fuel consumed. In fact, your new furnace is so efficient, over 90%* of the heat generated during combustion is captured and delivered inside your home. That is more than a 33%* increase in heating efficiency over conventional furnaces.

These are among the most energy-efficient furnaces you can buy today. They also are among the safest and most dependable. We are proud of the technological advances incorporated into the design of these furnaces. With only minimal care, your new furnace will deliver many years of money-saving home comfort and enjoyment. Spend just a few minutes with this manual to learn the operation of your new furnace and the small amount of maintenance it takes to help keep it operating at peak efficiency year after year.

*The output capacity and any representations of efficiency for this furnace are based on standard U.S. Department of Energy test procedures.

##### GENERAL FURNACE SAFETY

CERTIFIED

As an ENERGY STAR® partner, Carrier Corporation has determined that this product meets the ENERGY STAR® guidelines for energy efficiency.

• • • • •

ed art

U L T R A H I G H E F F I C I E N C Y G A F R N A C E

1

MODELS 58MXA (SHOWN) AND 58MCA FIXED-CAPACITY FURNACES

MODEL 58MVP VARIABLE-CAPACITY AND MODEL 58MTA TWO-STAGE FURNACES

2

##### FURNACE COMPONENTS

|1| |---|

|2| |---|

|3| |---|

|4| |---|

|5| |---|

|6| |---|

|7| |---|

|8| |---|

|9| |---|

Combustion-air intake connection to ensure contaminant-free air (right or left side).

Burner sight glass for viewing burner flame. Burner assembly (inside). Operates with energy-saving inshot burners and hot surface igniter for safe, dependable heating. Redundant gas valve. Safe and efficient. Features 1 gas control with 2 internal shutoff valves. Valve appearance varies with furnace model. Vent outlet. Uses PVC pipe to carry flue gas from the furnace’s combustion system (right or left side). Inducer motor. Pulls hot flue gases through the heat exchangers, maintaining negative pressure for added safety. Blower access panel safety interlock switch. Air filter and retainer. Condensate drain connection. Collects moisture condensed from burned gases for disposal into home drain system. (Location in furnace varies.)

|10|

|---|

|11| |---|

|12| |---|

|13| |---|

|14| |---|

|15| |---|

|16| |---|

|17| |---|

|18| |---|

|19| |---|

Heavy-duty blower. Circulates air across the heat exchangers to transfer heat into the home.

Secondary condensing heat exchanger (inside). Wrings out more heat through condensation. Constructed with polypropylene-laminated steel to ensure durability.

Primary serpentine heat exchanger (inside). Stretches fuel dollars with the S-shaped heat-flow design. Solid construction of corrosion-resistant aluminized steel means reliability.

Furnace control board. 3-amp fuse provides electrical and component protection. Light emitting diode (LED) on furnace control board. Code light is for diagnosing furnace operation and service requirements. Pressure switch(es) ensure adequate flow of flue gas through furnace and out vent system. Rollout switch (manual reset) to prevent overtemperature. Junction box for 115-v electrical power supply. (May be located on right or left side) Transformer (24v) behind furnace control board provides low-voltage power to furnace control board and thermostat.

17

2

3

1

| | | | | | | | |---|---|---|---|---|---|---| | | | | | | | |

12

4

18

| | | | |---|---|---| | | | |

5

5

16

9

6

need art

13

7

19

8

MODELS 58MXA, 58MCA, AND 58MTA FURNACES (UPFLOW POSITION)

3

5

2

17

1

5

15 14 13

16 9

10

8

##### MODEL 58MVP FURNACE (UPFLOW POSITION)

4

SAFETY CONSIDERATIONS

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 words—DANGER, WARNING, CAUTION and NOTE. DANGER, WARNING and CAUTION 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.

To minimize the possibility of serious personal injury, fire, furnace damage, or improper operation; carefully follow these safety rules:

• Keep the area around your furnace clear and free of combustible materials, gasoline, and other flammable liquids and vapors.

This furnace contains SAFETY DEVICES which must be MANUALLY RESET. If the furnace is left unattended for an extended period of time, have it checked periodically for proper operation. This precaution will prevent problems associated with no heat, such as frozen water pipes, etc. See “Before You Request a Service Call’’ section in this manual.

|WARNING

Fire Hazard! Failure to keep insulation clear of furnace could result in fire, personal injury/death or property damage.

!| |---|

|WARNING

Do not keep combustible materials, gasoline, and other flammable liquids or vapors around your furnace. Failure to follow this warning could result in fire, personal injury/death or property damage.

!| |---|

|WARNING

For proper and safe operation the furnace needs air for combustion and ventilation. Do not block or obstruct the openings on the furnace, air openings to the area in which the furnace is installed, and the space around the furnace. Failure to follow this warning could result in fire, personal injury/death or property damage.

!| |---|

BEFORE STARTING YOUR FURNACE Examine the furnace installation to determine that:

STARTING AND SHUTTING DOWN YOUR FURNACE

Instead of a continuously burning pilot flame which wastes valuable energy, your furnace uses an automatic, hot surface ignition system to light the burners each time the thermostat starts your furnace. Follow these important safeguards:

C

L O S E

| | |---| | | | |

910

11

7

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 furnace label. If you don’t smell gas, go to the next step.

|WARNING

If overheating occurs or the gas valve fails to shut off the gas supply, turn off the manual gas valve to the furnace BEFORE turning off the electrical supply. (See Fig. 9.) Failure to follow this warning could result in a fire or explosion, and personal injury/death or property damage.

!| |---|

| | | |---|---| | | |

| | | |---|---| | | |

| | | | |---|---|---|

| | |---| | |

For 58MTA and 58MVP

For 58MCA and 58MXA

OFF

ON

or

®

8

| | | |---|---| | | |

| | | |---|---| | | |

| | | | |---|---|---|

| | |---| | |

For 58MTA and 58MVP

| | |---|

OFF

ON

or

For 58MCA and 58MXA

16

17 18

###### N

After the hot surface igniter is heated for 17 seconds, the gas valve permits gas to flow to the main burners. After ignition and a time delay of about 60 sec, the furnace blower will start. Variable-capacity furnaces start at low speed until the control makes the necessary adjustments to operate the blower at either the low- or high-heat speed.

NOTE: If the burners fail to ignite after 4 attempts, the furnace control system will lock out. If lockout occurs, main burners fail to light, or blower does not come on, shut down the furnace and call your dealer for service.

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. 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 switch on automatically. When the room temperature reaches the temperature selected on the thermostat, the furnace will be switched off automatically. Some thermostats have a FAN mode with 2 selections: AUTO and ON. When set on AUTO, the furnace blower cycles on and off. In the ON mode, the furnace blower runs continuously. Continuous fan keeps the temperature level in your home more evenly balanced. It also permits the indoor air to be continuously filtered. ComfortFan™ –On all but the 58MCA, the blower speed can be increased or decreased if desired due to change of seasons, large gatherings in your home, etc. Simply change your FAN from ON to OFF for 1 to 3 seconds (or AUTO depending on your thermostat), and then return to ON. The blower will switch to the next higher speed. There are at least 3 speeds to choose from. If the blower is running on its highest speed, a request to change will direct the blower to return to its lowest speed.

SHUTTING DOWN YOUR FURNACE Should you ever need to shut down your furnace for service or maintenance, you will need to turn the furnace off. The following procedures must be followed:

19

®

##### 20

| | | |---|---| | | |

| | | | |---|---|---|

| | | |---|---| | | |

| | |---| | |

For 58MTA and 58MVP

##### 21

OFF

ON

or

For 58MCA and 58MXA

##### 22

|CAUTION

Furnace is not to be installed, operated, and then turned off and left turned off in an unoccupied structure during winter. (See “Heading South for the Winter” procedures in maintenance section on page 9). Freeze damage to furnace would occur.

!| |---|

PERFORMING ROUTINE MAINTENANCE NOTE: The qualified installer or agency must use only factory-authorized replacement parts, kits, and accessories when modifying this product.

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 and qualified service agency personnel. Observe safety precautions in this manual, on tags, and on labels attached to the furnace, and other safety precautions that may apply.

With proper maintenance and care, your furnace will operate economically and dependably. Instructions for basic maintenance are found on this and the following pages. However, before beginning maintenance, follow these safety precautions:

|WARNING

Turn off electrical power supply to your furnace before removing the access doors to service or perform maintenance. A failure to follow this warning could result in personal injury/death or property damage.

!| |---|

|CAUTION

Although special care has been taken to minimize sharp edges, be extremely careful when handling parts or reaching into the furnace. Failure to follow this caution would result in minor personal injury.

!| |---|

####### FILTERING OUT TROUBLE

|CAUTION

Never operate your furnace without a filter in place. Doing so may damage the furnace blower motor. An accumulation of dust and lint on internal parts of your furnace can cause a loss of efficiency and would cause minor property or product damage.

!| |---|

A dirty air filter will cause a loss of airflow in your duct system. When excessive loss of airflow occurs, the furnace may cycle on its safety controls. If this condition is left unattended, the furnace will eventually lock out. It is recommended that the furnace air filter be checked every 3 or 4 weeks and cleaned if necessary.

If installed with factory-specified disposable media filter, check or replace filter before each heating and cooling season. Replace disposable media filter at least once a year.

The air filter is normally located in the blower compartment (See Fig. 3 or 4.) or in the factory-supplied filter cabinet attached to the side or bottom of the furnace casing. If air filter has been installed in another location, contact your dealer for instructions. To inspect, clean, and/or replace the air filter(s), follow these steps:

a. Remove filter cabinet door (See Fig. 25 and 26.) NOTE: It will be necessary to remove 1 thumbscrew

NOTE: If washable filter that was shipped with the furnace has been replaced by: a) Factory specified disposable media filter–Do not clean. If dirty, replace only with media filter having the same part number and size. Install with airflow direction arrow pointing towards blower.

29 30 b) Electronic air cleaner (EAC) – Refer to EAC Owner’s Manual for maintenance information.

If your furnace air filter needs to be replaced, be sure to use a factory-authorized filter of the same size that was orginally supplied. Use the filter tables and compare your furnace size with the proper filter size.

##### 23 24

##### 25

| | |---|

##### 26

##### 31 32

##### 27 28

##### 33 34

When dirt, soot, scale, or rust is allowed to build up, your furnace can suffer a loss of efficiency and perform improperly. Accumulations on the main burners can result in firing out of normal sequence. This delayed ignition creates an alarmingly loud sound.

##### 35 36

FURNACE AIR FILTER TABLE AIR FILTER LOCATED IN BLOWER COMPARTMENT

|FURNACE CASING WIDTH (IN.)|FILTER SIZE (IN)|FILTER SIZE (IN)|FILTER TYPE| |---|---|---|---| |FURNACE CASING WIDTH (IN.)|Side Return†|Bottom Return|FILTER TYPE| |17-1/2|(1) 16 x 25 x 1*|(1) 16 x 25 x 1*|Cleanable| |21|(1) 16 x 25 x 1|(1) 20 x 25 x 1*|Cleanable| |24-1/2|(1 or 2) 16 x 25 x 1|(1) 24 x 25 x 1*|Cleanable|

AIR FILTER LOCATED IN FILTER CABINET

|FILTER CABINET HEIGHT (IN)|FILTER SIZE (IN)|FILTER TYPE| |---|---|---| |16|(1) 16 x 25 x 1* or (1) 16 x 25 x 4-5/16|Cleanable or Disposable| |20|(1) 20 x 25 x 1* or (1) 20 x 25 x 4-5/16|Cleanable or Disposable| |24|(1) 24 x 25 x 1* or (1) 24 x 25 x 4-5/16|Cleanable or Disposable|

*Factory-provided with the furnace. Filters may be field modified by cuttingfilter material and support rods (3) in filters. Alternate sizes and additional filters may be ordered from your dealer.

† Upflow only.

|CAUTION

Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves, and appropriate protective clothing. Failure to follow this caution could result in personal injury.

!| |---|

##### COMBUSTION AREA AND VENT SYSTEM

|DANGER

If holes are found in the pipes or if any portion has become disconnected, toxic fumes can escape into your home. DO NOT OPERATE YOUR FURNACE. Call your dealer for service. Failure to follow this warning could result in personal injury or death.

!| |---|

Visually inspect the combustion area and vent system before each heating season. Make sure that all PVC pipes leading into the combustion area and vent are free from any cracks and sags. Check the combustion-air intake and vent pipe on the outside of your home for blockage.

|CAUTION

If your furnace makes an especially loud noise when the main burners light, shut down your furnace and call your dealer. Failure to follow this caution would result in minor property damage.

!| |---|

To inspect the combustion area and vent system, you will need a flashlight. Refer to Fig. 3 or 4, and proceed as follows:

Inspect the gas burners, igniter area, and remainder of furnace for dirt, rust, soot, or scale.

37 38

|CAUTION

If dirt, rust, soot, or scale accumulations are found, call your dealer. Do not operate your furnace. Failure to follow this caution would result in minor property or product damage.

!| |---|

Upflow Downflow

| | |---|

##### 39

####### HEADING SOUTH FOR THE WINTER? DON’T FORGET YOUR FURNACE!

|CAUTION

If the furnace is installed in an unconditioned space where the ambient temperatures may be 32°F or lower, freeze protection measures must be taken to prevent minor property or product damage.

!| |---|

Since the furnace uses a condensing heat exchanger, some water will accumulate in the unit as a result of the heat transfer process. Therefore, once it has been operated, it cannot be turned off and left off for an extended period of time when temperatures will reach 32°F or lower unless winterized. Follow these procedures to winterize your furnace:

|CAUTION

Do not use ethylene glycol (Prestone II antifreeze coolant or equivalent). Failure of plastic components will occur.

!| |---|

A CHECK-UP CHECKLIST

Your furnace represents an important investment in your family’s comfort and your home’s value. To keep it performing properly and to prevent future problems, have a trained service specialist give your furnace a professional check-up annually. The following checklist can be used as a guideline to proper service:

NOTE: 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.

BEFORE YOU REQUEST A SERVICE CALL

If your furnace is not operating or not performing properly, you may save the expense of a service call by checking a few things yourself before calling for service.

FOR INSUFFICIENT AIRFLOW:

Follow this checklist step by step, advancing to the next step only if furnace fails to start.

NOTE: Turn off electrical supply before continuing with checklist.

• Check for obstructions around the vent termination. If the furnace still fails to operate, call your service representative. For your convenience, record the furnace product and serial numbers on back page. Should you ever require service, you will have ready access to the information needed by your service representative.

This furnace has a light-emitting-diode (LED) status code display to aid the installer, service technician, or homeowner while installing or servicing the unit. The LED code can be seen by removing the main furnace door and viewing the LED through the view port in the blower access panel.

INSTALLATION DATA Date Installed Dealer Name Address City State Zip Telephone

AIR CONDITIONER OR HEAT PUMP OUTDOOR UNIT: Product No. Model No. Serial No. INDOOR COIL: Product No. Model No. Serial No.

##### FURNACE

Product No. Model No. Serial No.

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the “Heating Equipment’’ or “Air Conditioning Contractors & Systems’’ heading for dealer listing by brand name. Have available the Model No., Series Letter, & Serial No. of your equipment to ensure correct replacement part.

######## Carrier Corporation 7310 West Morris St. Indianapolis, IN 46231

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Copyright 2004 Carrier Corporation Form: OM58-114 Replaces: OM58-108 Printed in the U.S.A. 8-04 PC 101 Catalog No. 535-80143