Weathermaker 9200
Weathermaker 9200
®
HEATING & COOLING
NOTE TO INSTALLER:
THIS MANUAL MUST BE LEFT WITH THE
EQUIPTMENT USER.
Your new furnace is truly a triumph of technology in home ••••• ••••• •••••
®
• • • • •
• • • • •
SPLIT-SYSTEM U L T R
G A S
A H I G H
F U R N
E F F I C
A N C E
I E N C Y
Product No.
Model No.
Serial No.
INDOOR COIL:
Product No.
Model No. 2
MODEL 58MVP
Serial No. VARIABLE-CAPACITY FURNACE
2
FURNACE COMPONENTS
1 Combustion-air intake connection to ensure
17
2
contaminant-free air (right or left side). 3
2 Burner sight glass for viewing burner flame. 1
3 Burner assembly (inside). Operates with energy- 4 12
saving inshot burners and hot surface ignitor for safe,
dependable heating.
18
5 5
4 Redundant gas valve. Safe, efficient. Features 1 gas
control with 2 internal shut-off valves. 11 14
5 Vent outlet. Uses PVC pipe to carry vent gases from 16
the furnace’s combustion system (right or left side). 6 15
6 Inducer motor. Pulls hot flue gases through the heat 9
exchangers, maintaining negative pressure for added 13
safety.
7
7 Blower access panel safety interlock switch. 10
19
8 Air filter and retainer.
8
9 Condensate drain connection. Collects moisture
condensed from burned gases for disposal into home
drain system.
3
10 Heavy-duty blower. Circulates air across the heat MODELS 58MXA AND 58MCA
exchangers to transfer heat into the home. FURNACES (UPFLOW POSITION)
11 Secondary condensing heat exchanger (inside).
Wrings out more heat through condensation.
Constructed with Polypropylene-laminated steel to
ensure durability. 17
2
12 Primary serpentine heat exchanger (inside). 3
Stretches fuel dollars with the S-shaped heat-flow 12
design. Solid construction of corrosion-resistant 1
aluminized steel means reliability. 4
18
13 Control center. 5 6
14 3-amp fuse provides electrical and component 5
protection.
11
15 Light emitting diode (LED) on control center. Code 15
lights are for diagnosing furnace operation and
service requirements. 14
16 Pressure switch(s) ensure adequate flow of flue 13
products through furnace and out vent system.
7
17 Rollout switch (manual reset) to prevent 16 19
overtemperature.
9
18 Junction box for 115-v electrical power supply.
10
8
20
19 Transformer (24v) behind control center provides
low-voltage power to furnace control center and
thermostat.
4
20 Limit switch (manual reset) on 58MVP only. MODEL 58MVP
FURNACE (UPFLOW POSITION)
3
IMPORTANT FACTS This furnace contains SAFETY DEVICES which must be
MANUALLY RESET. If the furnace is left unattended for an
Your gas furnace uses air from outside the home for com- extended period of time, have it checked periodically for
bustion and venting. It is not to be installed using in-house proper operation. This precaution will prevent problems
air. Therefore, both pipes must terminate outside the struc- associated with no heat, such as frozen water pipes, etc. See
ture and must not be obstructed in any way. section “Before You Request a Service Call” in this manual.
SAFETY CONSIDERATIONS
Installation and service of 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 oper-
ations must be performed by trained service personnel.
Observe safety precautions in this manual, on tags, and
labels attached to the furnace and other safety precautions
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 words DANGER, WARNING, and
CAUTION. These words are used with the safety-alert sym-
bol. DANGER identifies the most serious hazards which will
result in severe personal injury or death. WARNING signi-
fies hazards which could result in personal injury or death.
CAUTION is used to identify unsafe practices which would
5 result in minor personal injury or product and property
To minimize the possibility of serious personal injury, fire, damage.
damage to your furnace, 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. STARTING YOUR FURNACE
• Do not cover the furnace, store trash or debris near it, or in Instead of a continuously burning pilot flame which wastes
any way block the flow of fresh air to the unit. valuable energy, your furnace uses an automatic, hot surface
• A furnace installed in an attic or other insulated space must ignition system to light the burners each time the thermo-
be kept free and clear of insulating material. Examine the stat turns on your furnace. Follow these important
furnace area when installing the furnace or adding more safeguards:
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.
7
• Never attempt to light the burners manually with a match
or other source of flame.
• Read and follow the operating instructions on the furnace,
especially the item that reads as follows:
6 Wait 5 minutes to clear out any gas. Then smell for gas,
NOTE: The qualified installer or agency must use only
factory-authorized replacement parts, kits, and accessories including near the floor. If you smell gas, STOP! Follow “B”
when modifying this product. in the safety information above on this label. If you don’t
smell gas, go to the next step.
4
• If a suspected malfunction occurs with your gas control
system, such as the burners not lighting when they should,
refer to the shutdown procedures on the furnace, or in the
section, “Shutting Down Your Furnace” and call your dealer
as soon as possible.
! 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 in-
jury or death.
10 11
CHECK AIR FILTER: Before attempting to start your fur-
nace, be sure the furnace filter is clean and in place. See sec-
tion “Performing Routine Maintenance” in this manual.
Then proceed as follows:
OFF
STEPS FOR STARTING YOUR FURNACE
1. Set your room thermostat to the lowest temperature
setting. (See Fig. 8.)
2. Close the external manual gas valve. (See Fig. 9.)
3. Turn off electrical supply to the furnace. (See Fig. 10.)
12
NOTE: If the burners fail to ignite after 4 attempts, the fur-
CL nace control system will lockout. If lockout occurs, main
O
burners fail to light, or blower does not come on, shut down
SE
50 90
70
SYSTEM FAN
COOL OFF HEAT AUTO ON
8 9
4. Remove the furnace access door. (See Fig. 11.)
5. Turn control knob on the gas valve to the OFF position
and wait 5 minutes. Then smell for gas, including near
the floor. If you smell gas, STOP! Follow operating
instructions on furnace access door. (See Fig. 12.)
6. After waiting 5 minutes, turn control knob on the gas 13 14
valve to the ON position. (See Fig. 12.)
7. Replace furnace access door. (See Fig. 13.)
OP
8. Turn on electrical supply to the furnace and wait
EN
50 90
! CAUTION
Although special care has been taken to minimize
50
70
90
sharp edges, be extremely careful when handling
parts or reaching into the furnace.
SYSTEM FAN
COOL OFF HEAT AUTO ON
FILTERING OUT TROUBLE
16 17 A dirty filter will cause a loss of airflow in your duct system.
When excessive loss of airflow occurs, the furnace may
1. Set your room thermostat to the lowest temperature cycle on the safety controls. If this condition is left unat-
setting. (See Fig. 16.) tended, the furnace will eventually lockout. It is recom-
2. Close the external manual gas valve. mended that the furnace filter be checked every 3 or 4 weeks
(See Fig. 9.) and cleaned if necessary.
3. Turn off electrical supply to the furnace. ! CAUTION
(See Fig. 17.)
Never operate your furnace without a filter in place.
4. Remove furnace access door. Doing so may damage the furnace blower motor.
(See Fig. 11.) An accumulation of dust and lint on internal parts
5. Turn control knob on the gas valve to OFF position. of your furnace can cause a loss of efficiency.
(See Fig. 18.)
The air filter is normally located in the blower compartment.
6. Replace furnace access door. (See Fig. 13.) (See Fig. 3 or 4.) If filter has been installed in another loca-
7. If the furnace is being shut down because of a tion, contact your dealer for instructions. To inspect, clean
malfunction, call your dealer as soon as possible. and/or replace the air filter(s), follow these steps:
1. Turn off electrical supply to the furnace. (See Fig. 17.)
2. Remove furnace access door. (See Fig. 19.)
! CAUTION
3. Remove blower access panel. (See Fig. 20.)
Furnace is not to be installed, operated, and then
turned off and left turned off in an unoccupied
structure during winter. (See winterizing proce- NOTE: It will be necessary to remove 1 screw.
dures in maintenance section). • FILTER(S) LOCATED IN BOTTOM:
1. Slide filter retainer sideways until it is free of latch. (See
Fig. 21 and 22.)
PERFORMING ROUTINE MAINTENANCE • FILTER LOCATED IN SIDE:
With proper maintenance and care, your furnace will oper- 1. Remove filter retainer from latch. (See Fig. 23.)
ate economically and dependably. Instructions for basic 2. Gently remove filter and carefully turn the dirty side up
maintenance, which can easily be followed, are found on this (if dirty) to avoid spilling dirt from the filter.
and the following pages. However, before beginning mainte- (See Fig. 24.)
nance, follow these safety precautions: 3. Inspect the filter. If torn, replace it.
6
FURNACE FILTER TABLE
FURNACE
CASING FILTER SIZE* FILTER
WIDTH (IN.) (IN.) TYPE
17-1/2 (1) 16 x 25 x 1 Cleanable
21 (1) 20 x 25 x 1 Cleanable
24-1/2 (2) 16 x 25 x 1 Cleanable
* Furnace with a side return-air inlet may have a different filter size. Measure the filter to obtain the
correct size.
19 20
25 26
! CAUTION
If dirt, rust, soot, or scale accumulations are found,
23 24 call your dealer. Do not operate your furnace.
If your furnace filter needs to be replaced, 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 3. Inspect the combustion-air and vent pipes for sags, holes,
the proper filter size. cracks, or disconnections.
7
! CAUTION
Do not use ethylene glycol (Prestone II antifreeze
coolant or equivalent). Failure of plastic compo-
nents will occur.
27 28a
! 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 FUR-
NACE. Call your dealer for service.
29 A CHECKUP CHECKLIST
Your furnace represents an important investment in your
HEADING SOUTH FOR THE WINTER? family’s comfort and your home’s value. To keep it per-
forming properly and as a preventative to future problems,
DON’T FORGET YOUR FURNACE! have a trained service specialist give your furnace a profes-
sional check-up annually. The following checklist can be
used as a guideline to proper service:
! CAUTION • Inspect all flue gas passages, burners, heat exchangers,
If the furnace is installed in an unconditioned coupling box(es), and inducer assembly.
space where the ambient temperatures may be • Inspect all combustion-air and vent piping inside structure
32°F or lower, freeze protection measures must be and pipe terminations outside the structure.
taken. • Check gas pipes leading to and inside of your furnace for
leaks.
Since the furnace uses a condensing heat exchanger, some • Inspect and clean the blower motor and wheel.
water will accumulate in the unit as a result of the heat trans- NOTE: The inducer and blower motors are pre-lubricated
fer process. Therefore, once it has been operated, it cannot and require no additional lubrication. These motors can be
be turned off and left off for an extended period of time when identified by the absence of oil ports on each end of the
temperatures will reach 32°F or lower unless winterized. Fol- motor.
low these procedures to winterize your furnace: • Inspect and change or clean air filter(s) if necessary.
1. Obtain propylene glycol (RV/swimming pool anti- • Inspect all supply- and return-air ducts for obstructions, air
freeze or equivalent). leaks, and insulation. Remedy any problem when necessary.
8
• Inspect the return-air duct connection(s) at the furnace to • Is thermostat switch on HEAT?
ensure it is physically sound, sealed to the furnace casing,
• Check fuses and circuit breakers. Is electrical supply on?
and terminates outside the space containing the furnace.
• Inspect electrical wiring, connections, and components for • Is manual shut-off valve in gas supply pipe in open posi-
loose connections. tion? (Follow start-up procedures if you open gas valve.)
• Perform an operational checkout to determine whether NOTE: Turn off electrical supply before continuing with
your furnace is working properly and if it requires checklist.
adjustments. • Is control knob on gas valve in ON position? (Follow start-
• Inspect all condensate drain tubes and condensate trap up procedures if you must reset knob to ON.)
assembly for leaks. The condensate removal system should
be cleaned annually by a qualified service agency. Refer • Check manual reset flame rollout switch located on the
to the Service and Maintenance Instructions for further burner box. (See Fig. 2 or 3.) If furnace has experienced high
information. temperature conditions, this switch will shut off the furnace.
Reset it by pushing the button on the switch. If it trips again,
• Examine the physical support of the furnace. Support shut down the furnace and call for service. See section “Shut-
should be sound with no cracks, sagging, gaps, etc. around ting Down Your Furnace” in this manual.
the base.
• Check furnace for any obvious signs of deterioration. • Check for obstructions around the vent termination.
If the furnace still fails to operate, call your service
BEFORE YOU REQUEST A SERVICE CALL representative.
If your furnace is not operating or not performing properly, For your convenience, record the furnace product and serial
you may save the expense of a service call by checking a few numbers on page 2. Should you ever require service, you
things yourself before calling for service. will have ready access to the information needed by your
service representative.
FOR INSUFFICIENT AIRFLOW:
• Check for dirty air filter(s). This furnace has an LED operation and fault code display
to aid the installer, service technician, or homeowner
• Check for blocked return-air or supply-air grilles through- while installing or servicing the unit. The LED code can
out your home. Ensure they are open and unobstructed. be seen by removing the access door and viewing the
If problem still exists, call your dealer for service. LED(s) through the view port in the blower access panel.
IF FURNACE FAILS TO OPERATE: NOTE: Removing the blower access panel or turning off the
Follow this checklist step by step, advancing to the next step 115-v electrical power supply will terminate LED diagnostic
only if furnace fails to start. code display.
• Check thermostat for proper temperature. Is thermostat To decipher the meaning of the LED code, and suggested
set above room temperature? action, the following cross-reference can be used.
M Check to be sure manual shut-off valve in gas supply pipe is in the open position. (Follow start-up proce-
dure if you open gas line.)
Ignition Lockout or NOTE: Turn off the electrical supply and remove access doors before continuing with this
14 or 34 checklist.
Ignition Proving Fault
M Check to be sure control knob on gas valve is in ON position. (Follow start-up procedures if you must reset
dial to ON.)
24 Furnace Fuse Open M Check for blown fuse and possible short in 24-v wiring.
M Check to make sure that all PVC pipes leading into the combustion-air intake and vent/exhaust are free
31 Pressure Switch Not Closed from any cracks and sags. Also check the combustion-air intake and vent/exhaust pipes on the outside of
your home for blockage.
NOTES:
1. Light on continuously means control has power and working properly.
2. The status codes are a 2 digit number. The first digit is determined by the number of short flashes of the light and the second digit is determined by number of
long flashes of the light.
9
MODEL 58MVP DIAGNOSTIC CHART
(See Fig. 4.)
FAULT
CODE FAULT CODE DESCRIPTION CHECKLIST
M Check to be sure manual shut-off valve in gas supply pipe is in open position. (Follow start-up procedure if
you open gas line.)
NOTE: Turn off the electrical supply and remove access doors before continuing with this checklist.
Ignition Lockout or
14 or 34
Ignition Proving Fault M Check to be sure control knob on gas valve is in ON position. (Follow start-up procedures if you must reset
dial to ON).
M Check for disconnected ground wire.
24 Furnace Fuse Open M Check for blown fuse and possible short in 24-v wiring.
NOTES:
1. Red light 1 on continuously means furnace is operating in emergency heat.
2. Red light 2 on continuously means the microprocessor board has malfunctioned.
3. Yellow light on continuously means furnace is operating in high heat.
4. Green light on continuously means furnace is operating in low heat.
5. The status codes are a 2 digit number. The first digit is determined by the number of flashes of the yellow light and the second digit is determined by number of
flashes of the green light.
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.
Copyright 1994 Carrier Corporation Form: OM58-67 Replaces: OM58-61 Printed in the U.S.A. 6-94 PC 101 Catalog No. 535-882