Carrier 58GFA Furnace Problems

rakes9720

We have an 11 year old Carrier Model 58GFA funace with problems. When the furnace turns on, only the inducer motor runs. We connected a wire to bypass the pressure switch (bad idea) and the gas valve opens and the burners light; however, they are noisier and the touch the top of the hole leading into the heat exchanger. When the blower fan turns on, the flames turn orange like dust is blowing on them. If you open the blower door slightly, the flames go into the heat exchanger as they should. Also, if you remove the filter, the flames turn orange. Also, the fusible link had to be replaced and the draft safeguard switch trips occasionally. Finally, the flue pipe is not as hot as usual and sometimes the pilot light goes out. We recently replaced the inducer motor. I don't know how much (if any) of this is related. Any help would be appriciated. Thanks.

HVAC Doc

Check the flue pipe for obstructions. I would also make sure the inducer is sealed properly to its mount. Personally, I would call my contractor back and have him come out and and re-check his repair.

rakes9720

Thanks for answering.
We had the vent pipes cleaned out and checked for blockages (there were a lot of white ashes everywhere), but this did not change anything.

NickTech

What it appears you have is a breach in the integurity of you heat exchanger!
What that means is that the component that seperates your breathable air with the toxic products of combustion (carbon monoxide) is leaking. The tell tale sign is when your blower comes on and pressurizes the system, the leak is allowing the air the blow over the flames. Hence the flame dancing about, and all the soot and ash, and the pilot going out. If your flue was blocked it would over heat, it sounds like the heat is escaping through this crack, and you are expieriencing a cooler flue pipe. Now, your pressure switch is not making; either because it is malfuctioning, or most likely it does not sense the negative pressure drawn thru the combustion chamber because this crack or leak is stealing it, (so to speak).
Carbon monoxide is a killer. Shut the system down, have it tested and replace it!!
:Thumbs:

rakes9720

Did model 58GFA have a lot of problems. Do heat exchangers fail after 11 years?

Comfortman

the 58gfa was the lowest cost model of its kind with a carrier name on it
they are nothing BUT problems
its next to impossible to keep the inducer motor from sucking the pilot out
ive seen many where the pilot orifice was improperly enlarged just to end the nightmare of callbacks
do yourself a favor and replace it
i also agree with the above post that you may have a cracked heat exchanger
its just not worth it...they have come a long way in 11 years

NickTech

sure they do, i've seen them go as soon as the next year after install. there a a lot of contributing factors. As a general rule of thumb, a furnace life expectancy is about 12-15 years.

rakes9720

Thanks for the help. I've heard that Goodman furnaces are not reliable, and I also heard that Amana furnaces are high quality, and this year, an advertisement says that Goodman now uses Amana technologies. Would Goodman be a good choice now or not?

Comfortman

ill give you three guesses who makes amana equipment and the first two dont count

the amana is however their higher end line and fewer corners are cut

tinner73

you have a dog of a furnace now. don't make the same mistake with a Goodman/Amana. look into a Rheem or something comparable. this isn't a good time to be cheap, you'll have this furnace for a long time.

rakes9720

Are Carrier furnaces more dependable now, or should I find another company like Rheem?

tinner73

Rheem is good.

rakes9720

Thanks for all the help, and sorry for so many questions. Took off the inducer motor to look, and everything inside is black like carbon deposits. It was silver colored before. Any ideas on why it is there?

rakes9720

On Wednesday, the furnace exploded, waking people up, splitting all four heat exchangers, blowing the chimney cap off, and throwing ash in the basement and on the roof. Definatly time for a new one!! Not sure on what caused it, but it will not light without holding a torch in front of the burners, and the fan blows the flame completely out of the furnace because of the cracks. We have been running the heat pump (furnace blower running), is this okay, or should we not use the furnace at all? Thanks

NickTech

ummmmmmm.........

vlux

shame on you techs[?] for bashing a furnace manufacturer. I have installed Goodman for years without problems. Look at the components on a lot of differant furnacesv and you will be surprised at the similar parts or manufactures. All furnace manufacturers have there share of bad models. Dont bash guys, unless you have logitimate reasons. JMO Victor

HeatPro

I guess this was dredged up from 2005 to boost something. The question as to whether to use the Carrier furnace that blew the heat exchanger apart for the blower only for the heat pump was amusing - and not answered. Guess many thought the guy was joking around. I wonder what he has now - or if he's alive.


There were Goodman problems in the distant past that made a rep; but the newer tube exchangers don't seem to have complaints. Furnace manufacturers have no plans to continue failure - it just doesn't make money.

http://johnmills.net/hvacshots/pages/gmpheatex.html

This popular 80% furnace has been sold since the early 90s. The first few years of production have been suffering from failed crimp rings on the heat exchager. The cells are held together by the rings punched as you can see. But in the circled case, the ring failed allowing the metal to separate as it heats up. First symptom is tripped rollout switch because the draft is reduced and the flames aren't pulled in. Goodman was offering some labor allowances so check with your supplier if you find a bad one.

http://www.cpsc.gov/cpscpub/prerel/prhtml01/01189.html

neolitic

Was interesting to see that the guy was soooo stubborn
that he actually kept putzing around til it literally blew up!

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(Sorry....it seems there really are dumb questions)

GreaseMonkey

Sounds like this guy is pulling everyones leg here, i.e. still trying to light it after all four heat exchangers have blown apart.

HeatPro

Yeah. There are extra 'flame' points if you can look like you confused a pro by confusing a novice. Time on hand.