Carrier 58WAV Instruction manual

58WAV, 58ZAV
Induced-Combustion Furnaces
Service and Maintenance Instructions
For Sizes 045-155, Series 131
NOTE: Read the entire instruction manual before performing any
service or maintenance.
This symbol → indicates a change since the last issue.
Index
Page
SAFETY CONSIDERATIONS..................................................1-2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE ...........................................................................2
CARE AND MAINTENANCE................................................2-11
Air Filter Arrangement..........................................................2-3
Blower Motor and Wheel......................................................3-4
Cleaning Heat Exchanger......................................................4-5
Electrical Controls and Wiring.................................................6
Troubleshooting ...................................................................6-11
Unit Wiring Diagram................................................................8
Service Label ............................................................................9
Troubleshooting Guide ......................................................10-11
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 (NFGC) NFPA No.
54-1992/ANSI Z223.1-1992. In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1and .2-M91 Natural Gas and Propane 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 words DANGER, WARNING, and 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 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.
A94087
Fig. 1—Model 58ZAV Horizontal
®
ama
CANADIAN GAS ASSOCIATION
A PP R O VED
R
A94086
Fig.
2—Model 58ZAV
Downflow
A94085
Fig. 3—Model 58WAV
Upflow
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. 535-876
Printed in U.S.A.
Form 58W,Z-5SM
Pg 1
8-95
Replaces: 58W,Z-4SM
Tab 6a 8a
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.
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.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
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.
Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Follow the operating
instructions on label attached to furnace. A failure to follow
this warning could result in personal injury.
The minimum maintenance that should be performed on this
equipment is as follows:
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating
and cooling season. Clean and lubricate as necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
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.).
As with any mechanical equipment, personal injury can result
from sharp metal edges, etc., therefore, be careful when
removing parts.
AIR FILTER ARRANGEMENT
The air filter arrangement may vary depending on the application.
Refer to Table 1 or 2 for filter size information.
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching
control or wires.
Table 1—Filter Size Information for
Downflow/Horizontal Furnaces (In.)
5. Use this procedure for installed and uninstalled (ungrounded)
furnaces.
FURNACE
CASING WIDTH
14-3/16
17-1/2
21
24-1/2
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.
FILTER QUANTITY
AND SIZE
(2) 14 X 20 X 1
(2) 14 X 20 X 1
(2) 16 X 20 X 1
(2) 16 X 20 X 1
FILTER
TYPE
Cleanable
Cleanable
Cleanable
Cleanable
Table 2—Filter Size Information for Upflow
Furnaces (In.)
7. An ESD service kit (available from commercial sources) may
also be used to prevent ESD damage.
FURNACE
CASING WIDTH
CARE AND MAINTENANCE
14-3/16
17-1/2
21
24-1/2
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.
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
FILTER
TYPE
Cleanable
Cleanable
Cleanable
Cleanable
* Factory-provided with the furnace. Filters may be field modified as required
by cutting and folding the frame as indicated on the filter.
2
d. Furnaces are equipped with permanent, washable filters.
Clean filters with tap water. Spray water through filter in
opposite direction of airflow.
e. Rinse and let dry. Oiling or coating of filters is not
recommended or required.
f. Reinstall filters.
g. Replace blower access door.
AIRFLOW
h. Restore electrical power to furnace.
2. Upflow
Each furnace requires 1 or 2 filters which are installed in the
blower compartment. (See Fig. 6.) To remove filters for
cleaning or replacement, proceed as follows:
a. Disconnect electrical power before removing access doors.
A94307
Fig. 4—Horizontal Filter Arrangement
b. Remove blower and control access doors.
c. Release filter retainer from clip at front of furnace casing.
(See Fig. 6.) For side return, clips may be used on either or
both sides of the furnace.
AIRFLOW
INSTALLATION
POSITION
OF FILTERS
d. Slide filter(s) out.
e. Furnaces are equipped with permanent, washable filters.
Clean filters with tap water. Spray water through filter in
opposite direction of airflow.
RETURN-AIR
PLENUM
f. Rinse and let dry. Oiling or coating of filter is not
recommended or required.
g. Reinstall filter(s).
h. Replace blower and control access doors.
i. Restore electrical power to furnace.
BLOWER MOTOR AND WHEEL
For long life, economy, and high efficiency, clean accumulated dirt
and grease from the blower wheel and motor annually.
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 in AUTO mode), or every 2 years if
motor is in continuous operation (thermostat FAN in ON mode).
NOTE: Remember to disconnect the electrical supply before
removing access doors.
ACCESS DOOR
Clean and lubricate as follows:
A88486
1. Remove
2
screws
from
blower
access
door
(downflow/horizontal furnace only) and remove blower access
door.
Fig. 5—Downflow Filter Arrangement
2. Remove vent pipe enclosure (downflow/horizontal furnace
only) and disconnect short piece of vent pipe from relief box.
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.
3. Disconnect wires from auxiliary limit on blower housing
(downflow/horizontal furnace only).
4. Remove control.
1. Downflow/Horizontal
5. Disconnect electrical leads from control. (See Fig. 6 or 7.)
Note location of wires for reassembly.
Each furnace requires 2 filters which are installed in the
return-air duct. (See Fig. 4 and 5.) To remove filters for
cleaning or replacement, proceed as follows:
6. Remove screws holding blower assembly to blower deck and
slide blower assembly out of furnace.
a. Disconnect electrical power before removing blower access
door.
7. Loosen screw in strap holding motor capacitor to blower
housing and slide capacitor out from under strap.
b. Remove 2 screws from front of door and remove blower
access door.
8. Mark blower wheel, motor, and motor support in relation to
blower housing before disassembly to ensure proper reassembly.
c. Reach up behind top plate, tilt filters toward center of
return-air plenum, remove filters, and clean as needed.
Replace if torn.
9. Loosen setscrew holding blower wheel on motor shaft.
3
VENT PIPE
ENCLOSURE
DRAFT
SAFEGUARD
SWITCH
RELIEF
BOX
AUXILIARY
LIMIT
SWITCH
(WHEN USED)
24V
MOUNTING
SCREWS
COM W
FLUE
COLLECTOR
BOX
HUM
MOUNTING
SCREWS
CONTROL
BOARD
Y
R
G
CONTROL
BOARD
RELIEF
BOX
FILTER
RETAINER
DRAFT
SAFEGUARD
SWITCH
HUM
24V
COM W Y R G
WASHABLE
FILTER
MANUAL
RESET LIMIT
SWITCHES
A92063
A92064
Fig. 6—Model 58WAV Upflow
Fig. 7—Model 58ZAV Downflow
10. 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.
18. Reconnect wires to auxiliary limit switch on blower housing
(downflow/horizontal furnace only).
19. Reinstall vent pipe and enclosure (downflow/horizontal furnace only).
11. Lubricate motor (when oil ports are provided).
a. Remove dust caps or plugs from oil ports located at each
end of motor.
20. Turn on electrical power and check for proper rotation and
speed changes between heating and cooling.
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.
21. Replace blower access door. Secure with 2 screws
(downflow/horizontal furnace only).
CLEANING HEAT EXCHANGER
c. Allow time for total quantity of oil to be absorbed by each
bearing.
The following steps should be performed by a qualified service
technician.
d. Wipe excess oil from motor housing.
NOTE: Deposits of soot and carbon indicate the existence of a
problem which needs to be corrected. Take action to correct the
problem.
e. Replace dust caps or plugs on oil ports.
12. Remove blower wheel from housing.
a. Mark cutoff location to ensure proper reassembly.
If it becomes necessary to clean the heat exchanger because of
carbon deposits, soot, etc., proceed as follows:
b. Remove screws holding cutoff plate and remove cutoff
plate from housing.
1. Turn off gas and electrical power to furnace.
c. Lift blower wheel from housing through opening.
2. Remove 2 screws from front of blower access door
(downflow/horizontal furnace only) and remove control and
blower access doors.
13. 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.
3. Remove vent pipe enclosure (downflow/horizontal furnace
only) and disconnect vent pipe from relief box.
14. Reinstall blower wheel by reversing items 12 a through c. Be
sure wheel is positioned for proper rotation.
4. Remove 2 screws that secure relief box. (See Fig. 6 or 7.)
5. Disconnect wires to the following components.
15. Reassemble motor and blower by reversing items 5 through
10. If motor has ground wire, be sure it is connected as before.
a. Draft safeguard switch
b. Inducer motor
c. Pressure switch
d. Limit overtemperature switch(es)
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.
e. Gas valve
f. Hot surface ignitor
g. Flame-sensing electrode
h. Two wiring connectors leading to control
16. Reinstall blower assembly in furnace.
6. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage sealant.
17. Reinstall control. Connect blower electrical leads to control.
Please note that the common wire connection is 3/16 in. and
all other wire connections are 1/4 in. for assembly. DO NOT
FORCE.
7. Remove complete inducer assembly from furnace, exposing
flue openings.
4
8. Clean cells using field-provided small wire brush, steel spring
cable, reversible electric drill, and vacuum cleaner.
11 32"
13 32"
BURNER
a. Assemble wire brush and steel spring cable.
(1.) Use 48 in. of 1/4-in. diameter high-grade steel spring
cable (commonly known as drain clean-out or RotoRooter cable).
CELL
PANEL
(2.) Use 1/4-in. diameter wire brush (commonly known as
25-caliber rifle cleaning brush).
HOT
SURFACE
IGNITOR
ASSEMBLY
NOTE: The materials needed in items (1.) and (2.) can usually be
purchased at local hardware stores.
(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.
(4.) Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Clean each heat exchanger cell.
(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. 8.)
C
L
7 8"
IGNITOR
C
L
BURNER
IGNITOR
ASSEMBLY
A93347
Fig. 9—Position of Ignitor to Burner
9. 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.
10. Clean and replace flue collector assembly, making sure all 8
screws are secure.
11. Reinstall relief box.
12. Reconnect wires to the following components.
a. Draft safeguard switch
b. Inducer motor
A91252
c. Pressure switch
Fig. 8—Cleaning Heat Exchanger Cell
d. Limit overtemperature switch(es)
(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.
e. Gas valve
f. Hot surface ignitor
g. Flame-sensing electrode
(4.) Remove burner assembly and cell inlet plates.
h. Two wiring connectors leading to control
13. Reconnect vent pipe to relief box. Replace vent pipe enclosure
(downflow/horizontal furnace only).
Be very careful when removing the burner assembly to avoid
breaking the ignitor. See Fig. 9 for the correct ignitor location.
14. Replace blower access door only.
15. Turn on electrical power and gas.
(5.) Replace screws in center panel and cells before
cleaning.
16. Set thermostat and check furnace for proper operation.
(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.
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.
(7.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
(8.) Remove residue from each cell using vacuum cleaner.
(9.) Clean burner assembly using vacuum cleaner with soft
brush attachment.
17. Check for gas leaks.
(10.) Reinstall cell inlet plates and burner assembly. Care
must be exercised to center the burners in the cell
openings.
19. On downflow/horizontal furnaces, remove blower access
door, replace control access door first, then replace blower
access door and secure with 2 screws in front of door.
18. Replace control access door on upflow furnace.
5
ELECTRICAL CONTROLS AND WIRING
a. LED flashes a fault code 4 times. Record this fault code for
further troubleshooting.
b. Inducer motor operates for 10 sec, then turns off.
There may be more than 1 electrical supply to the unit. Check
accessories and cooling unit for additional electrical supplies.
c. Hot surface ignitor is energized for 15 sec, then deenergized.
The electrical ground and polarity for 115-v wiring must be
maintained properly. Refer to Fig. 10 for field wiring information
and to Fig. 12 for unit wiring information.
d. Main blower operates at cooling speed for 10 sec, then
turns off.
e. Main blower operates at heating speed for 10 sec, then
turns off.
NOTE: If the polarity is not correct, the STATUS LED on the
control center will flash rapidly and prevent the furnace from
operating. The control system also requires an earth ground for
proper operation of the control board and flame-sensing electrode.
Items a through e above will assist in furnace troubleshooting
since all components are functionally operated except the gas
valve. This procedure is also referred to as "Component Test."
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control board. (See Fig. 11.) 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 fuse of
identical size.
3. Operate furnace through 1 heat cycle to test for proper
operation and check LED status.
4. If furnace is operating properly and LED indicates proper
operation, replace control access door.
5. Component Test can also be initiated by performing the
following:
With power to the unit disconnected, check all electrical connections for tightness. Tighten all screws on electrical connections. If
any smoky or burned connections are found, disassemble the
connection, clean all parts, strip wire, and reassemble properly and
securely.
a. Remove control access door.
b. Remove blower access door.
c. Manually close blower access door switch.
Reconnect electrical power to the unit and observe unit through 1
complete operating cycle. Electrical controls are difficult to check
without proper instrumentation; if there are any discrepancies in
the operating cycle, contact your dealer and request service.
Blower access door switch opens 115-v power to control
center. No component operation can occur. Caution must be
taken when manually closing this switch for service purposes.
Failure to follow this warning could result in personal injury
or death.
For an explanation of fault codes, refer to service label located on
blower access door or Fig 13, and the troubleshooting guide.
The control center stores 1 fault code (the last fault to occur) for a
period of 48 hrs or until the 115- or 24-v power is interrupted.
d. BRIEFLY short (jumper) TEST, 1/4-in. quick-connect
terminal on control center (adjacent to LED diagnostic
light), and Com terminal on thermostat connection block.
(See Fig 11.)
NOTE: Removing blower access door will open blower access
door switch and terminate 115-v power to control center, and fault
code will be erased. Look into blower access door sight glass for
current LED status.
NOTE: If TEST to Com terminals are jumpered longer than 2 sec,
LED will flash rapidly, and retrieval request will be ignored.
1. To retrieve fault code, proceed with the following:
NOTE: NO thermostat signal may be present at control center,
and all blower time delay off periods must be completed.
e. Component Test will function as described in item 2 above.
f. Check LED status.
a. Leave 115-v power to furnace turned on.
g. If LED status indicates proper operation, release blower
access door switch, replace blower access door, and replace
control access door.
b. Look into blower access door sight glass for current LED
status.
NOTE: Leave blower access panel installed to maintain power to
control center to view current LED status.
TROUBLESHOOTING
Refer to the service label. (See Fig. 13.) Pages 10 and 11 contain
a troubleshooting guide. This guide 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.
c. Remove control access door.
d. BRIEFLY remove either wire from the main limit switch
until LED goes out, then reconnect it.
NOTE: If wire to main limit is disconnected longer than 4 sec,
main blower starts, and retrieval request is ignored.
The guide will help to identify the problem or failed component.
After replacing any component, verify correct operation sequence.
2. When above items have been completed, the following will
occur:
6
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
THERMOSTAT
TERMINALS
Y
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. 10—Heating and Cooling Application Wiring Diagram
BLOWER OFF DELAY
ADJUSTMENT SWITCH
24V THERMOSTAT
TERMINALS
G
R
Y
TEST/TWIN
W
Com
24V
HUM
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX)
LED OPERATION &
DIAGNOSTIC LIGHT
HARNESS CONNECTOR
SEC-1
24V TRANSFORMER SEC-2
3-AMP FUSE
SPARE 1
COOL
HEAT
BLOWER SPEED
SELECTION TERMINALS
SPARE 2
EAC 1 (BLACK)
EAC-ELECTRONIC AIR CLEANER
TERMINALS (115-VAC 1.5 AMP MAX)
115-VAC (L1)
POWER
SUPPLY
HOT SURFACE
IGNITOR
CONNECTOR
EAC 2 (WHITE)
115-VAC (L2) NEUTRAL
CONNECTION
INDUCER MOTOR
CONNECTOR
A93052
Fig. 11—Control Board
7
8
GV
GVR
HI/LO
HSI
HSIR
HUM
IDM
IDR
ILK
JB
LED
LGPS
LS
OL
ALS
BLWR
BLWM
CAP
CPU
DSS
EAC-1
EAC-2
FL
FRS
FSE
FU1
FU2
HSI
2
PL3
1
2
3
BLK
WHT
C OM
PR2
L2
BLOWER
SPEED
SELECT
EAC-2
IDM
HEAT SPARE-2
EAC-1
COOL SPARE-1
24 VAC-3A
FU1
FUSE
DSS
WHT (COM)
RED (LO)
BLU (MED LO)
NOTE #8
ILK
OL
BLK
RED
BLU
PRS
JB
BRN
GRN
WHT
BLK
FU2
L1
L1
FU1
IDR
HSIR
HSIR
HI/LO
IDR
CPU
BLWR
GVR-2
SEC-1
TRAN
PR1
EAC-2
EAC-1
NOTE #6
BLWR
2
1
HI/LO
PR2
PL5
GVR-1
GVR
SEC-2
24VAC
115VAC
PL2
2
1
1
9
6
5
8
2
3
4
1
7
2
3
HSI
OL
1-M
3-P
DSS
NOT USED
NOT USED
PL1
PRS
FRS2
IDM
CAP
FSE
NOTE #5
2-C
L2
FL
ALS
(WHEN USED)
NOTE #11
GV
LS
BLWM
START
(WHEN USED
FRS1
NOT USED
PL3
LO
MED LO
MED HI
HI
SPARE-2
NOTE #8
COOL
COM
COM
SPARE-1
HEAT
EQUIPMENT GROUND
A95335
1. If any of the original equipment wire is replaced use wire rated for 105°C.
2. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).
3. Blower motor speed selections are for average conditions, see installation instructions for details on
optimum speed selection.
4. Use only copper wire between the disconnect switch and the furnace junction box (JB).
5. This wire must be connected to furnace sheetmetal for control to detect flame.
6. Replace only with a 3 amp fuse.
7. Yellow lead not on all motors.
8. Blower-on delay, gas heating 45 seconds, cooling or heat pump 2 seconds.
9. Blower-off delay, gas heating 90, 135, 180 or 225 seconds, cooling or heat pump 90 seconds.
(135 seconds only on some models)
10. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will auto-reset
after three hours.
11. When used auxiliary limit switch (ALS) is on downflow models only. When used FL is on upflow
models only.
12. Some models may have spade quick connect terminals.
322869-101 REV. B
NOTES:
COM
G
Y
W
R
NOTE #12
HUM
TEST/TWIN
ILK
SCHEMATIC DIAGRAM
TO 115VAC FIELD DISCONNECT
(NATURAL GAS & PROPANE)
NOTE #4
NEUTRAL
→ Fig. 12—Unit Wiring Diagram
PLUG RECEPTACLE
FIELD SPLICE
EQUIPMENT GROUND
FIELD GROUND
FIELD WIRING TERMINAL
CONDUCTOR ON PCB
FIELD WIRING (24VAC)
FIELD WIRING (115VAC)
FACTORY WIRING (24VAC)
FACTORY WIRING (115VAC)
PCB TERMINAL
UNMARKED TERMINAL
JUNCTION
NEUTRAL
L1
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
NOTE #4
CAP
NOTE #5
2-C
GV
3-P
PRINTED CIRCUIT BOARD
9-CIRCUIT CONNECTOR
2-CIRCUIT PCB CONNECTOR
3-CIRCUIT IDM CONNECTOR
2-CIRCUIT HSI/PCB CONNECTOR
PRESSURE SWITCH, SPST-(N.O.)
COMPONENT TEST & TWIN TERMINAL
TRANSFORMER-115VAC/24VAC
GRN
BLWM
START
GRN
WHT (COM)
GRN
WHT
BLK
FL
1-M
BLU
YEL
FRS2
BRN
(WHEN USED)
PCB
PL1
PL2
PL3
PL5
PRS
TEST/TWIN
TRAN
WHT
FSE
LS
FRS1
(WHEN USED)
NOTE #12
ALS
YEL (MED HI)
BLK (HI)
RED
WHT
RED
ORN
AUXILIARY LIMIT SWITCH, OVERTEMP. -MANUAL RESET, SPST-(N.C.)
BLOWER MOTOR RELAY, SPST-(N.O.)
BLOWER MOTOR
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
DRAFT SAFEGUARD SWITCH
ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.5 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FUSIBLE LINK
FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FLAME PROVING ELECTRODE
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
(FIELD INSTALLED & SUPPLIED)
GAS VALVE-REDUNDANT OPERATORS
GAS VALVE RELAY, DPST-(N.O.)
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
HOT SURFACE IGNITOR (115 VAC)
HOT SURFACE IGNITOR RELAY, SPST-(N.O.)
24VAC HUMIDIFIER CONNECTION (.5 AMP. MAX.)
INDUCED DRAFT MOTOR
INDUCED DRAFT RELAY, SPST-(N.O.)
BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
JUNCTION BOX
LIGHT-EMITTING DIODE FOR STATUS CODES
LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LIMIT SWITCH, AUTO RESET, SPST(N.C.)
AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP. SW.
LEGEND
1
1
2
PL5
PL2
LED
G
R
Y
W
C OM
HUM
SEC-2
6 5 4
9 8 7
3 2 1
SEC-1
PL1
TEST/TWIN
HI/LO
RELAY
BLWR
GVR
225 SEC
180 SEC
135 SEC
IDR
BLK
120 VAC
L1 PR1
HSIR
BLK
90 SEC
BLOWER OFF DELAY
SELECTION CHART
NOTE #9
(NOT ON ALL MODELS)
BLK
SW2
1.5 AMP
PCB
WHT
BLOWER
OFF
DELAY
SW1
WHT
TRAN
SERVICE
STATUS
LED CODE
CONTINUOUS OFF CONTINUOUS ON RAPID FLASHING -
Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
Control has 24V power.
Line voltage (115V) polarity reversed. If twinned, refer to twinning
kit instructions.
EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST
DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY
THE NUMBER OF LONG FLASHES.
11 NO PREVIOUS CODE - Stored status codes are erased when power (115V or 24V) to control is
interrupted or 48 hours after each fault is cleared.
12 BLOWER ON AFTER POWER UP (115V or 24V) - Blower runs for 90 seconds, if unit
is powered up during a call for heat (R-W closed).
13 LIMIT OR FLAME ROLL-OUT SWITCH LOCKOUT - Auto reset after three hours. For flame
roll-out switch or fuse link, refer to #33.
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.
21 GAS HEATING LOCKOUT - Control will NOT auto reset.
Check for: - Stuck gas valve relay on control or miswire to gas valve circuit.
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is
de-energized. Inducer will run until fault is cleared. Check for:
- Stuck-open gas valve or leaky gas valve.
23 PRESSURE SWITCH DID NOT OPEN Check for:
- Obstructed pressure tubing.
- Defective pressure switch (stuck closed).
24 SECONDARY VOLTAGE FUSE IS OPEN
Check for: - Short circuit in secondary voltage (24V) wiring.
31 PRESSURE, DRAFT SAFEGUARD, OR AUXILIARY-LIMIT (when used) SWITCH DID
NOT CLOSE OR REOPENED - If open longer than five minutes, inducer shuts off for
15 minutes before retry. Check for:
- Proper vent sizing and condensate pitch.
- Inadequate Combustion air supply.
- Vent restriction or high winds.
- Low inducer voltage.
- Defective inducer motor or start capacitor.
- Disconnected or obstructed pressure tubing.
- Defective pressure switch or connections. If it opens after trial for ignition period, blower will
come on for 90 second recycle delay.
33 LIMIT OR FLAME ROLL-OUT SWITCH IS OPEN - If open longer than three minutes, code
changes to #13. Check for:
- Defective blower motor or start capacitor.
- Dirty filter or restricted duct system.
- Loose blower wheel.
- Defective switch or connections.
- Inadequate Combustion air supply Flame Roll-out Switch or fuse link.
- Open Flame Roll-out switch,or fuse link. Manual reset or replace.
34 IGNITION PROVING FAILURE - Control will try three more times before a lockout #14
occurs. If flame signal lost after trial for ignition period, blower will come on for
90 second recycle delay. Check for:
- Oxide buildup on flame sensor (clean with fine sandpaper).
- Proper flame sense microamps (.5 microamps D.C. minimum).
- Gas valve turned off. - Manual shut-off valve. - Low inlet gas pressure.
- Green wire MUST be connected to furnace sheet metal.
- Inadequate flame carryover or rough ignition.
COMPONENT TEST
To initiate the component test sequence,shut OFF the room thermostat or disconnect the "R"
thermostat lead. Briefly short the TEST terminal to the ’C’ terminal. Status LED will flash code and
then turn on the inducer motor, hot surface igniter, blower motor-heat speed, and blower motor-cool
speed for 10-15 seconds each.
3
9
6
TEST
4
1
7
STATUS
2
5
8
HUM
C
W
Y
R
G
320615-102 REV. D
A95336
→ Fig. 13—Service Label
9
10
START
Go to section with status code
determined.
Determine status code. The
status code is a 2 digit number
with the first digit determined by
the number of short flashes and
the second digit by the number of
long flashes.
Once status code is determined,
the control will go through a brief
component test sequence by
sequentially operating the inducer
motor, HSI, blower motor relay
heat speed, and cool speed for
approximately 10-15 sec, then go
off.
YES
Is red LED status light blinking
ON/OFF slowly with a
combination of short and long
flashes?
NO
Is red LED status light blinking
rapidly without a pause?
YES
Is red LED status light on?
NO
YES
NO
YES
Was there a previous fault code
other than No. 11?
Check for previous fault by
momentarily shorting the TEST
terminal and the C terminal until
the LED goes out. LED will flash
the status code of any previous
fault or the code No. 11 (1 short
and 1 long flash) if no previous
fault. After the control repeats the
code 3 times, it will sequentially
operate the inducer motor, HSI,
blower motor relay heat speed,
and cool speed for approximately
10-15 sec, then go off.
Check for correct line voltage
polarity. If units are twinned,
check for proper low-voltage
(24v) transformer phasing.
Replace control center.
YES
Is there 24v at SEC-1 and SEC-2?
YES
Is there 115v at L1 and L2?
NO
NO
NO
Run system through a heating or
cooling cycle to check operation.
Status codes are erased after 48
hrs or whenever power (115v
or 24v) is interrupted.
YES
Does control respond to W, Y,
or G 24-vac thermostat signals?
Replace transformer.
Replace door switch.
YES
Is there 115v going to switch?
YES
Is door switch closed?
TROUBLESHOOTING GUIDE
NO
NO
NO
Replace control if it does not
respond to 24-vac signal at W, Y,
or G screw terminals.
YES
Is 24 vac present at W, Y, or G
terminals on the control?
NO
Check room thermostat or
interconnecting cable.
NO
Close circuit breaker and
go back to start.
Check for continuity in wire from circuit
breaker to furnace.
YES
Is circuit breaker closed?
Close door switch and go to start.
11
24 LOW-VOLTAGE FUSE IS
OPEN - Check for:
• Short in low-voltage wiring
including thermostat leads
shorting to ductwork or
furnace cabinet. Disconnect
thermostat leads to isolate
short circuit.
23 PRESSURE SWITCH WILL
NOT OPEN - Check for:
• Disconnected or obstructed
pressure tubing.
• Defective pressure switch.
22 ABNORMAL FLAME PROVING
SIGNAL - Flame was sensed
while gas valve was
de-energized. Inducer will run
until fault is cleared.
Check for:
• Stuck open gas valve solenoid
or leak.
• Defective control board.
21 GAS HEATING LOCKOUT Turn off power and wait 5
minutes to retry.
Check for:
• Stuck closed gas valve relay
on control.
• Miswire or short to gas valve
wire.
14 IGNITION LOCKOUT - System
failed to ignite gas and prove
flame in 4 attempts. Control will
auto-reset in 3 hr.
See No. 34
13 LIMIT OR FLAME ROLLOUT
SWITCH LOCKOUT - Limit
switch was open longer than
3 minutes. Auto-reset will occur
after 3 hr. For flame rollout switch
or fuse link, see No. 33.
12 BLOWER ON AFTER POWER
UP (115V OR 24V) - Normal
operation. Blower will run for 90
sec when furnace power is
interrupted during a call for heat
and R-W closes.
11 NO PREVIOUS FAULT - Faults
are erased after 48 hrs or
whenever power (115V or 24V)
is interrupted. Run system
through a heating or cooling
cycle to recheck system.
YES
34 IGNITION PROVING FAILURE If flame is not sensed during the
trial for ignition period, the control
will repeat the ignition sequence
3 more times before going into
lockout, No. 14.
If flame signal is lost after trial for
ignition period, blower will come
on for 90 sec recycle delay.
Check for the following items first
before proceding to the next step.
• Gas valve turned off.
• Manual shut-off valve.
• Green wire must be connected
NO
to furnace sheet metal.
To determine whether the
problem is in the gas valve,
igniter, or flame sensor, the
system can be operated in the
component test mode to check
out the ignitor. First, remove the
R thermostat connection from the
control board and initiate the
component test sequence. Does
the ignitor glow orange/white hot
by the end of the 17 sec warm-up
period?
33 LIMIT OR FLAME ROLLOUT
SWITCH IS OPEN - If limit
switch is open longer than 3
minutes, code changes to No. 13.
Check for:
• Blower motor failure.
• Motor start capacitor.
• Open flame rollout switch or
fuse link, manual reset or
replace
• Inadequate combustion air
supply (flame rollout
switch or fuse link).
• Dirty filter.
• Defective limit switch or
connections.
• Loose blower wheel.
31 PRESSURE, DRAFT
SAFEGUARD (WHEN USED),
OR AUXILIARY LIMIT (WHEN
USED) SWITCH WILL NOT
CLOSE OR REOPEN - If open
longer than 5 minutes, inducer
shuts off for 15 minutes before
retry.
Check for:
• Proper vent sizing or pitch or
sag.
• Vent restrictions or high winds.
• Defective inducer motor.
• Low-line voltage (115v).
• Motor start capacitor.
• Low inlet gas pressure.
• Defective pressure switch or
connections. If it opens after
trial for igniton period, blower
will come on for 90 sec
recycle delay.
• Inadequate combustion air
(for draft safeguard and
auxiliary limit switches only).
Allow blower to come on and repeat
test to check for intermittent
operation.
YES
Do main burners stay on?
YES
Do main burners ignite?
YES
Does gas valve open and allow gas
to flow?
YES
Reconnect the R thermostat lead
and set thermostat to call for heat.
Connect voltmeter across gas valve
connections. Does gas valve
receive 24v?
Check for continuity in the harness
and ignitor. Replace defective
component.
YES
Unplug ignitor harness from control
center and inititate another
component test sequence and check
for 115v between pins 1 and 2 on
the board. Was there 115v present
for the 17 sec period?
NO
NO
NO
NO
NO
Fixed.
NO
Replace control board.
Will main burner ignite and stay on?
YES
NO
Replace electrode.
Is current near typical value?
YES
NO
Check connections and retry. If
current is near typical value and
control will not stay on, replace
control board.
Clean flame sensor with fine
sandpaper and recheck current.
Current is nominally 4.0 to 6.0
microamps.
YES
Repeat call for heat and check flame
sensor current during trial for ignition
period. Is the dc microamperes
below 0.5?
Check for:
• Inadequate flame carryover on
rough ignition.
• Low inlet gas pressure.
Check that all gas valves are turned
on. Replace valve.
Check connections. If OK, replace
control board.
Replace control board.
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
Copyright 1995 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
[ ] Classroom Service Training
58wz5sm
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. 535-876
Printed in U.S.A.
Form 58W,Z-5SM
Pg 12
8-95
Replaces: 58W,Z-4SM
Tab 6a 8a