Carrier INDUCED COMBUSTION 58YAV Instruction manual

58YAV
Induced-Combustion Furnaces
Visit www.carrier.com
Service and Maintenance Instructions
For Sizes 070-155, Series 100
NOTE: Read the entire instruction manual before performing any
service or maintenance.
These procedures are for size 66,000 through 154,000 Btuh input
units.
Index
Page
SAFETY CONSIDERATIONS .....................................................1
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE ...........................................................................2
CARE AND MAINTENANCE................................................2-10
Air Filter Arrangement .............................................................2
Blower Motor and Wheel......................................................2-3
Cleaning Heat Exchanger......................................................3-4
Electrical Controls and Wiring .............................................5-6
Troubleshooting ...................................................................6-10
Unit Wiring Diagram................................................................8
Troubleshooting Guide ........................................................9-10
Service Label ..........................................................................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
54-1999/ANSI Z223.1-1999 and the Installation Standards, Warm
Air Heating and Air Conditioning Systems (NFPA 90B)
ANSI/NFPA 90B. In Canada, refer to the CAN/CGA-B149.1- and
.2-M95 National Standard of Canada, 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, 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 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.
ama
CANADIAN GAS ASSOCIATION
®
A PP R O VED
R
REGISTERED QUALITY SYSTEM
A94085
Fig. 1—Model 58YAV Upflow Furnace
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.
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. 535-738
Printed in U.S.A.
Form 58YAV-2SM
Pg 1
8-99
Replaces: 58YAV-1SM
Tab 6a 8a
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation.
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.
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 and 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 from commercial sources) may
also be used to prevent ESD damage.
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 as necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
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 for filter size information.
Table 1—Filter Size Information for Upflow
Furnaces (In.)
FURNACE
CASING WIDTH
CARE AND MAINTENANCE
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.
14-3/16
17-1/2
21
24-1/2
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.
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.
Each furnace requires 1 or 2 filters which are installed in the
blower compartment. (See Fig. 2.) To remove filters for
cleaning or replacement, proceed as follows:
1. Disconnect electrical power before removing access doors.
2. Remove blower and control access doors.
2
dropped or bent as balance will be affected.
FLUE
COLLAR
8. If greasy residue is present on blower wheel, remove wheel
from the blower housing and wash it with an appropriate
degreaser. To remove wheel:
BLOCKED
VENT
SAFEGUARD
MOUNTING
SCREWS
RELIEF
BOX
GAS
VALVE
PRESSURE
SWITCH
a. Mark blower wheel location on shaft before disassembly to
ensure proper reassembly.
FLUE
COLLECTOR
BOX
b. Loosen setscrew holding blower wheel on motor shaft.
NOTE: Mark blower mounting arms, motor, and blower housing
so motor and each arm is positioned at the same location during
reassembly.
CONTROL
c. Mark blower wheel orientation and cutoff plate location to
ensure proper reassembly.
HUM
24V
COM W Y R G
d. Remove screws securing cutoff plate and remove cutoff
plate from housing.
FILTER
RETAINER
e. Remove bolts holding motor and 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 mount belly band
need not be removed unless motor is to be replaced.
WASHABLE
FILTER
A99284
Fig. 2—Model 58YAV Upflow Furnace
f. Remove blower wheel from housing.
3. Release filter retainer from clip at front of furnace casing. (See
Fig. 2.) For side return, clips may be used on either or both
sides of the furnace.
The blower wheel should not be dropped or bent as balance
will be affected.
4. Slide filter(s) out.
5. Furnaces are equipped with permanent, washable filters. Clean
filters with tap water. Spray water through filter in opposite
direction of airflow.
9. Reassemble motor and blower by reversing items 9a through
9f. Be sure to reattach ground wire.
10. Reinstall blower assembly in furnace.
6. Rinse and let dry. Oiling or coating of filter is NOT recommended or required.
11. Reinstall control and transformer support assembly in furnace.
7. Reinstall filter(s).
12. Reconnect blower leads to furnace control.
8. Replace blower and control access doors.
Refer to furnace wiring diagram and connect thermostat leads
if previously disconnected. (See Fig. 7.)
9. Restore electrical power to furnace.
BLOWER MOTOR AND WHEEL
NOTE: Refer to Table 2 for motor speed lead relocation if leads
were not identified before disconnection.
The following steps should be performed by a qualified service
technician.
To ensure long life, economy, and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.
→Table 2—Speed Selector
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.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Remove control and blower access doors.
3. Disconnect blower leads from furnace control. Note wire color
and location for reassembly.
COLOR
SPEED
Black
Yellow (When
present)
Blue
Red
White
High
FACTORYATTACHED TO
Cool
Medium-High
Spare
Medium-Low
Low
Common
Heat
Spare
L2/COM
All other factory wires can be left connected, but field
thermostat connections may need to be disconnected depending on their length and routing.
Heating air speed selection MUST be adjusted to provide
proper air temperature rise as specified on the rating plate.
Failure to adjust the heating speed may shorten heat exchanger life.
4. Remove 2 screws securing control and transformer support to
furnace.
5. Hang control and transformer support to side of furnace
casing.
6. Remove screws holding blower assembly to blower deck and
slide blower assembly out of furnace.
13. Turn on electrical supply. Manually close blower access door
switch. Use a piece of tape to hold switch closed. Check for
proper rotation and speed changes between heating and
cooling by jumpering R to W and then R to Y on furnace
control thermostat terminals.
7. Clean blower wheel and motor using a vacuum with soft brush
attachment. Do not remove or disturb balance weights (clips)
on blower wheel blades. The blower wheel should not be
3
(3.) Insert twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or strike with
ball-peen hammer. TIGHTNESS IS VERY IMPORTANT.
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.
Failure to follow this warning could result in electrical shock,
personal injury, or death.
(4.) Remove metal screw fitting from wire brush to allow
insertion into cable.
b. Clean each heat exchanger cell.
NOTE: If thermostat terminals are jumpered before blower access door switch is closed, blower will run for 90 sec before
beginning a heating or cooling cycle.
(1.) Attach variable-speed, reversible drill to end of 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. 3.)
14. If furnace is operating properly, REMOVE TAPE TO RELEASE BLOWER ACCESS DOOR SWITCH, replace
blower access door.
→ CLEANING HEAT EXCHANGER
(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.
The following steps should be performed by a qualified service
technician.
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, they 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, incorrect size, or
damaged manifold orifice(s), improper gas, or a restricted heat
exchanger. Action must be taken to correct the problem.
(4.) 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.
(5.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
(6.) Using vacuum cleaner, remove residue from each cell.
(7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
If it becomes necessary to clean the heat exchanger because of dust
or corrosion, proceed as follows:
(8.) Reinstall cell inlet plates and burner assembly. Care
must be exercised to center burners in cell openings.
1. Turn gas and electrical power to furnace OFF.
2. Remove control access door.
10. Clean flame sensor with fine steelwool.
3. Disconnect vent connector from furnace flue collar.
11. Remove old sealant from center panel and collector box flange
and apply new sealant to collector box flange and reinstall on
center panel, making sure all 8 screws are secure.
4. Remove 2 screws that secure relief box. (See Fig. 2.)
5. Disconnect wires to the following components. Mark wires to
aid in reconnection of:
d. Limit overtemperature switch(es).
NOTE: A releasing agent such as PAM cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or Dow-Corning 738) are needed before starting
installation. DO NOT substitute any other type of RTV sealant.
G.E. 162 (P771-9003) is available through RCD in 3-oz. tubes.
e. Gas valve.
12. Reinstall relief box and inducer assembly.
f. Hot surface igniter.
g. Flame-sensing electrode.
NOTE: If inducer assembly gasket is damaged, use RTV sealant
to seal inducer assembly to collector box.
h. Flame rollout switch(es), if applicable.
13. Reconnect wires to the following components.
a. Blocked vent safeguard switch.
b. Inducer motor.
c. Pressure switch.
6. Remove complete inducer assembly and relief box from
furnace.
a. Blocked vent safeguard switch.
7. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage collector box.
c. Pressure switch.
b. Inducer motor.
d. Limit overtemperature switch(es).
8. Remove burner assembly and cell inlet plates. IMPORTANT:
Replace screws in center panel and cells before cleaning.
NOTE: Be careful when removing burner assembly to avoid
breaking igniter. See Fig. 4 for correct igniter location.
9. Using field-provided small wire brush, steel spring cable,
reversible electric drill, and vacuum cleaner, clean cells as
follows:
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).
(2.) Use 1/4-in. diameter wire brush (commonly known as
25-caliber rifle cleaning brush).
NOTE: The materials needed in (1.) and (2.) can usually be
purchased at local hardware stores.
A91252
Fig. 3—Cleaning Heat Exchanger Cell
4
installation, service, or maintenance will cause this fuse to blow. If
fuse replacement is required, use ONLY a 3-amp fuse. The control
LED will display status code 24 when fuse needs to be replaced.
11 32"
13 32"
BURNER
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.
CELL
PANEL
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.
HOT
SURFACE
IGNITER
ASSEMBLY
→ The control in this furnace is equipped with an LED status light to
C
L
7 8"
IGNITER
C
L
BURNER
aid in installation, servicing, and troubleshooting. It can be viewed
through the sight glass or window on the blower access door. The
control indicates status with the LED on continuously, rapid
flashing, or a code composed of 2 digits. (The first digit is the
number short flashes, the second is the number of longs flashes.)
For an explanation of status codes, refer to service label located on
blower access door or Fig. 8, and the troubleshooting guide.
The control stores 1 status code (the last status code to occur) for
a period of 48 hr or until the 115- or 24-v power is interrupted.
IGNITER
ASSEMBLY
NOTE: Look into blower access door sight glass for current LED
status BEFORE removing the blower access door. Removing
blower access door will open blower access door switch and
terminate 115-v power to control, and status code will be erased.
A99286
Fig. 4—Position of Igniter to Burner
e. Gas valve.
f. Hot surface igniter.
1. To retrieve status code, proceed with the following:
g. Flame-sensing electrode.
NOTE: NO thermostat signal shall be present at control, and all
blower off delays must be completed.
h. Flame rollout switch(es), if applicable.
a. Leave 115-v power to furnace turned on.
14. Reinstall vent connector on furnace flue collar. After fully
assembling vent connector to furnace flue collar, securely
fasten vent connector to flue collar with 2 field-supplied,
corrosion-resistant, sheet metal screws located 180° apart and
midway up the collar.
b. Look into blower access door sight glass for current LED
status.
NOTE: Leave blower access panel installed to maintain power to
control to view current LED status.
15. Turn electrical power and gas to ON.
c. Remove control access door.
16. Set thermostat and check furnace for proper operation.
d. BRIEFLY remove either wire from the main limit switch
until LED goes out, then reconnect it.
17. Verify blower airflow and speed changes between heating and
cooling.
NOTE: If wire to main limit is disconnected longer than 4 sec,
main blower starts, and retrieval request is ignored.
18. Check for gas leaks.
2. When above items have been completed, the following will
occur:
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.
a. LED flashes a status code 4 times. Record this status code
for further troubleshooting.
b. Inducer motor starts and continues to run the entire
component test.
19. Replace control access door.
ELECTRICAL CONTROLS AND WIRING
c. Hot surface igniter is energized for 15 sec, then deenergized.
d. Main blower operates at heating speed 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.
e. Main blower operates at cooling speed for 10 sec, then
turns off.
The electrical ground and polarity for 115-v wiring must be
properly maintained. Refer to Fig. 5 for field wiring information
and to Fig. 7 for furnace wiring information.
f. Inducer motor stops.
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."
NOTE: If the polarity is not correct, the STATUS LED on the
control will flash rapidly and prevent the furnace from heating.
The control system also requires an earth ground for proper
operation of the control and flame-sensing electrode.
3. Operate furnace through 1 heat cycle to test for proper
operation and check LED status.
on the control. (See Fig. 6.) Any shorts of the 24-v wiring during
4. If furnace is operating properly and LED indicates proper
operation, replace control access door.
→ The 24-v circuit contains an automotive-type, 3-amp fuse located
5
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
NOTE 2
W
FIVE WIRE
THREE-WIRE
HEATING-ONLY
C
R
G
Y
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
DISCONNECT
208/230- OR
460-V
THREE
PHASE
BLOWER DOOR SWITCH
BLK
BLK
WHT
WHT
GND
115-V FIELDSUPPLIED
DISCONNECT
W
GND
AUXILIARY
J-BOX
C
O
N
T
R
O
L
R
208/230-V
SINGLE
PHASE
G
C
GND
NOTE 1
CONDENSING
UNIT
Y
24-V
TERMINAL
BLOCK
FURNACE
TWO
WIRE
NOTES: 1. Connect Y-terminal in furnace as shown for proper blower 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.
A98521
Fig. 5—Heating and Cooling Application Wiring Diagram
5. Component Test can also be initiated by performing the
following:
e. Component Test will function as described in item 2 above.
f. Check LED status.
a. Remove control access door.
g. If LED status indicates proper operation, RELEASE
BLOWER ACCESS DOOR SWITCH, replace blower
access door, and replace control access door.
b. Remove blower access door.
c. Manually close blower access door switch.
TROUBLESHOOTING
Refer to the service label. (See Fig. 8.) 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.
Blower access door switch opens 115-v power to control. 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.
→
d. BRIEFLY short (jumper) TEST, 3/16-in. quick-connect
terminal on control (adjacent to LED status light), and
COM-24V terminal on furnace control thermostat terminal
block. (See Fig. 6.)
The guide will help to identify the problem or failed component.
After replacing any component, verify correct operation sequence.
NOTE: If TEST to COM-24V terminals are jumpered longer than
2 sec, LED will flash rapidly, and test request will be ignored.
6
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 &
STATUS 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 1.0 AMP MAX)
115-VAC (L1)
POWER
SUPPLY
HOT SURFACE
IGNITER
CONNECTOR
EAC 2 (WHITE)
115-VAC (L2) NEUTRAL
CONNECTION
INDUCER MOTOR
CONNECTOR
A99258
Fig. 6—Furnace Control
7
8
PR1
GV
GVR
HI/LO
HSI
HSIR
HUM
IDM
IDR
ILK
JB
LED
LGPS
LS
OL
ALS
BLWR
BLWM
BVSS
CAP
CPU
DSS
EAC-1
EAC-2
FL
FRS
FSE
FU1
FU2
HSI
2
1
2
3
BLK
WHT
COM
PR2
L2
EAC-2
IDM
HEAT SPARE-2
EAC-1
24 VAC-3A
FU1 FUSE
BLOWER
SPEED COOL SPARE-1
SELECT
SEC-2
6 5 4
9 8 7
3 2 1
SEC-1
PL1
LED
G
R
Y
W
COM
HUM
BLU
WHT (COM)
RED (LO)
BLU (MED LO)
YEL (MED HI)
NOTE #7
WHT
FRS1
FSE
LS
ORN
ILK
OL
BRN
BRN
GRN
NOTE #5
2-C
GV
3-P
NOTE #13
(WHEN USED)
LGPS
GRN
WHT
BLK
FU2
NEUTRAL
L1
FUSED DISCONNECT
SWITCH (WHEN REQ'D)
NOTE #4
CAP
GRN
WHT (COM)
WHT
BLK
FL
1-M
PRS
FIELD SPLICE
PLUG RECEPTACLE
EQUIPMENT GROUND
YEL
L1
FU1
IDR
HSIR
BLWR
HSIR
IDR
CPU
BLWR
GVR-2
SEC-1
TRAN
PR1
EAC-2
EAC-1
PL2
HI/LO
GVR-1
GVR
SEC-2
24VAC
PR2
9
6
5
8
2
3
4
1
7
2
OL
1-M
3-P
DSS
NOT USED
NOT USED
PL1
NOTE #13
CAP
FL
2-C
GV
NOTE #14
FSE
NOTE #5
ALS
(WHEN USED)
NOTE #11
NOTE #13
PRS
LGPS
(WHEN USED)
LS
FRS2
IDM
BLWM
START
(WHEN USED)
NOTE #14
BVSS
(WHEN USED)
NOTE #11
FRS1
NOT USED
3 PL3
HSI
LO
MED LO
MED HI
HI
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
COM
1
2
1
NOTE #7
2 PL5
1
COM
COOL
SPARE-1
115VAC
HI/LO
SPARE-2
HEAT
EQUIPMENT GROUND
TO 115VAC FIELD DISCONNECT
NOTE #4
NOTE #6
NEUTRAL
L2
A98200e
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 some downflow models only. When used, FL is on upflow
models only.
12. Some models may have spade quick connect terminals.
13. Factory connected when LGPS is not used.
14. Factory connected when BVSS is not used. BVSS used when Chimney Adapter Accessory Kit is
installed.
322869-101 REV. E
NOTES:
COM
G
Y
W
R
NOTE #12
HUM
TEST/TWIN
ILK
L1
Fig. 7—Unit Wiring Diagram
FIELD WIRING TERMINAL
FIELD GROUND
CONDUCTOR ON PCB
FIELD WIRING (24VAC)
FACTORY WIRING (24VAC)
FIELD WIRING (115VAC)
FACTORY WIRING (115VAC)
UNMARKED TERMINAL
PCB TERMINAL
JUNCTION
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
JB
BLWM
START
PCB
PL1
PL2
PL3
PL5
PRS
TEST/TWIN
TRAN
BLK
RED
BLU
FRS2
ORN
(WHEN USED)
NOTE #11
ALS
(WHEN USED) NOTE #11
NOTE #14
ORN
(WHEN USED)
NOTE #14
BVSS
ORN
BLK (HI)
RED
WHT
RED
ORN
DSS
AUXILIARY LIMIT SWITCH, OVERTEMP. -MANUAL RESET, SPST-(N.C.)
BLOWER MOTOR RELAY, SPST-(N.O.)
BLOWER MOTOR
BLOCKED VENT SHUTOFF SWITCH, SPST - (N.C.)
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
PL3
SW1
SW2
TEST/TWIN
BLOWER
OFF
DELAY
HI/LO
RELAY
BLWR
GVR
225 SEC
180 SEC
IDR
BLK
L1
120 VAC
BLK
135 SEC
WHT
HSIR
BLK
90 SEC
BLOWER OFF DELAY
SELECTION CHART
NOTE #9
(NOT ON ALL MODELS)
WHT
PCB
1.5 AMP
TRAN
SERVICE
If status code recall is needed, do not remove power or blower door. Briefly remove and then
reconnect one main limit wire to display stored status code.
LED CODE
STATUS
CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and
SEC-2.
CONTINUOUS ON - Control has 24VAC power.
RAPID FLASHING - Line voltage (115VAC) 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
(115VAC or 24VAC) to control is interrupted or 48 hours after each fault is cleared.
12 BLOWER ON AFTER POWER UP (115VAC or 24 VAC) - 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 - Control will auto reset after
three hours. Reset switch or replace 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: - Mis-wired gas valve
-Defective control (Valve relay)
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is
de-energized. Inducer will run until fault is cleared.
Check for: - Leaky gas valve
- Stuck-open gas valve
23 PRESSURE SWITCH DID NOT OPEN - Check for:
- Obstructed pressure tubing.
- Pressure switch stuck closed.
24 SECONDARY VOLTAGE FUSE IS OPEN
Check for: - Short circuit in secondary voltage (24VAC) wiring.
31 PRESSURE, DRAFT SAFEGUARD, AUX-LIMIT SWITCH (when used*) OR BLOCKED
VENT SWITCH (when used) DID NOT CLOSE OR REOPENED
(DOWNFLOW ONLY*) If open longer than five minutes, inducer shuts off for 15
minutes before retry. Check for:
- Proper vent sizing
- Low inducer voltage (115VAC)
- Defective inducer motor
- Restricted vent
*- Defective Blower motor or capacitor
- Defective pressure switch
- Excessive wind
- Inadequate combustion air supply
- Disconnected or obstructed pressure tubing
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. Flame roll-out switch requires manual reset.
Check for:
- Defective blower motor or 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).
- Open Flame Roll-out Switch, or fuse link. Manual reset or replace.
34 IGNITION PROVING FAILURE - Control will try three more times before
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 steel wool).
- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).
- Gas valve defective or gas valve turned off.
- Defective Hot Surface Ignitor
- Manual valve shut-off.
- Low inlet gas pressure.
- Control ground continuity
- Green wire MUST be connected to furnace sheet metal.
- Inadequate flame carryover or rough ignition.
- Flame sensor must be ungrounded.
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 "Com
24V" terminal. Status LED will flash code and then turn ON the inducer motor.
The inducer motor will run for the entire component test. The hot surface ignitor,
blower motor-heat speed, and blower motor-cool speed will be turned ON for
10-15 seconds each. Gas Valve and Humidifier will not be turned on.
5
2
4
1
7
TEST
3
8
LED
9
6
Com
24V
HUM
W
Y
R
G
320615-102 REV. K (LIT)
A99233
Fig. 8—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.
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, the control will go
through a brief component test
sequence. The inducer will start
and run for the entire component
test. The HSI, blower motor heat
speed, and blower motor cool
speed will run for 10-15 sec each.
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 center.
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 hrs.
See No. 34
13 LIMIT OR FLAME ROLLOUT
SWITCH LOCKOUT Limit switch was open longer
than 3 minutes. Auto-reset will
occur after 3 hrs. Flame rollout
switch requires manual reset.
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,
R-W closed.
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
check 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,
ignitor, or flame sensor, the
system can be operated in the
component test mode to check
the ignitor. First, remove the
R thermostat connection from the
control center 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,
manual reset.
• Inadequate combustion air
supply (flame rollout switch
only).
• Dirty filter.
• Defective limit switch or
connections.
• Loose blower wheel.
31 PRESSURE 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 ignition period, blower
will come on for 90 sec
recycle delay.
• Inadequate combustion air.
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. Check
for 115v between pins 1 and 2 on
the control center. Was 115v present
for the 17-sec period?
NO
NO
NO
NO
NO
Fixed.
YES
Will main burner ignite and stay on?
YES
Is current near typical value?
NO
NO
A99123
Replace control center.
Replace electrode.
Check connections and retry. If
current is near typical value and
control will not stay on, replace
control center.
NO
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 microamps
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 center.
Replace control center.
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
[ ] Classroom Service Training
A94328
Copyright 1999 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
58yav2sm
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. 535-738
Printed in U.S.A.
Form 58YAV-2SM
Pg 12
8-99
Replaces: 58YAV-1SM
Tab 6a 8a