Carrier Deluxe 58MVP Instruction manual

58MVB
Deluxe 4-Way
Multipoise Variable-Capacity
Condensing Gas Furnace
Visit www.carrier.com
Service and Maintenance Instructions
For Sizes 040–120, Series 100
NOTE: Read the entire instruction manual before starting the
installation.
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could cause corrosion of heat
exchanger, fire, 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.
This symbol → indicates a change since the last issue.
A93040
TABLE OF CONTENTS
SAFETY CONSIDERATIONS .....................................................1
GENERAL......................................................................................2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........2
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could result in
dangerous operation, serious injury, death, or property damage.
Improper servicing could result in dangerous operation,
serious injury, death, or property damage.
- Before servicing, disconnect all electrical power to furnace.
- When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.
- Verify proper operation after servicing.
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow this warning could result in possible damage
to this equipment, serious personal injury, or death.
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.
CARE AND MAINTENANCE.....................................................3
Cleaning and/or Replacing Air Filter.......................................3
Blower Motor and Wheel Maintenance...................................4
Cleaning Burners ......................................................................5
Cleaning Heat Exchangers........................................................6
Flushing Collector Box and Drainage System ........................7
Servicing Hot Surface Igniter...................................................7
Electrical Controls and Wiring.................................................9
Checking Heat Tape Operation (If Applicable) ....................10
Winterizing..............................................................................10
WIRING DIAGRAMS.................................................................12
TROUBLESHOOTING ...............................................................12
SAFETY CONSIDERATIONS
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on the unit 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 hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may 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.
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified service
agency personnel should install, repair, or service heating equipment.
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
Printed in U.S.A.
Catalog No. 58MVB–1SM
Pg 1
8-05
Replaces: 58MVP-12SM
Tab 6a 8a
(NFPA 90B) ANSI/NFPA 90B. Wear safety glasses and work
gloves. Have a fire extinguisher available during start-up and
adjustment procedures and service calls.
GENERAL
→ This furnace can be installed as a direct vent (2-pipe) or
non-direct vent (1-pipe) condensing gas furnace. These instructions are written as if the furnace is installed in an upflow
application. An upflow furnace application is where the blower is
located below the combustion and controls section of the furnace,
and conditioned air is discharged upward. Since this furnace can be
installed in any of the 4 positions shown in Fig. 2, you may need
to revise your orientation to component location accordingly.
AIRFLOW
UPFLOW
HORIZONTAL
RIGHT
HORIZONTAL
LEFT
DOWNFLOW
AIRFLOW
A05069
AIRFLOW
→ Fig. 1—Multipoise Furnace in Upflow Orientation
AIRFLOW
A93041
Fig. 2—Multipoise Orientation
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
UNIT DAMAGE HAZARD
Failure to follow this caution may damage furnace components.
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.
Untrained personnel can perform basic maintenance functions
described in User’s Information Manual 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.
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.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Be careful of sharp metal edges, etc. Use care and wear
protective clothing, gloves, and safety glasses when removing
parts.
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.).
→ Follow
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching
control or wires.
all safety codes including the National Fuel Gas Code
(NFGC) NFPA 54-2002/ANSI Z223.1-2002 in the USA, CSA
B149.1-05 National Standard of Canada, Natural Gas and Propane
Installation Codes (NSCNGPIC) in Canada, and the Installation
Standards, Warm Air Heating and Air Conditioning Systems
5. Use this procedure for installed and uninstalled (ungrounded)
furnaces.
2
5. If equipped with factory specified disposable media filter,
replace only with a factory specified media filter of the same
size.
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.
6. Slide filter into cabinet.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
If filter is installed in furnace blower compartment:
7. An ESD service kit (available from commercial sources) may
also be used to prevent ESD damage.
1. Turn off electrical supply to furnace.
2. Remove main furnace door and blower access panel.
CARE AND MAINTENANCE
3. Release filter retainer wire. (See Fig. 3 or 4.)
For continuing high performance and to minimize possible furnace
failure, it is essential that maintenance be performed annually.
Consult your local dealer for maintenance and maintenance
contract availability.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace.
WASHABLE
FILTER
FILTER
SUPPORT
FILTER
RETAINER
The minimum maintenance that should be performed on this
equipment is as follows:
1. Check and clean or replace air filter each month as needed.
WASHABLE FILTER OR
DISPOSABLE MEDIA FILTER
IN FILTER CABINET
2. Check blower motor and wheel for cleanliness annually.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
A00232
4. Check for proper condensate drainage. Clean as necessary.
Fig. 3—Bottom Filter Arrangement
5. Check for blockages in combustion-air and vent pipes annually.
WASHABLE
FILTER
IN FURNACE
6. Check burners for cleanliness annually.
Step 1—Cleaning and/or Replacing Air Filter
FILTER
RETAINER
The air filter arrangement may vary depending on the application
or orientation.
FIRE, CARBON MONOXIDE AND POISONING
HAZARD
Failure to follow this warning could result in a fire, personal
injury, or death.
Never operate unit without a filter or with the blower access
panel removed. Operating a unit without a filter or with the
blower access door removed could cause damage to the
furnace blower motor. Dust and lint on internal parts of
furnace can cause a loss of efficiency.
WASHABLE FILTER OR
DISPOSABLE MEDIA
FILTER IN FILTER CABINET
A00233
NOTE: If the filter has an airflow direction arrow, the arrow must
point toward the blower.
Fig. 4—Filter Installed for Side Inlet
To clean or replace filters, proceed as follows:
NOTE: Filters shown in Fig. 3 and 4 can be in furnace blower
compartment or in filter cabinet, but not in both.
If filter is installed in filter cabinet adjacent to furnace:
1. Turn off electrical supply to furnace.
4. Slide filter out of furnace.
2. Remove filter cabinet door.
5. Furnaces are equipped with permanent, washable filter(s).
Clean filter by spraying cold tap water through filter in
opposite direction of airflow.
3. Slide filter out of cabinet.
4. If equipped with permanent, washable filter, clean filter by
spraying cold tap water through filter in opposite direction of
airflow. Rinse filter and let dry. Oiling or coating of the filter
is not recommended.
6. Rinse filter and let dry. Oiling or coating filter is not
recommended.
7. Slide filter into furnace.
3
BURNER ENCLOSURE PRESSURE
REFERENCE TUBE ASSEMBLY
CAP
COLLECTOR BOX TUBE
(PINK)
PLUG
COLLECTOR BOX
DRAIN TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX TUBE (GREEN)
INDUCER HOUSING (MOLDED) DRAIN TUBE
(BEHIND COLLECTOR BOX DRAIN TUBE)
CONDENSATE TRAP
COLLECTOR BOX DRAIN TUBE
(BLUE)
FIELD-INSTALLED
FACTORY-SUPPLIED DRAIN
TUBE COUPLING (RIGHT
DRAIN OPTION)
FIELD-INSTALLED
FACTORY-SUPPLIED DRAIN TUBE
COUPLING (LEFT DRAIN OPTION)
FIELD-INSTALLED
FACTORY-SUPPLIED
1/2-IN. CPVC STREET
ELBOWS (2) FOR LEFT
DRAIN OPTION
FIELD-INSTALLED FACTORYSUPPLIED DRAIN TUBE
A05110
→Fig. 5—Factory-Shipped Upflow Tube
Configuration
(Shown with Blower Access Panel Removed)
8. Recapture filter retaining wire.
(clips) on blower wheel vanes. Do not bend wheel or blades as
balance will be affected.
9. Replace blower access panel and main furnace door.
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:
10. Turn on electrical supply to furnace.
Step 2—Blower Motor and Wheel Maintenance
To ensure long life, economy, and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.
a. Mark blower wheel location on shaft before disassembly to
ensure proper reassembly.
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.
b. Loosen setscrew holding blower wheel on motor shaft.
NOTE: Mark blower mounting arms and blower housing so each
arm is positioned at the same hole location during reassembly.
The following items should be performed by a qualified service
technician.
c. Mark blower wheel orientation and cutoff plate location to
ensure proper reassembly.
Clean blower motor and wheel as follows:
d. Remove screws securing cutoff plate and remove cutoff
plate from housing.
1. Turn off electrical supply to furnace.
2. Remove main furnace door and blower access panel.
e. Remove bolts holding motor mounts to blower housing and
slide motor and mounts out of housing.
3. Disconnect wires
f. Remove blower wheel from housing.
All factory wires can be left connected, but field thermostat
connections may need to be disconnected depending on their
length and routing.
g. Clean wheel per instructions on degreaser cleaner. Do not
get degreaser in motor.
9. Reassemble motor and blower wheel by reversing items 8b
through 8f. Ensure wheel is positioned for proper rotation.
→ NOTE: Be sure to attach ground wire and reconnect blower
harness plugs to blower motor.
4. Position control box, transformer, and door switch assembly to
right side of furnace casing.
5. If condensate trap is located in left- or right-hand side of
furnace casing, proceed to item 6. Otherwise remove trap and
tubing as described below (See Fig. 5.):
10. Reinstall blower assembly in furnace.
a. Disconnect field drain connection from condensate trap.
11. Reinstall condensate trap and tubing if previously removed.
b. Disconnect drain and relief port tubes from condensate
trap.
a. Reinstall condensate trap in hole in blower shelf.
b. Connect condensate trap drain tubes. See Fig. 5 or tubing
diagram on main furnace door for proper tube location.
c. Remove condensate trap from blower shelf.
6. Remove screws securing blower assembly to blower shelf and
slide blower assembly out of furnace. Detach ground wire and
disconnect blower motor harness plugs from blower motor.
(1.) Connect 1 tube (blue or blue and white striped) from
collector box.
(2.) Connect 1 tube (violet or unmarked) from inducer
housing.
NOTE: Blower wheel is fragile. Use care.
7. Clean blower wheel and motor by using a vacuum with soft
brush attachment. Be careful not to disturb balance weights
(3.) Connect 1 tube (relief port, green or pink) from
collector box.
4
c. Connect field drain to condensate trap.
NOTE: Ensure tubes are not kinked or pinched, as this will affect
operation.
CELL
PANEL
MANIFOLD
MOUNTING
SCREWS
12. Reinstall control box, transformer, and door switch assembly
on blower shelf.
13. Reconnect wires.
a. Refer to furnace wiring diagram and connect thermostat
leads if previously disconnected. (See Fig. 21.)
GASKET
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Blower access panel 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.
MANIFOLD
GAS VALVE
REGULATOR
FITTING
14. Turn on electrical supply. Manually close blower access panel
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 G and R to Y/Y2 on furnace control
thermostat terminals. (See Fig. 15.)
GAS
CONTROL
VALVE
A02312
Fig. 6—Burner Box Assembly
15. If furnace is operating properly, release blower access panel
door switch, replace blower access panel, and replace main
furnace door.
14. Reinstall manifold, orifice, and gas valve assembly in burner
box. Ensure manifold seal grommet is installed properly and
burners fit over orifices.
Step 3—Cleaning Burners
The following items should be performed by a qualified service
technician. If the burners develop an accumulation of light dirt or
dust, they may be cleaned by using the following procedure:
→ 15.
1. Turn off gas and electrical supplies to furnace.
Reinsert the igniter wires in the slot in the manifold grommet,
dressing the wires to ensure there is no tension on the igniter
itself. (See Fig. 7.)
2. Remove main furnace door.
3. Remove burner box cover.
4. Using backup wrench, disconnect gas supply pipe from
furnace gas control valve.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace component damage.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous
operation.
5. Remove wires from gas valve. Note location for reassembly.
6. Remove burner box pressure tube from gas valve regulator
fitting.
→
→
7. Unplug igniter from harness.
8. Remove igniter leads from slot in manifold grommet.
9. Remove screws that secure manifold to burner box. (See Fig.
6.)
NOTE: Do not remove burner box from cell panel.
10. Remove manifold, orifices, and gas valve as 1 assembly.
11. Remove screws attaching burner assembly in burner box.
Use care when removing and reinstalling burners not to
strike the hot surface igniter.
→ NOTE:
12. Remove burner assembly from burner box.
NOTE: All burners are attached to burner bracket and can be
removed as 1 assembly.
IGNITER WIRES MUST
BE PLACED IN THIS SLOT
A05074
→ Fig. 7—Igniter Wire Placement
13. Clean burners with soft brush and vacuum.
5
→
PRIMARY HX
INLET OPENINGS
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Igniter wires must be securely placed in slot in manifold
grommet or else they could become pinched or severed and
electrically shorted.
16. Reconnect wires to gas valve and igniter. Refer to furnace
wiring diagram for proper wire location.
17. Reinstall burner box pressure tube to gas valve regulator
fitting.
18. Reinstall gas supply pipe to furnace gas control valve using
backup wrench on gas valve to prevent rotation and improper
orientation.
NOTE: Use propane gas resistant pipe dope to prevent gas leaks.
DO NOT use Teflon tape.
A96305
Fig. 8—Cleaning Inlet Openings of Primary Heat
Exchangers
FIRE, EXPLOSION, UNIT DAMAGE HAZARD
Failure to follow this warning could result in property
damage, personal injury, or death.
Gas valve switch MUST be facing forward or tilted slightly.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace component damage.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and hazardous operation.
19. Replace burner box cover.
20. Turn on gas and electrical supplies to furnace.
21. Check for gas leaks.
3. Disconnect wires or connectors to flame rollout switch, gas
valve, igniter, and flame sensor.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in
serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the
detection of leaks to check all connections.
4. Disconnect combustion-air intake pipe from intake housing.
5. Remove the pressure switch tube from intake housing.
6. Remove screws attaching intake housing to burner box, and
rotate intake housing away from burner box for removal.
7. Using backup wrench, disconnect gas supply pipe from
furnace gas control valve.
22. Replace main furnace door.
8. Disconnect pressure tubing from gas valve.
9. Remove 2 screws attaching top filler panel and rotate upwards
to gain access to screws attaching burner box to cell panel.
Step 4—Cleaning Heat Exchangers
The following items should be performed by a qualified service
technician.
10. Remove screws attaching burner box to cell panel. (See Fig.
6.)
PRIMARY HEAT EXCHANGERS
NOTE: Burner box, cover, manifold, gas valve, and burner
assembly should be removed as 1 assembly.
If the heat exchangers get an accumulation of light dirt or dust on
the inside, they may be cleaned by the following procedure:
11. Clean heat exchanger openings with a vacuum and a soft
brush. (See Fig. 8.)
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, both the primary and secondary heat exchangers
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, improper vent termination, incorrect size
or damaged manifold orifice(s), improper gas, or a restricted heat
exchanger (primary or secondary). Action must be taken to correct
the problem.
NOTE: After cleaning, inspect the heat exchangers to ensure they
are free of all foreign objects that may restrict flow of combustion
products.
12. Reverse items 4 through 10 for reassembly.
UNIT MAY NOT OPERATE
Failure to attach ground wire to an adequate casing ground
may cause the furnace control to lock out.
The ground wire from the gas valve MUST be attached to the
burner box attachment screw.
1. Turn off gas and electrical supplies to furnace.
2. Remove main furnace door.
NOTE: Be sure burner box gasket is installed between burner box
and cell panel. (See Fig. 6.) If gasket is damaged, replace it.
6
→ NOTE:
6. Disconnect drain tube from inducer housing. (See Fig. 10.)
Inspect combustion-air intake housing. If foamed gasket
was removed, check for any damage. If gasket is damaged in any
way, it must be repaired. To repair, remove damaged gasket
section, apply sealant releasing agent such as PAM cooking spray
or equivalent (must not contain corn nor canola oil, halogenated
hydrocarbons nor aromatic content, to prevent inadequate seal
from occurring) to burner box and apply a small bead of G.E. RTV
162, G.E. RTV 6702, or Dow-Corning RTV 738 sealant to edge of
combustion-air intake housing. (See Fig. 9.)
NOTE: Ensure the drain tube disconnected from the inducer
housing is higher than the collector box opening or water will flow
out of tube.
7. Remove inducer housing assembly by removing 4 bolts
attaching assembly to cell panel.
8. Flush inside of collector box with water until discharge from
condensate trap is clean and runs freely.
9. Inspect inside area of collector box for any pieces of foreign
materials and remove them if present.
13. Refer to furnace wiring diagram and reconnect wires to flame
rollout switch, gas valve, igniter, and flame sensor.
14. Reconnect pressure switch tubes to gas valve and intake
housing. Refer to tube routing label on main furnace door for
proper tube location. (See Fig. 10.) Be sure tubes are not
kinked.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace component damage.
DO NOT use wire brush or other sharp object to inspect or
dislodge materials in secondary heat exchangers as cutting of
the secondary heat exchanger protective coating may occur.
Flush with water only.
15. Turn on gas and electrical supplies to furnace.
16. Check furnace operation through 2 complete heat operating
cycles. Look through sight glass in burner enclosure to check
burners. Burner flames should be clear blue, almost transparent. (See Fig. 11.)
17. Check for gas leaks.
10. Reassemble inducer assembly by reversing items 5-7. Tighten
the vent coupling clamp screw(s) to 15 in.-lb of torque.
→ NOTE:
If seal between the inducer housing and the collector box
is damaged in any way, it must be repaired. To repair, apply
sealant releasing agent such as PAM cooking spray or equivalent
(must not contain corn nor canola oil, halogenated hydrocarbons
nor aromatic content, to prevent inadequate seal from occurring) to
inducer housing. (See Fig. 12.) Apply a small bead of G.E. RTV
162, G.E. RTV 6702, or Dow-Corning RTV 738 sealant to groove
in collector box.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in
serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the
detection of leaks to check all connections.
18. Replace main furnace door.
11. Refer to furnace wiring diagram and reconnect wires to
inducer motor and pressure switches or connectors.
SECONDARY HEAT EXCHANGERS
12. Reconnect pressure tubes to pressure switches. See diagram
on main furnace door for proper location of tubes. Be sure
tubes are not kinked. (See Fig. 10.)
NOTE: The condensing side (inside) of the secondary heat
exchangers CANNOT be serviced or inspected. A small number of
bottom outlet openings can be inspected by removing the inducer
assembly. See Flushing Collector Box and Drainage System
section for details on removing inducer assembly.
13. Turn on gas and electrical supplies to furnace.
14. Check furnace operation through 2 complete heat operating
cycles. Check area below inducer housing, vent pipe, and
condensate trap to ensure no condensate leaks occur. If leaks
are found, correct the problem.
Step 5—Flushing Collector Box and Drainage
System
1. Turn off gas and electrical supplies to furnace.
15. Check for gas leaks.
2. Remove main furnace door.
3. Disconnect inducer motor and pressure switch wires or
connectors.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in
serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the
detection of leaks to check all connections.
4. Disconnect pressure switch tubes.
5. Disconnect vent pipe from inducer housing outlet by loosening coupling clamp on inducer outlet.
16. Replace main furnace door.
Step 6—Servicing Hot Surface Igniter
RTV
BURN HAZARD
Failure to follow this caution may result in minor personal
injury.
Allow igniter to cool before removal. Normal operating
temperatures exceed 2000°F.
PAM
A93087
The igniter does NOT require annual inspection. Check igniter
resistance before removal.
Fig. 9—Combustion-Air Intake Housing Gasket
Repair
7
TUBE ROUTING
Furnace is shipped from factory in upflow configuration. Pressure tube and drain tube routing MUST match the diagrams below.
Tube location when used in UPFLOW application
Condensate Trap; Factory Installed
in Blower Shelf
Condensate Trap on LEFT
Side Optional
BURNER ENCLOSURE PRESSURE
REFERENCE TUBE ASSEMBLY
(Blower access panel removed)
BURNER ENCLOSURE PRESSURE
REFERENCE TUBE ASSEMBLY
CAP
CAP
COLLECTOR BOX TUBE
(PINK)
PLUG
COLLECTOR BOX TUBE
(PINK)
COLLECTOR BOX
DRAIN TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX TUBE (GREEN)
INDUCER HOUSING (MOLDED) DRAIN TUBE
(BEHIND COLLECTOR BOX DRAIN TUBE)
PLUG
COLLECTOR BOX TUBE
(GREEN)
COLLECTOR BOX
DRAIN TUBE
(BLUE & WHITE STRIPED)
CONDENSATE TRAP
COLLECTOR BOX DRAIN TUBE
(BLUE)
COLLECTOR BOX DRAIN TUBE
(BLUE)
FIELD-INSTALLED
FACTORY-SUPPLIED DRAIN
TUBE COUPLING (RIGHT
DRAIN OPTION)
FIELD-INSTALLED
FACTORY-SUPPLIED DRAIN TUBE
COUPLING (LEFT DRAIN OPTION)
CONDENSATE TRAP
FIELD-INSTALLED
FACTORY-SUPPLIED
1/2-IN. CPVC STREET
ELBOWS (2) FOR LEFT
DRAIN OPTION
FIELD-INSTALLED FACTORYSUPPLIED DRAIN TUBE
Condensate Trap on
LEFT Side
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
Condensate Trap on
RIGHT Side
Tube location when used in DOWNFLOW application
COLLECTOR BOX TUBE
(GREEN)
COLLECTOR BOX DRAIN TUBE
(BLUE)
CAP
CAP
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
COLLECTOR BOX TUBE (GREEN)
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX DRAIN TUBE
(BLUE)
COLLECTOR BOX TUBE
(PINK)
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
PLUG
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
EXTENSION TUBE
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
PLUG
COLLECTOR BOX EXTENSION TUBE
CONDENSATE TRAP
BURNER ENCLOSURE PRESSURE
REFERENCE TUBE ASSEMBLY
COLLECTOR BOX EXTENSION
DRAIN TUBE
DRAIN TUBES ROUTED IN
FRONT OF GAS VALVE
INDUCER HOUSING DRAIN TUBE (VIOLET)
Tube location when used on
HORIZONTAL - LEFT application
GAS VALVE
Tube location when used on
HORIZONTAL - RIGHT application
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
PLUG
CAP
COLLECTOR BOX DRAIN TUBE (BLUE)
PLUG
COLLECTOR BOX TUBE (PINK)
AUXILIARY "J" BOX
RELOCATED HERE
COLLECTOR
BOX TUBE
(GREEN)
BURNER
ENCLOSURE
PRESSURE
REFERENCE TUBE
ASSEMBLY
BURNER
ENCLOSURE
PRESSURE
REFERENCE
TUBE ASSEMBLY
CAP
COLLECTOR BOX
EXTENSION TUBE
CONDENSATE TRAP
COLLECTOR BOX EXTENSION DRAIN TUBE
CONDENSATE TRAP
DRAIN TUBE
COUPLING
COLLECTOR BOX TUBE
(PINK)
DRAIN TUBE
COUPLING
COLLECTOR BOX TUBE (PINK) RELOCATE TUBE BETWEEN BLOWER SHELF AND
INDUCER HOUSING FOR 040,060, AND 080 HEATING INPUT FURNACES
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX TUBE (GREEN)
COLLECTOR BOX
DRAIN TUBE (BLUE)
CONDENSATE TRAP
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
INDUCER HOUSING DRAIN TUBE (VIOLET)
NOTE: 1. All tubing must be connected securely and routed to avoid kinks and traps.
2. Pressure tubing must always slope away from pressure switch to collector box connection as shown.
3. HORIZONTAL-LEFT installations require the collector box pressure tube to be relocated between the inducer housing and
the blower shelf to prevent a trap.Refer to the Installation Instructions for further details.
325400-201 REV. C
(LIT - BOTTOM)
A00351
Fig. 10—Furnace Pressure and Drain Tubing Diagram
b. Remove igniter wires from slot in manifold grommet. (See
Fig. 7.)
1. Turn off gas and electrical supplies to furnace.
2. Remove main furnace door.
→
3. Disconnect igniter wire connection.
→
4. Check igniter resistance. Igniter resistance is affected by
temperature. Only check resistance when the igniter is at room
temperature.
a. Using an ohm meter, check resistance across both igniter
leads in connector.
→
→
b. Cold reading should be between 40 ohms and 70 ohms.
5. Remove igniter assembly.
→
a. Remove burner box cover.
8
c. Using a 1/4-in. driver, remove the single screw securing the
igniter bracket to the burner box bracket (See Fig. 13.) and
carefully withdraw the igniter and bracket assembly
through the front of the burner box without striking the
igniter on surrounding parts. Note that the igniter bracket
has a handle that extends to the front of the burner box to
aid in handling. (See Fig. 13.)
d. Inspect igniter for signs of damage or failure.
;;;;
BURNER FLAME
BURNER
UNIT DAMAGE HAZARD
Failure to follow this caution may result in premature failure
of the igniter.
The igniter is fragile. DO NOT allow it to hit burner box parts
while removing or replacing it.
→
e. If replacement is required, replace igniter on igniter bracket
and then install assembly into burner box to avoid damage
to the igniter.
6. To replace igniter and bracket assembly, reverse items 5a
through 5d.
→
MANIFOLD
7. Reconnect igniter wire connection and insert the igniter wires
in the slot in the manifold grommet, dressing the igniter wires
to ensure there is no tension on the igniter itself. (See Fig.7.)
A89020
Fig. 11—Burner Flame
→
PAM
→
RTV
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Igniter wires must be securely placed in slot in manifold
grommet or else they could become pinched or severed and
electrically shorted.
8. Reinstall burner box cover.
9. Turn on gas and electrical supplies to furnace.
10. Verify igniter operation by initiating control board self-test
feature or by cycling thermostat.
11. Replace main furnace door.
Step 7—Electrical Controls and Wiring
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
There may be more than 1 electrical supply to the unit. Check
accessories and cooling unit for additional electrical supplies.
The electrical ground and polarity for 115-v wiring must be
maintained properly. Refer to Fig. 15 for field wiring information
and to Fig. 21 for unit wiring information.
A93081
Fig. 12—Gasket on Collector Box
EXTENDED IGNITER
BRACKET HANDLE
→ NOTE:
If the polarity is not correct or furnace is not properly
grounded, the STATUS LED on the furnace control will flash
rapidly and prevent the furnace from operating. The control system
IGNITER
BRACKET
IGNITER BRACKET
MOUNTING SCREW
9/16˝
11/16˝
A05075
→ Fig. 13—Igniter Bracket
2-5/32˝
A04181
→ Fig. 14—Igniter
9
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
Y
R
G
1-STAGE
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATINGONLY
BLK
BLK
WHT
WHT
208/230- OR
460-VOLT
THREE
PHASE
W2
COM
W/W1
GND
Y/Y2
115-VOLT FIELD- JUNCTION
SUPPLIED
BOX
FUSED
CONTROL
DISCONNECT
BOX
NOTE 1
R
GND
CONDENSING
UNIT
G
24-VOLT
TERMINAL
BLOCK
FURNACE
208/230VOLT
SINGLE
PHASE
NOTES: 1. Connect Y/Y2-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.
A95236
Fig. 15—Field Wiring
also requires an earth ground for proper operation of the furnace
control and flame sensor.
UNIT AND PROPERTY DAMAGE
Failure to follow this caution may result in furnace component failures or water property damage.
If this furnace is to be operated in an unconditioned space
where the ambient temperatures may be 32°F or lower, freeze
protection measures must be taken. See CONDENSATE
DRAIN PROTECTION section of Installation, Start-up, and
Operating Instructions. (See Fig. 17.)
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the furnace control. (See Fig. 16.) 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. The furnace control LED will flash status code 24
when fuse needs to be replaced.
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.
Step 9—Winterizing
Reconnect electrical supply to unit and observe unit through 1
complete operating cycle and check for proper operation.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace component damage.
Freezing condensate left in the furnace may damage the
furnace.
Step 8—Checking Heat Tape Operation
(If Applicable)
In applications where the ambient temperature around the furnace
is 32°F or lower, freeze protection measures are required. If this
application is where heat tape has been applied, check to ensure it
will operate when low temperatures are present.
If the furnace will be off for an extended period of time in a
structure where the temperature will drop to 32°F or below,
winterize as follows:
NOTE: Heat tape, when used, should be wrapped around the
condensate drain trap and drain line. There is no need to use heat
tape within the furnace casing. Most heat tapes are temperature
activated, and it is not practical to verify the actual heating of the
tape. Check the following:
1. Turn off electrical supply to furnace.
2. Remove main furnace door.
3. Disconnect upper inducer housing drain connection cap from
inducer housing. (See Fig. 18.)
1. Check for signs of physical damage to heat tape such as nicks,
cuts, abrasions, gnawing by animals, etc.
4. Connect field-supplied 1/2-in. I.D. inducer housing tube to
upper inducer housing drain connection.
2. Check for discolored heat tape insulation. If any damage or
discolored insulation is evident, replace heat tape.
5. Insert funnel in tube and pour one quart of antifreeze,
propylene glycol (RV, swimming pool antifreeze, or equivalent) into funnel/tube until it is visible at point where condensate enters open drain. (See Fig. 19.)
3. Check that heat tape power supply circuit is on.
10
MODEL PLUG
CONNECTOR
COMMUNICATION
CONNECTOR
CONTINUOUS FAN
(CF) AIRFLOW
SETUP SWITCHES
FUTURE
APPLICATIONS
SW1 SETUP
SWITCHES AND
BLOWER OFFDELAY
AIR CONDITIONING
(A/C) AIRFLOW
SETUP SWITCHES
HUMIDIFIER
TERMINAL (24-VAC
0.5 AMP MAX.
ACRDJ – AIR
CONDITIONING
RELAY DISABLE
JUMPER
24-V THERMOSTAT
TERMINALS
FLASH
UPGRADE
CONNECTOR
(FACTORY
ONLY)
STATUS AND COMM
LED LIGHTS
PL3 – ECM BLOWER
HARNESS
CONNECTOR
3-AMP FUSE
TRANSFORMER 24-VAC
CONNECTIONS
115-VAC (L2) NEUTRAL
CONNECTIONS
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
115-VAC (L1) LINE
VOLTAGE CONNECTIONS
PL1 – LOW VOLTAGE MAIN
HARNESS CONNECTOR
PL2 – HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
A02278
Fig. 16—Variable-Capacity Furnace Control
11
ELECTRICAL SHOCK, UNIT MAY NOT OPERATE
HAZARD
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Blower access panel door switch opens 115-v power to
furnace control. No component operation can occur unless
switch is closed. Caution must be taken when manually
closing this switch for service purposes.
32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED
g. The AMBER LED will flash the status codes in the order
of occurence. Record status codes until status code 11
flashes (1 short and 1 long).
→
h. After status code #11 flashes, the status codes will repeat
until setup switch SW1-1 is turned off.
i. Remove tape to release blower access panel door switch
and replace blower access panel.
j. Operate furnace through 1 heat cycle to test for proper
operation and check LED status.
Fig. 17—Freeze Protection
k. If furnace is operating properly and LEDs indicate proper
operation, replace main furnace door.
A93058
2. Status codes are erased after 72 hours or they can be manually
erased by performing the following procedure:
a. Leave 115-v power to furnace turned on.
UNIT DAMAGE HAZARD
Failure of plastic components may occur.
Do not use ethylene glycol (Prestone II antifreeze/coolant or
equivalent automotive type).
b. Remove main furnace door.
c. Look into blower access panel sight glass for current LED
status code.
6. Replace drain connection cap and clamp to inducer housing.
d. Remove blower access panel.
7. Replace main furnace door.
e. Turn setup switch SW1-1 to ON position. (See Fig. 16 or
21 for location.)
8. Propylene glycol need not be removed before restarting
furnace.
WIRING DIAGRAMS
See Fig. 15, 16 and 21 for the Deluxe 4-Way Multipoise Furnace
wiring diagrams.
TROUBLESHOOTING
Use the troubleshooting guide, the status code LED on the furnace
control and the component test to isolate furnace operation
problems.
f. Jumper thermostat terminals R, W/W1, and Y/Y2 on
furnace control.
g. Manually close blower access panel door switch. Use a
piece of tape to hold switch closed.
h. After status code 11 flashes for at least 2 times, remove R,
W/W1, and Y/Y2 jumpers.
i. Turn setup switch SW1-1 to OFF position.
A more detailed troubleshooting guide is available from your
distributor.
j. Remove tape to release blower access panel door switch
and replace blower access panel.
For an explanation of status codes, refer to service label located on
back of main furnace door (See Fig. 20.)
k. Operate furnace through 1 heat cycle to check for proper
operation and check LED status.
The furnace control stores all status codes for a period of 72 hours,
regardless of 115-v or 24-v power interruption.
NOTE: Removing blower access panel opens blower access
panel door switch and terminates 115-v power to furnace control.
Before removing blower access panel or turning off 115-v power,
look into blower access panel sight glass for current LED status.
l. If furnace is operating properly and LEDs indicate proper
operation, replace main furnace door.
3. The control can also assist in troubleshooting by performing a
Component Test. The Component Test will functionally
operate all furnace components, except the gas valve.
NOTE: The component test feature will not operate if the furnace
control is receiving any thermostat signals or until all time delays
have expired.
1. To retrieve status code, proceed with the following:
NOTE: NO thermostat signal may be present at furnace control
and all blower time delay periods must be completed.
a. To initiate Component Test proceed with the following:
a. Leave 115-v power to furnace turned on.
b. Remove main furnace door.
(1.) Leave 115-v power to furnace turned on.
c. Look into blower access panel sight glass for current LED
status code.
(2.) Remove main furnace door.
d. Remove blower access panel.
(4.) Turn setup switch SW1-6 to ON position.
e. Turn setup switch SW1-1 to ON position. (See Fig. 16 or
21 for location.)
(5.) Manually close blower access panel door switch. Use
a piece of tape to hold switch closed.
f. Manually close blower access panel door switch. Use a
piece of tape to hold switch closed.
b. When items (1) through (5) above have been completed,
the following will occur:
(3.) Remove blower access panel.
12
Fig. 18—Inducer Housing Drain Tube
A99118
A99119
Fig. 19—Funnel in Drain Tube and Antifreeze
Running Through Trap
NOTE: To repeat component test, turn setup switch SW1-6 to
OFF and then back to ON.
c. After component test, perform the following:
(1.) Remove tape to release blower access panel door
switch and turn setup switch SW1-6 to OFF position.
(2.) Replace blower access panel.
(3.) Operate furnace through 1 heat cycle to check for
proper operation and check LED status.
(4.) If furnace is operating properly and LEDs indicate
proper operation, replace main furnace door.
(1.) Inducer motor operates at medium speed through step
(3), then turns off.
(2.) After waiting for 15 sec, hot surface igniter is energized for 15 sec, then de-energized.
(3.) Main blower motor operates at midrange airflow for
15 sec, then turns off.
(4.) After component operation test is completed, 1 or
more fault codes (11, 25, 41, or 42) will flash. See
service label on back of main furnace door or Fig. 20
for explanation of codes.
13
SERVICE
If status code recall is needed disconnect the "R" thermostat lead, reset power, and put setup switch "SW1-1" in
the ON position. To clear the status code history put setup switch "SW1-1" in the ON position and jumper
thermostat terminals "R", "W/W1", and "Y/Y2" simultaneously until status code #11 is flashed.
STATUS
LED CODE
CONTINUOUS OFF Check for 115 VAC at L1 and L2, and 24 VAC at SEC-1 and SEC-2.
CONTINUOUS ON Control has 24 VAC power.
RAPID FLASHING Line voltage (115 VAC) polarity is reversed.
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 automatically after 72 hours or as
specified above.
12 BLOWER ON AFTER POWER UP
- (115 VAC or 24 VAC) - Blower runs for 90 seconds, if unit is
powered up during a call for heat (R-W/W1 closed) or (R-W/W1 opens) during the blower
on-delay period.
13 LIMIT CIRCUIT LOCKOUT
- Lockout occurs if the limit, or flame rollout switch is open longer than
3 minutes or 10 successive limit trips occurred during high-heat. Control will auto reset after
3 hours. Refer to status code #33.
14 IGNITION LOCKOUT- Control will auto-reset after 3 hours. Refer to status code #34.
15 BLOWER MOTOR LOCKOUT- Indicates the blower failed to reach 250 RPM or the blower failed
to communicate within 30 seconds after being turned ON in two successive heating cycles.
Control will auto reset after 3 hours. Refer to status code #41.
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 (24 VAC) wiring.
25 MODEL SELECTION OR SETUP ERROR - Either indicates the model plug (PL4) is missing or incorrect
or setup switch "SW1-1" or "SW1-6" is positioned improperly. If code flashes only 4 times on
power-up control is defaulting to model selection stored in memory. Check the following:
- Thermostat call with "SW1-1" ON.
- Thermostat call with "SW1-6" ON.
- "SW1-1" and "SW1-6" both ON together.
- Two different furnace models twinned.
- Wiring diagram for model plug number and resistance values if code flashes continuously.
31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED - Indicates the high-heat
pressure switch input failed to close on a call for high-heat, or opened during high-heat.
Control relay may be defective or gas valve is mis-wired. Refer to status code #32.
32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - Indicates the low-heat pressure
switch input failed to close on a call for low-heat, or opened during low-heat. If opens during
blower on-delay period, blower will come on for the selected blower off-delay. If opens within
5 minutes after ignition the next heating cycle will be restricted to high-heat.
Check for:
- Proper vent sizing.
-Plugged condensate drain.
- Low inlet gas pressure (if LGPS used).
- Excessive wind.
- Restricted combustion air supply.
- Improper pressure switch wiring.
- Water in vent piping, possible sagging pipe. - Disconnected or obstructed pressure tubing.
- Failed or "Out-of-Calibration" pressure switches.
33 LIMIT CIRCUIT FAULT- Indicates the limit, or flame rollout is open or the furnace is operating in
high-heat only mode due to 2 successive low heat limit trips. Blower will run for 4 minutes or
until open switch remakes whichever is longer. If open longer than 3 minutes, code changes
to lockout #13. If open less than 3 minutes status code #33 continues to flash until blower shuts
off. Flame rollout switch requires manual reset. Check for:
- Improper or misaligned limit and/or limit shield.
- Defective switch or connections.
- Improper low-heat gas input adjustment.
- Loose blower wheel.
- Stuck high-heat solenoid in gas valve
- Proper rear air baffle.
34 IGNITION PROVING FAULT- Control will try three more times before a lockout #14 occurs. If
flame signal is lost during blower on-delay period, blower will come on for the selected blower
off-delay. Check for:
- Gas valve defective or turned "OFF".
- Defective Hot Surface Igniter
- Manual valve shut-off.
- Low inlet gas pressure
- Flame sensor must not be grounded.
- Inadequate flame carryover or rough ignition.
- Control ground continuity
- Green/Yellow wire MUSTbe connected to furnace sheet metal.
- Proper flame sense micro amps (.5 micro amps DC min., 4.0 - 6.0 nominal).
- Oxide buildup on flame sensor (clean with fine steel wool.)
41 BLOWER MOTOR FAULT
- Indicates the blower failed to reach 250 RPM or the blower failed to
communicate within the prescribed time limits. Thirty seconds after being turned ON or ten
seconds during steady-state operation.
42 INDUCER MOTOR FAULT- Indicates the inducer has not started within 20 seconds after a call for
heat, the inducer motor RPM is outside its valid range of operation, or the inducer RPM signal
was lost for 5 seconds during operation. Check for:
- Proper vent sizing.
- Restricted combustion air supply.
- Failed inducer motor.
- Improper motor wiring.
43 LOW-HEAT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE SWITCH IS CLOSED- Check for:
- Plugged condensate drain.
- Low inlet gas pressure (if LGPS used).
- Water in vent piping, possibly sagging pipe. - Improper pressure switch wiring.
- Stuck open low-heat pressure switch.
- Disconnected or obstructed pressure tubing.
45 CONTROL CIRCUITRY LOCKOUT
- Auto-reset after 1 hour lockout due to:
- Flame sense circuit falure.
- Gas valve relay stuck open.
- Software check error.
Reset power to clear lockout. Replace control if status code repeats.
COMPONENT TEST
To initiate the component test sequence, shut "OFF" the room thermostat or disconnect the "R" thermostat
lead. Reset power and then put setup switch "SW1-6" in the ON position to start the component test
sequence. Once initiated the furnace control will turn the inducer ON. The inducer motor will run for the entire
test. The hot surface igniter and blower motor will be turned ON for 15 seconds each. When the blower is
turned OFF the inducer will be turned OFF. When the component test is completed one or more of the
following codes will flash.
CODE
DESCRIPTION
11 Indicates the inducer and blower motor tested OK. Visual check of hot surface igniter required.
25 SETUP ERROR - Same as code 25 above.
41 BLOWER MOTOR FAULT - Indicates blower motor failed test. Check blower, wiring, and furnace control.
42 INDUCER MOTOR FAULT - Indicates inducer motor failed test. Check inducer, wiring and furnace
control.
To repeat component test turn setup switch "SW1-6" OFF and then back ON. After component test is
completed put setup switch "SW1-6" in the OFF position and reconnect the "R" thermostat lead.
328072-101 REV. A
A02279
Fig. 20—Service Label
14
PRINTED CIRCIUT BOARD
OAT
15
1
AB CD
1
4
1
PL1
GRN/YEL
GRY
875
8752
700 2
700
1050
1050
875
1225
1225
1400
1400
1050 1 1225
W2
Y1 DHUM G ComY/Y2
W/W1 R
24V
A/C
Air Conditioning (Adjustable Airflow -CFM)
ACR
Air Conditioning Relay, SPST (N.O.)
ACRDJ Air Conditioning Relay Defeat Jumper
BLWM Blower Motor (ECM)
CF
Continuous Fan (Adjustable Airflow -CFM)
COMMR Communication Relay, SPDT
CPU
Microprocessor / Circuitry
DHUM DHUM Connection (24VAC )
EAC-1 Electronic Air Cleaner Connection
(115VAC 1.0 Amp Max.)
EAC-2 Electronic Air Cleaner Connection (Common)
FRS
Flame Rollout Switch, Man. Reset, SPST(N.C.)
FSE
Flame-Proving Sensor Electrode
FUSE
Fuse, 3 Amp, Automotive Blade Type,
Factory Installed
GV
Gas Valve
GVR
Gas Valve Relay, DPST (N.O.)
HPS
High-Heat Pressure Switch, SPST (N.O.)
HPSR
High-Heat Pressure Switch Relay, SPST (N.C.)
HSI
Hot Surface Igniter (115VAC)
HSIR
Hot Surface Igniter Relay, SPST (N.O.)
HUM
24VAC Humidifier Connection (0.5 Amp Max.)
HUMR Humidifier Relay, SPST (N.O.)
IDM
Inducer Draft Motor, 2-Speed, Shaded Pole
IDR
Inducer Motor Relay, SPST (N.O.)
IHI/LOR Inducer Motor Speed Change Relay, SPDT
ILK
Blower Door Interlock Switch, SPST (N.O.)
AC
1 CF
1
OFF
RED
1225
1750 1 1750
17501 2100
1225
BLK
L1
PL2
WHT
WHT
LS
NOTE #11
NEUTRAL - L2
1
YEL
LPS
RED
WHT
WHT
WHT
BLU
PL12
IND
NOTE #7
BLK
4
BLK
ILK
GRN/YEL
PLUG RECEPTACLE
GROUND
EQUIPMENT
SCREW TERMINAL
FIELD WIRING
CONTROL
CONDUCTOR ON
WIRING (24VAC)
FIELD CONTROL
WIRING (24VAC)
FACTORY CONTROL
WIRING (115VAC)
FACTORY POWER
CONTROL TERMINAL
TERMINAL
JUNCTION
JB
R
COMMR
COM
Y/Y2
G
Y1
DHUM
W2
IDR
2
NOTE #5
PCB
L2
IHI/LOR
CPU
4
1
2
3
GVR
HPSR
LS
EAC-1
PL1-7
PL1-11
PL1-9
PL2
4
PL1-8
PL1-6
2
1
PL14
EAC-2
3
PL1-1
NOTE #3
C
PL1-10 M
GV
PL1-4
LGPS
(WHEN USED)
PL1-3
NOTE #8
PL1-2
HI
HPS
LPS
L2
FSE
PL1-5
24VAC
TRAN
SEC2
115VAC L2
SEC1
L1
NOTE #6
IDM
BLWM
PL11
FU1
PL13
12
6
1
2
10
4
L2
SCHEMATIC DIAGRAM
HSI
PL10
10
16
1
7
5
2
1
PL1-12
PL12
EQUIPMENT
GROUND
IND
NOTE #7
PCB
4
L2
HSIR
HUMR
PL12
3
ACR
FRS
EAC
L1
1
CPU
NOTE #5
PL3
ILK
TO 115VAC FIELD-DISCONNECT SWITCH
327971-101 REV. A
TRAN
A02291
If any of the original equipment wire is replaced use wire rated for 105°C.
Use only copper wire between the disconnect switch and the furnace junction box (JB).
This wire must be connected to furnace sheet metal for control to prove flame.
Symbols are electrical representation only.
Solid lines inside PCB are printed circuit board conductors and are not included in legend.
Replace only with a 3 amp fuse.
Inductor is used with 3/4 hp and 1 hp ECM Blower motors.
Factory connected when (LGPS) not used.
Blower off-delay, gas heating selections are (90, 120, 150, 180) seconds, cooling or heat pump
90 seconds or 5 seconds when dehumidify call is active.
10. Ignition lockout will occur after four consecutive unsuccessful trials for ignition. Control will
auto-reset after three hours.
11. Any of the 5 wires shown within the NEUTRAL L2 box can be connected to any terminal within the box.
12. Blower motor (BLWM) and Inducer motor (IDM) are locked-rotor overload protected by redundant
electronic control circuits.
NOTES:
1.
2.
3.
4.
5.
6.
7.
8.
9.
GND
HUM
W/W1
BLK WHT
FU2
FUSED OR CIRCUIT
BREAKER DISCONNECT
SWITCH (WHEN REQ’D)
NOTE #2
NEUTRAL
L1
PL14
54 3 2 1
BLWM
PL10
HSI
10 16 1 7
PL13
BLK
2
1
IDM
RED
PRINTED CIRCIUT BOARD
Fig. 21—Wiring Diagram
RED
BLK
4
ORN 2
YEL
10
BRN 1
WHT 12
6
BLK
WHT
ORN
FRS
LGPS (WHEN USED)
GRN/YEL
BLK
FSE
NOTE #8
RED
Inductor (Note #7)
Light Emitting Diode for Status Codes
Low Gas Pressure Switch, SPST (N.O.)
Low-Heat Pressure Switch, SPST (N.O.)
Limit Switch, Auto-Reset, SPST (N.C.)
Printed Circuit Board
12-Circuit Connector
4-Circuit HSI & IDM Connector
4-Circuit ECM BLWM Connector
4-Circuit Model Plug Connector
4-Circuit Communication Connector
2-Circuit OAT Connector
2-Circuit HSI Connector
IDM Connector (12-Circuit)
1-Circuit Inductor Splice Connector
16-Circuit ECM Blower Ctrl. Connector
5-Circuit ECM Blower Power Connector
Manual Switch, Status Code Recall, SPST (N.O.)
Manual Switch, Low-Heat Only, SPST(N.O.)
Manual Switch, Low-Heat Rise Adj. SPST (N.O.)
Manual Switch, Comfort/Efficiency Adjustment,
SPST (N.O.)
SW1-5 Manual Switch, Cooling CFM/Ton, SPST (N.O.)
SW1-6 Manual Switch, Component Test, SPST (N.O.)
SW1-7,8 Manual Switches, Blower Off-Delay, SPST(N.O.)
SW4-1 Manual Switch, Twinning Main (OFF) / Sec. (ON)
SW4-2&3 FOR FUTURE USE
TRAN Transformer, 115VAC / 24VAC
IND
LED
LGPS
LPS
LS
PCB
PL1
PL2
PL3
PL4
PL7
PL9
PL10
PL11
PL12
PL13
PL14
SW1-1
SW1-2
SW1-3
SW1-4
STATUS
CODE
LEDS
COMM
1. Default A/C airflow when A/C switches are in OFF position
2. Default cont. fan airflow when CF switches are in OFF position
700
525 2
OFF
123
MODEL
SIZE
040,060, DEF.
3.5T080
5T080,100 DEF.
120
DEF.
OFF
123
PL7
HPS
BRN
PL3
OFF
123
HUM
SW4
PL9
BRN
BLU
A/C OR CF AIRFLOW SELECTION CHART BASED ON 350 CFM/TON
PL8
HI
M
PL12
L
E
G
E
N
D
NOTE #3
C
GRN/YEL
PL4 - MODEL PLUG CHART
MODEL MODEL PIN RESISTANCE K
PLUG
SIZE
1-4
2-3
HK70EZ
5.1
040
008
75
5.1
060
009
91
5.1
3.5T080 010
120
5.1
5T-080
011
150
5.1
100
012
180
5.1
120
013
220
90
SEC
120
SEC
150
SEC
180
SEC
GV
CONNECTION DIAGRAM
OFF
123
SEC-2 SEC-1
OFF
123
FUSE 3-AMP
EAC-1
SW1-7,8
BLOWER OFF DELAY
SELECTION
OFF
123
ACRDJ
123
RED
GRN
YEL
BLU
PL4
SW1
OFF
123
YEL
EAC-2
OFF OFF OFF OFF
VS HSI
7 8 7 8 7 8 7 8
RED
GRN
YEL
BLU
ACRDJ
16
Go to section below for the status code
that was flashed.
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 AMBER LED status light blinking
ON/OFF slowly with a combination of
short and long flashes?
NO
Is AMBER LED status light blinking
rapidly without a pause?
YES
Is AMBER LED status light on?
START
YES
NO
YES
NO
NO
NO
Was there a previous status code other
than #11?
NO
To reca ll previous status codes disconnect the R
thermostat connection, reset power, and put setup
switch SW1-1 in the ON position. The AMBER LED
will flash the status codes in the order of occurrence.
Record status codes until status code #11 flashes (1
short and 1 long flash). After status code #11
flashes the status codes will repeat. Status codes
are erased after 72 hours or can be manually erased
by putting setup switch SW1-1 in the ON position
and jumpering R, W/W1, and Y/Y2 simultaneously
until status code #11 is flashed. When done put
setup switch SW1-1 in the OFF position.
Check for correct line voltage polarity. If
units are twinned, check for proper lowvoltage (24V) transformer phasing.
Replace furnace control.
YES
Is there 24V at SEC-1 and SEC-2?
YES
Is there 115V at L1 and L2?
YES
Replace furnace control.
Run system through a low-heat, highheat, or cooling cycle to check operation.
Status codes are erased after 72 hours
or can be manually erased by putting
setup switch SW1-1 in the ON position
and jumpering R, W/W1, and Y/Y2
simultaneously until status code #11 is
flashed.
YES
Does the control respond to W/W1, W2,
Y1, Y/Y2, and G (24V) thermostat
signals?
Replace transformer.
Replace door switch.
YES
Is there 115V going to switch?
Is door switch closed?
Troubleshooting Guide – Variable Speed
YES
NO
NO
NO
The thermostat is not compatible with the
furnace control. Either install a ballast
resistor, connect the Com24V thermostat
terminal to the thermostat, or replace the
thermostat.
NO
Does the problem repeat when using a
jumper wire?
Disconnect all the thermostat wires from
the furnace control.
YES
Is 24V present at W/W1, W2, Y1, Y/Y2 or
G thermostat terminals on the furnace
control?
NO
Check room thermostat or
interconnecting cable.
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.
NO
A02350a
17
24 SECONDARY VOLTAGE FUSE IS OPEN
Check for:
- Short circuit in secondary voltage (24V)
wiring including thermostat leads.
Disconnect thermostat leads to isolate
short circuit.
23 PRESSURE SWITCH DID NOT OPEN –
Check for:
- Obstructed pressure tube.
- Pressure switch stuck closed.
22 ABNORMAL FLAME-PROVING SIGNAL
Flame is proved while gas valve is deenergized. Inducer will run until fault is
cleared. Check for:
Stuck open or leaky gas valve.
21 GAS HEAT ING 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.
15 BLOWER MOTOR LOCKOUT – Indicates
the blower failed to reach 250 RPM or the
blower failed to communicate within 30
seconds after being turned ON in two
successive heating cycles. Control will
auto-reset after 3 hours. See code 41.
14 IGNITION LOCKOUT – System failed to
ignite gas and prove flame in 4 attempts.
Control will auto-reset after 3 hours. See
status code 34.
13 LIMIT CIRCUIT LOCKOUT – Lockout
occurs if the limit or flame rollout switch is
open longer than 3 minutes or 10
successive limit trips occurred during highheat. Control will auto-reset after 3 hours.
See code 33.
12 BLOWER ON AFTER POWER UP –
(115V OR 24V) – Normal operation.
Blower runs for 90 seconds, if unit is
powered up during a call for heat (RW/W1 closed) or when (R-W/W1 opens)
during the blower on-delay period.
11 NO PREVIOUS CODE – Status codes are
erased after 72 hours or can be manually
erased by putting setup switch SW1-1 in
the ON position and jumpering R, W/W1,
and Y/Y2 simultaneously until status code
#11 is flashed. Run system through a lowheat, high-heat, or cooling cycle to check
system.
*Set up switch SW1-3 to be ON if problem persists.
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 lockout #14
occurs. If flame signal is lost during the
blower on-delay period, blower will come on
for the selected blower off-delay. Check
the following items first before proceeding
to the next step.
- Gas valve turned off.
- Manual shut-off valve.
- Green/Yellow wire MUST be connected
to furnace sheet metal.
- Flame sensor must not be grounded.
To dete rmine whether the problem is in the
gas valve, igniter, or flame sensor the
system can be operated in component test
mode. To check the igniter remove the R
thermostat connection from the control,
reset power, and put setup switch SW1-6 in
the ON position to start the component test.
Does the igniter glow orange/white by the
end of the 15 second warm-up period?
33 LIMIT CIRCUIT FAULT – Indicates the
limit or flame rollout switch is open or the
furnace is operating in high-heat only
mode due to 2 successive low-heat limit
trips. Blower will run for 4 min. or until
open switch remakes whichever is longer.
If open longer than 3 min., code changes
to lockout #13. If open less than 3 min.
status code #33 continues to flash until
blower shuts off. Flame rollout switch
requires manual reset. Check for:
- Proper rear air baffle.
- Loose blower wheel.
- Defective switch or connections.
- Improper low-heat gas input adjustment.
- Improper or misaligned limit and/or limit
shield.
- Stuck high-heat solenoid in gas valve.
32 LOW-HEAT PRESSURE SWITCH DID
NOT CLOSE OR REOPENED – If opens
during blower on-delay period, blower will
come on for the selected blower off-delay.
If opens within 5 minutes after ignition the
next heating cycle will be restricted to
high-heat. Check for:
- Proper vent sizing.
- Low inlet gas pressure (if LGPS used).
- Restricted combustion air supply.
- Disconnected or obstructed pressure
tubing.
- Defective or miswired pressure switches
- Excessive wind. *
- Plugged condensate drain.
- Water in vent piping, possible sagging pipe
YES
NO
Fixed.
YES
Will main burners ignite and stay on?
YES
Is current near typical value?
Clean flame sensor with fine steel wool
and recheck current. Nominal current is
4.0 to 6.0 microamps.
Repeat call for heat and check flame
sensor current during trial for ignition
period. Is the DC microamps below 0.5?
NO
Do the main burners stay on?
YES
Do the 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?
Unplug igniter harness from control and
repeat component test by turning setup
switch SW1-6 OFF and then back ON.
Check for 115V between pin 3 and
NEUTRAL-L2 on the control. Was 115V
present for the 15 second period?
43 LOW-HEAT PRES SURE SWITCH OPEN
WHILE HIGH-HEAT PRESSURE
SWITCH IS CLOSED - Check for:
- Low-heat pressure switch stuck open.
- Disconnected or obstructed pressure
tubing.
- Improper pressure switch wiring.
- Low inlet gas pressure (if LGPS used).
- Plugged condensate drain.
- Water in vent piping, possible sagging
pipe.
NO
NO
NO
YES
NO
NO
NO
YES
NO
Replace furnace control.
Replace electrode.
Check connections and retry.
If current is near typical value
(4.0-6.0 nominal) and burners
will not stay on, repeat check
in high-heat. If burners will
still not stay on replace
control. If burners operate in
high-heat then switch to lowheat, check manifold
pressure. If OK, check
burner carryover and flame
sensor location.
Allow blower to come on and
repeat test to check for
intermittent operation.
Check for:
- Inadequate flame carryover
or rough ignition.
- Low inlet gas pressure.
- Proper firing rate.
Check that all gas valves are
turned on. Replace valve.
Check connections. If OK,
replace control.
Check for continuity in the
harness and igniter. Replace
defective component.
Replace furnace control.
45 CONTROL CIRCUITRY
LOCKOUT Auto-reset
after 1 hour lockout due
to:
- Flamecircuit failure.
- Gas valve relay stuck
open.
- Software check error.
Reset power to clear
lockout. Replace control
if code repeats.
A05076
18
42 INDUCER MOTOR FAULT – Indicates the
inducer motor has not started within 20
seconds after a call for heat, the inducer
motor RPM is outside its valid range of
operation, or the inducer RPM signal was
lost for 5 seconds during operation.
Check for:
- Proper vent sizing.
- Failed inducer motor.
- Restricted combustion air supply.
- Improper motor wiring.
31 HIGH-HEAT PRES SURE SWITCH OR
RELAY DID NOT CLOSE OR
REOPENED - Check for:
- Control relay may be defective.
- Gas valve is miswired.
- See status code 32.
25 INVALID MODEL SELECTION OR
SETUP ERROR – If status code 25 only
flashes 4 times on power-up the control is
missing its model plug PL4 and is
defaulting to the model selection stored in
memory. If status code 25 flashes
continuously it could indicate any of the
following:
- Model plug PL4 is missing and there is
no valid model stored in permanent
memory. This w ill happen if you forget
to install the model plug PL4 on a
service replacement control.
- Thermostat call with SW1-1 ON.
- Thermostat call with SW1-6 ON.
- SW1-1 and SW1-6 both ON.
- Two different furnace models twinned.
YES
Replace the blower control module attached to
the blower motor. Follow the instructions with
the blower control module to make sure the
entire blower motor does not need to be
replaced.
YES
Does the voltage fluctuate as described in the
previous step?
NO
Connect a DC voltmeter across PL3-4 BLUE
(+) and PL3-2 GREEN (-). Does the voltage
fluctuate as described two steps back?
NO
Replace the furnace control.
You have an open wire or bad terminal on the
BLUE wire between the furnace control and the
blower motor.
Replace the blower control module attached to
the blower motor. Follow the instructions with
the blower control module to make sure the
entire blower motor does not need to be
replaced.
NO
41 BLOWER MOTOR FAULT – Indicates the
blower failed to reach 250 RPM or the
blower failed to communicate within the
prescribed time limits. Thirty seconds
after being turned ON or ten seconds
during steady-state operation. Turn power
off and check the following items first
before proceeding to the next step.
- Rubbing blower wheel.
- Loose blower wheel.
- Wiring from furnace control to blower
motor.
Remove the R thermostat connection from
the furnace control, disconnect both
connectors from the blower motor PL13
and PL14. Does the blower wheel turn
freely?
YES
YES
YES
Turn pow er off, disconnect PL13 and
PL14 from the blower motor, then turn
power back on. Connect a DC voltmeter
across PL13-16 BLUE (+) and PL13-1
GREEN (-). The voltage should be near
0-VDC but it will fluctuate briefly several
times a second. If you have an analog
voltmeter the needle will briefly go high
several times a second. If you have a
digital voltmeter with a bar graph it will
show a large change in magnitude on the
bar graph several times a second. If you
have a standard digital voltmeter it will
show a brief fluctuation in voltage and the
magnitude may vary depending on the
voltmeter used.
NO
Turn power off, reconnect PL13 and
PL14 to the blower motor, then turn
power back on. Connect a DC voltmeter
across PL3-3 YELLOW (+) and PL3-2
GREEN (-). Does the voltage fluctuate
more than it did in the previous step?
The voltage just measured should be
very stable and should not fluctuate more
than .02-VDC. If the voltage fluctuates
more than this get a different voltmeter
before proceeding.
YES
Is there 5-VDC at PL13-16 YELLOW (+)
and PL13-1 GREEN (-)?
Replace the furnace control.
NO
Is there 12-VDC at PL3-1 RED (+) and
PL3-2 GREEN (-)?
NO
Is there 12-VDC at PL13-7 RED (+) and
PL13-1 GREEN (-)?
YES
Turn power back on. Is there 115VAC at
PL14-5 and PL14-4?
NO
YES
NO
A02350c
You have an open wire or bad
terminal on the YELLOW wire
between the furnace control and
the blower motor.
YES
Is there 5-VDC at PL3-3
YELLOW (+) and PL3-2
GREEN (-)?
NO
You have an open wire or bad
terminal on either the RED or
GREEN wire between the
furnace control and the blower
motor.
You have an open wire or bad
terminal on either the BLACK or
WHITE power leads between
the furnace control and the
blower motor. If you have a
power choke disconnect it and
check continuity.
19
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 1-800-644-5544
[ ] Packaged Service Training [ ] Classroom Service Training
A94328
Copyright 2005 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
58mvb1sm
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
Printed in U.S.A.
Catalog No. 58MVB–1SM
Pg 20
8-05
Replaces: 58MVP-12SM
Tab 6a 8a