Carrier 2-STAGE 58TMA Instruction manual

58TMA, 58TUA
Deluxe 2-Speed Gas-Fired
Induced-Combustion Furnace
Service and Maintenance Instructions
For Sizes 040-135, Series 100
NOTE: Read the entire instruction manual before performing any
service or maintenance.
This symbol → indicates a change since the last issue.
Index
Page
SAFETY CONSIDERATIONS..................................................1-2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE ...........................................................................2
CARE AND MAINTENANCE..................................................2-7
Air Filter Arrangement..........................................................2-3
Blower Motor and Wheel......................................................3-4
Cleaning Heat Exchanger......................................................4-6
Electrical Controls and Wiring .............................................6-7
Troubleshooting ...................................................................7-10
Unit Wiring Diagram................................................................8
Service Label ............................................................................9
Troubleshooting Guide ...........................................................10
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, tags, and
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 NFPA No. 541992/ANSI Z223.1-1992. In Canada, refer to the current edition of
the National Standard of Canada CAN/CGA-B149.1- and .2-M91
Natural Gas and Propane Gas Installation Codes. Wear safety
glasses and work gloves. Have fire extinguisher available during
start-up and adjustment procedures and service calls.
Recognize safety information. This is the safety-alert symbol
.
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage.
Fig. 1—Model 58TMA Horizontal
A94087
®
ama
CANADIAN GAS ASSOCIATION
A PP R O VED
R
Fig. 2—Model 58TMA
Downflow
A94086
A94085
Fig. 3—Model 58TUA Upflow
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 565-845
Printed in U.S.A.
Form 58T-3SM
Pg 1
1-95
Replaces: 58T-2SM
Tab 6a 8a
The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools, and
equipment. If you do not possess these, do not attempt to
perform any maintenance on this equipment other than those
procedures recommended in the User’s Manual. A FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS
PERSONAL INJURY, OR DEATH.
Never store anything on, near, or in contact with the furnace,
such as:
1. Spray or aerosol cans, rags, brooms, dust mops,
vacuum cleaners, or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning
compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other
volatile fluids.
3. Paint thinners and other painting compounds, paper
bags or other paper products.
A failure to follow this warning could result in corrosion
of the heat exchanger, fire, personal injury, or death.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and servicing to
protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools
which are held during the procedure. These precautions will
help to avoid exposing the control to electrostatic discharge
by putting the furnace, the control, and the person at the same
electrostatic potential.
Turn off the gas and electrical supplies to the unit before
performing any maintenance or service on it. Follow the
operating instructions on the label attached to the furnace. A
failure to follow this warning could result in personal injury.
The minimum maintenance that should be performed on this
equipment is as follows:
1. 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.
1. Check and clean air filter each month or more frequently if
required. Replace if torn.
2. Check blower motor and wheel for cleanliness each heating
and cooling season. Clean and lubricate as necessary.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
As with any mechanical equipment, personal injury can result
from sharp metal edges, etc.; therefore, be careful when
removing parts.
AIR FILTER ARRANGEMENT — The air filter arrangement
may vary depending on the application. Refer to Table 1 or 2 for
filter size information.
Table 1—Downflow/Horizontal Filter Size
Information (In.)
FURNACE
CASING WIDTH
14-3/16
17-1/2
21
24-1/2
(2)
(2)
(2)
(2)
FILTER
SIZE
14 X 20 X
14 X 20 X
16 X 20 X
16 X 20 X
1
1
1
1
FILTER
TYPE
Cleanable
Cleanable
Cleanable
Cleanable
Table 2—Upflow Filter Size Information (In.)
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.
FURNACE
CASING WIDTH
14-3/16
17-1/2
21
24-1/2
FILTER 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.
2
g. Reinstall filters.
h. Replace blower access door and turn on electrical supply to
furnace.
2. Upflow.
Each furnace requires 1 or 2 filters which are installed in the
blower compartment. (See Fig. 6.) To remove filters for
cleaning or replacement, proceed as follows:
a. Turn off electrical supply before removing blower and
control access doors.
AIRFLOW
12″
4″
b. Release filter retainer from clip at front of furnace casing.
(See Fig. 6.) For side return, clips may be used on either or
both sides of the furnace.
D
FIELD-SUPPLIED
FILTER RETAINERS
MOUNTING
SCREWS
A82173
DRAFT
SAFEGUARD
SWITCH
Fig. 4—Horizontal Filter Arrangement
AIRFLOW
RELIEF
BOX
INSTALLATION
POSITION
OF FILTERS
PRESSURE
SWITCHES
MAIN
LIMIT
SWITCH
RETURN-AIR
PLENUM
MANUAL
RESET
LIMIT
SWITCH
CONTROL
FILTER
RETAINER
WASHABLE
FILTER
ACCESS DOOR
A93393
Fig. 6—Model 58TUA Upflow
A88486
Fig. 5—Downflow Filter Arrangement
c. Slide filter out.
d. Clean filters by spraying tap water through filter from
opposite direction of airflow.
1. Horizontal and Downflow.
Each furnace requires 2 filters which are installed in the
return-air duct. (See Fig. 4 and 5.) To remove filters for
cleaning or replacement, proceed as follows:
e. Rinse and let dry. Oiling or coating of filter is not
recommended or required.
f. Place filter in furnace.
a. Turn off electrical supply before removing blower access
door.
g. Replace blower and control access doors and turn on
electrical supply to furnace.
b. Remove blower access door.
BLOWER MOTOR AND WHEEL — For long life, economy, and
high efficiency, clean accumulated dirt and grease from the blower
wheel and motor annually.
c. Reach up behind top plate, tilt filters toward center of
return-air plenum, remove filters, and clean as needed.
Replace if torn.
The following steps should be performed by a qualified service
technician:
d. Furnaces are equipped with permanent, washable filters.
e. Clean filters by spraying tap water through filter from
opposite direction of airflow.
Some motors have prelubricated sealed bearings and require no
lubrication. These motors can be identified by the absence of oil
ports on each end of the motor. For those motors with oil ports,
lubricate as follows:
f. Rinse and let dry. Oiling or coating of filters is not
recommended or required.
3
10. Lubricate motor (when oil ports are provided).
Lubricate motor every 5 years if motor is used on intermittent
operation (thermostat FAN switch in AUTO position), or every 2
years if motor is in continuous operation (thermostat FAN switch
in ON position).
a. Remove dust caps or plugs from oil ports located at each
end of motor.
b. Use a good grade of SAE 20 nondetergent motor oil and
put 1 teaspoon, 5 cc, 3/16 oz, or 16 to 25 drops in each oil
port. Do not over-oil.
Remember to disconnect the electrical supply before removing
access doors.
Clean and lubricate as follows:
c. Allow time for total quantity of oil to be absorbed into each
bearing.
1. Remove blower access door.
d. After oiling motor, be sure to wipe excess oil from motor
housing.
2. Disconnect vent pipe on downflow/horizontal furnace only.
a. Remove vent pipe enclosure.
e. Replace dust cap or plugs on oil ports.
b. Disconnect vent pipe and remove short piece of pipe from
furnace.
11. Remove blower wheel from housing.
a. Mark cutoff location to ensure proper reassembly.
AUXILIARY
LIMIT
SWITCH
b. Remove screws holding cutoff plate and remove cutoff
plate from housing.
VENT PIPE
ENCLOSURE
c. Lift blower wheel from housing through opening.
12. 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
dropped or bent as balance will be affected.
CONTROL
13. Reinstall blower wheel by reversing items 11 a. through c. Be
sure wheel is positioned for proper rotation.
MOUNTING
SCREWS
14. Reassemble motor and blower by reversing items 5 through 9.
If motor has ground wire, be sure it is connected as before.
DRAFT
SAFEGUARD
SWITCH
PRESSURE
SWITCHES
Be sure the motor is properly positioned in the blower
housing. The motor oil ports must be at a minimum of 45°
above the horizontal centerline of the motor after the blower
assembly has been reinstalled in the furnace.
RELIEF
BOX
15. Reinstall blower assembly in furnace.
16. Reinstall control. (See step C.13 for reassembly of vent pipe
and flue enclosure for downflow/horizontal furnaces.)
17. Connect blower electrical leads to control. Please note that
connections are polarized for assembly. DO NOT FORCE.
MANUAL
RESET
LIMIT
SWITCHES
CLEANING HEAT EXCHANGER
The following steps should be performed by a qualified service
technician:
A93394
NOTE: Deposits of soot and carbon indicate the existence of a
problem which needs to be corrected. Take action to correct the
problem.
Fig. 7—Model 58TMA Downflow
c. Disconnect wires from auxiliary limit on blower housing (if
present).
If it becomes necessary to clean the heat exchanger because of
carbon deposits, soot, etc., proceed as follows:
3. Disconnect blower electrical leads from control. (See Fig. 6
and 7.) Note location of wires for reassembly.
1. Turn gas and power to furnace to OFF.
4. Remove control.
2. Remove control and blower access doors.
5. Remove screws holding blower assembly to blower deck and
slide blower assembly out of furnace.
3. Remove vent pipe enclosure on downflow/horizontal furnace
only and disconnect vent pipe from relief box.
6. Loosen a screw in strap holding motor capacitor to blower
housing and slide capacitor out from under strap.
4. Remove 2 screws that secure relief box. (See Fig. 6 or 7.)
5. Disconnect wires to the following components. Mark wires to
aid in reconnection of:
7. Mark blower wheel, motor, and motor support in relation to
blower housing before disassembly to ensure proper reassembly.
a. Draft safeguard switch.
b. Inducer motor.
8. Loosen setscrew holding blower wheel on motor shaft.
c. Pressure switch(es).
9. Remove bolts holding motor and motor mount to blower
housing and slide motor and mount out of housing. Disconnect
ground wire attached to blower housing before removing
motor.
d. Limit overtemperature switch(es).
e. Gas valve.
f. Hot surface ignitor.
4
g. Flame-sensing electrode.
11 32"
13 32"
BURNER
h. Wiring connectors leading to control.
6. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage sealant.
7. Remove complete inducer assembly from furnace, exposing
flue openings.
CELL
PANEL
8. Using field-provided small wire brush, steel spring cable,
reversible electric drill, and vacuum cleaner, clean cells as
follows:
HOT
SURFACE
IGNITOR
ASSEMBLY
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 items (1.) and (2.) can usually be
purchased at local hardware stores.
(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.
(4.) Remove metal screw fitting from wire brush to allow
insertion into cable.
C
L
7 8"
IGNITOR
C
L
BURNER
IGNITOR
ASSEMBLY
b. Clean each heat exchanger cell.
Fig. 9—Position of Ignitor to Burner
(1.) Attach variable-speed, reversible drill to end of spring
cable (end opposite brush).
A93347
(8.) Repeat foregoing procedures until each cell in furnace
has been cleaned.
(2.) Remove cell outlet plates. IMPORTANT: Replace
screws in center panel before cleaning.
(9.) Using vacuum cleaner, remove residue from each cell.
(3.) Insert brush end of cable into upper opening of cell
and slowly rotate with drill. DO NOT force cable.
Gradually insert at least 36 in. of cable into 2 upper
passes of cell. (See Fig. 8.)
(10.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
(11.) Reinstall cell outlet plates and screws FIRST; then,
reinstall cell inlet plates and burner assembly. Care
must be exercised to center the burners in the cell
openings.
9. After cleaning flue openings, check sealant on flue collector to
ensure that it has not been damaged. If new sealant is needed,
contact your dealer or distributor.
10. Clean and replace flue collector assembly, making sure all 8
screws are secure.
11. Reinstall relief box.
12. Reconnect wires to the following components:
a. Draft safeguard switch.
b. Inducer motor.
A91252
c. Pressure switches.
Fig. 8—Cleaning Heat Exchanger Cell
d. Limit overtemperature switch(es).
(4.) Work cable in and out of cell 3 or 4 times to obtain
sufficient cleaning. DO NOT pull cable with great
force. Reverse drill and gradually work cable out.
e. Gas valve.
f. Hot surface ignitor.
g. Flame-sensing electrode.
(5.) Remove burner assembly and cell inlet plates.
h. Wiring connectors leading to control.
NOTE: Be very careful when removing the burner assembly to
avoid breaking the ignitor. See Fig. 9 for the correct ignitor
location.
13. Reconnect vent pipe to relief box. When applicable replace
vent pipe enclosure.
14. Replace blower door only.
(6.) IMPORTANT: Replace screws in center panel and
cells before cleaning.
15. Turn power and gas to ON.
16. Set thermostat and check furnace for proper operation.
(7.) 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.
17. Verify blower airflow and speed changes between heating and
cooling.
5
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
W
FOUR
WIRE
Y
R
G
1-STAGE
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
TWO-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
R
GND
208/230VOLT
SINGLE
PHASE
CONDENSING
UNIT
G
24-VOLT
TERMINAL
BLOCK
FURNACE
NOTE: Connect Y-terminal as
shown for proper
operation.
NOTE: If any of the original wire,
as supplied, must be replaced, use
same type or equivalent wire.
A93378
Fig. 10—Heating and Cooling Application Wiring Diagram
FIELD 24-VOLT WIRING
FIELD 115-, 208/230-, 460-VOLT WIRING
FACTORY 24-VOLT WIRING
FACTORY 115-VOLT WIRING
SIX
WIRE
W2
W1
Y2
R
G
Y1
2-STAGE
THERMOSTAT
TERMINALS
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATINGONLY
BLK
BLK
WHT
WHT
208/230- OR
460-VOLT
THREE
PHASE
W2
COM
208/230VOLT
SINGLE
PHASE
W/W1
GND
115-VOLT FIELD- JUNCTION
SUPPLIED
BOX
FUSED
CONTROL
DISCONNECT
BOX
Y1
Y2
R
GND
2-SPEED
CONDENSING
UNIT
G
24-VOLT
TERMINAL
BLOCK
FURNACE
→
C
Y/Y2
NOTE: Connect Y-terminal as
shown for proper
operation.
NOTE: If any of the original wire,
as supplied, must be replaced, use
same type or equivalent wire.
A93379
Fig. 11—Heating and Cooling Application Wiring Diagram for 2-Stage Thermostats and/or 2-Speed
Condensing Units
18. Check for gas leaks.
polarity is NOT correct, the furnace control will display code 02 on
the status LED and prevent heat operation. The control system also
requires an earth ground for proper operation of the microprocessor.
19. Replace control door.
NOTE: There may be more than 1 electrical supply to unit.
With power disconnected to unit, check all electrical connections
for tightness. Tighten all screws on electrical connections. If any
smoky or burned connections are noticed, disassemble the connection, clean all parts and stripped wire, and reassemble properly and
securely. Electrical controls are difficult to check without proper
instrumentation; therefore, reconnect electrical power to unit and
observe unit through 1 complete operating cycle.
The electrical ground and polarity for 115-v wiring must be
maintained properly. Refer to Fig. 10 and 11 for field wiring
information and to Fig. 12 for unit wiring information. If the
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the main control. Any 24-v electrical shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
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.
ELECTRICAL CONTROLS AND WIRING
6
and will respond with indoor blower operation.) This places the
control in the status recall mode and displays the first code stored
in memory. Record the code and repeat the disconnect and
reconnect of the red wire, recording each code until code 11 is
displayed indicating no additional faults. After the last code is
displayed or after 2 minutes in the code, recall mode the control
will return to normal standby mode.
replacement is required, use ONLY a 3-amp fuse. The control will
display code 24 when the fuse needs replacement.
The control in this furnace is equipped with an LED status light to
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 of short flashes, the second is the number of longs flashes.)
Refer to the service label on the blower compartment door for code
explanations and useful troubleshooting suggestions. (See Fig. 13.)
Use any recorded fault codes, the service label, and the troubleshooting diagram on the following pages to diagnose and correct
any problem condition.
It is important to note that the power to the furnace must not be
interrupted and the furnace blower door must not be removed until
the LED status code(es) is recorded. When power to the control is
interrupted, the status memory is erased.
→ TROUBLESHOOTING
Refer to the service label. (See Fig. 13.) Page 10 contains 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.
The control will store up to 5 previous codes but will not store
non-current code longer than 48 hr. To retrieve previous codes, if
present, no thermostat inputs to the control must be present and all
time delays must expire. Remove 1 of the red main limit wires 1
to 4 sec until the LED light goes out, then reconnect it. (See Fig.
6 and 7.) (Do not leave red wire disconnected for longer periods of
time as the control will assume an overtemperature condition exits
The guide will help to identify the problem or failed component.
After replacing any component, verify correct operation sequence.
7
RED
SWITCH
1
2
RED
ALS2
2-STAGE
FURNACE
CONTROL
RED
W2 Com W/ Y/
24V W1 Y2
R
G HUM
BLOWER-OFF DELAY
BLOWER-OFF DELAY
LOW-HEAT ONLY
HIGH-HEAT ONLY
*
LGPS
(WHEN USED)
NOTE #6
ALS1
DSS
LED
TWIN
TEST
S
M
TJ
RED
RED
ORN
YEL
P1
L2
EAC-2
SEC2
SEC1
FU1
LO-GAS EAC-1
HEAT
PARK
HI-GAS
HEAT
COMMON
HI-COOL
L1
PR1 PR2
PL2
1
2
PL6
HSI
BRN
GRY
3 PL3
COM
WHT
2
2
RED
BLK
YEL
BLU
BLK
BRN
BLK
C
BLWM
*
FU2
BRN
GRN
WHT
WHT
CAP
GRN
L2
L1
M
BLU
GRN
GV
GRN
FUSED DISCONNECT
SWITCH (WHEN REQ'D)
NOTE #1
JB
HI
P
BRN
PL7
WHT
NOTE #4
1
ILK
HPS
TRAN
**
BRN
PLUG RECEPTICLE
Fig. 12—Unit Wiring Diagram
To initiate the component test sequence with no thermostat inputs and with all inducer Post-Purge and
Blower-Off Delay periods completed, short the 'TWIN/TEST' terminal to the 'COM' terminal for about two
seconds. The control will turn ON the inducer motor Low-Speed, inducer motor High-Speed, HSI,
blower motor Low-Gas-Heat Speed, blower motor High-Gas-Heat Speed, and blower motor High-Cool
Speed for 7-15 seconds each. Neither the gas valve nor the humidifier will be turned ON.
COMPONENT TEST
FIELD SPLICE
EQUIPMENT GROUND
FIELD GROUND
FIELD WIRING SCREW TERMINAL
CONDUCTOR ON CONTROL
12-CIRCUIT CONNECTOR
9-CIRCUIT CONNECTOR
3-CIRCUIT IDM CONNECTOR
1-CIRCUIT FPS CONNECTOR
2-CIRCUIT HSI CONNECTOR
2-CIRCUIT LINE/NEUTRAL CONNECTOR
HIGH-HEAT-ONLY SWITCH, SPST-(MANUAL)
LOW-HEAT-ONLY SWITCH, SPST-(MANUAL)
BLOWER-OFF DELAY SETTING SWITCHES,
SPST-(MANUAL)
TJ
TWINNING JUMPER, SPDT FOR MASTER OR
SLAVE STATUS-(MANUAL CHANGE-OVER)
TRAN
TRANSFORMER-115VAC/24VAC
TWIN/TEST 1-CIRCUIT TWINNING BUSS CONNECTOR,
ALSO STATUS CODE RECALL
JUNCTION
TERMINAL
CONTROL TERMINAL
FACTORY POWER WIRING (115VAC)
FACTORY CONTROL WIRING (24VAC)
FIELD POWER WIRING (115VAC)
FIELD CONTROL WIRING (24VAC)
LO
PL1
PL2
PL3
PL4
PL6
PL7
SW1
SW2
SW3 & 4
BLU
RED
BLK
RED
1
WHT
GRN
HI
MED HI
MED LO
IDM
CONNECTION DIAGRAM
BLK
LEGEND
ALS1
AUXILIARY LIMIT SWITCH, OVERTEMP.–MANUAL RESET, SPST-(N.C.)
ALS2
AUXILIARY LIMIT SWITCH, OVERTEMP.–AUTO. RESET, SPST-(N.C.)
BHI/LOR BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLWM
BLOWER MOTOR, 4-SPEED, PERMANENT-SPLIT-CAPACITOR
BLWR
BLOWER MOTOR RELAY, SPST-(N.O.)
CAP
CAPACITOR
CPU
MICROPROCESSOR AND CIRCUITRY
DSS
DRAFT SAFEGUARD SWITCH
EAC-1
ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1 AMP MAX.)
EAC-2
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FRS1
FLAME ROLLOUT SWITCH OVERTEMP.–MANUAL RESET, SPST-(N.C.)
FRS2
FLAME ROLLOUT SWITCH OVERTEMP.–MANUAL RESET, SPST-(N.C.)
FSE
FLAME-PROVING SENSOR ELECTRODE
FU1
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FU2
FUSE, FIELD INSTALLED
GV
GAS VALVE-REDUNDANT LOW-HEAT OPERATORS, 2-STAGE
HPS
HIGH-HEAT PRESSURE SWITCH, SPST-(N.O.)
HPSR
HIGH-HEAT PRESSURE SWITCH RELAY, SPST-(N.C.)
HSI
HOT-SURFACE IGNITOR (115 VAC)
HSIR
HOT-SURFACE IGNITOR RELAY, SPST-(N.O.)
HUM
24VAC HUMIDIFIER CONNECTION (.5 AMP MAX.)
IDM
INDUCED 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.)
JB
JUNCTION BOX
LED
LIGHT-EMITTING DIODE FOR STATUS CODES
LGPS
LOW GAS-PRESSURE SWITCH, SPST-(N.O.)
LPS
LOW-HEAT PRESSURE SWITCH, SPST-(N.O.)
LS
LIMIT SWITCH, OVERTEMPERATURE-AUTO RESET, SPST-(N.O.)
MGVR
MAIN GAS VALVE RELAY, DPST-(N.O.)
–1 = VALVE
–2 = HUMIDIFIER
*
BLOWER-OFF
DELAY
SWITCH
(SEC.)
3
4
90 SEC
135 SEC
180 SEC
225 SEC
*
HEAT
SET-UP
SWITCH
NORM
HI HT
LO HT
ORN
ORN
ORN
YEL
#8
NOTE
YEL
FSE
PL4 WHT
WHT
FRS1
(WHEN USED)
1234
9 8 7
NOTE #8
LPS
WHT
RED
BLK
RED
ON
OFF
ON
OFF
FACTORY
SETTING
ON
OFF
ON
OFF
ON
OFF
3 2 1
1
GRN
BLK
BLK
WHT
WHT
(WHEN USED)
BLU
3 2 1
GRY
BLK
GRY
12 11 10
BLK
BLU
FRS2
WHT
RED
LS
NOTE #5
MGVR-2
24VAC
TRAN
115VAC
CPU
PARK
HI-COOL
MGVR-1
SEC2
PR2
PL2
PL1
HPSR
HI-GASHEAT
LO-GASHEAT
COMMON
EAC-2
TWINNING
JUMPER
TJ
SEC1
PR1
IHI/LOR
EAC-1
BHT/CLR
BHI/LOR
N/A
N/A
PL3
PL6
3
2
1
1
2
HI
FSE
P
HPS
PL4
C GV
NOTE#7
M
(WHEN USED)
LGPS
NOTE #8
7
8 N/A
11 N/A
10
1
4
5
DSS
NOTE #8 LPS
ALS1
LS
BRN
L2
BLWM
FRS2
HI
COM
IDM
LO
HSI
CAP
FRS1
3 (WHEN USED)
9
ALS2
6
12 N/A
2
2
6
5
1
8
7
4
9
3
COM
NOTE #4
BRN
LO
MED LO
MED HI
HI
(NATURAL GAS & PROPANE)
SCHEMATIC DIAGRAM
A94232
NOTES:
1. USE ONLY COPPER WIRE BETWEEN THE DISCONNECT SWITCH AND
THE UNIT.
2. IF ANY OF THE ORIGINAL WIRE, AS SUPPLIED, MUST BE REPLACED, USE
THE SAME OR EQUIVALENT TYPE WIRE.
3. INDUCER (IDM) AND BLOWER (BLWM) MOTORS CONTAIN INTERNAL AUTORESET THERMAL OVERLOAD SWITCHES.
4. BLOWER MOTOR SPEED SELECTIONS ARE FOR AVERAGE CONDITIONS.
SEE INSTALLATION INSTRUCTIONS FOR DETAILS ON OPTIMUM SPEED
SELECTION.
5. REPLACE ONLY WITH A 3-AMP FUSE.
6. AUXILIARY LIMIT SWITCHES (ALS1 & 2) USED ON DOWNFLOW MODELS
ONLY.
7. THIS WIRE MUST BE CONNECTED TO FURNACE SHEET METAL FOR
CONTROL TO PROVE FLAME.
8. FACTORY CONNECTED WHEN LGPS NOT USED.
9. SYMBOLS ARE AN ELECTRICAL REPRESENTATION ONLY.
10. BLOWER-ON DELAY: GAS HEATING 45 SECONDS, COOLING/HEAT PUMP 2
SECONDS.
11. COOLING/HEAT PUMP BLOWER-OFF DELAY IS 90 SECONDS.
12. IGNITION-LOCKOUT WILL OCCUR AFTER FOUR CONSECUTIVE UNSUCCESSFUL TRIALS-FOR-IGNITION. CONTROL WILL AUTOMATICALLY RESET
AFTER THREE HOURS.
13. CONTROL MUST BE GROUNDED AT PIN 10 OF 12-PIN CONNECTOR.
14. NA - NOT APPLICABLE
320854-401 REV. D
COM
Y/Y2
G
W2
SW1
SLAVE
W/W1 MASTER
TWIN
TEST
R
FU1
IDR
HSIR
BLWR
HUM
L1
PL7
TO 115VAC FIELD DISCONNECT SWITCH
NOTE #1
ILK
EQUIPMENT GROUND
SW4
SW3
SW2
8
WARNING
Service should be performed only by qualified persons.
SERVICE
If status code recall is needed, do not remove power or blower door.
LED CODE
STATUS
CONTINUOUS OFF Check for 115V at L1 and L2, and 24V at SEC1 and SEC2.
CONTINUOUS ON Control has 24V power.
RAPID FLASHING Line voltage polarity reversed. If twinned, 24V power
to one furnace may be out of phase with power to other furnace.
EACH OF THE FOLLOWING STATUS CODES IS A TWO-DIGIT NUMBER WITH
THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND
THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.
11 NO PREVIOUS CODE - Stored status codes are erased when power (115V or
24V) to control is interrupted or 48 hours after each fault is cleared.
12 BLOWER ON AFTER POWER UP - Blower runs for 90 seconds, if unit is
powered up during a call for heat (R-W/W1 closed). Note: 2-sec. ON-delay.
13 LIMIT OR FLAME ROLL-OUT (FRS) SWITCH LOCKOUT - Auto-reset after
three hours. FRS switch requires manual-reset.
Check for: - 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 LOW- OR HIGH-HEAT PRESSURE SWITCH DID NOT OPEN
Check for: - Obstructed pressure tubing
- Defective pressure switch (stuck closed)
24 SECONDARY VOLTAGE FUSE IS OPEN
Check for: - Short-circuit in secondary voltage (24V) wiring
31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR
REOPENED
Check for: -Control relay may be defective - Refer to #32
32 LOW-HEAT PRESSURE, DRAFT SAFEGUARD , OR AUX-LIMIT
(DOWNFLOW ONLY*) SWITCH DID NOT CLOSE OR REOPENED
Check for: - Proper vent sizing (and condensate pitch with side-wall vent)
- Low inducer voltage (115v)
* Blower motor and capacitor
- Defective inducer motor
- Defective pressure switch
- Excessive wind
- Restricted vent
- Inadequate combustion air supply
- Disconnected or obstructed pressure tubing
33 LIMIT OR FLAME ROLL-OUT (FRS) SWITCH IS OPEN - FRS switch
requires manual-reset.
Check for: - Inadequate combustion air supply (FRS switch only)
- Dirty filter or restricted duct system
- Loose blower wheel
- Defective switch or connections
- Blower motor or capacitor failure
34 IGNITION-PROVING FAULT - Control will retry three times before lockout #14.
Check for: - Oxide buildup on flame-proving sensor (clean with fine sandpaper).
- Proper flame-proving microamps (0.5 minimum)
- Proper control ground continuity
- Flame-proving sensor must be ungrounded
- Smooth flame carryover and ignition - Manual valve(s) OFF
43 LOW-HEAT PRESSURE, DRAFT SAFEGUARD, OR AUXILIARY LIMIT
SWITCH OPEN WHILE HIGH-HEAT PRESSURE SWITCH IS CLOSED
Check for: - Disconnected or obstructed pressure tubing
- Defective pressure switch (stuck open)
- Refer to #32 and #33
45 REPLACE CONTROL
320893-101 REV. A
A94169
Fig. 13—Service Label
9
NOTES:
1. Refer to information label on blower compartment door
for procedure for use of LED status codes and problem
solving suggestions.
2. LED indicator is viewed through window on blower
compartment door.
3. If 115-vac power is energized or interrupted during a
call for heat, the indoor blower will run for 90 sec before
a gas heating cycle begins – Code 12.
4. After replacing any component, verify correct operating
sequence.
TROUBLESHOOTING
GUIDE
! WARNING
ELECTRICAL SHOCK HAZARD
ONLY QUALIFIED AND TRAINED
SERVICE PERSONNEL SHOULD
PERFORM THIS PROCEDURE
If LED is flashing rapidly, check line voltage polarity.
If Code 24 is displayed, check for blown fuse.
If LED is OFF, check line voltage and 24-v transformer.
START
If Code 45 is displayed, replace control.
Turn thermostat OFF.
Is indoor blower on ?
On furnace control, note current
settings for setup switches 1 (SW-1)
and 2 (SW-2) then set SW-1 to OFF
and SW-2 to ON.
Yes
No
24v should be present across C and W. If not, check for:
1. Open thermostat.
2. Open 24-v fuse (FU1) – Code 24.
3. Failed transformer.
If Code 23 is displayed, the pressure switch(es) is stuck closed.
Replace switch and/or check pressure tube for blockage.
Cycle 115-v power
off for 3 sec, then on.
No
No
System malfunction – Code 21.
No
Continuous LED?
24v should be present across R
and C. If not, check for:
1. Open flame rollout switch
(FRS) – Code 33.
2. Open limit switch (LS) –
Code 33.
3. Check all low-voltage wiring
connections.
Replace control only if all checks
are OK.
115v should be present at the inducer motor. If so, replace inducer
motor. If not, check 115-v wiring.
Yes
Set thermostat to call for heat.
Set FAN switch to AUTO.
No
Draft inducer motor starts.
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
115v should be present at the ignitor. If so, replace the ignitor; if not,
check 115-vac wiring to ignitor.
Yes
No
Is Code 22 displayed?
Yes
LPS, DSS, or ALS open while HPS if closed (high-gas-heat only) –
Code 43.
Control will attempt to light burners 4 times (approximately 1 minute
between attempts – Code 34). Voltage is present at the gas valve for 7
sec during each ignition trial. System will lockout after 4 attempts.
Flame present when not normal.
Replace gas valve.
Is the gas valve control knob in the OPEN or ON position?
24v should be present across the gas valve terminals C and M/P
(and C and HI for high-fire test) during the 7 sec ignition trial. If
not, check all low-voltage wiring connections to valve.
15-sec inducer pre-purge.
Yes
Ignitor warms up and glows
orange/yellow; 17-sec warm-up.
If Code 32 is displayed check for:
1. Open gas inlet pressure switch (when used).
2. Open pressure switch (LPS) and/or tube – Code 32.
3. Open draft safeguard switch (DSS) – Code 32.
4. Open auxiliary switch (ALS)(downflow/horizontal only) – Code 32.
5. Check all low-voltage wiring connections.
No
If 24v are present, and main gas does not flow:
1. Supply pressure > 13.6-in. wc.
2. Replace gas valve.
Check ignitor position.
Check burner carryover gap.
Yes
No
Main burners ignite.
Check gas supply pressure (4.5-in. wc minimum).
Check manifold pressure (1.3- to 1.7-in. wc for low-fire; 3.2- to
3.8-in. wc for high fire).
Yes
Check for proper orifice size.
Is Code 31 (high-gas-heat only), 32, 33, or 34 displayed? Check
code information label to diagnose.
No
Main burners stay on.
No
No
Yes
Turn thermostat to OFF; gas valve
shuts off burners; 5-sec inducer
post purge.
No
Yes
Heating sequence of operation
complete. Remove blower door,
move setup switch 1 (SW-1) to ON
position and repeat process to check
high-fire operation. (When finished
return SW-1 and SW-2 to original
desired settings.)
115v should be present at the blower motor. If so, check capacitor.
If capacitor is OK, replace blower motor. If 115v are not present at
the blower motor, check all 115-v wiring to motor.
If not, check for:
1. Satisfied thermostat.
2. Open inlet gas pressure switch (when used).
3. Open pressure switch (LPS) – Code 32.
4. Open draft safeguard switch (DSS) – Code 32.
5. Open auxilliary limit (ALS)(downflow/horizontal only) – Code 32.
6. Open 24-v fuse (FU1) – Code 24.
7. Open limit switch (LS) – Code 13 or 33.
8. Open flame rollout switch (FRS) – Code 13 or 33.
9. Check 115-v line voltage – LED off.
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
Check for sources of electrical noise interference (electronic air
cleaners, nearby TV, or radio antennas).
Yes
Indoor blower motor stops after
90, 135, 180, or 225 sec.
Replace control if Code 45 is displayed, or if all checks are OK.
Clean flame sensor if microamps
are below nominal.
Check flame sensor microamps (4.0 nominal; 0.5 minimum for
control to recognize flame).
Yes
Furnace runs until call for
heat ends.
No
Check ground continutity from J-box to control.
Yes
Indoor blower motor starts on
heating speed after 45-sec
warm-up period.
Check polarity of 115-v power at J-box and control. Twinned
furnace polarities must match – rapid flashing LED.
No
If inducer and burners continue to operate, check for 24v at the
gas valve. If 24v are present, verify that the thermostat is open
across R and W. If no voltage is present, turn the gas valve
control knob to the OFF position. Replace gas valve.
24v should be present across R and C. If not, check for:
1. Open limit switch (LS) – Code 13 or 33.
2. Open flame rollout switch (FRS) – Code 13 or 33.
24v should not be present across R and G. If so, turn thermostat
FAN switch to AUTO.
A93386
Copyright 1995 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
58t3sm
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. 565-845
Printed in U.S.A.
Form 58T-3SM
Pg 10
1-95
Replaces: 58T-2SM
Tab 6a 8a