Download Carrier Deluxe 58MVP Instruction manual
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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