Service and Maintenance Instructions For Sizes 060
Contents
1. A96305 Fig 6 Cleaning Inlet Openings of Primary Heat Exchangers A93087 Fig 7 Combustion Air Intake Housing Gasket Repair 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 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door A CAUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and hazardous opera tion 3 Disconnect wires or connectors to rollout switch gas valve ignitor and flame sensor 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 gas valve TUBE ROUTING Furnace is shipped from factory in2. NOTE 5 THERMOSTAT FIVE Q TERMINALS FIELD SUPPLIED WIRE il DISCONNECT l l THREE WIRE i t D oe e el e HEATING SS 208 230 OR e Pe e ONLY C x m ae 460 V Y Pod THREE PHASE Reit Bar WS eno A So 115 V m NOTE SINGLE A E PA se PHASE yp e _e ate SE 4 Be gt O I zehn 208 230 V 2 H Laia So 1 Pre 0 0 e gt SINGLE 115 V AUXILIARY oe Nee E e PHASE FIELD SUPPLIED J BOX H 2 2 11 Ae un GND DISCONNECT __NOTE1_____ 47 CONDENSING SWITCH Gry UNIT 24 V TWO WIRE FURNACE TERMINAL CONTROL BLOCK NOTES CENTER 1 Connect Y or Y Y2 terminal as shown for proper cooling operation 2 Proper polarity must be maintained for 115 v wiring 3 Use W2 with 2 stage thermostat when zoning 4 If any of the original wire as supplied must be replaced use same type or equivalent wire 5 Some thermostats require a C terminal connection as shown A98325 Fig 11 Field Wiring 4 CAUTION A WARNING Never use matches candles flame or other sources of ignition to check for gas leakage Use a soap and water solution Failure to follow this warning could result in a fire personal injury or death 16 Replace main furnace door Step 6 Servicing Hot Surface Ignitor The ignitor does NOT require annual inspection Check ignitor resistance before removal 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Disconnect ignitor
3. b Connect condensate trap drain tubes See Fig 8 or tubing diagram on main furnace door for proper tube location 1 Connect 1 tube blue or blue and white striped from collector box 2 Connect 1 tube violet or unmarked from inducer housing 3 Connect 1 tube relief port green or pink from collector box NOTE Ensure tubes are not kinked or pinched as this will affect operation NOTE Refer to Table 1 for motor speed lead relocation if leads were not identified before disconnection Table 1 Speed Selection COLOR SPEED AS SHIPPED White Common Com Black High Cool Yellow Med High SPARE Oranget Med High Gas Heat Blue Med Low Spare High Gas Heat Red Low Low Gas Heat Continuous blower speed T Available on 5 speed blowers only 4 CAUTION Heating air speed selection MUST be adjusted to provide proper temperature rise as specified on the rating plate Failure to adjust the heating speed may shorten heat ex changer life c Connect field drain to condensate trap 13 Reconnect wires MANIFOLD MOUNTING Ka MANIFOLD GAS VALVE REGULATOR FITTING GAS VALVE A96304 Fig 5 Burner Box Assembly Refer to furnace wiring diagram and connect thermostat leads if previously disconnected See Fig 16 14 Turn on electrical supply Manually close blower access door switch Use a piece of tape to hold switch closed Check for proper rotation and speed changes betw
4. 0 5 minimum for control to recognize flame e 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 e If not check for 1 Satisfied thermostat 2 Open inlet gas pressure switch when used 3 Open propane low gas pressure switch LGPS Code 32 4 Open auxilliary limit ALS downflow horizontal only Code 32 5 Open 24 v fuse FU1 Code 24 6 Open limit switch LS Code 13 or 33 7 Open flame rollout switch FRS Code 13 or 33 8 Check 115 v line voltage LED off Check for sources of electrical noise interference electronic air cleaners nearby TV or radio antennas After replacing any component verify correct operating sequence START ie Y Turn thermostat OFF Qe 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 Cycle 115 v power off for 3 sec then on No Continuous LED gt Y Yes Set thermostat to call for heat Set FAN switch to AUTO i No Draft inducer motor starts PA Y Yes m No Is Code 22 displayed gt Y Yes Flame present when not normal y Replace gas valve 15 sec inducer pre purge e Y Yes Ignitor warms up and glows No orange yellow 17 sec warm up Y Yes No Main burners ignite o y Yes y No Main burners stay on l Yes I
5. Replace blower access door and main furnace door 10 Turn on electrical supply to furnace Step 2 Blower Motor and Wheel Maintenance To ensure long life economy and high efficiency clean accumu lated dirt and grease from blower wheel and motor annually 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 The following items should be performed by a qualified service technician Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove main furnace door and blower access door 3 Disconnect wires All factory wires can be left connected but field thermostat connections may need to be disconnected depending on their length and routing Remove control box mounting screws and position control box transformer and door switch assembly to right side of furnace casing 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 a Disconnect field drain connection from condensate trap b Disconnect drain and relief port tubes from condensate trap c Remove condensate trap from blower shelf Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace Clean blower wheel and motor by using a vacuum with soft brush attachmen
6. BLUE amp WHITE STRIPED 4 x COLLECTOR BOX TUBE INDUCER HOUSING DRAIN GREEN COLLECTOR BOX TUBE VIOLET i EXTENSION TUBE y 4 COLLECTOR BOX EXTENSION TUBE e BURNER ENCLOSURE PRESSU COLLECTOR BOX SER Tees gt REFERENCE TUBE ASSEMBL q DRAIN TUBE COUPLING p CONDENSATE TRAP COLLECTOR BOX IN BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY TUBE PINK DRAIN TUBES ROUTED IN p COLLECTOR BOX S FRONT OF GAS VALVE EXTENSION DRAIN TUBE INDUCER HOUSING DRAIN TUBE VIOLET I Tube location when used on Tube location when used on HORIZONTAL LEFT application HORIZONTAL RIGHT application AUXILIARY J BOX COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE COLLECTOR BOX EXTENSION TUBE BLUE amp WHITE STRIPED BLUE COLLECTOR BOX TUBE PINK i AUXILIARY J BOX RELOCATED HERE COLLECTOR BOX PLUG TUBE GREEN N BURNER ENCLOSURE Al q PRESSURE REFERENCE TUBE ASSEMBLY 4 D INDUCER HOUSING COLLECTOR BOX DRAINTUBE BURNERENCLOSURE See VIOLET PRESSURE REFERENCE e TUBE ASSEMBLY COLLECTOR BOX CONDENSATE TRAP D gt DRAIN TUBE BLUE COLLECTOR BOX COLLECTOR BOX DRAIN TUBE COLLECTOE BOX TUBE PIN TUBE GREEN 4 EXTENSION TUBE COLLECTOR BOX EXTENSION DRAIN TUBE COUPLING RELOCATE TUBE BETWEEN Blen COLLECTOR BOX DRAIN TUBE e TAAR ELF AND INDUCER HOUSING FOR BLUE AND WHITE STRIPED NOTE 060 AND 080 HEATING INPU
7. VALVE REDUNDANT LOW HEAT OPERATORS 2 STAGE HIGH HEAT PRESSURE SWITCH SPST N O HIGH HEAT PRESSURE SWITCH RELAY SPST N C HOT SURFACE IGNITER 115 VAC HOT SURFACE IGNITOR RELAY SPST N O 24VAC HUMIDIFIER CONNECTION 0 5 AMP MAX INDUCED DRAFT MOTOR 2 SPEED SHADED POLE INDUCER MOTOR RELAY SPST N O INDUCER MOTOR SPEED CHANGE RELAY SPDT BLOWER DOOR INTERLOCK SWITCH SPST N O JUNCTION BOX LIGHT EMITTING DIODE FOR STATUS CODES LOW GAS PRESSURE SWITCH SPST N O LOW HEAT PRESSURE SWITCH SPST N O LIMIT SWITCH OVERTEMPERATURE AUTO RESET SPST N C MAIN GAS VALVE RELAY DPST N O NOTE 7 WHEN USED LGPS 1 VALVE 2 HUMIDIFIER 12 CIRCUIT CONNECTOR 9 CIRCUIT CONNECTOR 4 CIRCUIT IDM CONNECTOR 2 CIRCUIT HSI CONNECTOR HIGH HEAT ONLY SWITCH SPST MANUAL LOW HEAT ONLY SWITCH SPST MANUAL BLOWER OFF DELAY SETTING SWITCHES SPST MANUAL TWINNING JUMPER SPDT FOR MAIN OR SECONDARY STATUS MANUAL CHANGE OVER TRANSFORMER 115VAC 24VAC 1 CIRCUIT TWINNING BUSS CONNECTOR ALSO COMPONENT TEST JUNCTION TERMINAL O CONTROL TERMINAL nTtcee L FACTORY POWER WIRING 115VAC NOTE FACTORY CONTROL WIRING 24VAC 1 Use only copper wire between the disconnect switch and the POWEI unit FIELD RUMRING 115VAC If any of the original wire as supplied must be replaced use FIELD CONTROL WIRING 24VAC
8. connection clean all parts strip wire and reassemble properly and securely Reconnect electrical supply to unit and observe unit through 1 complete operating cycle Electrical controls are difficult to check without proper instrumentation if there are any discrepancies in the operating cycle contact your dealer and request service EAC ELECTRONIC AIR CLEANER 115 VAC 1 AMP MAX I FUSE E d LED DIAGNOSTIC LIGHT TWIN TEST TERMINAL HUM HUMIDIFIER 24 VAC 0 5 AMP MAX g 24 VOLT z THERMOSTAT TERMINALS 4 FURNACE AND BLOWER OFF DELAY SETUP SWITCHES A01370 Fig 12 Two Stage Control 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 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 Check for signs of physical damage to heat tape such as nicks cuts abrasions g
9. only if all checks gt gt are OK No Replace control only if Code 45 is gt 4 displayed or if all checks are OK No gt Replace control only if Code 45 is displayed or if all checks are OK Replace control if Code 45 is dis No played or if all checks are OK Clean flame sensor if microamps are below nominal No Replace control only if Code 45 is gt 4 h 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 a 4 displayed or if all checks are OK No Replace control only if Code 45 is gt y h displayed or if all checks are OK A01056 14 15 Copyright 2001 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 58mta2sm Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations reek E E PC 101 Catalog No 535 80048 Printed in U S A Form 58MTA 2SM Pg 16 9 01 Replaces 58MTA 1SM al aj oa
10. open gas valve SWITCH DIDNOTOPEN Check for Obstructed pressure tubing Pressure switch stuck closed SEC ONDARY VOLTAGE FUSE IS OPEN Check for Short circuit in secondary voltage 24VAC wiring HIGH HEAT PRESSURE SWITCH OR RELAY DID NOTCLOSE OR REOPENED Checkfor Control relay may be defective Referto 82 LOVW HEAT PRESSURE DRAFT SAFEG UARD when used OR AUX LIMIT when used SWITCH DID NOTCLOSE ORREOPENED DOWNFLOWONLY If open longerthan five minutes inducer shuts off for 15 minutes before retry If it opens after tral for ignition period blower will come on for 90 second recycle delay Check for Defective blower motor orcapacitor Restricted vent Propervent sizing Low inducer voltage 115VAC Disconnected or obstructed pressure tubing Excessive wind Defective inducer motor Defective pressure switch Inadequate combustion air supply Low propane inlet gas pressure LIMITOR FLAME ROLL OUT SWITCH IS OPEN If open longer than three minutes code changesto 13 Flame roll out switch requires manual reset Check for Dirty filter or restricted duct system Loose blower wheel Defective blowermotoror capacitor Defective switch or connections Inadequate combustion air supply Flame roll out switch or fuse link open Open flame roll out switch orfuse link Manual reset or replace IGNMON PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal is lost after trial for ig
11. wire connection 4 Check ignitor resistance a Using an ohm meter check resistance across both ignitor leads in connector b Cold reading should be between 45 ohms and 90 ohms c If ohm reading is higher than 110 ohms ignitor is cracked and must be replaced 5 Remove ignitor assembly 4 CAUTION Allow ignitor to cool before removal Normal operation temperatures exceed 2000 a Do not remove ignitor from bracket while assembly is in furnace Using a 1 4 in nutdriver remove screw securing bracket and ignitor assembly to bottom of burner box The screw in the bracket is always located toward outside of burner box The screw may be hidden by inlet box or inlet pipe but can be removed without removing either After removing screw slide ignitor and bracket toward outside of burner box and pull straight out The ignitor is fragile DO NOT allow it to hit the side of the burner box opening while removing or replacing it b Inspect ignitor for a white area indicating a crack may be present If found replace ignitor NOTE A small crack cannot be seen on a new ignitor After a period of operation a white area will be visible around the crack c If replacement is required replace ignitor on ignitor bracket external to furnace to avoid damage as the silicon portion is very brittle and will easily crack or shatter d To remove ignitor from ignitor bracket remove screw holding ignitor ceramic block to bracket
12. 58MTA 4 Deluxe 4 Way Multipoise Variable Capacity Ar Direct Vent Condensing Gas Furnace Visit www carrier com Service and Maintenance Instructions For Sizes 060 120 Series 100 NOTE Read the entire instruction manual before starting the EFFICIENCY installation CERTIFIED ama This symbol indicates a change since the last issue CERTIFIED A93040 TABLE OF CONTENTS SAFETY CONSIDERATIONS ceennnnenesnennen 1 INTRODUCTION usina 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 2 CARE AND MAINTENANCE occooocccconccnoncononncconancnnnnconnnconnnccnnacono 2 Cleaning and or Replacing Air Filter nennene 3 Blower Motor and Wheel Maintenance 3 Cleaning Burners tostea e E A A RA 5 Cleaning Heat ExchangerS ccoccnocnonnoncnnonnnnnoninnionicnnnninnnnnininncnn 5 Primary Heat ExchangerS ooocncnncnncnnnnnnannnnnnnnnnnanincnccnncnncnos 5 Secondary Heat Exchangers ooconconcnocnnononnncnnnnnininncancnncnncnnos 7 Flushing Collector Box and Drainage System eee 7 Servicing Hot Surface Ignitor uceeeesesenesenenennennennn 8 Electrical Controls and Wiring eeeenenennene 8 Checking Heat Tape Operation If Applicable 9 Winferizme teens tkm 9 WIRING DIAGRAM uuusensesnsesensenensennesennenennennnennenennnnenann 9 TROUBLESHOOTIN Girard 9 Status Codes Component Test SAFETY CONSIDERATION
13. END BHI LOR BHT CLR BLWM BLWR CAP CPU EAC 1 EAC2 FRS FSE Fut Fu2 GV HPS HPSR HSI HSIR HUM IDM IDR IHI LOR ILK JB LED LGPS LPS LS 1 2 STAGE FURNACE 8 6 CONTROL I BLOWER OFF DELAY DM BLOWER OFF DELAY u Colm LOW HEAT ONLY E HGH HEAT ONLY zu 55 FUSED DISCONNECT SWITCH WHEN REQD Eno HSIR_ EAC1 EAC 2 Mi MED LO GRN YEL mon I HI GAS HEAT pr MED NOTE 14 SPARE H COOL SPARE I MED HI lo e IHI LOR bite DHI MED Hi YEL NOTE 14 MED ORNK PRI 115VAC me Fu TRAN SOUS ee 24VAC NOTE 5 MEDLO BLU olL we Com ME YN2 R G BLOWER MOTOR SPEED CHANGE RELAY SPDT BLOWER MOTOR SPEED CHANGE RELAY SPDT BLOWER MOTOR 4 or 5 SPEED PERMANENT SPLIT CAPACITOR BLOWER MOTOR RELAY SPST N O CAPACITOR 1 BLWM 2 IDM MICROPROCESSOR AND CIRCUITRY ELECTRONIC AIR CLEANER CONNECTION 115 VAC 1 AMP MAX ELECTRONIC AIR CLEANER CONNECTION COMMON FLAME ROLLOUT SWITCH OVERTEMP MANUAL RESET SPST N C FLAME PROVING SENSOR ELECTRODE FUSE 3 AMP AUTOMOTIVE BLADE TYPE FACTORY INSTALLED FUSE FIELD INSTALLED GAS
14. PORT Sy FILTER RETAINER ee A A WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET Fig 3 Bottom Filter Arrangement A00232 44 WARNING 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 Failure to follow this warning could result in personal injury or death The minimum maintenance that should be performed on this equipment is as follows 1 Ze Check and clean or replace air filter each month as required Check blower motor and wheel for cleanliness each heating or cooling season Check electrical connections for tightness and controls for proper operation each heating season Service as necessary Check for proper condensate drainage Clean as necessary Check for blockages in combustion air and vent pipes annu ally Check burners for cleanliness annually 4 CAUTION Personal injury could result from sharp metal edges etc Use st care when removing parts ep 1 Cleaning and or Replacing Air Filter The air filter arrangement may vary depending on the application or orientation 4 WARNING Never operate unit without a filter or with the blower access door removed Failure to follow this warning could result in a fire personal injury or death NOTE Ifthe filter has an airflow direction arrow the arrow must po in
15. ROSTATIC 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 CARE AND MAINTENANCE For continuing high performance and to minimize possible equip ment failure it is essential that maintenance be performed on this equipment Consult your local dealer about proper maintenance frequency and the availability of a maintenance contract WASHABLE FILTER FILTER SUP
16. S Installing and servicing heating equipment can be hazardous due to A92496 gas and electrical components Only trained and qualified personnel should install repair or service heating equipment Fig 1 Multipoise Furnace in Upflow Orientation Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations Follow all safety codes In the United States follow all safety must be performed by trained service personnel When working on codes including the National Fuel Gas Code NFGC NFPA heating equipment observe precautions in the literature on tags 54 1999 ANSI Z223 1 1999 and the Installation Standards Warm and on labels attached to or shipped with the unit and other safety Air Heating and Air Conditioning Systems NFPA 90B precautions that may apply ANSVNFPA 90B In Canada refer to the CAN CGA B 49 1 and Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book E E PC 101 Catalog No 535 80048 Printed in U S A Form 58MTA 2SM Pg 1 9 01 Replaces 58MTA 1SM a a oa 2 M00 National Standard of Canada Natural Gas and Propane Installation Codes NSCNGPIC Wear safety glasses and work gloves Have a fire extinguisher available during start up and adjustment procedures and service calls This is the safety alert symbol A When you see this symbol on the furnace and in instru
17. T STRIPED INDUCER HOUSING DRAIN TUBE VIOLET 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 326476 201 REV B 3 HORIZONTAL LEFT installations require the collector box pressure tube to be relocated between the inducer housing and the blower shelf to lit bottom prevent a trap Refer to the Installation Instructions for further details A01052 Fig 8 Furnace Pressure and Draining Tube Diagram 8 Disconnect pressure tubing from gas valve p A A WARNING 9 Remove 2 screws attaching top filler panel and rotate upwards to gain access to screws attaching burner box to cell panel The Braun o gas valve MUST be att ched to the burner box attachment screw Failure to attach this ground wire to an adequate casing ground will cause the furnace 5 control to lock out 10 Remove screws attaching burner box to cell panel See Fig NOTE Burner box cover manifold gas valve and burner assembly should be removed as 1 assembly NOTE Be sure burner box gasket is installed between burner box and cell panel If gasket is damaged replace it 11 Clean heat exchanger openings with a vacuum and a soft brush See Fig 6 NOTE Inspect combustion air intake housing If foamed gasket was re
18. and pull ceramic block out of bracket 6 To replace ignitor ignitor assembly reverse items 5a through 5d 7 Reconnect ignitor wire connection 8 Turn on gas and electrical supplies to furnace 9 Verify ignitor operation by initiating control board self test feature or by cycling thermostat 10 Replace main furnace door Step 7 Electrical Controls and Wiring 4 CAUTION 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 11 for field wiring information and to Fig 16 for unit wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash rapidly and prevent the furnace from operating The control system also requires an earth ground for proper operation of the control and flame sensing The 24 v circuit contains an automotive type 3 amp fuse located on the control center See Fig 12 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 3 amp fuse The control LED will display status code 24 when fuse needs to be replaced With power to the unit disconnected check all electrical connec tions for tightness Tighten all screws on electrical connections If any smoky or burned connections are found disassemble the
19. ane low gas pressure switch LGPS Code 32 4 Check all low voltage wiring connections 115v should be present at the ignitor If so replace the ignitor if not e check 115 vac wiring to ignitor LPS or LGPS open while HPS is 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 e Is the gas valve control knob in the OPEN or ON position 24v should be present across the gas valve terminals C and M and C and HI for high fire test during the 7 sec ignition trial If not check all low voltage wiring connections to valve e If 24v are present and main gas does not flow 1 Supply pressure gt 13 6 in we 2 Replace gas valve e Check ignitor position e Check burner carryover gap e Check gas supply pressure 4 5 in wc minimum e Check manifold pressure 1 3 to 1 7 in we for low fire 3 2 to 3 8 in wc for high fire e Check for proper orifice size Is Code 31 high gas heat only 32 33 or 34 displayed Check code information label to diagnose e Check polarity of 115 v power at J box and control Twinned furnace polarities must match rapid flashing LED e Check ground continutity from J box to control Check flame sensor microamps 4 0 nominal
20. burner bracket and can be removed as 1 assembly 11 Clean burners with soft brush and vacuum 12 Reinstall manifold orifice and gas valve assembly in burner box Ensure manifold seal grommet is installed properly and burners fit over orifices 13 Reconnect wires to gas valve Refer to furnace wiring diagram for proper wire location 14 Reinstall burner box pressure tube to gas valve regulator fitting 15 Reinstall gas supply pipe to gas 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 44 WARNING Gas valve switch or knob MUST be facing forward or tilted upward Failure to follow this warning could result in property damage personal injury or death 16 Replace burner box cover 17 Turn on gas and electrical supplies to furnace 18 Check for gas leaks 44 WARNING Never use matches candles flame or other sources of ignition to check for gas leakage Use a soap and water solution Failure to follow this warning could result in a fire personal injury or death 19 Replace main furnace door Step 4 Cleaning Heat Exchangers The following items should be performed by a qualified service technician PRIMARY HEAT EXCHANGERS If the heat exchangers get an accumulation of light dirt or dust on the inside they may be cleaned by the following procedure PRIMARY HX INLET OPENINGS
21. ce main furnace door SECONDARY HEAT EXCHANGERS 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 BURNER FLAME x BURNER MANIFOLD pp Fig 9 Burner Flame A89020 Step 5 Flushing Collector Box and Drainage System 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Disconnect inducer motor and pressure switch wires or connectors 4 Disconnect pressure switch tubes 5 Disconnect vent pipe from inducer housing outlet by loosen ing coupling clamp on inducer outlet 6 Disconnect drain tube from inducer housing See Fig 8 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 NOTE Ensure the drain tube disconnected from the inducer housing is higher than the collector box opening or water will flow out tube A93081 Fig 10 Gasket on Collector Box 9 Inspect inside area of collector box for any pieces of foreign materials and remove if present A CAUTION DO NOT use wire brush or other sharp object to inspect or dislodge materials in secondary heat exchangers as failure of th
22. ctions 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 would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation 44 WARNING The ability to properly perform maintenance on this equip ment requires certain knowledge mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User s Manual FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT SERIOUS PERSONAL INJURY OR DEATH 4 WARNING 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 com pounds plastic or plastic containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluids Paint thinners and other painting compounds paper bags or other paper products A failure
23. e secondary heat exchanger will occur Flush with water only 10 Reassemble inducer assembly by reversing items 5 7 Tighten 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 or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur to inducer housing See Fig 10 Apply a small bead of G E RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant to groove in collector box 11 Refer to furnace wiring diagram and reconnect wires to inducer motor and pressure switches or connectors 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 8 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 15 Check for gas leaks FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 208 230 460 V WIRING
24. e the control will return to normal standby mode Step 2 Component Test Use the Component Test to check furnace components for proper operation To initiate the component self test sequence shut off the room thermostat or disconnect the R thermostat lead Briefly approximately 2 sec short the TWIN TEST terminal to the Com 24V terminal The status LED will turn off The test sequence will be as follows 10 HITE JO HEE To A99119 Fig 15 Funnel in Drain and Antifreeze Running Through Trap The inducer will start and run on high speed After 7 sec the inducer motor will continue to run while the hot surface ignitor HSI is energized for 15 sec then de energized The inducer motor changes to low speed and continues to run the remainder of the component self test The blower motor operates on LO GAS HEAT speed for 7 sec 5 The blower motor operates on HI GAS HEAT speed for 7 sec 6 The blower motor operates on HI COOL speed for 7 sec 7 The gas valve and humidifier terminal HUM are not energized for safety reasons IT r 1 SET UP SWITCH FF DELAY EC 1135 SEC Cm mc CONNECTION DIAGRAM TO 115VAC FIELD DISCONNECT SWITCH SCHEMATIC DIAGRAM NATURAL GAS amp PROPANE GRY HPS HI D i ILK hr Equipment Grouno NOTE ES BHU LOR LOGAS HEAT LO BLU SWITCH 3 41 1180 SEC LEG
25. een heating and cooling by jumpering R to W W1 R to W W1 and W2 and then R to Y Y2 on control thermostat terminals See Fig 11 A WARNING Blower access door switch opens 115 v power to control No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in personal injury or death 15 If furnace is operating properly release blower access door switch replace blower access door and replace main furnace door 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 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Remove burner box cover 4 Using backup wrench disconnect gas supply pipe from gas valve 4 CAUTION Label all wires prior to disconnection when servicing con trols 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 Remove screws that secure manifold to burner box See Fig 5 8 Remove manifold orifices and gas valve as 1 assembly 9 Remove screws attaching burner assembly in burner box 10 Remove burner assembly from burner box NOTE All burners are attached to
26. est then shift to low speed for7 to 15 seconds All other components will be tested in the ame sequence asthe NON CONDENSING 320893 101 REV F Fig 17 Service Label 12 A01368 NOTES Refer to information label on blower compartment door for procedure for use of LED status codes and problem solving suggestions LED indicator is viewed through window compartment door on blower 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 TROUBLESHOOTING GUIDE e If LED is flashing rapidly check line voltage polarity e If Code 24 is displayed check for blown fuse e If LED is OFF check line voltage and 24 v transformer e If Code 45 is displayed replace control Is indoor blower on Y 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 e If Code 23 is displayed the pressure switch es is stuck closed Replace switch and or check pressure tube for blockage System malfunction Code 21 e 115v should be present at the inducer motor If so replace inducer motor If not check 115 v wiring e 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 Prop
27. ill be ON the entire length of the test Neither the gas valve nor the humidifier will be turned ON gt Fig 16 Wiring Diagram 326050 101 REV D SERVICE If status code recallisneeded do not remove poweror blower door Briefly remove and then reconnect one main limit wire to display stored status code LED CODE STATUS CONTINUOUS OFF Check for115VAC at L1 and L2 and 24VAC at SEC1 and SEC2 CONTINUOUS ON Control has 24VAC power RAPID RASHING Line voltage 115VAC polarity reversed If twinned referto twinning kit instructions Each of the following status codesisa two digit number with the first digit determined by the number of shortfla shes and the second digit by the number of long flashes NO PREVIOUS CODE Stored status codesare erased when power 115VAC or 24VAC to control isintemupted or 48 hours after each fault is cleared BLOWER ON AFTER POWER UP 115VAC or 24VAC Blower runs for 90 seconds if unit is powered up during a call forheat R W closed LIMITOR FLAME ROLL OUT SWITCH LOCKOUT Control will auto reset after three hours Reset switch orreplace fuse link Referto 83 IGNMON LOCKOUT Control will auto reset after three hours Referto 84 GAS HEATING LOCKOUT Control will NOT auto reset Checkfor Mis wired gasvalve Defective control valve relay ABNORMAL FLAME PROVING SIGNAL Fla me isproved while gas valve isde energized Inducer will run until fault iscleared Check for Leaky gasvalve Stuck
28. moved 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 products or equivalent must not contain corn or canola oil aromatic or 12 Reverse items 4 through 10 for reassembly halogenated hydrocarbons or inadequate seal may occur to burner NOTE After cleaning inspect the heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion 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 7 13 Refer to furnace wiring diagram and reconnect wires to rollout switch gas valve ignitor and flame sensor 14 Reconnect pressure switch tubes to gas valve and intake housing Refer to tube routing label on main furnace door or Fig 8 for proper tube location Be sure tubes are not kinked 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 transpar ent See Fig 9 17 Check for gas leaks 44 WARNING Never use matches candles flame or other sources of ignition to check for gas leakage Use a soap and water solution Failure to follow this warning could result in a fire personal injury or death 18 Repla
29. nawing by animals etc 4 CAUTION If this furnace is installed in an unconditioned space where the ambient temperatures may be 32 F or lower freeze protection measures must be taken See Fig 13 2 Check for discolored heat tape insulation If any damage or discolored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on Step 9 Winterizing 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED Nhe ATM A93058 Fig 13 Winterizing the Furnace 4 CAUTION Freezing condensate left in the furnace will damage the equipment 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 1 Turn off electrical supply to furnace 2 Remove main furnace door 3 Disconnect cap from unused drain tap on inducer housing See Fig 14 4 Insert funnel in drain tube and pour antifreeze propylene glycol RV swimming pool antifreeze or equivalent into furnace until it is visible at point where condensate enters open drain See Fig 15 5 Reconnect drain tube to inducer housing 6 Replace main furnace door 4 CAUTION Do not use ethylene glycol Prestone II antifreeze coolant or equivalent automotive type Failure of plastic components will occur WIRING DIAGRAM See Fig 16 for Wiring Diagram TROUBLESHOOTING Use the Troubleshooti
30. ndoor blower motor starts on No heating speed after 60 sec gt warm up period Yes Furnace runs until call for No m heat ends Y Yes Turn thermostat to OFF gas valve No shuts off burners 15 sec inducer post purge Y Yes Indoor blower motor stops after No 90 135 180 or 225 sec Y 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 e 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 e 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 e 24v should not be present across R and G If so turn thermostat FAN switch to AUTO 13 ELECTRICAL SHOCK HAZARD ONLY QUALIFIED AND TRAINED SERVICE PERSONNEL SHOULD PERFORM THIS PROCEDURE e 24v should be present across R Yes and C If not check for gt 1 Open flame rollout switch FRS Code 33 2 Open limit switch LS Code 33 3 Check all low voltage wiring connections Tro No Replace control
31. ng Guide the status code LED on the control and the Component Test to isolate furnace operation problems Step 1 Status Codes For an explanation of status codes refer to service label located on back of main furnace door or Fig 17 The control will store up to 5 previous codes but will not store a non current code longer than 48 hr NOTE Removing the blower access door will open the blower access door switch and terminate 115 v power to the control is interrupted To read current status code remove main furnace door The status code LED can be viewed through the sight glass on the blower access door A lo ITIL lo A99118 Fig 14 Inducer Housing Drain Tube NOTE NO thermostat signals may be present at control and all blower off delays must be expired to view previous codes To retrieve previous codes remove 1 of the red main limit wires 1 to 4 sec until the LED light goes out then reconnect it Do not leave red wire disconnected for longer periods of time as the control will assume an overtemperature condition exits and will respond with 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 mod
32. nition period blower will come on for 90 second recycle delay Check for Gas valve defective orgasvalve tumed off Oxide buildup on flame sensor clean with fine steel wool Properflame sense current 5 microampsD C min 4 0 6 0 nom in HIGH HEAT Green wire MUSTbe connected to fumace sheet metal Flame sensormust be ungrounded Manual valve shut off Defective hot surface ignitor Control ground continuity Inadequate flame canyover or rough ignition Low inlet gas pressure LOW HEATPRESSURE DRAFT SAFEG UARD when used ORAUX LIMIT when used SWITCH OPEN WHILE HIGH HEAT PRESSURE SWITCHISCLOSED Check for Pressure switch stuck open Disconnected or obstructed pressure tubing Refer to 32 and 83 Low propane inlet gas pressure REPLACE CONTROL COMPONENT TEST 112 CIRCUIT i CONNECTOR To initiate the component self test sequence shut off the room thermostat or disc onnect the R thermostat lead Briefly short the TWIN TEST terminal to the Com24V terminal Status LED will tum off NON CONDENSING FURNACE The control will tum ON the inducer motor low speed then Hr and remain on high speed forthe entire test The other components will be ON for7 to 15 seconds Hot surface ignitor Low heatblowerspeed High heat blower speed High cooling blower speed CONDENSING FURNACE The inducer motor will start in high speed and remain on high speed until the end of the t
33. t Be careful not to disturb balance weights clips on blower wheel vanes Do not bend wheel or blades as balance will be affected If greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel a Mark blower wheel location on shaft before disassembly to ensure proper reassembly 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 c Mark blower wheel orientation and cutoff plate location to ensure proper reassembly d Remove screws securing cutoff plate and remove cutoff plate from housing e Remove bolts holding motor mounts to blower housing and slide motor and mounts out of housing Disconnect capaci tor and ground wire attached to blower housing before removing motor f Remove blower wheel from housing 4 CAUTION The blower wheel should not be dropped or bent as balance will be affected 10 11 12 g Clean wheel per instructions on degreaser cleaner Reassemble motor and blower wheel by reversing items 8b through 8f Ensure wheel is positioned for proper rotation Reinstall blower assembly in furnace Reinstall control box transformer and door switch assembly on blower shelf Reinstall condensate trap and tubing if previously removed a Reinstall condensate trap in hole in blower shelf
34. t toward the blower To clean or replace filters proceed as follows If 1 2 3 4 filter is installed in filter cabinet adjacent to furnace Turn off electrical supply to furnace Remove filter cabinet door Slide filter out of cabinet If equipped with permanent washable filter clean filter by spraying cold tap water through filter in opposite direction of WASHABLE FILTER IN FURNACE E uN SS FILTER Be I RETAINER TR F WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET Fig 4 Filter Installed for Side Inlet airflow Rinse filter and let dry Oiling or coating of the filter is not recommended 5 If equipped with factory specified disposable media filter replace only with media filter having the same part number and size 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 1 Turn off electrical supply to furnace Remove main furnace door and blower access door 2 3 Release filter retainer wire See Fig 3 and 4 4 Slide filter out of furnace 5 Furnaces are equipped with permanent washable filter s Clean filter by spraying cold tap water through filter in opposite direction of airflow 6 Rinse filter and let dry Oiling or coating filter is not recommended 7 Slide filter into furnace 8 Recapture filter retainer wire 9
35. the same or equivalent type wire CONDUCTOR ON CONTROL Inducer IDM and blower BLWM motors contain internal auto reset thermal overload switches ED MTINGSCHEI TERMINAL Blower motor speed selections are for average conditions See FIELD GROUND Installation Instructions for details on optimum speed selection EQUIPMENT GROUND Replace only with a 3 AMP fuse FIELD SPLICE This wire must be connected to furnace sheet metal for control to prove flame PLUG RECEPTACLE Factory connected when LGPS not used Symbols are an electrical representation only BLOWER ON DELAY Gas heating 60 seconds Cooling Heat Pump 2 seconds BLOWER OFF DELAY Gas heating 90 135 180 or 225 seconds cooling or heat pump 90 seconds IGNITION LOCKOUT will occur after four consecutive unsuccessful trials for ignition Control will automatically reset after three hours Control must be grounded at pin 10 of 12 pin connector NA Not Applicable Not used Orange lead not available on all models COMPONENT TEST 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 High Speed HSI inducer motor Low Speed blower motor Low Gas Heat Speed blower motor High Gas Heat Speed and blower motor High Cool Speed for 7 15 seconds each the inducer motor w
36. to follow this warning can cause corrosion of the heat exchanger fire personal injury or death 4 CAUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation INTRODUCTION 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 must revise your orientation to component location accord ingly AIRFLOW A 2 UPFLOW HORIZONTAL HORIZONTAL RIGHT DOWNFLOW AIRFLOW AIRFLOW N AIRFLOW A93041 Fig 2 Multipoise Orientation ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 4 CAUTION Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will pre vent 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 1 Disconnect all power to the furnace DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CON TROL PRIOR TO DISCHARGING YOUR BODY S ELEC T
37. upflow configuration Pressure tube and drain tube routing MUST match the diagrams below Condensate Trap Factory Installed Tube location when used in UPFLOW application Condensate Trap on LEFT in Blower Shelf Side Optional BURNER ENCLOSURE BURNER ENCLOSURE Blower access panel removed PRESSURE REFERENCE EURNER ENCLOSURE gt TUBE ASSEMBLY or TUBE ASSEMBLY COLLECTOR BOX TUBE CAP CAP PINK f PLUG PLUG COLLECTOR BOX TUBE d COLLECTEREN I fa COLLECTOR BOX DRAIN PINK BLUE amp WHITE STRIPED COLLECTOR BOX TUBE GREEN HA COLLECTOR BOX DRAIN TUBE INDUCER HOUSING MOLDED DRAIN TUBE BLUE amp WHITE STRIPED BEHIND COLLECTOR BOX DRAIN TUBE CONDENSATE TRAP COLLECTOR DOK PRN TUBE COLLECTOR BOX DRAIN TUBE BLUE al FIELD INSTALLED j TRICHT DRAN OPTION FACTORY SUPPLIED DRAINTUBE D dl 472k INDUCER HOUSING DRAIN TUBE COUPLING LEFT DRAIN OPTION F Ne VIOLET FACTORY SUPPLIED 1 2 IN CPVC STREET ELBOWS 2 FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE gt FOR LEFT DRAIN OPTION dl FIELD INSTALLED K N FACTORY SUPPLIED CONDENSATE TRAP lt gt y i Condensate Trap on LEFT Side COLLECTOR BOX DRAIN TUBE BLUE CAP PLUGGED END COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX DRAIN PURE GREEN s BLUE amp WHITE STRIPED i n A COLLECTOR BOX TUBE RI PINK COLLECTOR BOX DRAIN TUBE 2 iS S
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