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Service and Maintenance Instructions

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1. Q OO SEC 1 oocq DOO 00d NI 115 VAC L1 S POWER SUPPLY IST o 9S i o al gt ES S TEST TWIN S 33 Z 24 V THERMOSTAT TERMINALS HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX LED OPERATION amp DIAGNOSTIC LIGHT HARNESS CONNECTOR 24 V TRANSFORMER SEC 2 3 AMP FUSE a a N so SPARE 1 HEAT o BLOWER SPEED Spn SELECTION TERMINALS 5 eo SPARE 2 p N EAC 1 EAC ELECTRONIC AIR CLEANER TERMINALS 115 VAC 1 5 AMP MAX EAC 2 115 VAC L2 NEUTRAL CONNECTION HOT SURFACE IGNITOR CONNECTOR INDUCER MOTOR CONNECTOR A95086 Fig 12 Control Center Step 9 Winterizing A CAUTION Freezing condensate left in the furnace will damage the equipment 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED ha SEN A93058 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 drain tube from inducer housing See Fig 13 4 Insert funnel in drain tube and pour antifreeze propylene glycol RV swimming pool antifreeze or equivalent into furn
2. 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 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 A 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 15 for unit wiring information NOTE If the polarity is not correct the STATUS LED on the control center will flash rapidly and prevent the furnace from operating The control system also requires an earth ground for proper operation of the control center and flame sensing The 24 v circu
3. The minimum maintenance that should be performed on this equipment is as follows 1 Check and clean or replace air filter each month as required 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 4 Check for proper condensate drainage Clean as necessary 5 Check for blockages in combustion air and vent pipes annu ally 6 Check burners for cleanliness annually WASHABLE FILTER FILTER RETAINER FILTER SUPPORT Fig 3 Bottom Filter Arrangement A93046 A CAUTION Personal injury could result from sharp metal edges etc Use care when removing parts Step 1 Cleaning and or Replacing Air Filter The air filter arrangement may vary depending on the application or orientation A CAUTION Never operate unit without a filter or with the blower access panel removed Failure to follow this warning could result in a fire or personal injury To clean or replace filters proceed as follows 1 Turn off electrical supply to furnace 2 Remove main furnace door and blower access panel 3 Release filter retainer wire See Figs 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 dr
4. HEATING amp COOLING 58MSA 4 Way Multipoise Fixed Capacity Condensing Gas Furnace Visit www carrier com Service and Maintenance Instructions For Sizes 040 120 Series 120 and 130 NOTE Read the entire instruction manual before starting the installation This symbol gt indicates a change since the last issue A93040 TABLE OF CONTENTS SAFETY CONSIDERATIONS 0 ccs ects sseeeeeeeeeeseneeseeetaes 1 GENERAL 0 pis apes E esas cae Sareea ees asics 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 2 CARE AND MAINTENANCE oooocoococccnnoncnnnnonnnnnnononncnnononnnncnncnnns 2 Cleaning and or Replacing Air FilteT ooonnicnnionnncninnnnnnnncnnns 3 Blower Motor and Wheel Maintenance eee eee 3 Cleaning Burne ts anin enrii ina e EEA AAA TRA 4 Cleaning Heat ExchangelS oconcnononcnncnnnnnnnnnnnnnonnnocnnnncnnrncnncnnnos 5 Flushing Collector Box and Drainage SYSE M a a settee ShessesteQuastes ENTE 6 Servicing Hot Surface Ignitor o ooocnnnnnnnnnonnonnnonnnnnnncnnnoccnnaos 7 Electrical Controls and WiriN8 oconcncicnninncnnnnnnnnnnnnnncnnnncnnnos 8 Checking Heat Tape Operation If Applicable Winterizing WIRING DIAGRAM rnana ea iiai eienn 9 TROUBLESHOOTING eaeoe testacea kia i 9 SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified person nel should install repair or service heating equipment Untrained personnel can p
5. 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 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 A CAUTION Allow ignitor to cool before removal Normal operation temperatures exceed 2000 F 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 A CAUTION The ignitor is fragile DO NOT allow it to hit the side of the burner box opening while removing or replacing it
6. Understand the signal words DANGER WARNING and CAU TION These words are used with the safety alert symbol DAN GER 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 expertise mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User s Manual FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT SERIOUS PERSONAL INJURY OR DEATH A 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 Failure to follow this warning can cause corrosion of the heat exchanger fire pers
7. 8 Furnace Pressure and Drain Tubing Diagram BURNER FLAME BURNER MANIFOLD Ed Fig 9 Burner Flame A89020 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 18 Replace 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 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 9 Inspect insi
8. Combustion Air Intake Housing Gasket Repair 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 for proper tube location Be sure tubes are not kinked See Fig 8 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 y TUBE ROUTING Furnace is shipped from factory in 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 Blower access panel removed Ali tonics BURNER ENCLOSURE PRESSURE REFERENCE TURE ASSEMBLY O os TUBE ASSEMBLY COLLECTOR BOX TUBE CAP PINK ra E COLLECTOR BOX TUBE OLER ao TUBE COLLECTOR BOX DRAIN PINK e TUBE aj INDUCER HOUSING MOLDED DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE BEHIND COLLECTOR BOX DRAIN TUBE 0 os BLUE amp WHITE STRIPED CONDENSATE TRAR COLLECTOR
9. EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES 11 NO PREVIOUS CODE Stored status codes are erased when power 115VAC or 24VAC to control is interrupted or 48 hours after each fault is cleared BLOWER ON AFTER POWER UP 115 VAC or 24VAC Blowerrunsfor90 seconds if unit is powered up during a call forheat R W closed UMITOR ARAME ROLL OUTSWITCH LOCKOUT Control will auto reset after three hours Reset switch or replace fuse link Refer to 83 IGNITION LOCKOUT Control will auto reset after three hours Refer to 84 GAS HEATING LOCKOUT Control will NOTauto reset Check for Miswired gas valve Defective control valve relay 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 gasvalve PRESSURE SWITCH DID NOTOPEN Check for Obstructed pressure tubing Pressure switch stuck closed SEC ONDARY VOLTAGE FUSE IS OPEN Check for Short circuit in secondary voltage 24VAC wiring PRESSURE DRAFT SAFEGUARD AUX LIMITSWITCH when used OR BLOCKED VENTSMWITCH when used DID NOTCLOSE OR REOPENED DOWNFLOW ONLY If open longer than five minutes inducer shuts off for 15 minutes before retry Checkfor Proper vent sizing Low inducer voltage 115VAC Defective inducer motor Defective Blower mo
10. WIRING 115VAC 6 FACTORY CONNECTED WHEN LGPS NOT USED 0 HUM 24VAC HUMIDIFIER CONNECTION 5 AMP MAX FIELD WIRING 24VAC 7 REPLACE ONLY WITH A 3 AMP FUSE gt IB NBUCER BEALE EY oo ZONDUCTOTON POB 8 YELLOW LEAD NOT ON ALL MOTORS BECINER ACCESS PANEL eno TESEO 9 BLOWER ON DELAY GAS HEATING 60 SECONDS COOLING OR HEAT PUMP 2 SECONDS Q NCTION BOX SPST N O FIELD WIRING TERMINAL 10 BLOWER OFF DELAY GAS HEATING 90 135 180 OR 225 SECONDS COOLING OR x TINE DODE F R STATUS CODES FIELD EARTH GROUND HEAT PUMP 90 SECONDS 135 SECONDS ONLY ON SOME MODELS 2 LOW GAS PRESSURE SWITCH SPST NO EQUIPMENT GROUND IGNITION LOCKOUT WILL OCCUR AFTER FOUR CONSECUTIVE UNSUCCESSFUL LIMIT SWITCH AUTO RESET SPST N C TRIALS FOR IGNITION CONTROL WILL AUTO RESET AFTER THREE HOURS 9 AUTO RESET INTERNAL MOTOR OVERLOAD TEMP SW FIELD SPLICE SOME MODELS MAY HAVE SPAD E QUICK CONNECT TERMINALS NI PRINTED CIRCUIT BOARD PLUG RECEPTACLE GAS VALVE LEADS ARE INTERCHANGEABLE ON SINGLE STAGE VALVES N Fig 15 Wiring Diagram A00197 SERVICE If status code recall is needed do not remove power or blower door Briefly remove and then reconnect one main limit wire to display stored status code LED CODE STATUS CONTINUOUS OFF Check for 115VAC at Ll and L2 and 24VAC at SEC 1 and SEC 2 CONTINUOUSON Control has 24VAC power RAPID FLASHING Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions
11. code changes to No 13 Check for Blower motor failure Motor start capacitor Open flame rollout switch manual reset Inadequate combustion air supply flame rollout switch only Dirty filter Defective limit switch or connections Loose blower wheel IGNITION PROVING FAILURE If flame is not sensed during the trial for ignition period the control will repeat the ignition sequence 3 more times before going into lockout No 14 If flame signal is lost after trial for ignition period blower will come on for 90 sec recycle delay Check for the following items first before proceding to the next step Gas valve turned off Manual shut off valve Green wire must be connected to furnace sheet metal To determine whether the problem is in the gas valve ignitor or flame sensor the system can be operated in the component test mode to check the ignitor First remove the R thermostat connection from the control center and initiate the component test sequence Does the ignitor glow orange white hot by the end of the 17 sec warm up period YES Unplug ignitor harness from control center and inititate another component test sequence Check for 115v between pins 1 and 2 on the control center Was 115v present for the 17 sec period YES Check for continuity in the harness and ignitor Replace defective component Reconnect the R thermostat lead and set thermostat to call for heat Connect voltmete
12. condensate trap b Disconnect drain and relief port tubes from condensate trap c Remove condensate trap from blower shelf 6 Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace 7 Clean blower wheel and motor by using a vacuum with soft brush attachment Be careful not to disturb balance weights clips on blower wheel vanes Do not bend wheel or blades as balance will be affected 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 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 g Clean wheel per instructions on degreaser cleaner 9 Reassemble motor and blower wheel by reversing items 8b through 8f Ensure wheel is positioned for proper rotation Be sure to attach ground wire 10
13. BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE i BLUE ELO INSTALLED Fi SUPPLIED FIELD INSTALLED CROAT DRAR OTON il RIGHT DRAIN OPTION FACTORY SUPPLIED DRAIN TUBE xs 1 INDUCER et DRAIN TUBE COUPLING LEFT DRAIN OPTION FIELDINSTALLED VIOLET FACTORY SUPPLIED 1 2 1N FIELD INSTALLED FACTORYSUPPLIED FNC STREET ELBOWS 2 DRAIN TUBE FOR LEFT DRAIN OPTION Condensate Trap on Condensate Trap on LEFT Side RIGHT Side COLLECTOR BOX CAP DRAIN TUBE BLUE PLUGGED END COLLECTOR BOX OO i TUBE GREEN f 3 COLLECTOR BOX DRAIN TUBE L z PLUG BLUE amp WHITE STRIPED Alh 4 COLLECTOR Box ig EXTENSION TUBE ETT COLLECTOR BOX CONDENSATE TRAP A EXTENSION TUBE o BURNER ENCLOSURE PRESSURE PO ECTON BOX REFERENCE TUBE ASSEMBLY PINK INDUCER HOUSING DRAIN TUBE VIOLET y PLUG CAP COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN BLUE TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK INDUCER HOUSING DRAIN OE EEN TUBE TUBE VIOLET Baai COLLECTOR BOX EXTENSION TUBE BURNER ENCLOSURE PRESSURE Tube location when used on HORIZONTAL LEFT application IT COLLECTOR BOX DRAIN TUBE e BLUE 8 WHITE STRIPED PL E A SUE CAP LA COLLECTOR BOX TUBE GREEN BURNER ENCLOS
14. Reinstall blower assembly in furnace 11 Reinstall condensate trap and tubing if previously removed a Reinstall condensate trap in hole in blower shelf 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 c Connect field drain to condensate trap NOTE Ensure tubes are not kinked or pinched as this will affect operation 12 Reinstall control box transformer and door switch assembly on blower shelf 13 Reconnect wires Refer to furnace wiring diagram and connect thermostat leads if previously disconnected See Fig 15 NOTE Refer to Table 1 for motor speed lead relocation if leads were not identified before disconnection FACTORY COLOR SPEED ATTACHED TO Black High Cool Yellow When Present Medium High Spare Blue Medium Low Heat Red Low Spare White Common Com A CAUTION Heating speed selection MUST be adjusted to provide proper temperature rise as specified on the rating table Failure to adjust the heating speed may shorten heat exchanger life 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
15. TCH WHEN REQD oR NOTE 4 e LEGEND PLI 9 CIRCUIT CONNECTOR BLWR BLOWER MOTOR RELAY SPST N O PL2 2 CIRCUIT PCB CONNECTOR BLWM BLOWER MOTOR PL3 3 CIRCUIT IDM CONNECTOR CAP CAPACITOR PL4 3 CIRCUIT IDM EXTENSION CONNECTOR CPU MICROPROCESSOR AND CIRCUITRY PL5 2 CIRCUIT HSI PCB CONNECTOR Com EAC 1 ELECTRONIC AIR CLEANER CONNECTION 115 VAC 1 5 AMP MAX PRS PRESSURE SWITCH SPST N O ON SWI 82 BLOWER OF DELAY NOTES FSE FLAME PROVING ELECTRODE TEST TWIN COMPONENT TEST amp TWIN TERMINAL 1 IF ANY OF THE ORIGINAL EQUIPMENT WIRE IS REPLACED USE WIRE RATED FOR 105C FU1 FUSE 3 AMP AUTOMOTIVE BLADE TYPE FACTORY INSTALLED TRAN TRANSFORNER 11SVAC 2AVAG 2 INDUCER IDM AND BLOWER BLWM MOTORS CONTAIN INTERNAL U PELOINSTALLED SUPPLIED o U UPT DEVICE ANTON 3 BLOWER MOTOR SPEED SELECTIONS ARE FOR AVERAGE CONDITIONS SEE INSTALLATION FIELD INSTALLED amp SUPPLIED Li y GND EQUIPMENT GROUND UNMARKED TERMINAL INSTRUCTIONS FOR DETAILS ON OPTIMUM SPEED SELECTION Gv CAS VAL VE REDUNDANT OPERATO RS PCB TERMINAL 4 USE ONLY COPPER WIRE BETWEEN THE DISCONNECT SWITCH AND THE VR VALVE RELAY DPST N O FACTORY WIRING 115VAC FURNACE JUNCTION BOX JB eo BLOWER vo EDN RELAY SPDT STORY WIPING vee 5 THIS WIRE MUST BE CONNECTED TO FURNACE SHEETMETAL FOR CONTROL TO PROVE FLAME HSIR HOT SURFACE IGNITOR RELAY SPST N O FIELD
16. URE AT PRESSURE REFERENCE TUBE ASSEMBLY o To 2 INDUCER HOUSING COLLECTOR BOX DRAIN TUBE EXTENSION TUBE VOLET COLLECTOR BOX CONDENSATE TRAP P gt DRAIN TUBE BLUE COW COUPLING RELCOATE Use BEI MEEN SL ONER ICTR BO EXTENSION DRAN TUBE SHELF AND INDUCER HOUSING FOR 040 060 AND 080 HEATING INPUT FURNACES 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 324999 201 REV C C prevent a trap Refer to the Installation Instructions for further details REFERENCE TUBE ASSEMBLY DRAIN TUBE COUPLING i 4 CONDENSATE TRAP ho DRAIN TUBES ROUTED IN COLLECTOR BOX FRONT OF GAS VALVE Y EXTENSION DRAIN TUBE GAS VALVE Tube location when used on HORIZONTAL RIGHT application COLLECTOR BOX DRAIN TUBE COLLECTOR BOX EXTENSION TUBE pue a COLLECTOR BOX TUBE PINK PLUG y AUXILIARY J BOX RELOCATED HERE aol y pe or BURNER ENCLOSURE PRESSURE REFERENCE J TUBE ASSEMBLY COLLECTOR BOX COLLECTOR BOX TUBE GREEN a e EXTENSION TUBE COLLECTOR BOX DRAIN TUBE CONDENSATE TRAP BLUE AND WHITE STRIPED INDUCER HOUSING DRAIN TUBE VIOLET S A00308 Fig
17. ace until it is visible at point where condensate enters open drain See Fig 14 5 Reconnect drain tube to inducer housing 6 Replace main furnace door A CAUTION Do not use ethylene glycol Prestone II antifreeze coolant or equivalent automotive type Failure of plastic components will occur WIRING DIAGRAM See Fig 15 for Wiring Diagram TROUBLESHOOTING For an explanation of fault codes refer to service label located on back of main furnace door or Fig 16 and the Troubleshooting Guide The control center stores 1 status code representing the last fault to occur for a period of 48 hrs or until the 115 or 24 v power is interrupted NOTE Removing blower access panel will open blower access panel door switch and terminates 115 v power to control center The status code will be erased Look into blower access panel sight glass for current LED status BEFORE removing blower access panel The unit s component test is a useful troubleshooting tool since it displays the current status code of the furnace and functionally operates all furnace components except the gas valve The com ponent test and methods to initiate it are described below AN do HIE oO Fig 13 Inducer Housing Drain Tube A99118 COMPONENT TEST SEQUENCE NOTE All components are functionally operated except the gas valve When the component test is initiated the following sequence of events occur
18. cooling by jumpering R to G and R to Y on control center thermostat terminals See Fig 11 A WARNING Blower access panel door switch opens 115 v power to control center 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 panel door switch replace blower access panel 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 5 Remove wires from gas valve Note location for reassembly A CAUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation 6 Remove burner box pressure tube from gas valve regulator fitting 7 Remove screws that secure manifold to burner box See Fig 5 MANIFOLD MOUNTING MANIFOLD GAS VALVE REGULATOR FITTING GAS VALVE A93295 Fig 5 Burner Box Assembly 8 Remove manifold orifices and gas valve as 1 assembly 9 Remove screws attachi
19. de 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 the secondary heat exchanger will occur Flush with water only 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 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 A93081 Fig 10 Gasket on Collector Box 11 Refer to furnace wiring diagram and connect wires to inducer motor and pressure switch or connectors 12 Reconnect pressure tubes to pressure switch 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
20. e TESTterminal to the Com 24V terminal Status LED will flash code and then tum ON the inducer motor The inducer motor will run forthe entire component test The hot surface ignitor blower motorheat speed and blower motorcool speed will be tumed ON for 10 15 secondseach GasValve and Humidifier will not be tumed on ly y Y olol R G 320615 102 REV K Fig 16 Service Label 12 A00307 13 vI START YES Is red LED status light blinking ON OFF slowly with a combination of short and long flashes 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 Is red LED status light on Is red LED status light blinking rapidly without a pause Go to section with status code determined Is there 115v at L1 and L2 Is there 24v at SEC 1 and SEC 2 Replace control center Check for correct line voltage polarity If units are twinned check for proper low voltage 24v transformer phasing Check for previous fault by momentarily shorting the TEST terminal and the C terminal until the LED goes out LED will flash the status code of any previous fault or the code No 11 1 short and 1 long flash if no previous fault After the control repeats the code 3 times the control will go through a brief component test seque
21. er 3 hrs Flame rollout switch requires manual reset See No 33 IGNITION LOCKOUT System failed to ignite gas and prove flame in 4 attempts Control will auto reset in 3 hrs See No 34 GAS HEATING LOCKOUT Turn off power and wait 5 minutes to retry Check for Stuck closed gas valve relay on control Miswire or short to gas valve wire ABNORMAL FLAME PROVING SIGNAL Flame was sensed while gas valve was de energized Inducer will run until fault is cleared Check for Stuck open gas valve solenoid or leak Defective control center PRESSURE SWITCH WILL NOT OPEN Check for Disconnected or obstructed pressure tubing Defective pressure switch LOW VOLTAGE FUSE IS OPEN Check for Short in low voltage wiring including thermostat leads shorting to ductwork or furnace cabinet Disconnect thermostat leads to isolate short circuit 31 PRESSURE SWITCH WILL NOT CLOSE OR REOPEN If open longer than 5 minutes inducer shuts off for 15 minutes before retry Check for Proper vent sizing or pitch or sag Vent restrictions or high winds Defective inducer motor Low line voltage 115v Motor start capacitor Low inlet gas pressure Defective pressure switch or connections If it opens after trial for ignition period blower will come on for 90 sec recycle delay Inadequate combustion air LIMIT OR FLAME ROLLOUT SWITCH IS OPEN If limit switch is open longer than 3 minutes
22. erform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in the literature on tags and on labels attached to or shipped with the unit and other safety precautions that may apply Follow all safety codes In the United States follow all safety codes including the National Fuel Gas Code NFGC NFPA 54 1999 ANSI Z223 1 1999 and the Installation Standards Warm Air Heating and Air Conditioning Systems NFPA 90B A98306 Fig 1 Multipoise Furnace in Upflow Orientation EFFICIENCY ATING CERTIFIED ama CERTIFIED REGISTERED QUALITY SYSTEM ANSI NFPA 90B In Canada refer to the CAN CGA B 49 1 and 2 M95 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 Recognize safety information This is the safety alert symbol A When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Catalog No 535 80007 Tab 6a 8a Printed in U S A Form 58MSA 4SM Pg 1 10 00 Replaces 58MSA 3SM
23. he right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Catalog No 535 80007 Printed in U S A Tab 6a 8a Form 58MSA 4SM Pg 16 10 00 Replaces 58MSA 3SM
24. here the ambient temperatures may be 32 F or lower freeze protection measures must be taken 1 Check for signs of physical damage to heat tape such as nicks cuts abrasions gnawing by animals etc 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 FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING NOTE 2 FIVE FIELD SUPPLIED WIRE THREE WIRE HEATING ONLY BLK BLK 7001 0 7 Sa me GND 115 V AUXILIARY FIELD SUPPLIED J BOX DISCONNECT CONTROL BOX 24 V TERMINA BLOCK THERMOSTAT m OO TERMINALS l l l l l DISCONNECT e o e e e 0 e l e Le 0el e 208 230 OR 460 V THREE PHASE a Eee E ia 01 PHASE 1 3 lt 4 _ ty PND 1 CONDENSING UNIT TWO WIRE FURNACE NOTES 1 2 Connect Y terminal as shown for proper operation 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 A98209 Fig 11 Field Wiring 8
25. ion block See Fig 12 NOTE If TEST to Com terminals are jumpered longer than 2 sec LED will flash rapidly and retrieval request will be ignored 5 When above items have been completed the component test sequence will occur as described in the Component Test Sequence section above NOTE Be sure to record the status code which is flashed 4 times at start of component test for further troubleshooting 6 After component test is completed and furnace is operating properly release blower access panel door switch replace blower access panel and replace main furnace door SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including Unit Familiarization e Installation Overview e Maintenance e 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 calloacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Copyright 2000 CARRIER Corp 7310 W Morris St e Indianapolis IN 46231 Classroom Service Training A94328 58MSA4SM Manufacturer reserves t
26. it 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 fuse of identical size 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 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 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 A CAUTION If this furnace is installed in an unconditioned space w
27. n above items have been completed the component test sequence will occur as described ain the Comonent Test Sequence section above NOTE Be sure to record the status code which is flashed 4 times at start of component test for further troubleshooting 6 After component test is completed and LED is ON continu ously indicating the furnace is ready to operate when a signal from the thermostat is received replace main furnace door INITIATING COMPONENT TEST AND RETRIEVING STA TUS CODE BY JUMPERING CONTROL TEST TERMINAL 1 Remove main furnace door 2 Remove blower access panel 3 Manually close blower access panel door switch Use a piece of tape to hold switch closed 10 IT A A ES m WHEN USED TO 115VAC FIELD DISCONNECT SCHEMATIC DIAGRAM LGP sw2 P C B BLOWER GPS SEE NOTE 10 ae L1 2 FF NOT ON ALL MODELS LAY Swi iLk NOTE 4 BLOWER OFF DELAY SELECTION CHART TEST TWIN 90 SEC F NOTE 13 Ma 135 sec av 180 sec GRN YEL NOTE 5 MM WHT 24 VAC 3A WHT COM FUSE GRN YEL E SELECT ARE TEST TWIN Fuji _ NOTE 7 L2 Faci A 1 NOTE 12 SES GVR 2 EAC 2 E RQ w FUSED DISCONNECT I D SWI
28. n of light dirt or dust on the inside they may be cleaned by the following procedure 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 3 Disconnect wires or connectors to rollout switch gas valve ignitor and flame sensor A CAUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation 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 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
29. nce The inducer will start and run for the entire component test The HSI blower motor heat speed and blower motor cool speed will run for 10 15 sec each Was there a previous fault code other than No 11 Is door switch closed Is there 115v going to switch Replace door switch Replace transformer Troubleshooting Guide NO Close door switch and go to start YES Is circuit breaker closed Check room thermostat or interconnecting cable NO Is 24 vac present at W Y or G terminals on the control YES YES Does control respond to W Y or G 24 vac thermostat signals Run system through a heating or Replace control if it does not cooling cycle to check operation respond to 24 vac signal at W Y Status codes are erased after 48 or G screw terminals hrs or whenever power 115v or 24v is interrupted Close circuit breaker and go back to start Check for continuity in wire from circuit breaker to furnace A99123a SI NO PREVIOUS FAULT Faults are erased after 48 hrs or whenever power 115v or 24v is interrupted Run system through a heating or cooling cycle to check system BLOWER ON AFTER POWER UP 115V OR 24V Normal operation Blower will run for 90 sec when furnace power is interrupted during a call for heat R W closed LIMIT OR FLAME ROLLOUT SWITCH LOCKOUT Limit switch was open longer than 3 minutes Auto reset will occur aft
30. ng burner assembly in burner box 10 Remove burner assembly from burner box NOTE All burners are attached to 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 A 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 accumulatio
31. onal injury or death GENERAL 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 gt UPFLOW HORIZONTAL HORIZONTAL LEFT RIGHT DOWNFLOW AIRFLOW AIRFLOW Vv AIRFLOW A93041 Fig 2 Multipoise Orientation ELECTROSTATIC DISCHARGE ESD PRECAUTIONS A 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 TROSTATIC 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 discha
32. panel 10 Remove screws attaching burner box to cell panel See Fig 5 NOTE Burner box cover manifold gas valve and burner assembly should be removed as 1 assembly 11 Clean heat exchanger openings with a vacuum and a soft brush See Fig 6 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 A WARNING The ground wire from the gas valve MUST be attached to the burner box attachment screw Failure to attach this ground wire to an adequate casing ground will cause the furnace control to lock out NOTE Be sure burner box gasket is installed between burner box and cell panel If gasket is damaged replace it PRIMARY HX INLET OPENINGS A93080 Fig 6 Cleaning Inlet Openings of Primary Heat Exchangers NOTE 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 or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur 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 7 A93087 Fig 7
33. r across gas valve connections Does gas valve receive 24v Does gas valve open and allow gas NO to flow YES Do main burners ignite NO YES NO Do main burners stay on YES Allow blower to come on and repeat test to check for intermittent operation Check connections If OK replace control center Replace control center Check that all gas valves are turned on Replace valve Check for Inadequate flame carryover on rough ignition Low inlet gas pressure Repeat call for heat and check flame sensor current during trial for ignition period Is the DC microamps below 0 5 YES Check connections and retry If current is near typical value and control will not stay on replace control center Clean flame sensor with fine sandpaper and recheck current Current is nominally 4 0 to 6 0 microamps Is current near typical value YES NO Replace electrode Will main burner ignite and stay on NO Replace control center YES A99123b 44 WARNING Blower access panel door switch opens 115 v power to control center No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in electrical shock personal injury or death 4 BRIEFLY short jumper TEST 1 4 in quick connect termi nal on control center adjacent to the LED diagnostic light and the Com terminal on thermostat connect
34. rged 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 annually on this equipment Consult your local dealer for maintenance and maintenance contract availability A 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
35. s 1 LED flashes a status code 4 times 2 Inducer motor starts and continues to run for remainder of component test 3 Hot surface ignitor is energized for 15 sec then de energized Main blower operates at cooling speed for 10 sec then turns off Main blower operates at heating speed for 10 sec then turns off 6 Inducer motor stops Component test can be initiated by one of the following proce dures INITIATING COMPONENT TEST AND RETRIEVING STA TUS CODE BY REMOVING MAIN LIMIT SWITCH WIRE NOTE NO thermostat signal may be present at control center and all blower time delay of periods must be completed 1 Leave 115 v power to furnace turned on 2 3 Remove main furnace door Look into blower access panel sight glass for current LED status NOTE Leave blower access panel installed to maintain power to control center to view current LED status 4 BRIEFLY remove either wire from the main limit switch until the LED goes out then reconnect it Ao HEE o 11 Fig 14 Funnel in Drain and Antifreeze Running Through Trap A CAUTION Make sure the limit switch wire does not contact any metallic component such as the gas valve If wire is shorted 3 amp fuse on control center will blow NOTE If wire to main limit is disconnected longer than 4 sec the control senses limit circuit is open Mian blower will start and retrieval request will be ignored 5 Whe
36. tor orcapacitor Restricted vent Defective pressure switch Excessive wind Inadequate combustion air supply Disconnected orobstructed pressure tubing If it opens after trial for ignition period blower will come on for 90 second recycle delay LIMITOR FLAME ROLL OUTSMITCH IS OPEN If open longer than three minutes code changesto 13 Flame roll out switch requires manual reset Checkfor Defective blowermotoror capacitor Dirty filter or restricted duct system Loose blower wheel Defective switch or connections Inadequate combustion air supply Fla me Roll out Switch or fuse link open Open Flame Rollout switch or fuse link Manual reset orreplace IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost after trial for ignition period blower will come on for 90 second recycle delay Check for Oxide buildup on flame sensor clean with fine steel wool Proper flame sense microamps 5 microa mps D C min 4 0 6 0 nominal Gas valve defective orgas valve tumed off Defective Hot Surface Ignitor Manual valve shut off Low inlet gas pressure Control ground continuity Green wire MUSTbe connected to fumace sheet metal Inadequate flame canyover or rough ignition Flame sensor must be ungrounded COMPONENT TEST To initiate the component test sequence shut OFF the room thermostat or disconnect the R thermostat lead Briefly short th
37. y Oiling or coating filter is not recommended 7 Place filter in furnace 8 Replace blower access panel and main furnace door Turn on electrical supply to furnace NOTE If the filter has cross mesh binding the binding must face the blower If the filter has an air direction arrow the arrow must point toward the blower 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 panel WASHABLE FILTER RA FILTER RETAINER Fig 4 Filter Installed for Side Inlet 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 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 a Disconnect field drain connection from

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