Carrier 58MXA Service and Maintenance Instructions - A
Contents
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3. B e el el L 460 V L T 1 ee e Mala Ce TT C fas I TO m 9 i e e H jei pian 208 230 V INGLE GND T HALSA eae R GH t b zt Ii 40 jane 115 V FIELD AUXILIARY O A el ie e SUPPLIED _ J BOX L FA i GND DISCONNECT ua NOTE i CONDENSING C ora UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A99440 Fig 11 Field Wiring TWINNING AND OR BLOWER OFF DELAY COMPONENT TEST TERMINAL tons OFF DELAY lt sE z HUMIDIFIER TERMINAL LO 24 VAC 0 5 AMP MAX 24 V THERMOSTAT Q TERMINALS 88 z A TRANSFORMER 24 VAC ST resnim CONNECTIONS 2 3 AMP FUSE 7 LED OPERATION amp 3 E DIAGNOSTIC LIGHT m E z z PL1 LOW VOLTAGE MAIN 115 VAC L INEUTRAL P s HARNESS CONNECTOR CONNECTIONS o U l Eran 1 AMP E L EAC 1 445yvac PRI SPARE 1 SPARED EAN 115 VAC L1 LINE PL2 HOT SURFACE z VOLTAGE CONNECTION IGNITER amp INDUCER BLOWER SPEED SELECTION TERMINALS MOTOR CONNECTOR EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02142 Fig 12 Control Center 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED VL Z lt A93058 Fig 13 Winterizing the Furnace Step 8 Checking
4. Blower off delay gas heating selections are 90 120 150 or 180 seconds cooling or heat pump 90 seconds or 5 seconds when dehumidify call is active 326796 101 REV A 12 Fig 16 Wiring Diagram A02157 SERVICE If status code recall is needed briefly remove then reconnect one main limit wire to display stored status code On RED LED boards do not remove power or blower door before initiat ing status code recall After one status code recall is completed component test will occur LED CODE STATUS CONTINUOUS OFF Check for 115VAC at L1 amp L2 amp 24VAC at SEC 1 amp SEC 2 CONTINUOUS ON Control has 24VAC power RAPID FLASHING Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions 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 code is erased automatically after 72 hours On RED LED boards stored status codes can also be erased when power 115 VAC or 24 VAC to control is interrupted 12 BLOWER ON AFTER POWER UP 115 VAC or 24 VAC Blower runs for 90 seconds if unit is powered up during a call for heat R W closed or R W opens during blower on delay 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if the limit or flame rollout switch is open longer than 3 minutes Control will auto reset after three hours R
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6. 6 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book u PC 101 Catalog No 535 80099 Printed in U S A Form 58MXA 9SM Pg 1 11 02 Replaces 58MXA 8SM al aloa EFFICIENCY RATING CERTIFIED CERTIFIED REGISTERED QUALITY SYSTEM SAFETY CONSIDERATIONS Recognize safety information This is the safety alert symbol When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING 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 Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified service agency personnel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions described in User s Information Manual such as cleaning and replacing air filters All other operations must be performed by trained
7. TUBE INDUCER HOUSING DRAIN TUBE VIOLET aH 7 GREEN COLLECTOR BOX EXTENSION TUBE BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY DRAIN TUBE COUPLING lt CONDENSATE TRAP DRAIN TUBES ROUTED IN O COLLECTOR BOX FRONT OF GAS VALVE EXTENSION DRAIN TUBE GAS VALVE Tube location when used on HORIZONTAL RIGHT application COLLECTOR BOX DRAIN TUBE COLLECTOR BOX EXTENSION TUBE BLUE N COLLECTOR BOX TUBE PINK PLUG a AUXILIARY J BOX RELOCATED HERE p a o CAP BURNER ENCLOSURE PRESSURE REFERENCE JI TUBE ASSEMBLY COLLECTOR BOX COLLECTOR BOX TUBE GREEN s f lt EXTENSION TUBE COLLECTOR BOX DRAIN TUBE CONDENSATE TRAP BLUE AND WHITE STRIPED INDUCER HOUSING DRAIN TUBE VIOLET 324999 201 REV C A00308 Fig 8 Furnace Pressure and Drain Tubing Diagram 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 A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in
8. 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 A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commer cially available soap solution made specifically for the detection of leaks to check all connections A fire or explo sion may result causing property damage personal injury or loss of life 17 Check for gas leaks 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
9. and qualified service agency 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 including the National Fuel Gas Code NFGC NFPA 54 2002 ANSI Z223 1 2002 in the U S A Na tional Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 00 NSCNGPIC in Canada and the Installa tion Standards Warm Air Heating and Air Conditioning Systems NFPA 90B ANSI NFPA 90B Wear safety glasses and work gloves Have a fire extinguisher available during start up and adjustment procedures and service calls A CAUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation 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 A UPFLOW HORIZONTAL HORIZONTAL RIGHT DOWNFLOW AIRFLOW AIRFLOW Z AIRFLOW A93041 Fig 2 Multipoise Orientation ELECTROSTATIC DISCHARGE ESD PRECAUTIONS CAUTION Electrostati
10. 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 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 A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commer cially available soap solution made specifically for the detection of leaks to check all connections A fire or explo sion may result causing property damage personal injury or loss of life 18 Check for gas leaks 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 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 a
11. 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 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 the secondary heat exchanger will occur Flush with water only 10 Reassemble inducer assembly by reversing items 5 through 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 which can cause an inadequate seal to 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 Condensate Trap Factory Installed in Blower Shelf Blower access panel removed BURNEH ENCLOSURE TUBE ASSEMBLY COLLECTOR BOX TUBE CAP PINK
12. sec short the TWIN TEST terminal to the Com 24V terminal The status LED will turn off The test sequence will be as follows 1 LED flashes last status code or code 11 4 times Record this status code for further troubleshooting 2 The inducer will start and continue to run until test is over 3 Hot surface igniter HSI is energized for 15 sec then de energized 4 Blower operates on continuous FAN speed for 10 sec then turns off 5 The blower motor operates on HEATING speed for 10 sec then turns off 6 The blower motor operates on COOLING speed for 10 sec then turns off 7 Inducer turns off 8 The gas valve and humidifier terminal HUM are not energized for safety reasons dVOd LI DY CALNYd fe o S o R ut m NOTE 6 BLOWER OFF DELAY JUMPER SELECT PCB 90 150 WHEN USED LGPS TEST TWIN HUM SEC 2 EAC 2 L2 m SEC 1 LED1 RED RED GRN YEL GRN YEL 12345678 91011 COOL HEAT BHT CLR SPARE 1 SPARE 2 BLK HI FUSED OR CIRCUIT BREAKER DISCONNECT SWITCH WHEN REQD 2 B t a g gt CONTN
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14. 58MXA 4 4 Way Multipoise Fixed Capacity HEATING amp COOLING Direct Vent Condensing Gas Furnace Visit www carrier com Service and Maintenance Instructions For Sizes 040 140 Series 160 A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property dam age Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnect ing Reconnect wires correctly Verify proper operation after servicing A WARNING A93040 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 vo
15. Heat Tape Operation If Applicable A CAUTION If this furnace is to be operated in an unconditioned space where the ambient temperatures may be 32 F or lower freeze protection measures must be taken See Fig 13 See CONDENSATE DRAIN PROTECTION section of Installa tion Start Up and Operating Instructions In applications where the ambient temperature around the furnace is 32 F or lower freeze protection measures are required If 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 Fig 14 Inducer Housing Drain Cap 10 Fig 15 Funnel in Drain and Antifreeze Running Through Trap 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 Step 9 Winterizing A 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 wi
16. OMOOT SNI1V3H SVD YE poo SNIS 89S sinou E JOYE 19s 1 o ne IIIA O1JUOD s dwaye y u tuue J avoid pue seb liu6 9 pajre uu s S 1NOMDOT NOILIND EE p09 Bag sinou JeYye 4 S91 0 NE IIM oljuoO sanul uey 18Buo u do SI YOUMS 1nol o4 SWE 10 1lLui Y J SINDDO 1noxo90 LANOY907 LINDYIO LINK ponad Aejap uo JaMmo q ay Buunp suedo M H4 u ym JO p soj M y 10 e9 e Buunp dn pasamod SI UN J SPUODES 06 JO suni JAMO uolye1ado JeWJON AZ HO ASL L dN d3AAOd ti314V NO H3AAO18 wWa sAs 49949 0 J9 9 Bullooo 10 Buyeay e yno Wayshs uny pa dnejul S Avz 40 ASL L 4amod ISA u UuA p sLia aq osje ued s poo snje s p iols spseog G31 dgy uo sunoy ZZ Jaye paseia are S poo p310 S GOO SNOIAAYd ON 15 Copyright 2002 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 58mxa9sm E Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 Tab 6a 8a PC 101 Catalog No 535 80099 Printed in U S A Form 58MXA 9SM Pg 16 11 02 Replaces 58MXA 8SM
17. PLUG COLLECTOR BOX TUBE GREEN INDUCER HOUSING MOLDED DRAIN TUBE BEHIND COLLECTOR BOX DRAIN TUBE CONDENSATE TRAP COLLECTOR BOX DRAIN TUBE BLUE FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE COUPLING FIELDINSTALLED A RIGHT DRAIN OPTION FACTORY SUPPLIED DRAIN TUBE hd COUPLING LEFT DRAIN OPTION FIELD INSTALLED FACTORY SUPPLIED 1 2 IN CPVC STREET ELBOWS 2 FOR LEFT DRAIN OPTION FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE Condensate Trap on LEFT Side COLLECTOR BOX DRAIN TUBE BLUE PLUGGED END COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTORBOX EXTENSION TUBE 2 PLUG COLLECTOR BOX EXTENSION TUBE CONDENSATE TRAP COLLECTOR BOX BURNER ENCLOSURE PRESSURE TUBE PINO REFERENCE TUBE ASSEMBLY INDUCER HOUSING DRAIN TUBE VIOLET Tube location when used on HORIZONTAL LEFT application COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED PLUG cap COLLECTOR BOX ZC TUBE GREEN BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY INDUCER HOUSING COLLECTOR BOX EXTENSION TUBE einen COLLECTOR BOX CONDENSATE TRAP DRAIN TUBE BLUE COLLECTOF BOX TUBE CIN RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 040 060
18. TGROUND FIELD SPLICE PLUG RECEPTACLE NOTES TO 115VAC FIELD DISCONNECT SCHEMATIC DIAGRAM NOTE 2 bb NATURAL GAS amp PROPANE u GND J EQUIPMENT GROUND PRI 115VAC LGPS WHEN USED 10 5 NOTE 3 inna l H l l 11 Com poB NOTE 5 If any of the original equipment wire is replaced use wire rated for 105 C Use only copper wire between the disconnect switch and the furnace junction box JB This wire must be connected to furnace sheet metal for control to prove flame Symbols are electrical representation only Solid lines inside PCB are printed circuit board conductors and are not included in legend Replace only with a 3 amp fuse Inducer IDM and blower BLWM motors contain internal auto reset thermal overload switches OL Neutral connections are interchangeable within the NEUTRAL connector block Blower motor speed selections are for average conditions see installation instructions for details on optimum speed selection YELLOW lead not on all motors Factory connected when LGPS is not used Ignition lockout will occur after four consecutive unsuccessful trials for ignition Control will auto reset after three hours Blower on delay gas heating 60 seconds cooling or heat pump 2 seconds
19. UOUS FAN SELECTRELAY SPDT BLOWER MOTOR SPEED CHANGE RELAY SPDT BLOWER MOTOR RELAY SPSF N O BLOWER MOTOR PERMANENTSPLIT CAPACITOR CAPACITOR MICROPROCESSOR AND CIRCUITRY ELECTRONIC AIR CLEANER CONNECTION 115 VAC 1 0 AMP MAX ELECTRONIC AIR CLEANER CONNECTION COMMON FLAME ROLLOUTSW MANUAL RESET SPSF N C FLAME PROVING ELECTRODE FUSE 3 AMP AUTOMOTIVE BLADE TYPE FACTORY INSTALLED FUSE OR CIRC UIT BREAKER CURRENT INTERRUPT DEVIC E FIELD INSTALLED amp SUPPLIED EQUIPMENT GROUND GASVALVE REDUNDANT GASVAIVE RELAY DPSF N O HOTSURFACE IGNITER 115 VAC HOTSURFACE IG NITER RELAY SPSF N O 24VAC HUMIDIFIER CONNECTION 0 5 AMP MAX INDUCED DRAFTMOTOR PSC INDUCED DRAFT MOTOR RELAY SPSF N O BLOWER ACCESS PANEL INTERLOC K SWITCH SPSF N O BLOWER OFF DELAY J UMPER SELECTOR JUNCTION BOX LG HFEMITTING DIODE FOR STATUS CODES AMBER LOW GAS PRESSURE SWITCH SPST N O UMITSWITCH AUTO RESET SPST N C AUTO RESETINTERNAL MOTOR OVERLOAD TEMPERATURE SWITCH N C PRINTED CIRCUIT BOARD CONTROL 11 CIRCUITPCB CONNECTOR 2 CIRCUM CONNECTOR 2 CIRCUTHS CONNECTOR 3 CIRCUITIDM EXTENSION CONNECTOR PRESSURE SWITCH SPSF N O COMPONENTTEST amp TWIN TERMINAL TRANSFORMER 115VAC 24VAC JUNCTION UNMARKED TERMINAL PCB CONTROL TERMINAL FACTORY WIRING 115VAC FACTORY WIRING 24VAC FIELD WIRING 115VAC FIELD WIRING 24VAC CONDUCTOR ON CONTROLPCB FIELD WIRING SCREW TERMINAL FIELD EARTH GROUND EQUIPMEN
20. annu ally 6 Check burners for cleanliness annually A CAUTION Be careful of sharp metal edges etc Use care and wear protective clothing safety glasses and gloves when removing parts Failure to follow this caution could result in personal injury Step 1 Cleaning and or Replacing Air Filter The air filter arrangement may vary depending on the application or orientation Filter could be located in furnace blower compart ment or in the filter cabinet but not in both A WARNING 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 A CAUTION Operating a unit without a filter or with the blower access door removed could cause damage to the furnace blower motor Dust and lint on internal parts of furnace can cause a loss of efficiency NOTE If the filter has an airflow direction arrow the arrow must point toward the blower WASHABLE FILTER IN FURNACE w K SS FILTER Be ale RETAINER ERS fF WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET Fig 4 Filter Installed for Side Inlet 02 To clean or replace filters proceed as follows If filter is installed in filter cabinet adjacent to furnace 1 Turn off electrical supply to furnace 2 Remove filter cabinet door 3 Slide filter out of cabinet 4 If equipped with permanent washable filter clean filt
21. c 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 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 fu
22. efer to 33 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 21 GAS HEATING LOCKOUT Conirol will NOT auto reset Check for Mis wired gas valve Defective control valve relay 22 ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve 23 PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Pressure switch stuck closed 24 SECONDARY VOLTAGE FUSE IS OPEN Check for Short circuit in secondary voltage 24VAC wiring 31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five minutes inducer shuts off for 15 minutes before retry Check for Excessive wind Proper vent sizing Defective inducer motor Low inducer voltage 115VAC Defective pressure switch Inadequate combustion air supply Restricted vent Disconnected or obstructed pressure tubing Low inlet gas pressure if LGPS used If it opens during blower on delay period blower will come on for the selected blower off delay LIMIT CIRCUIT FAULT Indicates a limit or flame rollout is open Blower will run for 4 minutes or until open switch remakes whichever is longer If open longer than 3 minutes code changes to lockout 13 If open less than 3 minutes status code 33 continues to flash until blower shuts off Flame rollout switch requires manual reset Check for Restricted vent Proper
23. er by spraying cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oiling or coating of the filter is not recommended 5 If equipped with factory specified disposable media filter replace only with a factory authorized filter of the same 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 panel 2 3 Release filter retainer wire See Fig 3 or 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 Replace blower access panel 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 a
24. f 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 A 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 CELL MANIFOLD MOUNTING a MANIFOLD GAS VALVE REGULATOR FITTING GAS VALVE A96304 Fig 5 Burner Box Assembly NOTE Do not remove burner box from cell panel 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 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 furnace gas control valve using
25. field drain to condensate trap 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 reconnection if leads were not identified before disconnection A CAUTION Heating 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 exchanger life Table 1 Speed Selection FACTORY COLOR SPEED ATTACHED TO Black High Cool Yellow When Present Medium High Spare Blue Medium Low Heat Red Low Fan White Common Com A WARNING Blower access door switch opens 115 v power to furnace control No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in personal injury or death 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 by performing a component self test as shown at the bottom of Service Label See Fig 16 15 If furnace is operating properly remove tape to 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 o
26. iter is fragile DO NOT allow it to hit the side of the burner box opening while removing or replacing it b Inspect igniter for a white area indicating a crack may be present If found replace igniter NOTE A small crack cannot be seen on a new igniter After a period of operation a white area will be visible around the crack c If replacement is required replace igniter on igniter bracket external to furnace to avoid damage as the silicon portion is very brittle and will easily crack or shatter d To remove igniter from igniter bracket remove screw holding igniter ceramic block to bracket and pull ceramic block out of bracket 6 To replace igniter igniter assembly reverse items 5a through 5d 7 Reconnect igniter wire connection 8 Turn on gas and electrical supplies to furnace BURNER FLAME BURNER MANIFOLD A Fig 9 Burner Flame A89020 A93081 Fig 10 Gasket on Collector Box 9 Verify igniter operation by initiating furnace 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 polari
27. latile fluids 3 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 personal injury or death NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue A99007 TABLE OF CONTENTS Fig 1 Multipoise Furnace in Upflow Orientation SAFETY CONSIDERATIONS crecsecee cece eeeseeneees 2 eo s Servicing Hot Surface Igniter eseeeeseeeeteeeeteeeeees 7 GENERA D EE ER AN EA E RRENEN OD 2 Electrical Controls and Wiring ccsssssssssssssssssssssseeeesseseeee 8 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 2 Checking Heat Tape Operation If Applicable 10 CARE AND MAINTENANCE cccccccccsccccccectececcesttececeetutscceesnecece 2 Winterizing PEPIS ETETETT TETEA TT T E T EA 10 Cleaning and or Replacing Air Filter 3 WIRING DIAGRAM m Qusan aa EERE Ea 11 Blower Motor and Wheel Maintenance 3 TROUBLESHOOTING ass 11 Cleaning Burners a naassss 4 Status CodeS vise uuu uns umala assays 11 Cleaning Heat Exchangers a assassssssss 5 Component Testga a u ku A Mi S aussi 11 Primary Heat Exchangers asss 5 Secondary Heat Exchangers aaa 6 Flushing Collector Box and Drainage System
28. ll 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 13 4 Connect field supplied 1 2 in LD tube to upper inducer housing drain connection A CAUTION Do not use ethylene glycol Prestone II antifreeze coolant or equivalent automotive type Failure of plastic components will occur 5 Insert funnel in tube and pour up to 1 quart antifreeze propylene glycol RV swimming pool antifreeze or equiva lent into funnel until it is visible at point where condensate enters open drain See Fig 14 Make sure limit switch or flame rollout switch wire does not 6 Reconnect drain cap to inducer housing 7 Replace main furnace door 8 Propylene glycol need not be removed before restarting furnace WIRING DIAGRAM See Fig 16 for Wiring Diagram TROUBLESHOOTING Use the Troubleshooting Guide the status code LED on the cotntrol and the Component Test to isolate furnace operation problems STATUS CODES For an explanation of status codes refer to service label located on back of main furnace door or Fig 17 and the Troubleshooting Guide The stored status code will NOT be erased from the control memory if 115 or 24 v power is interrupted NOTE Removing the blower access door will open the blower access door switch and terminate 115 v power to the control To read curre
29. nd wheel as follows 1 Turn off electrical supply to furnace 2 Remove main furnace door and blower access panel 3 Disconnect blower motor wires from furnace control Field thermostat connections may need to be disconnected depending on their length and routing 4 Remove control box mounting screws and position control box transformer and door switch assembly to right side of furnace casing 5 If condensate trap is located in left or right hand side of furnace casing proceed to item 6 otherwise remove trap and tubing as described below See Fig 8 top left 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 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
30. nt status code remove main furnace door The status code LED can be viewed through the sight glass on the blower access door NOTE NO thermostat signals may be present at control and all blower off delays must be completed to view previous codes A CAUTION contact any metal component such as gas valve If wire is shorted 3 amp fuse on furnace control will blow To retrieve previous codes remove 1 of the red main limit or flame rollout switch wires for 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 exists and will respond with blower operation This places the control in the status recall mode and displays the last code stored in memory 11 Record the code After the last code is displayed the control will perform the component test and then return to normal standby mode COMPONENT TEST A WARNING Blower access panel door switch opens 115 v power to control board 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 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
31. oards only blower motor HEAT speed and blower motor COOL speed will be turned ON for 10 15 seconds each Gas Valve and Humidifier will not be turned on 327884 101 REV B A02270 Fig 17 Service Label 13 ey0cc0V YEISOWJ9Y BY BoeR dad 10 Je SOWaY ul 0 EUILULA 1e souu u ApZWOD ey 1D99uuo5 1O1SIS 1 1SP eq P E SU JAY 101 U09 BoeUINY OU UUM lqn eduuo2 zou si e souu u BY L am 1 duun e Buisn u ym e d uu qoid y s oq 101 u09 BOeUINY y WO1 S JIA Je SOWAY Y L 1o uuoosiq 101 U09 oguunj y UO S BUILUS JeJSOWEY 9 10 ZA A quaseud J L A M I Juased AtZ SI qe5 Buio uuoo1 lu JO JE SOWIAY WOO 49049 LUVLS 0 yoRq 06 pue Jayealg N9119 so O BOBUINY 0 JayO4q 1InO1I9 LUO 1IA u AYINUUOD JO 9049 ON SHA pasoj JOYBOIG N11 S LUVLS 0 yoeq 06 pue y yms 100p so o onuoo opguuni BoR day p ldnulul S AtZ 10 AGL L J A u UA PESeJd Aq osje UBD Sapod snle s p 10 s spieoq q31 GAY UO sunoy ZZ 194e pasesa ale s po2 sns uoljeJado yoayd 0 O O Buljooo Jo Bugeay e yno uu ls s uny Esleubls 1elsouueul Atz pue ZA A Quasaid j A M 0 puodsa onmuo2 y s oq SHA yams 0 BuloB AG 3134 S SHA L L Uey 49ulo apoo snes snoad e 3194 SEM UO PSUJN q JOU IIIA J IJIpluunu pue AJLA SeH uSe spuo5 s SI 01 40 uni IIIA p ds 7009 pue p ds IV3H Auo spueog
32. q31 HIANY p ds Ny4 Jo OW 1 M0Jq ISH 8u1 IS 1u uoduuoo unu y 10 UNI pue es IIIA 499npul u L 929u nb s 1s 1 1u uoduuoo jag e uBnouu oB jim oluoo y s uin p po2 y sle d 1 olluoo y 191JV po2 snolA981d ou SEM a19U Ji use Buol pue 1ious L L po2 sNye s 10 po2 snlels snolA81d Y YSL m G37 o s oB q31 Y Inun peua APZWOD 0 EUIJE NIML LSAL 2U Bunuous luplu uuouu Aq apoo snlels snolAasd ay 2994 osje UBD noy lje9 9 apoo snyejs Buneniu o10jaq jaued sseooe JaMo q 10 J MOd AOW I JOU OP olluoo a37 qat UO poo2 SNIS paiojs Ae dsip o YMS 1nojioli SWEJ 10 YAMS JWI y WOY m GAY uo JOsUUODAI pue sowa AYLIQ po2 SNIS 2091 OL Buiseyd sawojsuesy AZ aGey0A mo Jadoid 10 Y09049 Puu ae yeUoysued op d ti spun J Qlue jod ae aul 47991109 104 YOOYUD YOUMS 100p aoRjdey 04 u09 BoRUINY op d H SHA 2 OAS PUE 93S E Ave 9194 S SHA P2SO 9 YAMS 100P S ZT PUE 1712 ASL 8194 S ON ACINDS SNILOOHS318 Ot L paysey sem 12y po2o sNje s y 10 MOJ Q uono8s 0 09 sS uselJ Buoj zo seaquinu y q p puodes y pue s uselJ1ious jo Jaquunu y Aq p uluui p 461p suy Y YM sequinu p Z si pPO9 SNIS By poo SNIS uluu 9l q Esoysey Buo pue joys Jo uollguiquuo2 e UNIA A mo s 4qO NO Bunullq 1uBI snes q31 SI sned e InoullA lpide1 Buyung 446i sniels q31 SI SHA uo ybi seys G37 S
33. 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 capcitor and ground wire attached to blower housing before remov ing motor Motor mounts need not be removed from motor f Remove blower wheel from housing A CAUTION The blower wheel should not be dropped or bent as balance will be affected g Clean wheel per instructions on degreaser cleaner Do not get degreaser in the motor 9 Reassemble motor and blower wheel by reversing items 8b through 8f Ensure wheel is positioned for proper rotation Tighten set screw to 140 160 in Ib torque 10 Reinstall blower assembly in furnace 11 Reinstall control box transformer and door switch assembly on blower shelf 12 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 NOTE Ensure tubes are not kinked or pinched as this will affect operation 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
34. rnace 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 furnace failure it is essential that maintenance be performed annually on this equipment Consult your local dealer for proper maintenance and maintenance contract availability WASHABLE FILTER FILTER SUPPORT SSH FILTER RETAINER ee ZAG WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET A00232 Fig 3 Bottom Filter Arrangement 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 The minimum maintenance that should be performed on this equipment is as follows 1 Check and clean or replace air filter each month as needed 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
35. s 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 dangerous operation 3 Disconnect wires or connectors to flame rollout switch gas valve igniter 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 8 Disconnect pressure tubing from gas valve 9 Remove 2 screws attaching top filler panel and rotate upwards to gain access to screws attaching burner box to cell panel 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 combu
36. serious injury death or property damage Never test for gas leaks with an open flame Use a commer cially available soap solution made specifically for the detection of leaks to check all connections A fire or explo sion may result causing property damage personal injury or loss of life 15 Check for gas leaks 16 Replace main furnace door Step 6 Servicing Hot Surface Igniter The igniter does NOT require annual inspection Check igniter resistance before removal Turn off gas and electrical supplies to furnace Remove main furnace door Disconnect igniter wire connection pe D Check igniter resistance a Using an ohm meter check resistance across both igniter leads in connector b Cold reading should be between 45 ohms and 90 ohms c If ohm reading is higher than 110 ohms igniter is cracked and must be replaced 5 Remove igniter assembly A CAUTION Allow igniter to cool before removal Normal operating temperatures exceed 2000 F a Do not remove igniter from bracket while assembly is in furnace Using a 1 4 in nutdriver remove screw securing bracket and igniter 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 igniter and bracket toward outside of burner box and pull straight out A CAUTION The ign
37. stion products 12 Reverse items 4 through 10 for reassembly PRIMARY HX INLET OPENINGS A96305 Fig 6 Cleaning Inlet Openings of Primary Heat Exchangers A CAUTION 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 See Fig 5 If gasket is damaged replace it 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 Combustion Air Intake Housing Gasket Repair 13 Refer to furnace wiring diagram and reconnect wires to flame rollout switch gas valve igniter and flame sensor 14 Reconnect pressure switch tubes to gas valve and intake housing Refer to tube routing label on main furnace door for proper tube location Be sure tubes are not kinked See Fig 8 15 Turn on gas
38. ty is not correct the STATUS LED on the furnace control will flash rapidly and prevent the furnace from operating The control system also requires an earth ground for proper operation of the furnace control and flame sensor 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 fuse of identical size 3 amp The control LED will flash 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 connection clean all parts strip wire and reassemble properly and securely Reconnect electrical supply to unit and observe unit through 1 complete operating cycle for proper operation FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING NOTE 2 THERMOSTAT FIVE WIRE TERMINALS FIELD SUPPLIED THREE WIRE DISCONNECT HEATING ONLY o E ass BLOWER DOOR SWITCH I gt 208 230 OR
39. vent sizing Loose blower wheel Excessive wind Dirty filter or restricted duct system Defective blower motor or capacitor Defective switch or connections Inadequate combustion air supply Flame Roll out Switch open IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for Control ground continuity Flame sensor must not be grounded Oxide buildup on flame sensor clean with fine steel wool Proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal Gas valve defective or gas valve turned off Manual valve shut off Defective Hot Surface Ignitor Low inlet gas pressure Inadequate flame carryover or rough ignition Green Yellow wire MUST be connected to furnace sheet metal CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to Gas valve relay stuck open Flame sense circuit failure Software check error Reset power to clear lockout Replace control if status code repeats es COMPONENT TEST w To initiate the component test sequence shut OFF the room thermostat or disconnect the R thermostat lead Briefly short the TEST TWIN terminal to the Com 24V ter minal Status LED will flash code and then turn ON the inducer motor The inducer motor will run for the entire component test The hot surface ignitor blower motor FAN speed AMBER LED b
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