58PAV, 58RAV Induced-Combustion Furnaces Service
Contents
1. uogejedo rewon HO ASLL NO Uejs s yoayo 0 81049 6ullooo Jo Buneeu e uieis s uny peidnuejur SI 10 AG Jamod JO 519 Jaye paseia ale Syne4 INVA SNOIAAYd ON 13 14 15 SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs is available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training A94328 Copyright 2000 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 58pri5sm m A A A A A A A A A I UE Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations rook amp 5 101 Catalog No 535 773 Printed in U S A Form 58P R 15SM Pg 16 10 00 Replaces 58P R 14SM al al 8a2. JO JUSA Bes 40 yoyd 10 Burzis Juan Jadolg 10 osauD 810499 G 10 yo sinus 1eonpul sejnuiui uey uado J N3dO3H HO 35012 LON TIIM HOLIMS 3HnSS3Hd jou 11045 ol speo 1e souu ul loeuuoosld eulqeo eoeuunj 10 ysomjonp ol Buoys Yejsouueu 6ulpnloul eBeyoA wo ul HOUS Jol 19849 NAO SI 3504 39VL10A MO1 yams aunssald Buigni ainssaid pajon11sqo Jo pejoeuuoosiq 49905 N3dO LON TIM HILIMS 3Hh SS3Hd Jeluso 01 U09 yea JO plouajos seb uedo yon s Y99049 pejeejo si Inun uni Jeonpul sem 526 JIUA pasuas sem TUNDIS 3IWV14 TVINHONSV 526 ol 1095 10 ellwsIN Joquoo uo Kelas se yonlS Y90949 ol s lnultu S pue Jamod yo un 103201 5NILV3H SVO YE ON 88S say Ul 1950 IM 1 s1duu ne A01d pue Se6 lluBi weIs S INOADOT ON 88S 1959 jenuew yms lnollol eure 4 SAY Jele INDIO esej olnV uey uado sem uos uT 103201 HOLIMS 10071109 AWV14 HO LINIT pasoj easy 10 e SI 1amod seoeunj uaym 995 06 JO uni
3. uonoeuuoo ay 18114 ay 398u2 ol Isa juauoduoo ay ui pajelado eq wajs s eui eue 10 526 ay ui si ay J9yJaym OL eaw 19945 oi AJEA jjo inus jenueyy peuunl sey deis jxau ay ol e10jeq 1511 swa 6ulwollol eui 104 YOOYD Reap ejo oa1 295 06 104 uo poued 20 814 Jaye 150 S y y ON noyo5ol 2 eouenbes y jeada Iw eui poued uou 104 eur y pesues jou si Jl 3HnTIvd SNIAOtid NOLLINDI S8uM 85001 Suonoeuuoo JO YOUMS eAnoejeq lnollol eurejj Alddns uoNsnqwoo ejenbepeu 19591 jenueui lnollol uedo Jolloedeo 5 einjrej Y09949 ON ol epoo sapnu uey uedo si y9yms wull N3dO SI HOLIMS 1nOT10H AWV14 HO uonsnquioo eyenbepeu Kejap ajo oas 225 06 104 UO Il ponad 10 peu Jaye suedo 1 y suonoeuuoo JO Y9 IMS eJnsseJd eAnoejeg einsseid se Joyoedeo uels LL sull J4olou eAnoejeq spum
4. Fig 12 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control center will flash rapidly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 11 Any shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY 3 amp fuses The control LED will display status code 24 when fuse needs to be replaced With power to the unit disconnected check all electrical connec tions for tightness Tighten all screws on electrical connections If any smoky or burned connections are found disassemble the connection clean all parts strip wire and reassemble properly and securely Reconnect electrical power to the 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 The control in this furnace is equipped with an LED status light to aid in installation servicing and troubleshooting It can be viewed through the sight glass or window on blower access door The control indicates status with the LED on continuously rapid flashing or a code composed of 2 digits The first digit is
5. 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 12 BLOWER ON AFTER POWER UP 115VAC or 24 VAC Blower runs for 90 seconds if unit is powered up during a call for heat R W closed 13 LIMIT OR FLAME ROLL OUT SWITCH LOCKOUT Control will auto reset after three hours Reset switch or replace fuse link Refer to 33 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 21 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control Valve relay 22 ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve 23 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 DRAFT SAFEGUARD AUX LIMIT SWITCH when used OR BLOCKED VENT SWITCH when used DID NOT CLOSE OR REOPENED DOWNFLOW ONLY If open longer than five minutes inducer shuts off for 15 minutes before retry Check for Proper vent sizing Low inducer voltage 115VAC Defective inducer motor Defective Blower motor or capacitor Restricted vent Defective
6. junction box JB 5 This wire must be connected to furnace sheetmetal for control to detect flame 6 Replace only with a 3 amp fuse 7 Yellow lead not on all motors 8 Blower on delay gas heating 45 seconds cooling or heat pump 2 seconds 9 Blower off delay gas heating 90 135 180 or 225 seconds cooling or heat pump 90 seconds 135 seconds only on some models 10 Ignition lockout will occur after four consecutive unsuccessful trials for ignition Control will auto reset after three hours 11 When used auxiliary limit switch ALS is on some downflow models only When used FL is on upflow models only 12 Some models may have spade quick connect terminals 13 Factory connected when LGPS is not used 14 Factory connected when BVSS is not used BVSS used when Chimney Adapter Accessory Kit is installed 15 Gas valve leads are interchangeable on single stage valves 322869 101 REV H A00304 Fig 12 Furnace Wiring Diagram 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 L1 and L2 and 24VAC at SEC 1 and S 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
7. maintenance contract 44 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 3 Paint thinners and other painting compounds paper bags or other paper products A failure to follow this warning could result in corrosion of the heat exchanger fire personal injury or death 44 WARNING Turn off the gas and electrical supplies to the unit before performing any maintenance or service Follow the operating instructions on label attached to furnace A failure to follow this warning could result in personal injury The minimum maintenance that should be performed on this equipment is as follows 1 Check and clean air filter each month or more frequently if required Replace if torn 2 Check blower motor and wheel for cleanliness each heating and cooling season Clean and lubricate as necessary 3 Check electrical connections for tightness and controls for proper operation each heating season Service as necessary 44 CAUTION As with any mechanical equipment personal injury can result from sharp metal edges etc therefore be careful when removing parts AIR FILTER ARRANGEMENT The air filter arrangement
8. may vary depending on the application Refer to Table 1 or 2 for filter size information gt Table 1 Filter Size Information for Downflow Horizontal Furnaces In FURNACE FILTER QUANTITY FILTER CASING WIDTH AND SIZE TYPE 2 16 X 20 X 1 Cleanable 2 16 X 20 X 1 Cleanable 2 16 X 20 X 1 Cleanable Table 2 Filter Size Information for Upflow Furnaces In FILTER QUANTITY AND SIZET FILTER Side Return Bottom Return TYPE FURNACE CASING WIDTH 14 3 16 1 16 X25 X t 1 14 X25 X1 Cleanable 17 1 2 1 16 X25 X t 1 16 X 25 X 1 Cleanable 21 1 16 X 25 X1 1 20 X 25 X t Cleanable 24 1 2 2 16 X 25 X 1 Factory provided with the furnace T Filters may be field modified as required by cutting to desired size 1 24 X 25 X t Cleanable AIRFLOW A94307 Fig 4 Horizontal Filter Arrangement INSTALLATION POSITION OF FILTERS RETURN AIR PLENUM A88486 Fig 5 Downflow Filter Arrangement 44 WARNING Never operate unit without a filter or with filter access door removed A failure to follow this warning could result in fire personal injury or death 1 Downflow Horizontal Each furnace requires 2 filters which are installed in the return air duct See Fig 4 and 5 To remove filters for cleaning or replacement proceed as follows a Disconnect electrical pow
9. releasing agent such as PAM cooking spray or equiva lent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 13 Reinstall relief box and inducer assembly NOTE If inducer assembly gasket is damaged use RTV sealant to seal inducer assembly to collector box NOTE A releasing agent such as PAM cooking spray or equiva lent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 14 Reconnect wires to the following components Blocked vent safeguard switch p Inducer motor Pressure switch Q Limit overtemperature switch es Gas valve Hot surface igniter Flame sensing electrode ma gq gt c Flame rollout switch es if applicable 15 Reinstall internal vent pipe and enclosure on downflow furnaces only by reversing items 4a through 4c NOTE A releasing agent such as PAM cooking spray or equiva lent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate
10. technician 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 Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove 2 screw from blower access door downflow horizontal furnace only and remove blower access door 3 Downflow only a Disconnect vent connector from furnace flue collar See Fig 7 b Remove internal vent pipe enclosure cover c Disconnect and remove short piece of vent pipe from within furnace d Disconnect and remove vent pipe enclosure Push bottom side backward to release tabs NOTE Vent pipe is SCREWED and RTV sealed to relief box 4 Disconnect blower leads from furnace control Note wire color and location for reassembly Also disconnect auxiliary limit switch leads downflow only if present All other factory wires can be left connected but field thermostat connections may need to be disconnected depend ing on their length and routing 5 Remove 2 screws securing control and transformer support to furnace 6 Hang control and transformer support to front of furnace casing FLUE COLLAR MOUNTING BLOCKED SCREWS v VENT 2 SAFEGUARD ____ ND PRESSURE RELIEF Ole S
11. the number of short flashes the second is the number of long flashes For an explanation of status codes refer to service label located on blower access door or Fig 13 and the troubleshooting guide The control stores 1 status code the last status to occur for a period of 48 hrs or until the 115 or 24 v power is interrupted NOTE Look into blower access door sight glass for current LED status Removing blower access door will open blower access door switch and terminate 115 v power to control and status code will be erased 1 To retrieve status code proceed with the following NOTE NO thermostat signal may be present at control center and all blower OFF delays must be completed a Leave 115 v power to furnace turned on b Look into blower access door sight glass for current LED status FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING NOTE 2 THERMOSTAT FIVE WIRE O O TERMINALS FIELD SUPPLIED THREE WIRE EN DISCONNECT BLOWER DOOR I gt 8 208 230 OR eire ei e i 460 V I e 0 0 e PARSE 411 e a 9 N e e ei 208 230 V GND U JL jt e SINGLE 115 V FIELD AUXILIARY O yaaa s e SUPPLIED _ J BOX LIC
12. thermostat connection block component test See Fig 11 c Hot surface igniter is energized for 15 sec then de NOTE If TEST to Cow 24V terminals are jumpered longer than energized 2 sec LED will flash rapidly and test request will be ignored d Main blower operates at cooling speed for 10 sec then e Component Test will function as described in item 2 above turns off f Check LED status g If LED status indicates proper operation RELEASE BLOWER ACCESS DOOR SWITCH replace blower access door and replace control access door TROUBLESHOOTING Refer to the service label See Fig 13 Pages 10 and 11 contain a troubleshooting guide This guide can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and follow the appropriate arrow to the next 4 If furnace is operating properly and LED indicates proper item operation replace control access door e Main blower operates at heating speed for 10 sec then turns off f Inducer motor stops Items a through e above will assist in furnace troubleshooting since all components are functionally operated except the gas valve This procedure is also referred to as Component Test 3 Operate furnace through 1 heat cycle to test for proper operation and check LED status The guide will help to identify the problem or failed component 5 Component Test can also be initiated by performing the After replacing any comp
13. 100 IM pue anjeA jeoidAy si Juano JI A181 pue suonoeuuoo Yoayd SHA S 0 eui s ponad uoniuDi 10 zuana 10sues pue jeay 10 2 jeaday eunsseJd seb jajul uoniuBi uo JeAO Aueo eurejj ejenboepeu Y09049 ade day uo peuunj ase seb yey yoaudD Jelueo aoeldel YO J suonoeuuoo yoadD 19 ua9 Ionuoo aoejday jueniuuejul JO 499uo ol 159 yeadas pue uo euioo ol Jewolq SHA uo ejs oq S3A aub oq 0 526 pue uedo seb saog 9909 seoq suonoeuuoo 526 ssoloe JOBUUOD 10 e9 ol lelsouujedl Jos pue pea 5 y ay loeuuooeyd ueuoduioo asejday Jolu6I pue sseuJey ay Ainuluoo 20 Y99049 SHA pouad oes ay JO jueseJd AGL SEM 4eluao eui UO z pue suid AG 104 49949 eouenbes 159 jueuoduioo JeUloue 0 4U00 uuo1j soyub 6nldun O N pejoeuuoo aq JSNW M u991S SHA ponad 99s y JO pue eui Aq joy y Seoq eouenbes 158 y ejeniuir pue Jeluso y
14. 58PAV 58RAV Induced Combustion Furnaces HEATING amp COOLING Visit www carrier com Service and Maintenance Instructions For Sizes 045 155 Series 170 and 180 NOTE Read the entire instruction manual before performing any service or maintenance This symbol indicates a change since the last issue These procedures are for size 44 000 through 154 000 Btuh input units Index Page SAFETY CONSIDERATIONS retenu enano 1 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE nnn ro trina rri 2 CARE AND MAINTENANCE aasan 2 11 Air Filter Arran g CMent socio 2 3 Fig 1 Model 58RAV Horizontal Blower Motor and Wheel sess 3 5 Cleaning Heat Exchanger sese 5 6 Electrical Controls and Wiring sese 6 7 7 13 Unit Wiring Diagram eerte trn oe 9 Service Label uy aaa ront askama ERES ened 10 Troubleshooting GuId e l u us s Gua 10 13 SAFETY CONSIDERATIONS EFFICIENCY RATING CERTIFIED Installing and servicing heating equipment can be hazardous due to ama gas and electrical components Only trained and qualified person nel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heati
15. IEEE IDM INDUCED DRAFT MOTOR o CONDUCTOR ON POB IDR INDUCED DRAFT RELAY SPST N O s FIELD WIRING TERMINAL ILK BLOWER ACCESS PANEL INTERLOCK SWITCH SPST N O FIELD GROUND JB JUNCTION BOX LED LIGHT EMITTING DIODE FOR STATUS CODES aA EQUIPMENT GROUND LGPS LOW GAS PRESSURE SWITCH SPST N O A FIELD SPLICE LS LIMIT SWITCH AUTO RESET SPST N C j PLUG RECEPTACLE OL AUTO RESET INTERNAL MOTOR OVERLOAD TEMP SW SCHEMATIC DIAGRAM NATURAL GAS amp PROPANE TO 115VAC FIELD DISCONNECT 24VAC 21 NOT USED 2 TESTTWN NOTE 6 SEC2 FRS1 FRS2 wee fS rom HUM WHEN USED i rei NOTE 11 FE R OA Zu 1 aJ WHEN USED SN ss NBS L o 3 ALS NOTE 14 WHENUSED CPU NOTE 15 GVR 1 e Y NOTE 5 G p gt FSE 6 Go gt 81 NOT USED gt gt gl nor useD NOTES 1 If any of the original equipment wire is replaced use wire rated for 105 C 2 Inducer IDM and blower BLWM motors contain internal auto reset thermal overload switches OL 3 Blower motor speed selections are for average conditions see installation instructions for details on optimum speed selection 4 Useonly copper wire between the disconnect switch and the furnace
16. L 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 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 periodic maintenance be performed on this equipment Consult your local dealer as to the proper frequency of maintenance and the availability of a
17. RS2 GRN YEL SEC1 SEC2 GRN YEL T NOTE 5 H LO m m BLU 1 BLK RELAY 24 VAC 3A FUI FUSE FUSED DISCONNECT SWITCH WHEN REQD 4 peii i joer K FU T 1 NEUTRAL I GND 1 1 I 4 LEGEND ALS AUXILIARY LIMIT SWITCH OVERTEMP MANUAL RESET SPST N C BLWR BLOWER MOTOR RELAY SPST N O PCB PRINTED CIRCUIT BOARD BLWM BLOWER MOTOR PL1 9 CIRCUIT CONNECTOR BVSS BLOCKED VENT SHUTOFF SWITCH SPST N C PL2 2 CIRCUIT PCB CONNECTOR CPU MICROPROCESSOR AND CIRCUITRY iss SCIRGUITIDMSONNECTOR DSS SAFEGUARD SWITCH PL5 2 CIRCUIT HSI PCB CONNECTOR EAC 1 ELECTRONIC AIR CLEANER CONNECTION 115 VAC 1 5 AMP MAX PRS PRESSURE SWITCH SPST N O EAC 2 ELECTRONIC AIR CLEANER CONNECTION COMMON TEST TWIN COMPONENT TEST amp TWIN TERMINAL FL FUSIBLE LINK TRAN TRANSFORMER 115VAC 24VAC FRS FLAME ROLLOUT SW MANUAL RESET SPST N C FSE FLAME PROVING ELECTRODE e JUNCTION FU1 FUSE 3 AMP AUTOMOTIVE BLADE TYPE FACTORY INSTALLED UNMARKED TERMINAL FU2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE FIELD INSTALLED amp SUPPLIED GV GAS VALVE REDUNDANT OPERATORS TEN FACTORY WIRING 115VAC GVR GAS VALVE RELAY DPST N O HI LO BLOWER MOTOR SPEED CHANGE RELAY SPDT TO WINS ADC HSI HOT SURFACE IGNITOR 115 FIELD WIRING 115VAC HSIR SURFACE IGNITOR RELAY SPST N O FIELD WIRING 24VAC HUM 24vAC HUMIDIFIER CONNECTION 5 AMP MAX
18. UL 1591 jueuodujoo aus ay 104 uni pue M Jeonpul ay eouenbes 1591 jeuq e ay saun e epoo eui sjeada ay JeJV ou y ysej Buoj pue OUS ON ay 10 yne snolA81d Aue epoo Snlels eui ysey q31 1no 5206 q31 eui igun Ieuluuel O ay pue leuluuuel 1531 ay Buiuous Ajuejueuroui Aq snolAejd Jol Y99049 leuuolsue pz 1edoJd 10 pauuim ae syun j Ayejod eull 1994100 104 Y99049 Jeluseo onuoo eoe deu 32 938 PU OAS I Ave 91991 S ZI pue 112 ASH epoo snlels uonoes 09 seusej Jaquinu eui 16Ip puooes ay saysej poys jo Jequunu y q peuluuelep HBIp 15114 eut UNA Jequunu Z e s epoo snjejs y 9poo 5 euiuuejeg Sysel pue uoys jo e yum Amols J4O NO 1461 smeis q31 pei sl esned e pide 146 seis q31 uo 161 snes q31 sI LYVLS S3A uo ejs pue luBi 1 uinq IM 2166V Jelueo eoe deu SHA epoJjoeje anjen jeoidA queno s Q 9 01 Q A euruou si Juano Juano Yoay9a pue jededpues YIM Josues eure uealD Jeluso LIS
19. V terminal 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 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 0 R G 320615 102 REV K LIT Fig 13 Service Label 10 A99233 11 SIeuluuel M9J9S 5 JO A M Je eubls 9eA pz ol jou 1 101 U09 ay uo 9 JO A M 1e Juasaid ven yz S 6ulloeuuoolelul JO elsouuedl WOO ol u jinuguoo JO yosdD uelis ol yoeq pue Jeyeelq esolD cpesolo eyeeiq S EIS ol pue 100p 95019 peldnuaelul si Apg 10 GLL Je od I A Uu UA JO sy 8p Jaye sapos SnlelS yoado ol 6ullooo Jo Bune u e U6noldl uaelsAs uny 2sleufls elsouuedl 9eA pz 9 10 A M 01 puodsai seoq Jeuuolsue eoejdeu 5 Joop yams ol 3194 S 2 S LL ON uey apoo snoina d e 3194 SEM u9e 295 G 0 10 peeds 009 pue p ds yeay ISH SO
20. WITCH BOX lt x r FLUE COLLECTOR GAS BOX VALVE CONTROL FILTER RETAINER WASHABLE M FILTER A00261 Fig 6 Model 58PAV Upflow 7 Remove screws holding blower assembly to blower deck and slide blower assembly out of furnace 8 Clean blower wheel and motor using a vacuum with soft brush attachment Do not remove or disturb balance weights clips on blower wheel blades The blower wheel should not be dropped or bent as balance will be affected 9 If a 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 motor and blower housing so motor and each arm is positioned at the same 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 and motor mounts to blower housing and slide motor and mounts out of housing Disconnect capacitor and ground wire attached to blower housing before removing motor Motor mount belly band need not be removed unless motor is to be replaced f Remove blower wheel from housing CAUTION The blower wheel should not be dropped or be
21. er before removing blower access door b Remove screw from front of door and remove blower access door c Reach up behind top plate tilt filters toward center of return air plenum remove filters and clean as needed Replace if torn d Furnaces are equipped with permanent washable filters Clean filters with tap water Spray water through filter in opposite direction of airflow e Rinse and let dry Oiling or coating of filters is not recommended or required f Reinstall filters g Replace blower access door h Restore electrical power to furnace 2 Upflow Each furnace requires 1 or 2 filters which are installed in the blower compartment See Fig 6 To remove filters for cleaning or replacement proceed as follows a Disconnect electrical power before removing access doors b Remove blower and control access doors c Release filter retainer from clip at front of furnace casing See Fig 6 For side return clips may be used on either or both sides of the furnace d Slide filter s out e Furnaces are equipped with permanent washable filters Clean filters with tap water Spray water through filter in opposite direction of airflow f Rinse and let dry Oiling or coating of filter is not recommended or required g Reinstall filter s h Replace blower and control access doors i Restore electrical power to furnace BLOWER MOTOR AND WHEEL The following steps should be performed by a qualified service
22. l 58PAV Upflow 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 535 773 Printed in U S A Form 58P R 15SM Pg 1 10 00 Replaces 58P R 14SM al aloa 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 44 CAUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE 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 TRO
23. ng 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 000000 000000 um 1m 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 NFPA 90B In Canada refer to the CAN CGA B149 1 and 2 M95 National Standard of Canada Natural Gas and Propane Installation Codes NSCNGPIC Wear safety glasses and work gloves Have fire extinguisher available num MID A94086 during start up and adjustment procedures and service calls Fig 2 Model 58RAV Recognize safety information This is the safety alert symbol Downflow 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 a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation REGISTERED QUALITY SYSTEM A94085 Fig 3 Mode
24. ng steps should be performed by a qualified service technician NOTE If the heat exchangers get a heavy accumulation of soot and carbon they 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 incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger Action must be taken to correct the problem If it becomes necessary to clean the heat exchanger because of dust or corrosion proceed as follows 1 Turn gas and electrical power to furnace OFF 2 Remove control and blower access doors 3 Disconnect vent connector from furnace flue collar 4 Disconnect internal vent pipe and enclosure on downflow furnaces only a Remove internal vent pipe enclosure cover b Disconnect and remove short piece of vent pipe from within furnace NOTE Vent pipe is SCREWED and RTV sealed to relief box c Remove vent pipe enclosure by removing screw in upper back Push bottom side backward to release tabs 5 Remove 2 screws that secure relief box See Fig 6 or 7 6 Disconnect wires to the following components Mark wires to aid in reconnection of a Blocked vent safeguard switch b Inducer motor Pressure switch a Limit overtemperature switch es e Gas val
25. nt as balance will be affected 10 Reassemble motor and blower by reversing items 9a through 9f Be sure to reattach ground wire 11 Reinstall blower assembly in furnace 12 Reinstall control and transformer support assembly in furnace 13 Reconnect blower leads to furnace control and auxiliary limit switch leads downflow only Refer to furnace wiring diagram and connect thermostat leads if previously disconnected see Fig 12 FLUE COLLAR VENT PIPE ENCLOSURE AUXILIARY LIMIT SWITCH WHEN USED MOUNTING y CONTROL SCREWS BLOCKED VENT RELIEF SAFEGUARD BOX PRESSURE SWITCH MANUAL GAS RESET LIMIT VALVE SWITCHES A99285 Fig 7 Model 58RAV Downflow NOTE Refer to Table 3 for motor speed lead relocation if leads were not identified before disconnection Table 3 Speed Selector FACTORY ATTACHED TO Black High Cool Yellow When present Blue Medium Low Heat Red Low Spare White Common L2 COM Medium High Spare 44 CAUTION Heating air speed selection MUST be adjusted to provide proper air temperature rise as specified on the rating plate Failure to adjust the heating speed may shorten heat ex changer life 14 Downflow furnaces only Reinstall internal vent pipe and enclosure by reversing items 3a through 3d NOTE A releasing agent such as PAM cooking spray or e
26. nto end of spring cable and crimp tight with crimping tool or strike with ball peen hammer TIGHTNESS IS VERY IMPOR TANT 4 Remove metal screw fitting from wire brush to allow insertion into cable b Clean each heat exchanger cell 1 Attach variable speed reversible drill to end of spring cable end opposite brush 2 Insert brush end of cable into upper opening of cell and slowly rotate with drill DO NOT force cable Gradually insert at least 36 in of cable into 2 upper passes of cell See Fig 9 3 Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning DO NOT pull cable with great force Reverse drill and gradually work cable out 4 Insert brush end of cable in lower opening of cell and proceed to clean 2 lower passes of cell in same manner as 2 upper passes 5 Repeat foregoing procedures until each cell in furnace has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly A91252 Fig 9 Cleaning Heat Exchanger Cell 8 Reinstall cell inlet plates and burner assembly Care must be exercised to center burners in cell openings 11 Clean flame sensor with fine steelwool 12 Remove old sealant from center panel and collector box flange and apply new sealant to collector box flange and reinstall on center panel making sure all 8 screws are secure NOTE A
27. onent verify correct operation sequence following 24 V THERMOSTAT TERMINALS TEST TWIN HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX LED OPERATION amp DIAGNOSTIC LIGHT HARNESS CONNECTOR OO 24 V TRANSFORMER SEC 2 SPARE 1 BLOWER SPEED SELECTION TERMINALS SPARE 2 EAC 1 EAC ELECTRONIC AIR CLEANER TERMINALS 115 VAC 1 0 AMP MAX EAC 2 115 VAC L2 NEUTRAL CONNECTION HOT SURFACE INDUCER MOTOR IGNITOR CONNECTOR CONNECTOR 115 VAC L1 N POWER SUPPLY A99255 Fig 11 Furnace Control J i ns ms WHEN USED WHEN USED Sw2 G 7 NOTE 14 NOTE 11 WHEN USED PCB BLOWER R DSS BVSS ALS PRS LGPS NOTE 9 De Y NOT ON ALL MODELS swi w ORN ORN ORN ORN ORN AD ea BLOWEROFFDELAY Com N 73 SELECTION CHART um HUM T YEL I 90 SEC TEST TWIN mm NOTE 14 3 I I 1 28 135 sec 1 1 M NOTE Cue 15 m 180 5 555 RED E I ER 225 5 WHEN USED NOTE 11 ev E 6 99 WHT FSE FL 586 RED FRS1 F
28. pressure switch Excessive wind Inadequate combustion air supply Disconnected or obstructed pressure tubing If it opens after trial for ignition period blower will come on for 90 second recycle delay LIMIT OR FLAME ROLL OUT SWITCH IS OPEN If open longer than three minutes code changes to 13 Flame roll out switch requires manual reset Check for Defective blower motor or capacitor Dirty filter or restricted duct system Loose blower wheel Defective switch or connections Inadequate combustion air supply Flame Roll out Switch or fuse link open Open Flame Roll out Switch or fuse link Manual reset or replace 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 microamps D C min 4 0 6 0 nominal Gas valve defective or gas valve turned off Defective Hot Surface Ignitor Manual valve shut off Low inlet gas pressure Control ground continuity Green wire MUST be connected to furnace sheet metal Inadequate flame carryover or rough ignition Flame sensor must be ungrounded COMPONENT TEST E To initiate the component test sequence shut OFF the room thermostat or disconnect the R thermostat lead Briefly short the TEST terminal to the Com 24
29. quiva lent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 15 Reinstall vent connector to furnace flue collar After fully assembling vent connector to furnace flue collar securely fasten vent connector to flue collar with 2 field supplied corrosion resistant sheet metal screws located 180 apart and midway up the collar 16 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 between heating and cooling by jumpering R to W and then R to Y on furnace control thermostat terminals 44 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 electrical shock personal injury or death NOTE If thermostat terminals are jumpered before blower ac cess door switch is closed blower will run for 90 sec before beginning a heating or cooling cycle 17 If furnace is operating properly REMOVE TAPE TO RE LEASE BLOWER ACCESS DOOR SWITCH replace blower access door CLEANING HEAT EXCHANGER The followi
30. seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 16 Reinstall vent connector on furnace flue collar After fully assembling vent connector to furnace flue collar securely fasten vent connector to flue collar with 2 field supplied corrosion resistant sheet metal screws located 180 apart and midway up the collar 17 Replace blower access door only 18 Turn electrical power and gas to ON 19 Set thermostat and check furnace for proper operation 20 Verify blower airflow and speed changes between heating and cooling 21 Check for gas leaks A WARNING Never use a match or other open flame to check for gas leaks Use a soap and water solution A failure to follow this warning could result in fire personal injury or death 22 Replace control access door on upflow furnace 23 On downflow horizontal furnaces remove blower access door replace control access door first then replace blower access door and secure with screws in front of door 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 properly maintained Refer to Fig 10 for field wiring information and to
31. usce GND DISCONNECT 9 LA 2 CONDENSING 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 A98521 Fig 10 Heating and Cooling Application Wiring Diagram NOTE Leave blower access panel installed to maintain power to a Remove control access door control to view current LED status b Remove blower access door c Remove control access door c Manually close blower access door switch d BRIEFLY remove either wire from the main limit switch until LED goes out then reconnect it A WARNING NOTE If wire to main limit is disconnected longer than 4 sec main blower starts and retrieval request is ignored Blower access door switch opens 115 v power to control No component operation can occur Caution must be taken when 2 When above items have been completed the following will manually closing this switch for service purposes Failure to occur follow this warning could result in personal injury or death a LED flashes a status code 4 times Record this status code d BRIEFLY short jumper TEST 3 16 in quick connect for further troubleshooting terminal on control adjacent to LED diagnostic light and b Inducer motor starts and continues to run the entire Com 24V terminal on furnace
32. ve f Hot surface igniter g Flame sensing electrode h Flame rollout switch es if applicable 7 Remove complete inducer assembly and relief box from furnace 8 Remove 8 screws that secure flue collector box to center panel Be careful not to damage collector box 9 Remove burner assembly and cell inlet plates IMPORTANT Replace screws in center panel and cells before cleaning NOTE Be careful when removing burner assembly to avoid breaking igniter See Fig 8 for correct igniter location 12 11 32 BURNER I F CELL a PANEL E Ds SURFACE IGNITER ASSEMBLY TA o av E NI TA L IGNITER 7 8 i BURNER IGNITER ASSEMBLY A99286 Fig 8 Position of Igniter to Burner 10 Using field provided small wire brush steel spring cable reversible electric drill and vacuum cleaner clean cells as follows a Assemble wire brush and steel spring cable 1 Use 48 in of 1 4 in diameter high grade steel spring cable commonly known as drain clean out or Roto Rooter cable 2 Use 1 4 in diameter wire brush commonly known as 25 caliber rifle cleaning brush NOTE The materials needed in 1 and 2 can usually be purchased at local hardware stores 3 Insert twisted wire end of brush i
Download Pdf Manuals
Related Search