Service and Maintenance Instructions
Contents
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6. COLLECTOR BOX BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY TUBE PINK INDUCER HOUSING DRAIN TUBE VIOLET Tube location when used on HORIZONTAL LEFT application COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED PLUG ITAN cap _ t BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY INDUCER HOUSING COLLECTOR BOX DRAIN TUBE EXTENSION TUBE VIOLET COLLECTOR BOX CONDENSATE TRAP DRAIN TUBE BLUE COUPLING RELOCATE TUBE BETWEEN LOWER COLLECTOR BOX EXTENSION DRAIN TUBE RELOCATE VRE IPLOWER 040 060 AND 080 HEATING INPUT FURNACES COLLECTOR BOX TUBE GREEN 1 All tubing must be connected securely and routed to avoid kinks and traps prevent a trap Refer to the Installation Instructions for further details 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 COLLECTOR BOX TUBE GREEN 4 COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE Condensate Tapion Tube location when used in DOWNFLOW application Condensate Trap on COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK INDUCER HOUSING DRAIN TUBE VIOLET DRAIN TUBE COUPLING DRAIN TUBES
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14. 8 Flush inside of collector box with water until discharge from condensate trap is clean and runs freely 9 Inspect inside area of collector box for any pieces of foreign materials and remove them if present BURNER FLAME BURNER MANIFOLD gt Fig 11 Burner Flame A89020 A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace compo nent damage Do not use wire brush or other sharp object to inspect or dislodge materials in secondary heat exchangers as cutting the secondary heat exchanger protective coating may 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 15 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 halogenated hydrocarbons nor aromatic content to prevent inadequate sealing to inducer hous ing See Fig 12 Apply a small bead of G E 162 67 bo 11 12 13 14 15 02 or Dow Corning RTV 738 sealant to groove in collector Refer to furnace wiring diagram and reconnect wires to inducer motor and pressure switch or connectors Reconnect pressure tubes to pressure switch See diagram on main furnace door for proper location of tubes Be sure
15. HEATING amp COOLING 58MCB 4 Way Multipoise Fixed Capacity Condensing Gas Furnace Visit www carrier com Service and Maintenance Instructions For Sizes 040 140 Series 100 A93040 NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue 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 ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in possible damage to this equipment serious personal injury or death The ability to properly perform maintenance on this 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 A WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could cause corrosion of heat exchanger fire personal injury or death Never store anything o
16. SAFETY CONSIDERATIONS Recognize safety information This is the safety alert symbol A 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 may result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 101 Tab 8a Printed in U S A Catalog No 58MCB 1SM Pg 1 8 05 Replaces 58MCA 10SM 05078 Fig 1 Multipoise Furnace in Upflow Orientation 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 and q
17. 16 Reconnect wires to gas valve and igniter Refer to furnace wiring diagram for proper wire location 17 Reinstall burner box pressure tube to gas valve regulator fitting 18 Reinstall gas supply pipe to furnace gas control valve using backup wrench on gas valve to prevent rotation and improper orientation NOTE Use propane gas resistant pipe dope to prevent gas leaks DO NOT use Teflon tape IGNITER WIRES MUST BE PLACED IN THIS SLOT A05074 gt Fig 7 Igniter Wire Placement PRIMARY HX INLET OPENINGS A96305 Fig 8 Cleaning Inlet Openings of Primary Heat Exchangers A WARNING FIRE EXPLOSION UNIT DAMAGE HAZARD Failure to follow this warning could result in property damage personal injury or death Gas valve switch MUST be facing forward or tilted upward 19 Replace burner box cover 20 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 21 Check for gas leaks A93087 Fig 9 Combustion Air Intake Housing Gasket Repair 22 Replace main furnace door Step 4 Cleaning Heat Exchangers The following items should be performed by a qualified service
18. 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 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 COMPONENT TEST To initiate the component test sequence shut OFF the room thermostat or disconnect the thermostat lead Briefly short the TEST TWIN terminal to the Com 24V ter minal Status LED will
19. Opening the blower access door will open the blower door switch and shut off power within the furnace When power to the furnace is shut off by either method the status code will be lost because the code is not stored while power is removed for any reason To Begin Component Self Test A WARNING ELECTRICAL SHOCK AND UNIT MAY NOT OPERATE HAZARD Failure to follow this warning could result in electrical shock personal injury or death Blower access panel door switch opens 115 v power to control board No component operation can occur Caution must be taken when manually closing this switch for service purposes Remove blower access door Disconnect the thermostat R lead from furnace control board Manually close blower door switch BR U N For approximately 2 sec short jumper the Com 24v terminal on control to the TEST TWIN 3 16 in quick connect terminal on control until LED turns off Remove jumper from termi nals See Fig 16 NOTE If TEST TWIN Com 24v terminals are jumpered longer than 2 sec LED will flash rapidly and ignore component test request Component test sequence for single stage furnace is as follows a LED will display status code 11 four times b Inducer motor starts and continues to run until Step f of component test sequence c After 7 sec the hot surface igniter is energized for 15 sec then off d Blower motor operates on HEAT speed for 10 sec e Blower motor op
20. RETAINER WASHABLE FILTER FILTER SUPPORT RETAINER A93045 Fig 4 Filter Installed for Side Inlet 93046 Fig 3 Bottom Filter Arrangement NOT move or shuffle your feet DO NOT touch ungrounded A CAUTION objects etc CUT HAZARD 4 If you touch ungrounded objects recharge your body with static electricity firmly touch furnace again before touching control or wires Failure to follow this caution may result in personal injury Be careful of sharp metal edges etc Use care and wear protective clothing safety glasses and gloves when removing 5 Use this procedure for installed and uninstalled ungrounded parts furnaces Step 1 Cleaning and or Replacing Air Filter 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 The air filter arrangement may vary depending on the application or orientation A WARNING FIRE CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in fire personal injury or death Never operate unit without a filter or with the blower access panel removed Operating a unit without a filter or with the blower access door remov
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23. DRAIN TUBE ELBOWS 2 FOR COUPLING RIGHT LEFT DRAIN OPTION DRAIN OPTION 01030 Fig 5 Factory Shipped Upflow Tube Configuration Shown with Blower Access Panel Removed 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 3 Disconnect blower motor wires from furnace control Field thermostat connections may need to be disconnected depend ing 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 5 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 Detach ground wire and disconnect blower motor harness plugs from blower motor NOTE Blower wheel is fragile Use care 7 Clean blower wheel and m
24. High Cool Yellow When Present Medium High Spare Blue Medium Low Heat Red Low Spare White Common Com 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 20 A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death 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 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 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 furnace gas control valve A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace compo nent damage Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation 5 Remo
25. 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 boards 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 Fig 20 Service Label 13 A02270 12200 12 614 01 06186 3 lt T i yeay 10 091 10 061 OZL 06 are Buneoy seb fep 30145 0734 NONO ee 7 z duind yy 10 spucoas 09 seb Kejap EL LNANdINOA mad O38 123000 4043000 SMT En sinoy ally Jaye 5 7314 SNNOOS or ORUOD ORIG so sfeu nyssedonsun a TWNIAHAL D YOLOSTSS 440 ir S40 0w U
26. 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 6 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 8 in Blower Shelf BURNER ENCLOSURE Blower access panel removed gt PRESSURE REFERENCE TUBE ASSEMBLY COLLECTOR BOX TUBE PINK 7 PLUG COLLECTOR BOX DRAIN Pa TUBE BLUE amp WHITE STRIPED CONDENSATE TRAP COLLECTOR BOX TUBE GREEN INDUCER HOUSING MOLDED DRAIN TUBE BEHIND COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE DRAIN TUBE COUPLING FIELDINSTALLED X RIGHT DRAIN OPTION FACTORY SUPPLIED DRAIN TUBE ad COUPLING LEFT DRAIN OPTION FIELDINSTALLED FACTORY SUPPLIED 1 2 IN __ CPVC STREET ELBOWS 2 FI ELDINSTALLED FACT FOR LEFT DRAIN OPTION FIELD INSTALLED FACTORY SUPPLIED LEFT Side COLLECTOR BOX DRAIN TUBE BLUE PLUGGED END COLLECTOR BOX TUBE GREEN BLUE amp WHITE STRIPED COLLECTOR ___ EXTENSION TUBE COLLECTOR BOX DRAIN TUBE ee PLUG COLLECTOR BOX CONDENSATE TRAP EXTENSION TUBE
27. 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 as improper adjustment of manifold pressure insufficient or poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger primary or secondary Action must be taken to correct the problem 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace compo nent damage 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
28. ECTRICAL SHOCK HAZARD Failure to follow this warning could result in electrical shock personal injury or death Igniter wires must be securely placed in slot in manifold grommet or else they could become pinched or severed and electrically shorted 8 Reinstall burner box cover 9 Turn on gas and electrical supplies to furnace 10 Verify igniter operation by initiating furnace control self test feature or by cycling thermostat 11 Replace main furnace door Step 7 Electrical Controls and Wiring A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death There may be more than 1 electrical supply to the furnace Check accessories and cooling unit for additional electrical supplies The electrical ground and polarity for 115 v wiring must be maintained properly Refer to Fig 15 for field wiring information and to Fig 21 for furnace wiring information NOTE If the polarity is not correct or the furnace is not properly grounded 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 16 Any direct shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse re
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30. OPERATION amp DIAGNOSTIC LIGHT PL1 LOW VOLTAGE MAIN 115 VAC L2 NEUTRAL HARNESS CONNECTOR CONNECTIONS 115 VAC L1 LINE PL2 HOT SURFACE VOLTAGE CONNECTION IGNITER amp INDUCER BLOWER SPEED MOTOR CONNECTOR SELECTION TERMINALS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02100 Fig 16 Control Center WIRING DIAGRAM See Fig 21 for Wiring Diagram TROUBLESHOOTING Use the Troubleshooting Guide the status code LED on the cotntrol and the Component Test to isolate furnace operation problems 32 F MINIMUM INSTALLED AMBIENT OR FREEZE STATUS CODES PROTECTION REQUIRED For an explanation of status codes refer to service label located on back of main furnace door or Fig 20 Tt NOTE Removing the blower access door will open the blower access door switch and terminate 115 v power to the control This will erase all stored status codes To read current status code remove main furnace door The status code LED can be viewed through the sight glass in the blower access door 93058 NOTE NO thermostat signals should be present at control and all blower off delays must be completed to view previous codes Fig 17 Winterizing the Furnace 11 HITE Eo Fig 18 Inducer Housing Drain HITTITE Lo HELE Fig 19 Funnel in Drain Tube a
31. ROUTED IN ee irs en TUBE COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX COLLECTOR BOX TUBE GREEN 7 lt EXTENSION TUBE 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 Side Optional BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY COLLECTOR BOXTUBE PINK BLUE amp WHITE STRIPED CONDENSATE gt INDUCER HOUSING DRAIN TUBE VIOLET RIGHT Side PLUG COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE GREEN 4 COLLECTOR BOX EXTENSION TUBE BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY FRONT OF GAS VALVE Tube location when used on HORIZONTAL RIGHT application COLLECTOR BOX TUBE PINK a AUXILIARY J BOX RELOCATED HERE RY mi O N BURNER ENCLOSURE Y PRESSURE REFERENCE if TUBE ASSEMBLY COLLECTOR BOX DRAIN TUBE BLUE AND WHITE STRIPED CONDENSATE TRAP INDUCER HOUSING DRAIN TUBE VIOLET A00308 Fig 10 Furnace Pressure and Drain Tubing Diagram NOTE After cleaning inspect the heat exchangers to ensure they are free o
32. amage or discolored insulation is evident replace the tape 3 Check that heat tape power supply circuit is on 10 Step 9 Winterizing A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in furnace compo nent damage Freezing condensate left in the furnace may damage the furnace 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 cap from unused drain tap on inducer housing See Fig 18 4 Connect field supplied 1 2 in I D tube to upper inducer housing drain connection A CAUTION UNIT DAMAGE HAZARD Failure of plastic components may occur Do not use ethylene glycol Prestone II antifreeze coolant or equivalent automotive type 5 Insert funnel in tube and pour up to one quart of 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 19 6 Reconnect drain cap to inducer housing 7 Replace main furnace door 8 Propylene glycol need not be removed before restarting furnace TWINNING AND OR BLOWER OFF DELAY COMPONENT TEST TERMINAL J2 JUMPER HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX 24 V THERMOSTAT TERMINALS TRANSFORMER 24 VAC CONNECTIONS 3 AMP FUSE LED
33. ecurely Reconnect electrical supply to unit and observe unit through 1 complete operating cycle for proper operation 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 heat tape has been applied check to ensure it will operate when low temperatures are present A CAUTION UNIT AND PROPERTY DAMAGE HAZARD Failure to follow this caution may result in furnace compo nent failures or water property damage 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 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 17 See CONDENSATE DRAIN PROTECTION sec tion of Installation Start Up and Operating Instructions NOTE Heat tape when used should be wrapped around the condensate drain trap and drain line There is no need to use heat tape within the furnace casing Most heat tapes are temperature activated and it is not practical to verify the actual heating of the tape Check the following 1 Check for signs of physical damage to heat tape such as nicks cuts abrasions gnawing by animals etc 2 Check for discolored heat tape insulation If any d
34. ed could cause damage to the furnace blower motor Dust and lint on internal parts of furnace can cause a loss of efficiency 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 about proper mainte nance and maintenance contract availability 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 A WARNING To clean or replace the filters proceed as follows ELECTRICAL SHOCK HAZARD 1 Turn off electrical supply to furnace Failure to follow this warning could result in personal injury Remove main furnace door and blower access panel or death Turn off the gas and electrical supplies to the unit before performing any maintenance or service Follow the operating instructions on the label attached to the furnace 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 The minimum maintenance that should be performed on this opposite direction of airflow equipment is as follows aie 6 Rinse filter and let dry Oiling
35. erates on COOL speed for 10 sec f Inducer motor stops 5 Reconnect R lead to furnace control board remove tape from blower door switch and reinstall blower door 6 Operate furnace per instruction on outer door 7 Verify furnace shut down by lowering thermostat setting below room temperature 8 Verify that furnace restarts by raising thermostat setting above room temperature 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 12 amp 24VAC at SEC 1 8 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 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 o
36. f all foreign objects that may restrict flow of combustion products 12 Reverse items 4 through 10 for reassembly A CAUTION UNIT MAY NOT OPERATE Failure to attach this ground wire to an adequate casing ground may cause the furnace control to lock out The ground wire from the gas valve MUST be attached to the burner box attachment screw NOTE Be sure burner box gasket is installed between burner box and cell panel See Fig 6 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 halogenated hydrocarbons nor aromatic content to prevent inadequate sealing to burner box and apply a small bead of G E RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant to edge of combustion air intake housing See Fig 9 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 10 15 Turn on gas and electrical supplies to furnace 16 Check furnace operation through 2 complete heat operating cycles Look th
37. n 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 TABLE OF CONTENTS SAFETY CONSIDERATION Ssenari 1 GENERAL ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 2 CARE AND 3 Cleaning and or Replacing Air Filter eee eee 3 Blower Motor and Wheel 3 Cleaning BONETS assisar ie e E 5 Cleaning 6 Primary Heat Exchansers s cssii sstecsccciasscscasitnevesteesceosianeave 6 Secondary Heat Exchangers 8 Flushing Collector Box and Drainage System 8 Servicing Hot Surface Igiiter csseccssseesssecescssersessensess 9 Electrical Controls and Wiring eee 9 Checking Heat Tape Operation If Applicable 10 10 WIRING S 11 TROUBLESHOOTING ca 11 Stats S 11 Component Tests riria ira A NEE 12
38. n delay 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if the limit or flame rollout switch 15 open longer than 3 minutes Control will auto reset after three hours 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 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
39. nd Antifreeze Running Through Trap A99119 A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in damage to unit components Make sure limit switch wire does not contact any metallic component such as the gas valve If wire is shorted the 3 amp fuse on furnace control board will blow and the unit will not operate To retrieve previous codes remove 1 of the red main limit 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 12 respond with blower operation This places the control in the status recall mode and displays the first code stored in memory 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 NOTE The furnace control component test allows all compo nents to run for a short time except the gas valve and humidifier terminal HUM are not energized for safety reasons The EAC 1 terminal is energized when the blower is energized This feature helps diagnose a system problem in case of a component failure The component test feature will not operate if any thermostat signal is present at the control and not until all time delays are completed NOTE Record the status code BEFORE opening the blower access door and before shutting off power to furnace
40. ohms 5 Remove igniter assembly A CAUTION BURN HAZARD Failure to follow this caution may result in minor personal injury Allow igniter to cool before removal Normal operating temperatures exceed 2000 F a Remove burner box cover b Remove igniter wires from slot in manifold grommet See Fig 7 c Using a 1 4 in driver remove the single screw securing the igniter bracket to the burner box bracket See Fig 13 and carefully withdraw the igniter and bracket assembly through the front of the burner box without striking the igniter on surrounding parts Note that the igniter bracket has a handle that extends to the front of the burner box to aid in handling See Fig 13 d Inspect igniter for signs of damage or failure A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in premature failure of the igniter The igniter is fragile DO NOT allow it to hit the side of the burner box parts while removing or replacing it e If replacement is required replace igniter on igniter bracket and then install assembly to burner box to avoid damage to the igniter A04181 gt Fig 14 Ilgniter 6 To replace igniter and bracket assembly reverse items 5a through 5d 7 Reconnect igniter wire connection and insert the igniter wires in the slot in the manifold grommet dressing the igniter wires to ensure there is no tension on the igniter itself See Fig 7 A WARNING EL
41. ons rook 5 101 Printed in U S A Catalog No 58MCB 1SM Pg 20 8 05 Replaces 58MCA 10SM al aj 8
42. or coating of filter is not 1 Check and clean or replace air filter each month as needed recommended 2 Check blower motor and wheel for cleanliness annually 7 Slide filter into furnace 3 Check electrical connections for tightness and controls for 8 Recapture filter retainer wire proper operation each heating season Service as necessary 9 Replace blower access panel and main furnace door 4 Check for proper condensate drainage Clean as necessary 10 Turn on electrical supply to furnace 5 Check for blockages in combustion air and vent pipes annu Step 2 Blower Motor and Wheel Maintenance ally To ensure long life economy and high efficiency clean accumu 6 Check burners for cleanliness annually lated dirt and grease from blower wheel and motor annually kK NI PLUG CAP N COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE PINK Sr COLLECTOR BOX TUBE GREEN D 7 INDUCER HOUSING MOLDED DRAIN eee gt TUBE BEHIND COLLECTOR F DRAIN TUBE COLLECTOR BOX E DRAIN TUBE BLUE CONDENSATE CI FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE COUPLING LEFT DRAIN OPTION SS FIELD INSTALLED FACTORY SUPPLIED DRAIN TUBE FIELD INSTALLED FACTORY SUPPLIED FIELD INSTALLED FACTORY SUPPLIED 10 1 CPVC STREET
43. otor 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 Motor mounts need not be removed from motor f Remove blower wheel from housing A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in noise or furnace component failure 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 cleaner in motor 9 Reassemble motor and blower wheel by reversing items 8b through 8f Ensure wheel is positioned for proper rotation Be sure to reat
44. own in Fig 2 you may need to revise your orientation to component location accordingly AIRFLOW lt 4 UPFLOW HORIZONTAL HORIZONTAL RIGHT DOWNFLOW AIRFLOW AIRFLOW v AIRFLOW A93041 Fig 2 Multipoise Orientations ELECTROSTATIC DISCHARGE ESD PRECAUTIONS A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may damage furnace compo nents 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 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 WASHABLE FILTER FILTER
45. placement 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 FIELD 24 WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING NOTE 2 THERMOSTAT FIVE WIRE OO TERMINALS FIELD SUPPLIED THREE WIRE l DISCONNECT HEATING ONLY e 208 230 OR BLOWER DOOR Rosle 460 V Leer mi 1 1 Lo l L o ___ 3 3 9 ef E ______ wer ______ 455 e je ad INGLE 2 25 PHASE 115 V FIELD 2 E SUPPLIED L H OND DISCONNECT O NOTE JL ail CONDENSING UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation Some thermostats require a terminal connection as shown If any of the original wire as supplied must be replaced use same type or equivalent wire 02174 Fig 15 Field Wiring any smoky or burned connections are found disassemble the connection clean all parts strip wire and reassemble properly and s
46. rough sight glass in burner enclosure to check burners Burner flames should be clear blue almost transpar ent See Fig 11 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 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 10 NOTE Ensure the drain tube disconnected from the inducer housing is higher than the collector box opening or water will flow out of tube 7 Remove inducer housing assembly by removing 4 bolts attaching assembly to cell panel
47. tach ground wire Tighten setscrew to 140 to 160 in lb torque NOTE Be sure to attach ground wire and reconnect blower harness plugs to blower motor 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 10 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 field drain to condensate trap NOTE Ensure tubes are not kinked or pinched as this will affect operation 13 Reconnect wires Refer to furnace wiring diagram and connect thermostat leads if previously disconnected See Fig 21 NOTE Refer to Table 1 for motor speed lead reconnection if leads were not identified before disconnection A CAUTION UNIT DAMAGE HAZARD Failure to adjust the heating speed may shorten heat ex changer life Heating speed selection MUST be adjusted to provide proper temperature rise as specified on the rating plate Table 1 Speed Selection FACTORY COLOR SPEED ATTACHED TO Black
48. tubes are not kinked See Fig 10 Turn on gas and electrical supplies to furnace 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 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 Check for gas leaks A93081 Fig 12 Gasket on Collector Box LJ EXTENDED IGNITER BRACKET HANDLE IGNITER BRACKET MOUNTING SCREW 05075 gt Fig 13 lgniter Bracket 16 Replace main furnace door Step 6 Servicing Hot Surface Igniter The igniter does NOT require annual inspection Check igniter resistance before removal 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Disconnect igniter wire connection 4 Check igniter resistance Igniter resistance is affected by temperature Only check resistance when the igniter is at room temperature a Using an ohm meter check resistance across both igniter leads in connector b Cold reading should be between 40 ohms and 70
49. ualified 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 05 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 EFFICIENCY CERTIFIED 150 9001 2000 CERTIFIED REGISTERED A CAUTION ELECTRICAL SHOCK AND UNIT DAMAGE HAZARD Failure to follow this caution may result in minor personal injury or damage to furnace Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation GENERAL This furnace can be installed as a direct vent 2 pipe or non direct vent 1 pipe condensing gas furnace These in structions 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 sh
50. ve wires from gas valve Note location for reassembly 6 Remove burner box pressure tube from gas valve regulator fitting MANIFOLD MOUNTING MANIFOLD GAS VALVE REGULATOR FITTING GAS VALVE A96304 Fig 6 Burner Box Assembly 7 Unplug igniter from harness 8 Remove igniter leads from slot in manifold grommet 9 Remove screws that secure manifold to burner box See Fig 6 NOTE Do not remove burner box from cell panel 10 Remove manifold orifices and gas valve as one assembly 11 Remove screws attaching burner assembly in burner box NOTE Use care when removing and reinstalling burners not to strike the hot surface igniter 12 Remove burner assembly from burner box NOTE burners are attached to burner bracket and can be removed as 1 assembly 13 Clean burners with soft brush and vacuum 14 Reinstall manifold orifice and gas valve assembly in burner box Ensure manifold seal grommet is installed properly and burners fit over orifices 15 Reinsert the igniter wires in the slot in the manifold grommet dressing the wires to ensure there is no tension on the igniter itself See Fig 7 A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in electrical shock personal injury or death Igniter wires must be securely placed in slot in manifold grommet or else they could become pinched or severed and electrically shorted
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